JPH1024435A - Manufacture of synthetic resin in-mold foamed molded object fitted with skin and mold used therein - Google Patents

Manufacture of synthetic resin in-mold foamed molded object fitted with skin and mold used therein

Info

Publication number
JPH1024435A
JPH1024435A JP8182355A JP18235596A JPH1024435A JP H1024435 A JPH1024435 A JP H1024435A JP 8182355 A JP8182355 A JP 8182355A JP 18235596 A JP18235596 A JP 18235596A JP H1024435 A JPH1024435 A JP H1024435A
Authority
JP
Japan
Prior art keywords
mold
thermoplastic resin
skin material
synthetic resin
foamed
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
Application number
JP8182355A
Other languages
Japanese (ja)
Inventor
Kiyoshi Matsuki
清 松木
Yoriki Kakimoto
頼輝 柿本
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kanegafuchi Chemical Industry Co Ltd
Original Assignee
Kanegafuchi Chemical Industry Co Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Kanegafuchi Chemical Industry Co Ltd filed Critical Kanegafuchi Chemical Industry Co Ltd
Priority to JP8182355A priority Critical patent/JPH1024435A/en
Priority to PCT/JP1997/002272 priority patent/WO1998000287A1/en
Priority to CNB971943273A priority patent/CN1157283C/en
Priority to EP97928530A priority patent/EP0960719B1/en
Priority to DE69730526T priority patent/DE69730526T2/en
Priority to US09/142,210 priority patent/US6261489B1/en
Publication of JPH1024435A publication Critical patent/JPH1024435A/en
Pending legal-status Critical Current

Links

Abstract

PROBLEM TO BE SOLVED: To apply beautiful appearance to the surface of the thermoplastic resin skin material integrated with a synthetic resin in-mold foamed molded object without forming beads patterns to the surface of the skin material and to improve manufacturing efficiency. SOLUTION: A thermoplastic resin skin material 3 is arranged on one mold 5 among two molds 5 constituting a mold and, after mold clamping, a mold 7 is filled with foamable beads 8 and heated by steam heating to foam the foamable beads 8 to mutually fuse them and these foamable beams 8 are integrally fused to the thermoplastic resin skin material 3 to produce a synthetic resin in-mold foamed molded object fitted with the skin. In this method, fine unevenness 9 having predetermined roughness is preliminarily formed on the surface 5a of one mold 5 and the unevenness 9 is transferred to the surface 3a of the thermoplastic resin skin material 3 along with the mutual fusion of the foamable beads 8 and the integral fusion of the foamable beads 8 and the thermoplastic resin skin material 3 to keep the surface roughness of the thermoplastic resin skin material 3 almost uniform.

Description

【発明の詳細な説明】DETAILED DESCRIPTION OF THE INVENTION

【０００１】[0001]

【発明の属する技術分野】この発明は、例えば自動車用
内装材等に使用される表皮付き合成樹脂型内発泡成形体
の製造方法及びその製造に使用する金型に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a foamed molded article in a synthetic resin mold having a skin used for, for example, interior materials for automobiles, and a mold used for producing the molded article.

【０００２】[0002]

【従来の技術】従来のこの種の表皮付き合成樹脂型内発
泡成形体の製造方法としては、例えば、成形型を構成す
る２つの金型のいずれか一方の金型に熱可塑性樹脂表皮
材を配置して型締め後、この成形型内に発泡ビーズを充
填し、蒸気加熱によりこれら発泡ビーズを発泡させて互
いに融着させると共に、これら発泡ビーズと前記熱可塑
性樹脂表皮材を融着一体化させる、いわゆる同時一体成
形が知られている。2. Description of the Related Art As a conventional method of manufacturing a foamed molded article in a synthetic resin mold with a skin, for example, a thermoplastic resin skin material is used in one of two molds constituting a molding die. After placing and closing the mold, the molding beads are filled with foam beads, and the foam beads are foamed by steam heating to be fused together, and the foam beads and the thermoplastic resin skin material are fused and integrated. A so-called simultaneous integral molding is known.

【０００３】この方法においては、図２６に示すよう
に、前記一方の金型５の表面５ａは平滑に形成され、ま
た、前記熱可塑性樹脂表皮材３の表面３ａは、所定粗さ
で略一様につや消し加工されて微細な凹凸１９が形成さ
れていることが多い。In this method, as shown in FIG. 26, the surface 5a of the one mold 5 is formed to be smooth, and the surface 3a of the thermoplastic resin skin material 3 is formed with a predetermined roughness of approximately one surface. In many cases, fine irregularities 19 are formed by matting.

【０００４】このような第１の従来例においては、前記
成形型内７に発泡ビーズ８を充填した後、蒸気加熱によ
りこれら発泡ビーズ８を型内発泡させる際には、前記発
泡ビーズ８の発泡力Ｆにより、前記熱可塑性樹脂表皮材
３の表面３ａの所定範囲Ｄは、その裏面３ｂから他の範
囲Ｅより強く押圧されて、前記一方の金型５の表面５ａ
により強く押し付けられる。In the first conventional example, when the foaming beads 8 are filled in the molding die 7 and the foaming beads 8 are foamed in the mold by steam heating, the foaming beads 8 are foamed. The predetermined range D of the front surface 3a of the thermoplastic resin skin material 3 is pressed more strongly by the force F than the other range E from the rear surface 3b, and the front surface 5a of the one mold 5 is pressed.
Pressed more strongly.

【０００５】ここで、前記熱可塑性樹脂表皮材３は蒸気
加熱により軟化状態となっているので、図２７に示すよ
うに、上記のようにしてより強く押し付けられた前記範
囲Ｄには、元のつや消し加工による微細な凹凸１９より
粗さが細かい微細な凹凸１９ｄが形成される。また、前
記他の範囲Ｅも、範囲Ｄより弱い力ではあるが前記一方
の金型５の表面５ａに押し付けられるため、この他の範
囲Ｅにも前記つや消し加工による微細な凹凸１９と粗さ
が略同程度か又はわずかに細かい微細な凹凸１９ｅが形
成される。しかし、前記一方の金型５の表面５ａにより
強く押し付けられた分、前記範囲Ｄの微細な凹凸１９ｄ
がより細かくなっているため、この範囲Ｄの部分が平面
視で円形状のいわゆるビーズ模様として現れ、得られる
表皮付き合成樹脂型内発泡成形体５１の外観の見栄えが
良くないという問題点があった。[0005] Here, since the thermoplastic resin skin material 3 is in a softened state due to steam heating, as shown in FIG. Fine irregularities 19d having a smaller roughness than the fine irregularities 19 formed by the matting process are formed. The other range E is also weaker than the range D, but is pressed against the surface 5a of the one mold 5, so that the other range E has fine irregularities 19 and roughness due to the matting process. Substantially the same or slightly fine fine irregularities 19e are formed. However, the minute unevenness 19d in the range D corresponds to the pressure strongly pressed by the surface 5a of the one mold 5.
Has a problem that the portion in the range D appears as a so-called bead pattern having a circular shape in a plan view, and the appearance of the resulting synthetic resin mold foam 51 with a skin is not good. Was.

【０００６】また、このような問題点を解決した第２の
従来例としては、例えば、図２８に示すように、前記熱
可塑性樹脂表皮材３として、表面５３ａをつや消し加工
して微細な凹凸１９を形成した熱可塑性樹脂シート５３
と、該熱可塑性樹脂シート５３の裏面５３ｂに貼付けら
れた熱可塑性樹脂押出発泡シート５４とからなる積層シ
ート２３を用い、前記熱可塑性樹脂シート５３が前記一
方の金型５側に、また、前記熱可塑性樹脂押出発泡シー
ト５４が前記発泡ビーズ８側に向くように配置し、上記
と同様にして製造する方法が知られている。As a second conventional example which solves such a problem, for example, as shown in FIG. 28, as the thermoplastic resin skin material 3, the surface 53a is frosted to form fine irregularities 19. -Formed thermoplastic resin sheet 53
And a laminated sheet 23 composed of a thermoplastic resin extruded foam sheet 54 attached to a back surface 53b of the thermoplastic resin sheet 53, and the thermoplastic resin sheet 53 is provided on the one mold 5 side, A method is known in which a thermoplastic resin extruded foam sheet 54 is arranged so as to face the foam beads 8 and manufactured in the same manner as described above.

【０００７】この方法においては、前記発泡ビーズ８を
型内発泡させる際、前記熱可塑性樹脂押出発泡シート５
４が前記発泡ビーズ８の発泡力Ｆによりその裏面５４ｂ
から押圧されても、この熱可塑性樹脂押出発泡シート５
４がいわゆるクッション材の役割を果たして、前記熱可
塑性樹脂シート５３の表面５３ａまでその押圧力Ｆが作
用しにくくなるため、上記のようなビーズ模様が現れな
いようになっている。In this method, when the foam beads 8 are foamed in a mold, the thermoplastic resin extruded foam sheet 5
4 is the back surface 54b due to the foaming force F of the foam beads 8.
This extruded thermoplastic resin foam sheet 5
4 serves as a so-called cushion material, so that the pressing force F hardly acts on the surface 53a of the thermoplastic resin sheet 53, so that the above-mentioned bead pattern does not appear.

【０００８】更に、第３の従来例としては、例えば、２
つの金型の間に合成樹脂型内発泡成形体２と熱可塑性樹
脂表皮材３を配置して型締め、加圧する際、熱及び／又
は接着剤でこれら合成樹脂型内発泡成形体２と熱可塑性
樹脂表皮材３を一体化させる、いわゆる後貼り成形が知
られている。Further, as a third conventional example, for example,
When the foamed molded article 2 in the synthetic resin mold and the skin material 3 of the thermoplastic resin are arranged between two molds and the mold is clamped and pressurized, the foamed molded article 2 in the synthetic resin mold and the heat are bonded with heat and / or an adhesive. A so-called post-paste molding in which the plastic resin skin material 3 is integrated is known.

【０００９】前記合成樹脂型内発泡成形体２と熱可塑性
樹脂表皮材３を熱で融着一体化する場合を図２９に示す
が、この場合も上記と同様、前記熱可塑性樹脂表皮材３
と当接する一方の金型１５の表面１５ａは平滑に形成さ
れ、また、前記熱可塑性樹脂表皮材３の表面３ａは、所
定粗さで略一様につや消し加工されて微細な凹凸１９が
形成されていることが多い。一方、前記合成樹脂型内発
泡成形体２の表面２ａは、フラットでないことが多い。
なお、熱をかけないで合成樹脂型内発泡成形体２と熱可
塑性樹脂表皮材３の間に介在させた接着剤で一体化する
場合や、あるいは熱と接着剤を併用して一体化する場合
も同様の状態となっている。FIG. 29 shows a case where the above-mentioned synthetic resin mold foam molded article 2 and thermoplastic resin skin material 3 are fused and integrated by heat. In this case, as in the above case, the thermoplastic resin skin material 3 is fused.
The surface 15a of one of the molds 15 in contact with the surface 3a is formed smooth, and the surface 3a of the thermoplastic resin skin material 3 is matted almost uniformly with a predetermined roughness to form fine irregularities 19. Often have. On the other hand, the surface 2a of the synthetic resin molded foam 2 is often not flat.
In addition, when integrating with an adhesive interposed between the foamed molded article 2 in the synthetic resin mold and the thermoplastic resin skin material 3 without applying heat, or when integrating with a combination of heat and an adhesive Is in a similar state.

【００１０】[0010]

【発明が解決しようとする課題】しかしながら、上記第
２の従来例においては、前記熱可塑性樹脂押出発泡シー
ト５４を押出発泡成形により別途製造し、前記熱可塑性
樹脂シート５３に貼付けておく必要があるので、製造工
程が煩雑で生産効率が良くないという問題点がある。However, in the second conventional example, it is necessary to separately manufacture the extruded thermoplastic resin foam sheet 54 by extrusion foam molding and affix it to the thermoplastic resin sheet 53. Therefore, there is a problem that the manufacturing process is complicated and the production efficiency is not good.

【００１１】また、上記第３の従来例においては、前記
合成樹脂型内発泡成形体２の表面２ａがフラットでない
ため、この合成樹脂型内発泡成形体２と熱可塑性樹脂表
皮材３を融着一体化する際には、図２９に示すように、
加圧力Ｇにより、前記熱可塑性樹脂表皮材３の表面３ａ
の所定範囲Ｄは、その裏面３ｂから他の範囲Ｅより強く
押圧されて、前記一方の金型１５の表面１５ａにより強
く押し付けられる。In the third conventional example, since the surface 2a of the synthetic resin foam 2 is not flat, the synthetic resin foam 2 and the thermoplastic resin skin material 3 are fused. At the time of integration, as shown in FIG.
By the pressing force G, the surface 3a of the thermoplastic resin skin material 3
The predetermined range D is pressed more strongly from the back surface 3b than the other range E, and is pressed more strongly by the front surface 15a of the one mold 15.

【００１２】そのため、上記第１の従来例と同様、前記
範囲Ｄの部分が平面視で円形状のいわゆるビーズ模様と
して現れ、得られる表皮付き合成樹脂型内発泡成形体５
１の外観の見栄えが良くないという問題点がある。ま
た、合成樹脂型内発泡成形体２と熱可塑性樹脂表皮材３
を熱と接着剤を併用して一体化する場合も、同様にビー
ズ模様が現れる。なお、熱をかけないで接着剤で一体化
する場合にも、ビーズ模様が現れるので、上記と同様の
問題点がある。Therefore, similarly to the first conventional example, the portion of the range D appears as a so-called bead pattern having a circular shape in a plan view, and the resultant foamed synthetic resin mold 5 with a skin is obtained.
There is a problem that the appearance of No. 1 is not good. In addition, the synthetic resin molded foam 2 and the thermoplastic resin skin material 3
In the case where are integrated by using both heat and an adhesive, a bead pattern similarly appears. It should be noted that even when integrated with an adhesive without applying heat, a bead pattern appears, so that there is the same problem as described above.

【００１３】この発明は、以上のような問題点に鑑みて
なされたものであり、合成樹脂型内発泡成形体に一体化
された熱可塑性樹脂表皮材の表面にビーズ模様が現れず
に外観が美麗であると共に、生産効率が良好な表皮付き
合成樹脂型内発泡成形体の製造方法及びその製造に使用
する金型を提供することを目的とする。SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and has an appearance in which a bead pattern does not appear on the surface of a thermoplastic resin skin material integrated with a foamed molded article in a synthetic resin mold. An object of the present invention is to provide a method for producing a foamed molded article in a synthetic resin mold with a skin, which is beautiful and has good production efficiency, and a mold used for the production.

【００１４】[0014]

【課題を解決するための手段】上記目的を達成するため
の請求項１の表皮付き合成樹脂型内発泡成形体の製造に
使用する金型の手段とするところは、成形型を構成する
２つの金型のいずれか一方の金型に熱可塑性樹脂表皮材
を配置して型締め後、この成形型内に発泡ビーズを充填
し、蒸気加熱によりこれら発泡ビーズを発泡させて互い
に融着させると共に、これら発泡ビーズと前記熱可塑性
樹脂表皮材を融着一体化させる表皮付き合成樹脂型内発
泡成形体の製造に使用する金型において、前記一方の金
型の表面に、所定粗さの微細な凹凸を形成したことにあ
る。In order to achieve the above object, there is provided a mold used for producing a foamed molded article in a synthetic resin mold having a skin according to the present invention. After placing the thermoplastic resin skin material in one of the molds and clamping the mold, filling the molding beads with foam beads, foaming these foam beads by steam heating and fusing them together, In a mold used for producing a foamed molded article in a synthetic resin mold having a skin in which the foam beads and the thermoplastic resin skin material are fused and integrated, fine irregularities having a predetermined roughness are formed on the surface of the one mold. Has been formed.

【００１５】請求項２の手段とするところは、２つの金
型の間に合成樹脂型内発泡成形体と熱可塑性樹脂表皮材
を配置して型締め、加圧する際、熱及び／又は接着剤で
これら合成樹脂型内発泡成形体と熱可塑性樹脂表皮材を
一体化させる表皮付き合成樹脂型内発泡成形体の製造に
使用する金型において、前記熱可塑性樹脂表皮材と当接
する一方の金型の表面に、所定粗さの微細な凹凸を形成
したことにある。According to a second aspect of the present invention, there is provided a synthetic resin in-mold foamed product and a thermoplastic resin skin material disposed between two molds, and when the mold is clamped and pressed, heat and / or adhesive may be applied. In a mold used for manufacturing a synthetic resin-molded internal foamed article with a skin that integrates the synthetic resin-molded foamed molded article and the thermoplastic resin skin material, one mold that comes into contact with the thermoplastic resin skin material is used. Is that fine irregularities having a predetermined roughness are formed on the surface of the substrate.

【００１６】請求項３の手段とするところは、前記微細
な凹凸の粗さが、表面粗さ測定器を用いて測定した表面
粗さ波形において、振幅５乃至１５０μｍ、波長３０乃
至６００μｍの範囲であることにある。According to a third aspect of the present invention, the roughness of the fine irregularities is within a range of 5 to 150 μm in amplitude and 30 to 600 μm in wavelength in a surface roughness waveform measured using a surface roughness measuring device. There is to be.

【００１７】請求項４の手段とするところは、前記微細
な凹凸に加えて製品意匠模様用凹凸を形成したことにあ
る。According to a fourth aspect of the present invention, in addition to the fine irregularities, irregularities for a product design pattern are formed.

【００１８】請求項５の表皮付き合成樹脂型内発泡成形
体の製造方法の手段とするところは、成形型を構成する
２つの金型のいずれか一方の金型に熱可塑性樹脂表皮材
を配置して型締め後、この成形型内に発泡ビーズを充填
し、蒸気加熱によりこれら発泡ビーズを発泡させて互い
に融着させると共に、これら発泡ビーズと前記熱可塑性
樹脂表皮材を融着一体化させる表皮付き合成樹脂型内発
泡成形体の製造方法において、前記一方の金型の表面
に、所定粗さの微細な凹凸をあらかじめ形成しておき、
前記発泡ビーズ相互の融着及びこれら発泡ビーズと前記
熱可塑性樹脂表皮材の融着一体化と共に、該熱可塑性樹
脂表皮材の表面に前記微細な凹凸を転写することによっ
て、この熱可塑性樹脂表皮材の表面粗さを略一様に保持
することにある。According to a fifth aspect of the present invention, there is provided a method for producing a foamed molded article in a synthetic resin mold having a skin, wherein a thermoplastic resin skin material is disposed on one of two molds constituting the molding die. After the mold is closed, the foamed beads are filled in the mold, and the foamed beads are foamed by steam heating to be fused to each other, and the foamed beads and the thermoplastic resin skin material are fused and integrated. In the method of manufacturing a foamed molded article in a synthetic resin mold, on the surface of the one mold, fine irregularities having a predetermined roughness are formed in advance,
By transferring the fine irregularities to the surface of the thermoplastic resin skin material together with the fusion of the foam beads to each other and the fusion and integration of the foam beads and the thermoplastic resin skin material, Is to maintain the surface roughness of the substrate substantially uniformly.

【００１９】請求項６の手段とするところは、成形型を
構成する２つの金型のいずれか一方の金型に熱可塑性樹
脂表皮材を配置して型締め後、この成形型内に発泡ビー
ズを充填し、蒸気加熱によりこれら発泡ビーズを発泡さ
せて互いに融着させると共に、これら発泡ビーズと前記
熱可塑性樹脂表皮材を融着一体化させる表皮付き合成樹
脂型内発泡成形体の製造方法において、前記一方の金型
の表面に、凹凸転写用部材をあらかじめ接合しておき、
前記発泡ビーズ相互の融着及びこれら発泡ビーズと前記
熱可塑性樹脂表皮材の融着一体化と共に、該熱可塑性樹
脂表皮材の表面に、前記凹凸転写用部材の表面に形成し
た微細な凹凸を転写することによって、この熱可塑性樹
脂表皮材の表面粗さを略一様に保持することにある。According to a sixth aspect of the present invention, a thermoplastic resin skin material is disposed on one of the two molds constituting the molding die, the mold is clamped, and the expanded beads are placed in the molding die. And foaming these foamed beads by steam heating and fusing them together, and in a method for producing a foamed synthetic resin type inner molded article in which the foamed beads and the thermoplastic resin skin material are fused and integrated, On the surface of the one mold, an uneven transfer member is joined in advance,
Along with the fusion of the foam beads to each other and the fusion of the foam beads and the thermoplastic resin skin material, the fine irregularities formed on the surface of the irregularity transfer member are transferred to the surface of the thermoplastic resin skin material. By doing so, the surface roughness of the thermoplastic resin skin material is maintained substantially uniformly.

【００２０】請求項７の手段とするところは、成形型を
構成する２つの金型のいずれか一方の金型に熱可塑性樹
脂表皮材を配置して型締め後、この成形型内に発泡ビー
ズを充填し、蒸気加熱によりこれら発泡ビーズを発泡さ
せて互いに融着させると共に、これら発泡ビーズと前記
熱可塑性樹脂表皮材を融着一体化させる表皮付き合成樹
脂型内発泡成形体の製造方法において、前記一方の金型
の表面に、凹凸転写用粒子状物を付着させて所定粗さの
微細な凹凸をあらかじめ形成しておき、前記発泡ビーズ
相互の融着及びこれら発泡ビーズと前記熱可塑性樹脂表
皮材の融着一体化と共に、該熱可塑性樹脂表皮材の表面
に前記微細な凹凸を転写することによって、この熱可塑
性樹脂表皮材の表面粗さを略一様に保持することにあ
る。According to a seventh aspect of the present invention, a thermoplastic resin skin material is disposed on one of the two molds constituting the molding die, the mold is clamped, and the expanded beads are placed in the molding die. And foaming these foamed beads by steam heating and fusing them together, and in a method for producing a foamed synthetic resin type inner molded article in which the foamed beads and the thermoplastic resin skin material are fused and integrated, On the surface of the one mold, fine irregularities having a predetermined roughness are formed in advance by adhering fine particles for irregularity transfer onto the surface of the one mold, and the foam beads are fused together and these foam beads and the thermoplastic resin skin. The object of the present invention is to maintain the surface roughness of the thermoplastic resin skin material substantially uniform by transferring the fine irregularities to the surface of the thermoplastic resin skin material together with the fusion bonding of the materials.

【００２１】請求項８の手段とするところは、前記成形
型内に発泡ビーズを充填した後、他方の金型に形成した
蒸気孔から水蒸気を供給して前記発泡ビーズが互いに融
着する温度より低い温度でこれら発泡ビーズを予備加熱
し、その状態で所定時間保持して前記発泡ビーズを水蒸
気で蒸らし、次いで前記発泡ビーズが互いに融着する温
度以上の温度でこれら発泡ビーズを本加熱することにあ
る。According to another aspect of the present invention, after the foaming beads are filled in the molding die, steam is supplied from a steam hole formed in the other mold and the temperature at which the foaming beads fuse together is determined. Preliminarily heating these expanded beads at a low temperature, maintaining the state for a predetermined time, steaming the expanded beads with steam, and then fully heating these expanded beads at a temperature equal to or higher than the temperature at which the expanded beads are fused to each other. is there.

【００２２】請求項９の手段とするところは、前記発泡
ビーズを水蒸気で蒸らした後、前記成形型内に残留する
ドレインを除去してから本加熱することにある。According to a ninth aspect of the present invention, after the foam beads are steamed with steam, the drain remaining in the mold is removed, and then the main heating is performed.

【００２３】請求項１０の手段とするところは、２つの
金型の間に合成樹脂型内発泡成形体と熱可塑性樹脂表皮
材を配置して型締め、加圧する際、熱及び／又は接着剤
でこれら合成樹脂型内発泡成形体と熱可塑性樹脂表皮材
を一体化させる表皮付き合成樹脂型内発泡成形体の製造
方法において、前記熱可塑性樹脂表皮材と当接する一方
の金型の表面に、所定粗さの微細な凹凸をあらかじめ形
成しておき、前記合成樹脂型内発泡成形体と熱可塑性樹
脂表皮材の一体化と共に、該熱可塑性樹脂表皮材の表面
に前記微細な凹凸を転写することによって、この熱可塑
性樹脂表皮材の表面粗さを略一様に保持することにあ
る。According to a tenth aspect of the present invention, when a foamed molded article in a synthetic resin mold and a skin material of a thermoplastic resin are arranged between two molds, and the mold is clamped and pressed, heat and / or adhesive may be used. In the method for producing a synthetic resin foam inside molded article with a skin to integrate the synthetic resin foam molded article and the thermoplastic resin skin material, the surface of one of the molds in contact with the thermoplastic resin skin material, Preparing fine irregularities of a predetermined roughness in advance, and transferring the fine irregularities to the surface of the thermoplastic resin skin material together with the integration of the synthetic resin mold foam and the thermoplastic resin skin material. Thus, the surface roughness of the thermoplastic resin skin material is kept substantially uniform.

【００２４】請求項１１の手段とするところは、２つの
金型の間に合成樹脂型内発泡成形体と熱可塑性樹脂表皮
材を配置して型締め、加圧する際、熱及び／又は接着剤
でこれら合成樹脂型内発泡成形体と熱可塑性樹脂表皮材
を一体化させる表皮付き合成樹脂型内発泡成形体の製造
方法において、前記熱可塑性樹脂表皮材と当接する一方
の金型の表面に、凹凸転写用部材をあらかじめ接合して
おき、前記合成樹脂型内発泡成形体と熱可塑性樹脂表皮
材の一体化と共に、該熱可塑性樹脂表皮材の表面に、前
記凹凸転写用部材の表面に形成した微細な凹凸を転写す
ることによって、この熱可塑性樹脂表皮材の表面粗さを
略一様に保持することにある。According to the eleventh aspect, a foamed molded article in a synthetic resin mold and a skin material of a thermoplastic resin are disposed between two molds, and when the molds are clamped and pressed, heat and / or adhesive may be used. In the method for producing a synthetic resin foam inside molded article with a skin to integrate the synthetic resin foam molded article and the thermoplastic resin skin material, the surface of one of the molds in contact with the thermoplastic resin skin material, The concavo-convex transfer member was bonded in advance, and together with the integration of the synthetic resin mold foam molded article and the thermoplastic resin skin material, on the surface of the thermoplastic resin skin material, on the surface of the concavo-convex transfer member. By transferring fine irregularities, the surface roughness of the thermoplastic resin skin material is maintained substantially uniformly.

【００２５】請求項１２の手段とするところは、２つの
金型の間に合成樹脂型内発泡成形体と熱可塑性樹脂表皮
材を配置して型締め、加圧する際、熱及び／又は接着剤
でこれら合成樹脂型内発泡成形体と熱可塑性樹脂表皮材
を一体化させる表皮付き合成樹脂型内発泡成形体の製造
方法において、前記熱可塑性樹脂表皮材と当接する一方
の金型の表面に、凹凸転写用粒子状物を付着させて所定
粗さの微細な凹凸をあらかじめ形成しておき、前記合成
樹脂型内発泡成形体と熱可塑性樹脂表皮材の一体化と共
に、該熱可塑性樹脂表皮材の表面に前記微細な凹凸を転
写することによって、この熱可塑性樹脂表皮材の表面粗
さを略一様に保持することにある。According to a twelfth aspect of the present invention, when a foamed article in a synthetic resin mold and a skin material of a thermoplastic resin are arranged between two molds, and the mold is clamped and pressed, heat and / or adhesive may be applied. In the method for producing a synthetic resin foam inside molded article with a skin to integrate the synthetic resin foam molded article and the thermoplastic resin skin material, the surface of one of the molds in contact with the thermoplastic resin skin material, Fine irregularities of a predetermined roughness are formed in advance by adhering the irregularity transfer particulates, and together with the integration of the synthetic resin foam molded article and the thermoplastic resin skin material, the thermoplastic resin skin material is formed. By transferring the fine irregularities to the surface, the surface roughness of the thermoplastic resin skin material is maintained substantially uniformly.

【００２６】請求項１３の手段とするところは、前記微
細な凹凸の粗さが、表面粗さ測定器を用いて測定した表
面粗さ波形において、振幅５乃至１５０μｍ、波長３０
乃至６００μｍの範囲であることにある。According to a thirteenth aspect of the present invention, the roughness of the fine irregularities is 5 to 150 μm in amplitude and 30 to 30 μm in a surface roughness waveform measured using a surface roughness measuring device.
To 600 μm.

【００２７】請求項１４の手段とするところは、前記一
方の金型の表面に、前記微細な凹凸に加えて製品意匠模
様用凹凸をあらかじめ形成しておき、前記熱可塑性樹脂
表皮材の表面に前記微細な凹凸を転写する際に、前記製
品意匠模様用凹凸をも転写することにある。According to a fourteenth aspect, in addition to the fine irregularities, irregularities for a product design pattern are previously formed on the surface of the one mold, and the irregularities are formed on the surface of the thermoplastic resin skin material. In transferring the fine irregularities, the object is to also transfer the irregularities for the product design pattern.

【００２８】請求項１５の手段とするところは、前記凹
凸転写用部材の表面に、前記微細な凹凸に加えて製品意
匠模様用凹凸をあらかじめ形成しておき、前記熱可塑性
樹脂表皮材の表面に前記微細な凹凸を転写する際に、前
記製品意匠模様用凹凸をも転写することにある。According to a fifteenth aspect, in addition to the fine irregularities, a product design irregularity is previously formed on the surface of the irregularity transfer member, and the surface of the thermoplastic resin skin material is formed on the surface of the thermoplastic resin skin material. In transferring the fine irregularities, the object is to also transfer the irregularities for the product design pattern.

【００２９】請求項１６の手段とするところは、前記熱
可塑性樹脂表皮材を配置する前に、該熱可塑性樹脂表皮
材の表面に製品意匠模様用凹凸をあらかじめ形成してお
くことにある。According to a sixteenth aspect, prior to disposing the thermoplastic resin skin material, irregularities for a product design pattern are formed in advance on the surface of the thermoplastic resin skin material.

【００３０】[0030]

【発明の実施の形態】以下、この発明の実施形態を図面
に基づいて説明するが、既述の従来技術と同じ構成につ
いては、同一符号を付してその説明を省略する。なお、
下記の第１乃至第５実施形態では、いわゆる同時一体成
形の場合、第６及び第７実施形態では、いわゆる後貼り
成形の場合について説明する。DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described with reference to the drawings. The same components as those of the above-described prior art will be denoted by the same reference numerals and description thereof will be omitted. In addition,
In the following first to fifth embodiments, the case of so-called simultaneous integral molding will be described, and in the sixth and seventh embodiments, the case of so-called post-paste molding will be described.

【００３１】図１に示すように、第１実施形態の製造方
法は、合成樹脂型内発泡成形体２と、該合成樹脂型内発
泡成形体２の表面２ａに融着一体化された表面粗さが略
一様な熱可塑性樹脂表皮材３とからなる表皮付き合成樹
脂型内発泡成形体１の製造に係るものである。As shown in FIG. 1, in the manufacturing method of the first embodiment, a synthetic resin molded foam 2 and a surface roughness fused and integrated on the surface 2a of the synthetic molded foam 2 are used. The present invention relates to the production of a foamed molded article 1 in a synthetic resin mold with a skin, comprising a thermoplastic resin skin material 3 having a substantially uniform thickness.

【００３２】この製造方法は、図２乃至図１０に示すよ
うに、成形型４を構成する２つの金型５，６のうち、一
方の金型５に熱可塑性樹脂表皮材３を配置して型締め
後、この成形型内７に発泡ビーズ８を充填し、蒸気加熱
によりこれら発泡ビーズ８を発泡させて互いに融着させ
ると共に、これら発泡ビーズ８と前記熱可塑性樹脂表皮
材３を融着一体化させる表皮付き合成樹脂型内発泡成形
体１の製造方法において、前記一方の金型５の表面５ａ
に、所定粗さの微細な凹凸９をあらかじめ形成してお
き、前記発泡ビーズ８相互の融着及びこれら発泡ビーズ
８と前記熱可塑性樹脂表皮材３の融着一体化と共に、該
熱可塑性樹脂表皮材３の表面３ａに前記微細な凹凸９を
転写することによって、この熱可塑性樹脂表皮材３の表
面粗さを略一様に保持するものである。In this manufacturing method, as shown in FIGS. 2 to 10, the thermoplastic resin skin material 3 is disposed on one of the two dies 5 and 6 constituting the forming die 4. After the mold clamping, the inside of the molding die 7 is filled with foam beads 8, and the foam beads 8 are foamed by steam heating and fused to each other, and the foam beads 8 and the thermoplastic resin skin material 3 are integrally fused. In the method for producing a foamed synthetic resin in-mold 1 with a skin to be formed, the surface 5a of the one mold 5
In advance, fine irregularities 9 having a predetermined roughness are formed in advance, and the thermoplastic beads are fused together with the foam beads 8 and the fusion of the foam beads 8 and the thermoplastic resin skin material 3 together. By transferring the fine irregularities 9 to the surface 3a of the material 3, the surface roughness of the thermoplastic resin skin material 3 is maintained substantially uniformly.

【００３３】即ち、図２に示すように、まず、前記一方
の金型５に、前記熱可塑性樹脂表皮材３を配置して型締
めする。That is, as shown in FIG. 2, first, the thermoplastic resin skin material 3 is placed in the one mold 5 and the mold is clamped.

【００３４】ここで、前記成形型４は、例えば水平方向
に型締め及び型開き可能な２つの金型５，６で構成され
ている。Here, the molding die 4 comprises, for example, two dies 5, 6 which can be clamped and opened in the horizontal direction.

【００３５】前記一方の金型５は、例えば、横断面が凹
状で且つ内部にチャンバー５ｂが形成され、その表面５
ａ側には、前記チャンバー５ｂと連通する複数の減圧孔
５ｃが形成されている。そして、前記チャンバー５ｂに
は、蒸気弁Ａ１、減圧弁Ｂ１、ドレイン弁Ｃ１がそれぞ
れ接続されている。なお、この一方の金型５としては、
他に、例えばニッケル電鋳等により製造され、前記チャ
ンバー５ｂと連通する微細な通気孔をその表面５ａ全体
又は任意の箇所に有していて通気性がある通気性電鋳型
（例えば、ポーラスデンチュウ，商品名，江南特殊産業
社製）や、あるいは、金属又はセラミック粒子を所定条
件で焼結して表面５ａ全体に微細な通気孔を形成した通
気性金属型若しくは通気性セラミック型（例えば、ポー
セラックスII，商品名，新東工業社製）等を使用しても
よい。The one mold 5 has, for example, a concave cross section and a chamber 5b formed therein, and has a surface 5b.
A plurality of decompression holes 5c communicating with the chamber 5b are formed on the side a. The steam valve A1, the pressure reducing valve B1, and the drain valve C1 are connected to the chamber 5b. In addition, as this one mold 5,
Alternatively, a gas-permeable electroforming mold (for example, Porous Denchu, for example), which is manufactured by nickel electroforming or the like and has fine air holes communicating with the chamber 5b on the entire surface 5a or at an arbitrary position and has air permeability. (Trade name, manufactured by Gangnam Special Sangyo Co., Ltd.) or a permeable metal mold or a permeable ceramic mold (for example, Porcelax) in which metal or ceramic particles are sintered under predetermined conditions to form fine air holes throughout the surface 5a. II, trade name, manufactured by Shinto Kogyo Co., Ltd.).

【００３６】前記他方の金型６は、例えば、横断面が凸
状で且つ内部にチャンバー６ｂが形成され、その表面６
ａ側には、前記チャンバー６ｂと連通する複数の蒸気孔
６ｃが形成されている。そして、前記チャンバー６ｂに
は、蒸気弁Ａ２、減圧弁Ｂ２、ドレイン弁Ｃ２がそれぞ
れ接続されており、前記成形型内７へ発泡ビーズ８を充
填するためのフィーダー１０が設けられている。The other mold 6 has, for example, a convex cross section and a chamber 6b formed inside.
On the a side, a plurality of steam holes 6c communicating with the chamber 6b are formed. A steam valve A2, a pressure reducing valve B2, and a drain valve C2 are connected to the chamber 6b, respectively, and a feeder 10 for filling the foaming beads 8 into the mold 7 is provided.

【００３７】前記熱可塑性樹脂表皮材３としては、例え
ば、塩化ビニル系樹脂や、あるいはポリエチレン系樹
脂、ポリプロピレン系樹脂等のポリオレフィン系樹脂等
からなる熱可塑性樹脂シート等が挙げられる。なお、こ
の熱可塑性樹脂表皮材は、当該表皮付き合成樹脂型内発
泡成形体の表皮として使用されるので、その用途に応じ
て着色剤等により所望の色に着色しておけばよい。Examples of the thermoplastic resin skin material 3 include a thermoplastic resin sheet made of a vinyl chloride resin or a polyolefin resin such as a polyethylene resin or a polypropylene resin. Since the thermoplastic resin skin material is used as the skin of the foamed molded article in the synthetic resin mold with the skin, it may be colored to a desired color with a coloring agent or the like according to its use.

【００３８】この熱可塑性樹脂表皮材３を一方の金型５
の表面５ａに配置するには、他の成形型等であらかじめ
真空成形等により前記一方の金型５の表面５ａ形状に適
合するように成形したものを配置してもよいし、あるい
は、可撓性を有する場合には、この成形型内７に挿入し
て真空成形等を行うことによって配置してもよい。This thermoplastic resin skin material 3 is placed in one mold 5
In order to dispose it on the surface 5a of the one mold 5, it may be arranged by another molding die or the like so as to conform to the shape of the surface 5a of the one mold 5 in advance by vacuum molding or the like. If it has the property, it may be arranged by inserting it into the mold 7 and performing vacuum molding or the like.

【００３９】なお、図３に示すように、この熱可塑性樹
脂表皮材３の表面３ａは、通常の場合と同様、あらかじ
め所定粗さでつや消し加工して微細な凹凸１９を形成し
ておいてもよい。As shown in FIG. 3, the surface 3a of the thermoplastic resin skin material 3 may be previously matted with a predetermined roughness to form fine irregularities 19 in the same manner as in a normal case. Good.

【００４０】また、前記一方の金型５の表面５ａには、
あらかじめ所定粗さの微細な凹凸９が形成されている。
この微細な凹凸９を形成するには、例えば、ブラストや
エッチング等の種々の従来技術を利用することができ
る。On the surface 5a of the one mold 5,
Fine irregularities 9 having a predetermined roughness are formed in advance.
In order to form the fine irregularities 9, various conventional techniques such as blasting and etching can be used.

【００４１】ここで、得られる表皮付き合成樹脂型内発
泡成形体１が、例えば他の部材に取付けるための取付具
等を必要とする場合には、前記他方の金型６の表面６ａ
にあらかじめ所定形状のインサート材（図示せず）を配
置しておき、前記発泡ビーズ８の型内発泡の際に、この
インサート材と合成樹脂型内発泡成形体２とが一体化さ
れるようにしてもよい。Here, when the obtained molded article 1 in the synthetic resin mold with a skin requires, for example, a fixture for attaching to another member, the surface 6a of the other mold 6 is required.
An insert material (not shown) having a predetermined shape is arranged in advance so that the insert material and the synthetic resin mold foam 2 are integrated when the foam beads 8 are foamed in the mold. You may.

【００４２】次に、図４に示すように、前記フィーダー
１０から成形型内７へ発泡ビーズ８を充填する。Next, as shown in FIG. 4, foam beads 8 are filled into the mold 7 from the feeder 10.

【００４３】前記発泡ビーズ８を構成する合成樹脂とし
ては、例えば、ポリオレフィン系樹脂やポリスチレン系
樹脂等が挙げられる。Examples of the synthetic resin constituting the expanded beads 8 include a polyolefin resin and a polystyrene resin.

【００４４】前記ポリオレフィン系樹脂としては、例え
ば、低密度ポリエチレン、中密度ポリエチレン、高密度
ポリエチレン、直鎖状低密度ポリエチレン、エチレン−
酢酸ビニル共重合体、プロピレンホモポリマー、エチレ
ン−プロピレンランダム共重合体、エチレン−プロピレ
ンブロック共重合体、エチレン−プロピレン−ブテンラ
ンダム３元共重合体、プロピレン−塩化ビニル共重合
体、プロピレン−ブテン共重合体、プロピレン−無水マ
レイン酸共重合体、ポリ（ブテン−１）等のポリエチレ
ン系樹脂やポリプロピレン系樹脂等が挙げられ、これら
を単独で又は２種以上を混合して使用することができ
る。Examples of the polyolefin resin include low-density polyethylene, medium-density polyethylene, high-density polyethylene, linear low-density polyethylene, ethylene-
Vinyl acetate copolymer, propylene homopolymer, ethylene-propylene random copolymer, ethylene-propylene block copolymer, ethylene-propylene-butene random terpolymer, propylene-vinyl chloride copolymer, propylene-butene copolymer Examples include a polymer, a propylene-maleic anhydride copolymer, a polyethylene resin such as poly (butene-1) and a polypropylene resin, and these can be used alone or as a mixture of two or more.

【００４５】このポリオレフィン系樹脂は、無架橋の状
態のものが好ましいが、パーオキサイドや放射線等によ
り架橋させたものであってもよい。The polyolefin resin is preferably in a non-crosslinked state, but may be crosslinked by peroxide or radiation.

【００４６】また、このポリオレフィン系樹脂に、他の
熱可塑性樹脂を混合したものも使用できる。このような
熱可塑性樹脂としては、前記ポリプロピレン系樹脂と混
合する場合には、例えば低密度ポリエチレン、直鎖状低
密度ポリエチレン、ビニル芳香族系ポリマー、ポリブテ
ン、アイオノマー等が挙げられる。そして、前記ポリエ
チレン系樹脂と混合する場合には、例えばビニル芳香族
系ポリマー、ポリブテン、アイオノマー等が挙げられ
る。なお、これらの場合の熱可塑性樹脂の配合量として
は、ポリオレフィン系樹脂１００重量部に対して２０重
量部以下、より好ましくは、５乃至１０重量部とするの
が望ましい。A mixture of the polyolefin resin and another thermoplastic resin can also be used. When mixed with the polypropylene resin, examples of such a thermoplastic resin include low-density polyethylene, linear low-density polyethylene, vinyl aromatic polymer, polybutene, and ionomer. When mixed with the polyethylene resin, examples thereof include a vinyl aromatic polymer, polybutene, and an ionomer. In these cases, the blending amount of the thermoplastic resin is preferably 20 parts by weight or less, more preferably 5 to 10 parts by weight, based on 100 parts by weight of the polyolefin resin.

【００４７】前記発泡ビーズは、例えば、上記のような
合成樹脂をあらかじめ粒子状に成形加工しておき、耐圧
容器中でこの合成樹脂粒子に揮発性発泡剤を含有させ、
攪拌しながら水中に分散させ、加圧下で所定の発泡温度
まで加熱した後、この水分散物を低圧域に放出する方法
等によって、予備発泡させた状態で製造しておけばよ
い。The foamed beads are formed, for example, by molding the above-mentioned synthetic resin into particles in advance, and in a pressure vessel, the synthetic resin particles contain a volatile foaming agent.
The dispersion may be dispersed in water with stirring, heated to a predetermined foaming temperature under pressure, and then preliminarily foamed by a method of releasing the aqueous dispersion into a low-pressure region.

【００４８】この発泡ビーズを型内発泡させる際の発泡
倍率としては、３倍より小さい場合には、得られる合成
樹脂型内発泡成形体の緩衝性等が低下する傾向があり、
６０倍より大きい場合には、前記合成樹脂型内発泡成形
体の収縮が大きくなると共に、柔らかくなり過ぎて強度
等が低下する傾向があるので、３乃至６０倍、好ましく
は５乃至５０倍、より好ましくは８乃至４５倍、特に好
ましくは１０乃至３５倍が望ましい。このような発泡ビ
ーズとしては、例えば、エペランＰＰ（商品名，鐘淵化
学工業社製，発泡倍率１５倍）等を好適に使用できる。If the expansion ratio at the time of expanding the expanded beads in the mold is smaller than 3 times, the obtained foamed molded article in a synthetic resin mold tends to have a reduced buffering property.
When the ratio is more than 60 times, the shrinkage of the foamed molded article in the synthetic resin mold becomes large, and the resin becomes too soft, and the strength and the like tend to decrease. Therefore, 3 to 60 times, preferably 5 to 50 times, Preferably it is 8 to 45 times, particularly preferably 10 to 35 times. As such foam beads, for example, Eperan PP (trade name, manufactured by Kaneka Chemical Co., Ltd., expansion ratio: 15) can be preferably used.

【００４９】この際、前記一方の金型５の表面５ａには
熱可塑性樹脂表皮材３が配置されていて、型締めした状
態では、前記他方の金型６の蒸気孔６ｃからしか成形型
内７の空気が逃げないので、前記発泡ビーズ８を充填し
易くするために、充填時にこれら発泡ビーズ８が落下し
ない程度に少し型開きし、その隙間から前記空気を逃が
すようにしてもよい。At this time, the thermoplastic resin skin material 3 is disposed on the surface 5a of the one mold 5, and when the mold is clamped, only the steam hole 6c of the other mold 6 allows the inside of the mold to be inserted. Since the air of 7 does not escape, in order to easily fill the foam beads 8, the mold may be opened slightly so that the foam beads 8 do not drop during filling, and the air may escape from the gap.

【００５０】なお、前記発泡ビーズ８は、あらかじめ内
部に加圧ガスを浸透させて内圧を付与した状態で前記成
形型内７へ充填してもよいし、また、加圧ガスを用いて
圧縮した状態で充填してもよいし、あるいは、内圧の付
与や圧縮を行うことなく、そのままの状態で充填しても
よい。The foamed beads 8 may be filled in the molding die 7 in a state where a pressurized gas has been previously penetrated into the inside and an internal pressure has been applied, or the foamed beads 8 may be compressed using a pressurized gas. It may be filled in a state, or may be filled as it is without applying internal pressure or compressing.

【００５１】また、この発泡ビーズ８の型内発泡により
得られる前記合成樹脂型内発泡成形体２と前記熱可塑性
樹脂表皮材３との接着性を向上させるために、必要に応
じて前記発泡ビーズ８と接触するこの熱可塑性樹脂表皮
材３の裏面３ｂに、あらかじめ接着剤を塗布しておいて
もよい。この接着剤としては、例えば、合成樹脂の有機
溶媒溶液、樹脂エマルジョン、樹脂パウダー等が挙げら
れる。また、これらに使用される合成樹脂としては、例
えば、エチレン−酢酸ビニル樹脂、ポリプロピレン、ポ
リエチレン、エチレン−プロピレンコポリマー、塩素化
ポリプロピレン、塩素化ポリエチレン、エチレン−プロ
ピレン−ブテンターポリマー、これらの混合物等のポリ
オレフィン系樹脂等が挙げられる。In order to improve the adhesion between the synthetic resin in-mold foam molded article 2 obtained by in-mold foaming of the foam beads 8 and the thermoplastic resin skin material 3, the foam beads 8 may be used as necessary. An adhesive may be applied in advance to the back surface 3 b of the thermoplastic resin skin material 3 that comes into contact with 8. Examples of the adhesive include a synthetic resin solution in an organic solvent, a resin emulsion, a resin powder, and the like. Examples of the synthetic resin used for these include, for example, ethylene-vinyl acetate resin, polypropylene, polyethylene, ethylene-propylene copolymer, chlorinated polypropylene, chlorinated polyethylene, ethylene-propylene-butene terpolymer, and mixtures thereof. Polyolefin resins and the like can be mentioned.

【００５２】その後、図５に示すように、前記他方の金
型６のチャンバー６ｂに接続した蒸気弁Ａ２を開いて水
蒸気Ｓを前記蒸気孔６ｃから成形型内７へ供給し、前記
発泡ビーズ８を加熱発泡させる。Then, as shown in FIG. 5, the steam valve A2 connected to the chamber 6b of the other mold 6 is opened to supply steam S from the steam hole 6c to the inside of the molding die 7, and the foam beads 8 Is heated and foamed.

【００５３】この際、前記発泡ビーズ８が互いに融着す
る温度以上の温度でこれら発泡ビーズ８を本加熱する前
に、互いに融着する温度より低い温度でこれら発泡ビー
ズ８をあらかじめ予備加熱しておけば、発泡ビーズ８が
互いに融着することなく充分に加熱された状態とするこ
とができる。At this time, before the expanded beads 8 are fully heated at a temperature higher than the temperature at which the expanded beads 8 are fused to each other, the expanded beads 8 are preliminarily heated at a temperature lower than the temperature at which the expanded beads 8 are fused to each other. If so, the expanded beads 8 can be in a sufficiently heated state without fusing each other.

【００５４】なお、前記発泡ビーズ８が互いに融着する
温度とは、深さが５０ｍｍ程度の成形型内７へ発泡ビー
ズ８を充填し、所定温度（所定圧力）の水蒸気Ｓを１０
乃至２０秒間この成形型内７へ供給した時に、前記発泡
ビーズ８が互いに融着して合成樹脂型内発泡成形体２の
形状を保持可能な状態となる最低温度をいう。The temperature at which the foam beads 8 are fused to each other means that the foam beads 8 are filled into a mold 7 having a depth of about 50 mm, and steam S at a predetermined temperature (predetermined pressure) is applied to the mold 10 at a temperature of 10 mm.
This is the lowest temperature at which the foam beads 8 are fused to each other when they are supplied to the inside of the mold 7 for 20 seconds or so, and the shape of the foam molded article 2 in the synthetic resin mold can be maintained.

【００５５】この発泡ビーズ８が互いに融着する温度
は、使用される合成樹脂の種類等によって異なるので、
あらかじめこの温度を調べてから、前記予備加熱の際の
水蒸気Ｓの温度を設定すればよい。この水蒸気Ｓの温度
としては、低すぎる場合には、予備加熱による効果が充
分に発揮されなくなる傾向があるので、この発泡ビーズ
８が互いに融着する温度をＴ（℃）とした場合、（Ｔ−
３５）乃至Ｔ（℃）、好ましくは（Ｔ−３０）乃至（Ｔ
−３）（℃）、より好ましくは（Ｔ−２５）乃至（Ｔ−
５）（℃）の範囲とするのが望ましい。また、前記水蒸
気Ｓの圧力は、上記の温度範囲となるように適宜調整す
ればよい。The temperature at which the expanded beads 8 fuse to each other depends on the type of synthetic resin used and the like.
After checking this temperature in advance, the temperature of the steam S at the time of the preheating may be set. If the temperature of the water vapor S is too low, the effect of the preheating tends to be insufficient, so that when the temperature at which the expanded beads 8 fuse to each other is T (° C.), (T −
35) to T (° C.), preferably (T-30) to (T
-3) (° C), more preferably (T-25) to (T-
5) It is desirable that the temperature be in the range of (° C.). Further, the pressure of the steam S may be appropriately adjusted so as to be in the above-mentioned temperature range.

【００５６】また、上記のようにして予備加熱した後、
その状態で所定時間保持して前記発泡ビーズ８を水蒸気
Ｓで蒸らせば、前記発泡ビーズ８間に供給された水蒸気
Ｓの潜熱を有効に利用できるので、特に厚さが大きい合
成樹脂型内発泡成形体２を成形する場合等、前記発泡ビ
ーズ８をより均一に加熱できるという利点がある。After preheating as described above,
If the foamed beads 8 are steamed with the steam S while maintaining the state for a predetermined time, the latent heat of the steam S supplied between the foamed beads 8 can be effectively used. There is an advantage that the foam beads 8 can be more uniformly heated, for example, when the foam molded body 2 is molded.

【００５７】なお、予備加熱した後は、水蒸気Ｓの供給
を続けた状態で蒸らしてもよいし、あるいは水蒸気Ｓの
供給を停止し、更に必要に応じてドレイン弁Ｃ２を開け
た状態で蒸らしてもよい。この蒸らしの際の保持時間
は、前記成形型内７における発泡ビーズ８層の厚さ、発
泡ビーズ８の大きさ、形状、発泡倍率等によって異なる
が、例えば、発泡ビーズ８層の厚さが５０ｍｍ程度のも
のでは、約３秒間以上、好ましくは約５秒間以上、より
好ましくは約１０秒間以上とすることが望ましい。After the preheating, the steam may be steamed while the supply of steam S is continued, or the steam may be steamed while the supply of steam S is stopped and the drain valve C2 is opened as necessary. Is also good. The holding time during the steaming varies depending on the thickness of the foamed bead 8 layer, the size and shape of the foamed bead 8 in the molding die 7, the foaming ratio, and the like. On the order of about 3 seconds or more, it is desirable that the time is about 5 seconds or more, and more preferably about 10 seconds or more.

【００５８】前記発泡ビーズ８を水蒸気Ｓで蒸らした後
は、前記発泡ビーズ８間にドレイン（水分）が存在し、
その状態で本加熱すれば発泡ビーズ８相互の融着不良が
生じることがあるため、前記ドレインを除去することが
望ましい。After steaming the foam beads 8 with steam S, a drain (water) exists between the foam beads 8,
If the main heating is performed in this state, defective fusion between the foam beads 8 may occur, so it is desirable to remove the drain.

【００５９】このドレインを除去する方法としては、例
えば、図６に示すように、前記他方の金型６のチャンバ
ー６ｂに接続した減圧弁Ｂ２を開いて前記蒸気孔６ｃか
ら成形型内７を真空引きする方法や、あるいは、成形型
４を少し型開きして２つの金型５，６間に隙間を設け、
前記蒸気孔６ｃから発泡ビーズ８が互いに融着しない程
度の高温で且つ乾燥した空気を通気させて前記隙間から
ドレインを除去する方法等が挙げられる。As a method for removing the drain, for example, as shown in FIG. 6, a pressure reducing valve B2 connected to the chamber 6b of the other mold 6 is opened to evacuate the inside of the mold 7 from the steam hole 6c. By pulling, or opening the mold 4 slightly to provide a gap between the two molds 5, 6,
For example, a method may be used in which the drain is removed from the gap by passing a high-temperature and dry air through which the foam beads 8 do not fuse with each other from the vapor hole 6c.

【００６０】次に、前記発泡ビーズ８が互いに融着する
温度以上の温度で本加熱する。この本加熱は、図７に示
すように、前記蒸気弁Ａ２を開いて水蒸気Ｓを前記蒸気
孔６ｃから成形型内７へ供給することにより行われる。
この際、上記のように、水蒸気Ｓによる蒸らしを行った
後、ドレインを除去するために前記成形型内７を真空引
きしていた場合には、前記本加熱のための水蒸気Ｓをよ
りスムーズに成形型内７へ供給することができる。Next, main heating is performed at a temperature equal to or higher than the temperature at which the foam beads 8 are fused to each other. As shown in FIG. 7, the main heating is performed by opening the steam valve A2 and supplying steam S from the steam hole 6c to the inside of the molding die 7.
At this time, as described above, if the inside of the mold 7 is evacuated to remove the drain after performing the steaming with the steam S as described above, the steam S for the main heating is more smoothly removed. It can be supplied to the mold 7.

【００６１】また、この際の水蒸気Ｓの温度は、前記発
泡ビーズ８が互いに融着する温度以上であればよいが、
高すぎる場合には、得られる合成樹脂型内発泡成形体２
の収縮が大きくなり過ぎる傾向があるので、前記発泡ビ
ーズ８が互いに融着する温度より３０℃高い温度、好ま
しくは２５℃高い温度を超えないようにするのが望まし
い。At this time, the temperature of the water vapor S may be higher than the temperature at which the foam beads 8 are fused to each other.
If it is too high, the resulting synthetic resin mold foamed article 2
Since the shrinkage of the foamed beads 8 tends to become too large, it is desirable not to exceed a temperature 30 ° C. higher than the temperature at which the foam beads 8 are fused together, preferably 25 ° C. higher.

【００６２】上記のようにして本加熱した後は、前記発
泡ビーズ８に、水蒸気Ｓによる熱を充分に伝達させるた
めに、その状態を保持することが望ましい。この際の保
持に要する時間は、例えば、発泡ビーズ８層の厚さが５
０ｍｍ程度のものに対しては約２秒間以上、好ましくは
約５秒間以上であることが望ましいが、その時間が長す
ぎる場合には、得られる合成樹脂型内発泡成形体２に収
縮が生じるので、このような収縮が生じない範囲内で適
宜設定すればよい。After the main heating as described above, it is desirable to maintain the state in order to sufficiently transfer the heat of the steam S to the foam beads 8. The time required for holding at this time is, for example, that the thickness of the foamed bead 8 layer is 5
It is desirable that the length is about 2 seconds or more, and preferably about 5 seconds or more for about 0 mm. However, if the time is too long, the resulting synthetic resin mold molded article 2 shrinks. It may be set appropriately within a range in which such shrinkage does not occur.

【００６３】次いで、前記成形型４を型開きすれば、図
８に示すように、前記発泡ビーズ８の型内発泡により得
られた合成樹脂型内発泡成形体２と、該合成樹脂型内発
泡成形体２の表面２ａに融着一体化された熱可塑性樹脂
表皮材３とからなる耳部３ｃを有する表皮付き合成樹脂
型内発泡成形体１ａが得られる。Next, when the molding die 4 is opened, as shown in FIG. 8, the synthetic resin molded foam 2 obtained by in-mold foaming of the expanded beads 8 and the synthetic resin molded foam 2 are formed. A foamed synthetic resin-in-mold 1a with a skin having an ear 3c comprising a thermoplastic resin skin material 3 fused and integrated to the surface 2a of the molded body 2 is obtained.

【００６４】なお、型開きする前に、前記成形型４はあ
らかじめ冷却しておいてもよい。また、得られた表皮付
き合成樹脂型内発泡成形体１ａは、成形型４から脱型し
た後、例えば常圧下、５０乃至８０℃で３乃至２４時間
程度、養生、乾燥することが望ましい。また、この実施
形態のように、前記熱可塑性樹脂表皮材３の端部が余っ
て前記耳部３ｃが形成される場合には、脱型後、上記の
ように養生、乾燥してから前記耳部３ｃを切断すれば、
図１に示す表皮付き合成樹脂型内発泡成形体１を得るこ
とができる。The mold 4 may be cooled before opening the mold. Further, it is desirable that the obtained molded foam 1a with a skin inside the synthetic resin mold is released from the molding die 4 and then cured and dried at 50 to 80 ° C. under normal pressure for about 3 to 24 hours. Further, as in this embodiment, in the case where the ear portion 3c is formed with the end portion of the thermoplastic resin skin material 3 remaining, after the mold is released, the ear portion 3c is cured and dried as described above. If the part 3c is cut,
The foamed molded article 1 with a skin shown in FIG. 1 can be obtained.

【００６５】以上のように、前記発泡ビーズ８を予備加
熱をし、水蒸気Ｓにより蒸らした後、本加熱すれば、発
泡ビーズ８から合成樹脂型内発泡成形体２を製造するの
と同時に、該合成樹脂型内発泡成形体２と前記熱可塑性
樹脂表皮材３とを融着一体化でき、しかも、前記合成樹
脂型内発泡成形体２には発泡ビーズ８の融着不良の発生
がない表皮付き合成樹脂型内発泡成形体１を製造するこ
とができる。As described above, the foam beads 8 are pre-heated, steamed with steam S, and then fully heated. The synthetic resin mold foam 2 and the thermoplastic resin skin material 3 can be fused and integrated, and the synthetic resin mold foam 2 has a skin with no defective fusion of the foam beads 8. The foamed molded article 1 in a synthetic resin mold can be manufactured.

【００６６】ここで、前記本加熱の際には、図９に示す
ように、前記発泡ビーズ８の発泡力Ｆにより、前記熱可
塑性樹脂表皮材３の表面３ａの所定範囲Ｄは、その裏面
３ｂから他の範囲Ｅより強く押圧されて、前記一方の金
型５の表面５ａにより強く押し付けられる。この状態に
おいては、前記熱可塑性樹脂表皮材３は蒸気加熱により
軟化状態となっているので、図１０に示すように、上記
のようにしてより強く押し付けられた前記範囲Ｄには、
前記一方の金型５の表面５ａにあらかじめ形成した前記
微細な凹凸９が転写されて、微細な凹凸９ｄが形成され
る。Here, at the time of the main heating, as shown in FIG. 9, the predetermined range D of the front surface 3a of the thermoplastic resin skin material 3 is changed by the foaming force F of the foam beads 8 to the rear surface 3b. Is pressed more strongly than the other range E, and is more strongly pressed against the surface 5a of the one mold 5. In this state, since the thermoplastic resin skin material 3 is in a softened state by steam heating, as shown in FIG. 10, in the range D pressed more strongly as described above,
The fine irregularities 9 formed in advance on the surface 5a of the one mold 5 are transferred to form fine irregularities 9d.

【００６７】また、前記他の範囲Ｅも、範囲Ｄより弱い
力ではあるが前記一方の金型５の表面５ａに押し付けら
れるため、他の範囲Ｅにも前記微細な凹凸９が転写され
て、微細な凹凸９ｅが形成される。この場合、前記範囲
Ｄと他の範囲Ｅとは、前記一方の金型５の表面５ａに押
し付けられる力が異なるため、それぞれに形成される微
細な凹凸９ｄ，９ｅの粗さも異なることがあるが、前記
一方の金型５の表面５ａにあらかじめ形成した微細な凹
凸９を適宜の粗さとしておけば、これら微細な凹凸９
ｄ，９ｅの粗さを略同程度とすることができる。従っ
て、このような場合、前記熱可塑性樹脂表皮材３の表面
粗さは略一様に保持されることになり、従来のようなビ
ーズ模様が現れることはない。The other area E is also weaker than the area D, but is pressed against the surface 5a of the one mold 5, so that the fine irregularities 9 are also transferred to the other area E. Fine irregularities 9e are formed. In this case, since the range D and the other range E have different forces pressed against the surface 5a of the one mold 5, the roughness of the fine irregularities 9d and 9e formed respectively may be different. If the fine irregularities 9 formed in advance on the surface 5a of the one mold 5 are made to have an appropriate roughness, these fine irregularities 9
The roughness of d and 9e can be made substantially the same. Therefore, in such a case, the surface roughness of the thermoplastic resin skin material 3 is maintained substantially uniform, and the conventional bead pattern does not appear.

【００６８】なお、前記微細な凹凸９の粗さは、表面粗
さ測定器を用いて測定した表面粗さ波形において、振幅
５乃至１５０μｍ、波長３０乃至６００μｍ、好ましく
は振幅７乃至１００μｍ、波長５０乃至４００μｍ、よ
り好ましくは振幅１０乃至７０μｍ、波長６０乃至３０
０μｍの範囲であることが望ましい。この範囲である場
合には、前記微細な凹凸９が転写されることによって前
記熱可塑性樹脂表皮材３の表面３ａに形成される前記微
細な凹凸９ｄ，９ｅの粗さを確実に略同程度とできるた
め、外観の見栄えをより効果的に良好にできるという利
点がある。The roughness of the fine irregularities 9 is determined by measuring the surface roughness waveform measured by using a surface roughness measuring instrument with an amplitude of 5 to 150 μm, a wavelength of 30 to 600 μm, preferably an amplitude of 7 to 100 μm, and a wavelength of 50 to 50 μm. To 400 μm, more preferably an amplitude of 10 to 70 μm, and a wavelength of 60 to 30
It is desirable to be in the range of 0 μm. In this range, the roughness of the fine irregularities 9d and 9e formed on the surface 3a of the thermoplastic resin skin material 3 by the transfer of the fine irregularities 9 is surely substantially the same. Therefore, there is an advantage that the appearance can be improved more effectively.

【００６９】また、上記の範囲の表面粗さは、例えば、
研摩紙（サンドペーパー）等の表面粗さと比較すると、
ほぼ♯１０００（１０００番）乃至♯１００（１００
番）程度の粗さに対応する。The surface roughness in the above range is, for example,
Compared to the surface roughness of abrasive paper (sandpaper),
Almost $ 1000 (# 1000) to $ 100 (100
No.) degree of roughness.

【００７０】前記表面粗さ測定器としては、例えば、触
針式表面粗さ測定器（例えば、東京精密社製，商品名：
サーフコム５７０Ａ，触針先端５μｍＲ）や、あるいは
非接触式表面粗さ測定器（例えば、ペルテン社製，アン
プ部型式：ペルトメーターＳ３Ｐ，センサー部型式：非
接触プローブ，フォコディン）等が挙げられる。As the surface roughness measuring device, for example, a stylus type surface roughness measuring device (for example, manufactured by Tokyo Seimitsu Co., trade name:
Surfcom 570A, stylus tip 5 μmR) or a non-contact type surface roughness meter (for example, manufactured by Pelten, amplifier type: Pertometer S3P, sensor type: non-contact probe, phocodin) and the like.

【００７１】ここで、前記微細な凹凸９の粗さが、上記
の表面粗さ波形において、振幅５μｍ、波長３０μｍよ
り小さい場合、即ち、前記微細な凹凸９の粗さが細かす
ぎる場合には、既述した第１の従来例と同様、前記範囲
Ｄの微細な凹凸９ｄの粗さが他の範囲Ｅの微細な凹凸９
ｅの粗さより細かくなってビーズ模様が現れるため、好
ましくない。また、振幅１５０μｍ、波長６００μｍを
超える場合、即ち、前記微細な凹凸９の粗さが粗すぎる
場合には、逆に、前記微細な凹凸９ｄの粗さが前記微細
な凹凸９ｅの粗さより粗くなって上記とはコントラスト
が逆のビーズ模様が現れるため、好ましくない。Here, when the roughness of the fine irregularities 9 is smaller than the amplitude 5 μm and the wavelength 30 μm in the above-mentioned surface roughness waveform, that is, when the roughness of the fine irregularities 9 is too fine, As in the first conventional example described above, the roughness of the fine unevenness 9d in the range D is smaller than that of the fine unevenness 9 in the other range E.
This is not preferable because it becomes finer than the roughness of e and a bead pattern appears. On the other hand, when the amplitude exceeds 150 μm and the wavelength exceeds 600 μm, that is, when the roughness of the fine irregularities 9 is too coarse, the roughness of the fine irregularities 9d becomes larger than the roughness of the fine irregularities 9e. Thus, a bead pattern having a contrast opposite to the above appears, which is not preferable.

【００７２】図１１及び図１２に示すように、第２実施
形態に係る表皮付き合成樹脂型内発泡成形体２１の製造
方法は、上記第１実施形態において、前記一方の金型５
の表面５ａに、前記微細な凹凸９に加えて製品意匠模様
用凹凸１２をあらかじめ形成しておき、前記熱可塑性樹
脂表皮材３の表面３ａに前記微細な凹凸９を転写する際
に、前記製品意匠模様用凹凸１２をも転写するものであ
る。As shown in FIG. 11 and FIG. 12, the method of manufacturing the foamed molded article in a synthetic resin mold 21 with a skin according to the second embodiment is the same as that of the first embodiment.
In addition to the fine irregularities 9, a product design pattern irregularity 12 is previously formed on the surface 5 a of the thermoplastic resin skin material 3, and when the fine irregularities 9 are transferred to the surface 3 a of the thermoplastic resin skin material 3, the product The design pattern irregularities 12 are also transferred.

【００７３】前記製品意匠模様用凹凸１２としては、例
えば皮シボ等が挙げられ、前記微細な凹凸９は、この製
品意匠模様用凹凸１２の表面にも形成しておけばよい。
この製品意匠模様用凹凸１２は、種々の従来技術を利用
して形成できるが、これら製品意匠模様用凹凸１２と微
細な凹凸９とをエッチングにより形成する場合には、前
記製品意匠模様用凹凸１２が明瞭に現れるようにするた
めに、製品意匠模様用凹凸１２を形成した後に、微細な
凹凸９を形成するのが望ましい。Examples of the product design pattern irregularities 12 include, for example, leather grain, and the fine irregularities 9 may be formed on the surface of the product design pattern irregularities 12.
The product design pattern irregularities 12 can be formed using various conventional techniques. However, when the product design pattern irregularities 12 and the fine irregularities 9 are formed by etching, the product design pattern irregularities 12 are used. It is desirable to form the fine irregularities 9 after forming the product design pattern irregularities 12 so as to clearly show the irregularities.

【００７４】なお、前記製品意匠模様用凹凸１２を形成
したことにより、図１１のように、前記熱可塑性樹脂表
皮材３が、一方の金型５の表面５ａに対して隙間Ｈを開
けて配置された場合でも、上記第１実施形態と同様の操
作を行えば、前記発泡ビーズ８の型内発泡の際にこの熱
可塑性樹脂表皮材３が全体的に前記一方の金型５に押し
付けられるので、図１２に示すように、前記熱可塑性樹
脂表皮材３の表面３ａに前記製品意匠模様用凹凸１２が
転写されると共に、前記微細な凹凸９が転写されて微細
な凹凸９ｄ（９ｅ）が形成される。従って、上記第１実
施形態と同様、前記微細な凹凸９を適宜な粗さとしてお
けば、前記製品意匠模様用凹凸１２を含む熱可塑性樹脂
表皮材３の表面粗さが略一様となる。By forming the irregularities 12 for the product design pattern, the thermoplastic resin skin material 3 is arranged with a gap H with respect to the surface 5a of one mold 5 as shown in FIG. Even in this case, if the same operation as in the first embodiment is performed, the thermoplastic resin skin material 3 is entirely pressed against the one mold 5 when the foam beads 8 are foamed in the mold. As shown in FIG. 12, the irregularities 12 for a product design pattern are transferred to the surface 3a of the thermoplastic resin skin material 3, and the fine irregularities 9 are transferred to form fine irregularities 9d (9e). Is done. Therefore, as in the first embodiment, if the fine irregularities 9 are appropriately made rough, the surface roughness of the thermoplastic resin skin material 3 including the product design pattern irregularities 12 becomes substantially uniform.

【００７５】このように、前記一方の金型５の表面５ａ
に、前記微細な凹凸９に加えて製品意匠模様用凹凸１２
をあらかじめ形成しておけば、ビーズ模様が現れないと
共に、製品意匠模様用凹凸１２をも有する表皮付き合成
樹脂型内発泡成形体２１を製造できるので、当該表皮付
き合成樹脂型内発泡成形体２１に高級感等を付与するこ
とができる。As described above, the surface 5a of the one mold 5
In addition to the fine irregularities 9, irregularities 12 for product design
Is formed in advance, the bead pattern does not appear, and the synthetic resin foam-in-mold with molded skin 21 having the product design pattern irregularities 12 can also be manufactured. Luxurious feeling and the like.

【００７６】図１３に示すように、第３実施形態に係る
表皮付き合成樹脂型内発泡成形体１の製造方法は、上記
第１実施形態において、前記一方の金型５の表面５ａ
に、凹凸転写用部材１３をあらかじめ接合しておき、前
記発泡ビーズ８相互の融着及びこれら発泡ビーズ８と前
記熱可塑性樹脂表皮材３の融着一体化と共に、該熱可塑
性樹脂表皮材３の表面３ａに、前記凹凸転写用部材１３
の表面１３ａに形成した微細な凹凸９を転写することに
よって、この熱可塑性樹脂表皮材３の表面粗さを略一様
に保持するものである。As shown in FIG. 13, the method of manufacturing the foamed synthetic resin mold 1 with a skin according to the third embodiment differs from the first embodiment in that the surface 5a of the one mold 5 is different from that of the first embodiment.
In advance, the irregularity transfer member 13 is joined in advance, and the fusion of the foam beads 8 and the fusion of the foam beads 8 and the thermoplastic resin skin material 3 are performed together with the fusion of the foam beads 8 and the thermoplastic resin skin material 3. The surface transfer member 13 is provided on the surface 3a.
By transferring the fine irregularities 9 formed on the surface 13a, the surface roughness of the thermoplastic resin skin material 3 is maintained substantially uniformly.

【００７７】前記凹凸転写用部材１３としては、例え
ば、金属板、合成樹脂板、研摩布、研摩紙又は耐水研摩
紙（サンドペーパー）、金属製又は合成樹脂製の網目状
面材等が挙げられ、前記一方の金型５の表面５ａ形状に
適合して形成しておくと共に、その表面１３ａには、エ
ッチングやブラスト、あるいは微粒子を付着させる等の
方法により、微細な凹凸９を形成しておけばよい。そし
て、この微細な凹凸９側を外側に向けて接着剤等による
接着や磁着等により、前記一方の金型５の表面５ａにあ
らかじめ接合しておけばよい。なお、前記微細な凹凸９
を形成するのと、この凹凸転写用部材１３を前記一方の
金型５の表面５ａ形状に適合するように形成する順序と
しては、特に限定されるものではなく、また必要に応じ
て、前記一方の金型５の減圧孔５ｃと連通する複数の連
通孔等を形成しておいてもよい。Examples of the uneven transfer member 13 include a metal plate, a synthetic resin plate, an abrasive cloth, an abrasive paper or a water-resistant abrasive paper (sandpaper), and a mesh-like surface material made of a metal or a synthetic resin. The surface 13a of the one mold 5 is formed in conformity with the shape of the surface 5a, and fine irregularities 9 are formed on the surface 13a by a method such as etching, blasting, or attaching fine particles. I just need. Then, the fine unevenness 9 may be bonded to the surface 5a of the one mold 5 in advance by bonding with an adhesive or magnetically with the fine unevenness 9 facing outward. The fine irregularities 9
And the order in which the uneven transfer member 13 is formed so as to conform to the shape of the surface 5a of the one mold 5 is not particularly limited. A plurality of communication holes communicating with the decompression holes 5c of the mold 5 may be formed.

【００７８】このように、前記凹凸転写用部材１３を一
方の金型５の表面５ａに接合した場合でも、上記と同様
の操作を行えば、第１実施形態と同様の表皮付き合成樹
脂型内発泡成形体１を製造することができる。そのた
め、既存の設備をそのまま利用できると共に、この凹凸
転写用部材１３を着脱自在としておけば付け替え可能で
あるので、多種類の設備に利用できるという利点があ
る。As described above, even when the concave / convex transfer member 13 is joined to the surface 5a of one mold 5, if the same operation as described above is performed, the same synthetic resin mold with skin as in the first embodiment can be obtained. The foam molded article 1 can be manufactured. For this reason, the existing equipment can be used as it is, and if the uneven transfer member 13 is detachable, it can be replaced, so that there is an advantage that it can be used for various types of equipment.

【００７９】なお、この実施形態においては、前記凹凸
転写用部材１３の表面１３ａに微細な凹凸９を形成した
場合について説明したが、これに限定されるものではな
く、上記第２実施形態のように、凹凸転写用部材１３の
表面１３ａに、前記微細な凹凸９に加えて製品意匠模様
用凹凸１２を形成しておいてもよい。In this embodiment, the case where the fine irregularities 9 are formed on the surface 13a of the irregularity transferring member 13 has been described. However, the present invention is not limited to this, and is similar to the second embodiment. Then, in addition to the fine irregularities 9, irregularities 12 for a product design pattern may be formed on the surface 13 a of the irregularity transferring member 13.

【００８０】図１４に示すように、第４実施形態に係る
表皮付き合成樹脂型内発泡成形体１の製造方法は、上記
第１実施形態において、前記一方の金型５の表面５ａを
平滑に形成し、該平滑な表面５ａに、凹凸転写用粒子状
物１４を付着させて所定粗さの微細な凹凸９をあらかじ
め形成しておき、前記発泡ビーズ８相互の融着及びこれ
ら発泡ビーズ８と前記熱可塑性樹脂表皮材３の融着一体
化と共に、該熱可塑性樹脂表皮材３の表面３ａに前記微
細な凹凸９を転写することによって、この熱可塑性樹脂
表皮材３の表面粗さを略一様に保持するものである。As shown in FIG. 14, the method of manufacturing the foamed synthetic resin mold 1 with a skin according to the fourth embodiment differs from the first embodiment in that the surface 5a of the one mold 5 is smoothened. The fine irregularities 9 having a predetermined roughness are previously formed on the smooth surface 5a by adhering the irregular transfer particles 14 to the smooth surface 5a. By transferring the fine irregularities 9 to the surface 3a of the thermoplastic resin skin material 3 together with the fusion and integration of the thermoplastic resin skin material 3, the surface roughness of the thermoplastic resin skin material 3 is reduced to approximately one. It is something to keep.

【００８１】前記凹凸転写用粒子状物１４としては、例
えば、金属粉等が挙げられ、前記一方の金型５の表面５
ａに、接着剤等による接着や磁着等により付着させてお
けばよい。また、その粒径としては、この凹凸転写用粒
子状物１４により形成される微細な凹凸９の粗さが、既
述の表面粗さ測定器を用いて測定した表面粗さ波形にお
いて、振幅５乃至１５０μｍ、波長３０乃至６００μｍ
の範囲となるようにしておくのが望ましい。Examples of the irregular transfer particles 14 include metal powder and the like.
It may be attached to a by adhesion with an adhesive or the like or magnetic adhesion. As for the particle size, the roughness of the fine irregularities 9 formed by the irregularity transfer particulate matter 14 has an amplitude of 5 in the surface roughness waveform measured using the surface roughness measuring device described above. ~ 150μm, wavelength 30 ~ 600μm
It is desirable to keep the range.

【００８２】このように、前記凹凸転写用粒子状物１４
を用いて一方の金型５の表面５ａに微細な凹凸９を形成
しておけば、上記第３実施形態と同様、第１実施形態と
同様の表皮付き合成樹脂型内発泡成形体１を製造するこ
とができる。そのため、既存の設備をそのまま利用でき
るという利点がある。As described above, the particles 14 for transferring unevenness are used.
If fine irregularities 9 are formed on the surface 5a of one of the molds 5 by using the same method, a foamed synthetic resin mold 1 with a skin similar to that of the first embodiment is manufactured as in the third embodiment. can do. Therefore, there is an advantage that existing equipment can be used as it is.

【００８３】なお、この実施形態においては、前記凹凸
転写用粒子状物１４により前記一方の金型５の表面５ａ
に微細な凹凸９を形成した場合について説明したが、こ
れに限定されるものではなく、上記第２実施形態のよう
に、前記一方の金型５の表面５ａに、前記凹凸転写用粒
子状物１４により形成された微細な凹凸９に加えて製品
意匠模様用凹凸１２を形成しておいてもよい。In this embodiment, the surface 5a of the one mold 5 is formed by the irregular transfer particles 14.
Although the case where the fine unevenness 9 is formed is described above, the present invention is not limited to this, and as in the second embodiment, the surface of the one mold 5 has the surface In addition to the fine irregularities 9 formed by 14, irregularities 12 for product design patterns may be formed.

【００８４】図１５に示すように、第５実施形態に係る
表皮付き合成樹脂型内発泡成形体２１の製造方法は、上
記第１実施形態において、前記一方の金型５に熱可塑性
樹脂表皮材３を配置する前に、該熱可塑性樹脂表皮材３
の表面３ａに製品意匠模様用凹凸１２をあらかじめ形成
しておくものである。As shown in FIG. 15, the method of manufacturing the foamed synthetic resin in-mold 21 according to the fifth embodiment is the same as that of the first embodiment except that the one mold 5 is provided with a thermoplastic resin skin material. 3 before placing the thermoplastic resin skin material 3
Are formed in advance on the surface 3a of the product.

【００８５】前記熱可塑性樹脂表皮材３の表面３ａに製
品意匠模様用凹凸１２を形成する方法としては、例えば
絞付け機等を使用する方法等、種々の従来技術を利用す
ることができる。なお、前記製品意匠模様用凹凸１２の
表面は、この実施形態のようにつや消し加工して微細な
凹凸１９を形成しておいてもよいし、あるいは、図１６
に示すように、平滑にしておいてもよい。As a method for forming the irregularities 12 for the product design pattern on the surface 3a of the thermoplastic resin skin material 3, various conventional techniques such as a method using a squeezing machine can be used. The surface of the product design pattern irregularities 12 may be matted to form fine irregularities 19 as in this embodiment, or FIG.
As shown in FIG.

【００８６】図１５のように、この熱可塑性樹脂表皮材
３を前記一方の金型５の表面５ａに配置した後、上記第
１実施形態と同様の操作を行えば、熱可塑性樹脂表皮材
３の表面３ａに前記微細な凹凸９が転写されて微細な凹
凸９ｄ（９ｅ）が形成され、図１２に示す上記第２実施
形態と同様の表皮付き合成樹脂型内発泡成形体２１を製
造することができる。As shown in FIG. 15, after the thermoplastic resin skin material 3 is placed on the surface 5a of the one mold 5, the same operation as in the first embodiment is performed to obtain the thermoplastic resin skin material 3. The fine irregularities 9 are transferred to the surface 3a of the first member to form fine irregularities 9d (9e), and the same foamed synthetic resin mold 21 as the second embodiment shown in FIG. 12 is manufactured. Can be.

【００８７】このように、前記熱可塑性樹脂表皮材３の
表面３ａにあらかじめ製品意匠模様用凹凸１２を形成し
ておいた場合でも、上記第２実施形態と同様、得られる
表皮付き合成樹脂型内発泡成形体２１にビーズ模様が現
れずに外観が美麗であると共に、前記製品意匠模様用凹
凸１２により高級感等を付与できるという利点がある。
また、前記一方の金型５の表面５ａに製品意匠模様用凹
凸１２を形成しておかなくてもよいので、コストダウン
を図ることもできる。As described above, even in the case where the product design pattern irregularities 12 are formed on the surface 3a of the thermoplastic resin skin material 3 in advance, as in the second embodiment, the obtained synthetic resin mold with a skin is not required. There is an advantage that the bead pattern does not appear on the foamed molded body 21 and the appearance is beautiful, and that the product design pattern irregularities 12 can give a sense of quality and the like.
Further, since it is not necessary to form the product design pattern irregularities 12 on the surface 5a of the one mold 5, the cost can be reduced.

【００８８】なお、この実施形態においては、前記製品
意匠模様用凹凸１２をあらかじめ形成した熱可塑性樹脂
表皮材３を、表面５ａに微細な凹凸９を形成した前記一
方の金型５に配置する場合について説明したが、これに
限定されるものではなく、上記第３又は第４実施形態の
ように、前記一方の金型５の表面５ａに接合された凹凸
転写用部材１３に配置したり、あるいは、前記凹凸転写
用粒子状物１４により微細な凹凸９が形成された一方の
金型５の表面５ａに配置してもよい。In this embodiment, the thermoplastic resin skin material 3 on which the product design pattern irregularities 12 are formed in advance is placed on the one mold 5 having the fine irregularities 9 formed on the surface 5a. However, the present invention is not limited to this. For example, as in the third or fourth embodiment, the concave / convex transfer member 13 bonded to the surface 5a of the one mold 5 may be disposed, or Alternatively, it may be arranged on the surface 5a of one of the molds 5 on which the fine irregularities 9 are formed by the irregularity transfer particles 14.

【００８９】以上、上記第１乃至第５実施形態において
は、前記一方の金型５が、横断面が凹状に形成された凹
型（雌型）である場合について説明したが、これに限定
されるものではなく、一方の金型５が横断面が凸状に形
成された凸型（雄型）で、且つ、前記他方の金型６が凹
状に形成された凹型（雌型）であってもよい。As described above, in the first to fifth embodiments, the case where the one mold 5 is a concave mold (female mold) having a concave cross section has been described. However, the present invention is not limited to this. However, even if one mold 5 is a convex mold (male mold) having a convex cross section and the other mold 6 is a concave mold (female mold) having a concave shape. Good.

【００９０】次に、いわゆる後貼り成形の場合について
説明する。図１７乃至図２３に示すように、第６実施形
態に係る表皮付き合成樹脂型内発泡成形体３１の製造方
法は、２つの金型１５，１６の間に合成樹脂型内発泡成
形体２と熱可塑性樹脂表皮材３を配置して型締め、加圧
する際、例えば熱でこれら合成樹脂型内発泡成形体２と
熱可塑性樹脂表皮材３を融着一体化させる表皮付き合成
樹脂型内発泡成形体３１の製造方法において、前記熱可
塑性樹脂表皮材３と当接する一方の金型１５の表面１５
ａに、所定粗さの微細な凹凸９をあらかじめ形成してお
き、前記合成樹脂型内発泡成形体２と熱可塑性樹脂表皮
材３の融着一体化と共に、該熱可塑性樹脂表皮材３の表
面３ａに前記微細な凹凸９を転写することによって、こ
の熱可塑性樹脂表皮材３の表面粗さを略一様に保持する
ものである。Next, the case of so-called post-paste molding will be described. As shown in FIGS. 17 to 23, the method of manufacturing the foamed synthetic resin mold 31 according to the sixth embodiment includes the step of forming the foamed synthetic resin mold 2 between two molds 15 and 16. When the thermoplastic resin skin material 3 is arranged, clamped, and pressed, for example, the synthetic resin foam molding 2 with a skin is formed by fusing and integrating the synthetic resin foam molding 2 and the thermoplastic resin skin material 3 by heat. In the method for manufacturing the body 31, the surface 15 of one of the molds 15 in contact with the thermoplastic resin skin material 3.
a, fine irregularities 9 having a predetermined roughness are formed in advance, and the surface of the thermoplastic resin skin material 3 is fused together with the fusion molding of the synthetic resin molded foam 2 and the thermoplastic resin skin material 3. By transferring the fine irregularities 9 to 3a, the surface roughness of the thermoplastic resin skin material 3 is maintained substantially uniformly.

【００９１】即ち、図１７に示すように、まず、前記２
つの金型１５，１６の間に合成樹脂型内発泡成形体２と
熱可塑性樹脂表皮材３を配置し、図１８に示すように、
型締めする。That is, as shown in FIG.
Between the two dies 15 and 16, the synthetic resin foam molded article 2 and the thermoplastic resin skin material 3 are arranged, and as shown in FIG.
Close the mold.

【００９２】前記２つの金型１５，１６は、例えば、上
下方向に型締め及び型開き可能であって、前記熱可塑性
樹脂表皮材３と当接する一方の金型１５が下型とされ、
且つ、前記合成樹脂型内発泡成形体２と当接する他方の
金型１６が上型とされている。そして、前記一方の金型
１５の表面１５ａには、前記合成樹脂型内発泡成形体２
の表面２ａ形状に適合する凹部１５ｄが形成され、前記
他方の金型１６の表面１６ａはフラットに形成されてい
る。更に、少なくとも前記一方の金型１５は、蒸気又は
電熱線等により所定温度まで加熱可能としてもよい。The two dies 15 and 16 can be closed and opened, for example, in the vertical direction, and one of the dies 15 that comes into contact with the thermoplastic resin skin material 3 is a lower die.
Further, the other mold 16 which is in contact with the synthetic resin molded foam 2 is an upper mold. Then, on the surface 15a of the one mold 15, the synthetic resin mold foam molded article 2 is provided.
A concave portion 15d conforming to the shape of the surface 2a is formed, and the surface 16a of the other mold 16 is formed flat. Further, at least one of the molds 15 may be capable of being heated to a predetermined temperature by steam or heating wire.

【００９３】前記合成樹脂型内発泡成形体２は、既述の
発泡ビーズ８を型内発泡させてあらかじめ所定形状に製
造しておく。なお、この合成樹脂型内発泡成形体２の表
面２ａは、既述した第３の従来例と同様、フラットにな
っていなくてもよい。The above-mentioned synthetic resin in-mold foamed article 2 is manufactured in a predetermined shape in advance by foaming the above-described foam beads 8 in the mold. The surface 2a of the synthetic resin molded foam 2 does not have to be flat as in the third conventional example described above.

【００９４】前記熱可塑性樹脂表皮材３は、あらかじめ
真空成形等により前記一方の金型１５の表面１５ａ形状
に適合するように成形したものを配置してもよいし、あ
るいは、可撓性を有する場合には、この一方の金型１５
で真空成形等を行うことによって配置してもよい。ま
た、真空成形等を行わずに配置する場合は、例えば、図
１９及び図２０に示すように、前記一方の金型１５を上
型とし、且つ、他方の金型１６を下型として、前記熱可
塑性樹脂表皮材３を合成樹脂型内発泡成形体２に載置す
る等して配置してもよい。この場合、図２０のように型
締め、加圧する際には、賦形し易くするために熱をかけ
るのが望ましい。The thermoplastic resin skin material 3 may be previously formed by vacuum forming or the like so as to conform to the shape of the surface 15a of the one mold 15 or may have flexibility. In this case, this one mold 15
And may be arranged by performing vacuum forming or the like. In the case of disposing without performing vacuum forming or the like, for example, as shown in FIGS. 19 and 20, the one mold 15 is set as an upper mold, and the other mold 16 is set as a lower mold, The thermoplastic resin skin material 3 may be placed on the synthetic resin mold foam molded article 2 or the like. In this case, when the mold is clamped and pressurized as shown in FIG. 20, it is desirable to apply heat to facilitate shaping.

【００９５】次に、図２１に示すように、図１８に示す
状態において、加圧力Ｇによって加圧する際、熱で前記
合成樹脂型内発泡成形体２と熱可塑性樹脂表皮材３を融
着一体化させる。この場合、合成樹脂型内発泡成形体２
と熱可塑性樹脂表皮材３を配置する前、これらを配置し
た後、型締めした後、又は加圧した後のいずれかで加熱
してもよいし、あるいは、配置、型締め、又は加圧のい
ずれかと同時に加熱してもよい。また、あらかじめ所定
温度に加熱しておき、所定の段階で合成樹脂型内発泡成
形体２と熱可塑性樹脂表皮材３が融着する温度に昇温し
てもよい。更に、これら合成樹脂型内発泡成形体２と熱
可塑性樹脂表皮材３が融着する温度以上にあらかじめ加
熱しておき、所定の段階で加熱を中止してその余熱によ
り融着してもよい。いずれにしても、加圧時において合
成樹脂型内発泡成形体２と熱可塑性樹脂表皮材３を融着
一体化できればよい。Next, as shown in FIG. 21, in the state shown in FIG. 18, when pressurized by the pressing force G, the synthetic resin mold inner foam molded body 2 and the thermoplastic resin skin material 3 are integrally fused by heat. To In this case, the foam molded article 2 in the synthetic resin mold
Before and after arranging the thermoplastic resin skin material 3, after arranging them, after clamping, or after pressing, heating may be performed, or placement, clamping, or pressing. You may heat simultaneously with either. Alternatively, it may be heated to a predetermined temperature in advance, and may be heated to a temperature at which the synthetic resin foam molded article 2 and the thermoplastic resin skin material 3 are fused at a predetermined stage. Furthermore, it is also possible to heat in advance at a temperature higher than the temperature at which the synthetic resin molded foam 2 and the thermoplastic resin skin material 3 are fused, stop the heating at a predetermined stage, and fuse with the residual heat. In any case, it is only necessary that the foamed molded article 2 in the synthetic resin mold and the skin material 3 of the thermoplastic resin can be fused and integrated at the time of pressurization.

【００９６】そして、冷却等をしてから型開きすれば、
図２２に示すように、表皮付き合成樹脂型内発泡成形体
３１が得られる。Then, if the mold is opened after cooling, etc.,
As shown in FIG. 22, a synthetic resin molded foam 31 with a skin is obtained.

【００９７】なお、前記熱可塑性樹脂表皮材３の表面３
ａは、図２１のように、通常の場合と同様、あらかじめ
所定粗さでつや消し加工して微細な凹凸１９を形成して
おいてもよい。また、前記一方の金型１５の表面１５ａ
には、あらかじめ所定粗さの微細な凹凸９が形成されて
いる。この場合も上記と同様、前記微細な凹凸９の粗さ
としては、既述の表面粗さ測定器を用いて測定した表面
粗さ波形において、振幅５乃至１５０μｍ、波長３０乃
至６００μｍの範囲であることが望ましい。The surface 3 of the thermoplastic resin skin material 3
As shown in FIG. 21, as in the normal case, a may be frosted with a predetermined roughness to form fine irregularities 19 in advance. Also, the surface 15a of the one mold 15
Are formed in advance with fine irregularities 9 having a predetermined roughness. Also in this case, as described above, the roughness of the fine unevenness 9 is in the range of 5 to 150 μm in amplitude and 30 to 600 μm in wavelength in the surface roughness waveform measured using the surface roughness measuring device described above. It is desirable.

【００９８】この際、前記合成樹脂型内発泡成形体２の
表面２ａはフラットでないので、加圧力Ｇにより、前記
熱可塑性樹脂表皮材３の表面３ａの所定範囲Ｄは、その
裏面３ｂから他の範囲Ｅより強く押圧されて、前記一方
の金型１５の表面１５ａにより強く押し付けられる。こ
の場合も上記第１実施形態と同様、この状態において
は、前記熱可塑性樹脂表皮材３は熱により軟化状態とな
っているので、図２３に示すように、前記範囲Ｄには、
前記一方の金型１５の表面１５ａにあらかじめ形成した
前記微細な凹凸９が転写されて、微細な凹凸９ｄが形成
される。At this time, since the front surface 2a of the foamed molded article 2 in the synthetic resin mold is not flat, the predetermined range D of the front surface 3a of the thermoplastic resin skin material 3 is changed from the rear surface 3b to another surface by the pressing force G. It is more strongly pressed than the range E, and is more strongly pressed against the surface 15 a of the one mold 15. Also in this case, as in the first embodiment, in this state, the thermoplastic resin skin material 3 is in a softened state by heat, and therefore, as shown in FIG.
The fine irregularities 9 previously formed on the surface 15a of the one mold 15 are transferred to form fine irregularities 9d.

【００９９】また、前記他の範囲Ｅも、範囲Ｄより弱い
力ではあるが前記一方の金型１５の表面１５ａに押し付
けられるため、この他の範囲Ｅにも前記微細な凹凸９が
転写されて、微細な凹凸９ｅが形成される。この場合も
前記微細な凹凸９を適宜な粗さとしておけば、前記微細
な凹凸９ｄ，９ｅの粗さを略同程度とできるので、前記
熱可塑性樹脂表皮材３の表面粗さが略一様に保持され
て、従来のようなビーズ模様が現れることはない。Although the other area E is also weaker than the area D, it is pressed against the surface 15a of the one mold 15, so that the fine irregularities 9 are transferred to the other area E. , Fine irregularities 9e are formed. Also in this case, if the fine irregularities 9 are made to have an appropriate roughness, the roughness of the fine irregularities 9d and 9e can be made substantially the same, so that the surface roughness of the thermoplastic resin skin material 3 is substantially uniform. , And the bead pattern unlike the related art does not appear.

【０１００】図２４及び図２５に示すように、第７実施
形態に係る表皮付き合成樹脂型内発泡成形体４１の製造
方法は、上記第６実施形態において、前記合成樹脂型内
発泡成形体２と熱可塑性樹脂表皮材３の間に接着剤１７
を介在させ、熱と接着剤１７を併用して融着一体化させ
るものである。As shown in FIGS. 24 and 25, the method for manufacturing the foamed synthetic resin mold 41 according to the seventh embodiment is the same as that of the above-described foamed molded article 2 in the sixth embodiment. Adhesive 17 between the resin and the thermoplastic resin skin material 3
And the heat and the adhesive 17 are used together to fuse and integrate.

【０１０１】前記接着剤１７としては、既述の同時一体
成形の場合と同様、例えば、合成樹脂の有機溶媒溶液、
樹脂エマルジョン、樹脂パウダー等が挙げられる。この
接着剤１７は、前記合成樹脂型内発泡成形体２の表面２
ａ又は熱可塑性樹脂表皮材３の裏面３ｂにあらかじめ塗
布しておけばよい。The adhesive 17 is, for example, an organic solvent solution of synthetic resin,
Resin emulsion, resin powder and the like can be mentioned. This adhesive 17 is applied to the surface 2 of the synthetic resin mold foam 2.
a or the back surface 3b of the thermoplastic resin skin material 3 may be applied in advance.

【０１０２】前記合成樹脂型内発泡成形体２と熱可塑性
樹脂表皮材３を２つの金型１５，１６の間に配置して型
締め、加圧する際、熱と接着剤でこれらを融着一体化さ
せる場合には、図２４に示すように、上記第６実施形態
と同様、前記合成樹脂型内発泡成形体２の表面２ａはフ
ラットでないので、加圧力Ｇにより、前記熱可塑性樹脂
表皮材３の表面３ａの所定範囲Ｄが他の範囲Ｅより強く
押圧される。そのため、上記第６実施形態と同様、図２
５のように、この熱可塑性樹脂表皮材３の表面３ａに
は、微細な凹凸９が転写されて、微細な凹凸９ｄ，９ｅ
が形成される。従って、前記微細な凹凸９を適宜な粗さ
としておけば、微細な凹凸９ｄ，９ｅの粗さを同程度と
できるので、ビーズ模様が現れることがない。When the foamed molded article 2 in the synthetic resin mold and the skin material 3 of the thermoplastic resin are arranged between the two dies 15 and 16 and the molds are clamped and pressed, they are fused and integrated with heat and an adhesive. 24, the surface 2a of the synthetic resin molded foam 2 is not flat, as shown in FIG. 24, so that the thermoplastic resin skin material 3 The predetermined range D of the surface 3a is pressed more strongly than the other range E. Therefore, as in the sixth embodiment, FIG.
As shown in FIG. 5, fine irregularities 9 are transferred to the surface 3a of the thermoplastic resin skin material 3, and fine irregularities 9d and 9e are formed.
Is formed. Therefore, if the fine irregularities 9 are made to have an appropriate roughness, the fine irregularities 9d and 9e can have the same roughness, so that a bead pattern does not appear.

【０１０３】このように、前記接着剤１７を使用すれ
ば、前記合成樹脂型内発泡成形体２と熱可塑性樹脂表皮
材３の接着性を向上させることができると共に、この接
着剤１７として適宜なものを使用すれば、前記合成樹脂
型内発泡成形体２が溶融しない温度でも接着できるの
で、高温に加熱する必要がないという利点がある。As described above, the use of the adhesive 17 can improve the adhesiveness between the foamed molded article 2 in the synthetic resin mold and the skin material 3 of the thermoplastic resin. The use of such a material has the advantage that it is not necessary to heat it to a high temperature because it can be bonded even at a temperature at which the synthetic resin molded foam 2 does not melt.

【０１０４】なお、この実施形態においては、合成樹脂
型内発泡成形体２と熱可塑性樹脂表皮材３を熱と接着剤
１７を併用して融着一体化させているが、これに限定さ
れるものではなく、熱をかけずに接着剤１７で一体化さ
せてもよい。この場合の接着剤１７としては、室温で接
着性を有するものや、あるいは、室温硬化型のもの等を
使用すればよい。このように、接着剤１７で一体化させ
る場合においても上記と同様、加圧力Ｇにより前記熱可
塑性樹脂表皮材３の表面３ａに微細な凹凸９ｄ，９ｅが
形成されるので、ビーズ模様が現れることはない。In this embodiment, the synthetic resin molded foam 2 and the thermoplastic resin skin material 3 are fused and integrated by using heat and the adhesive 17, but the invention is not limited to this. Instead, it may be integrated with the adhesive 17 without applying heat. As the adhesive 17 in this case, an adhesive having an adhesive property at room temperature, or an adhesive that cures at room temperature may be used. As described above, when the adhesive 17 is used to integrate the same, the pressing force G forms fine irregularities 9d and 9e on the surface 3a of the thermoplastic resin skin material 3 in the same manner as described above. There is no.

【０１０５】以上、上記第６及び第７実施形態において
は、前記２つの金型１５，１６を上下方向に型締め及び
型開き可能としたが、これに限定されるものではなく、
水平方向等に型締め及び型開き可能としてもよい。As described above, in the sixth and seventh embodiments, the two dies 15 and 16 can be closed and opened in the vertical direction. However, the present invention is not limited to this.
The mold may be clamped and opened in a horizontal direction or the like.

【０１０６】更に、前記一方の金型１５の表面１５ａに
微細な凹凸９を形成した場合について説明したが、これ
に限定されるものではなく、上記第２乃至第５実施形態
と同様、前記一方の金型１５の表面１５ａに前記微細な
凹凸９に加えて製品意匠模様用凹凸１２をあらかじめ形
成しておいたり、あるいは、前記熱可塑性樹脂表皮材３
の表面３ａに製品意匠模様用凹凸１２をあらかじめ形成
しておいてもよい。また、既述の凹凸転写用部材１３を
使用したり、あるいは、凹凸転写用粒子状物１４により
前記微細な凹凸９を形成してもよい。Further, the case where the fine irregularities 9 are formed on the surface 15a of the one mold 15 has been described. However, the present invention is not limited to this case. In addition to the fine irregularities 9, the product design pattern irregularities 12 are previously formed on the surface 15 a of the mold 15, or the thermoplastic resin skin material 3
May be formed in advance on the surface 3a. Further, the above-mentioned fine unevenness 9 may be formed by using the above-mentioned unevenness transferring member 13 or by using the unevenness transferring particulate matter 14.

【０１０７】なお、上記第１乃至第７実施形態において
は、前記熱可塑性樹脂表皮材３として、通常の場合と同
様に表面３ａをつや消し加工して微細な凹凸１９を形成
したものを用いたが、これに限定されるものではなく、
つや消し加工していないものを用いることもできる。In the first to seventh embodiments, as the thermoplastic resin skin material 3, the surface 3a is matted to form fine irregularities 19 as in the usual case. , But is not limited to this
A non-matted material can also be used.

【０１０８】[0108]

【実施例】次に、この発明を実施例により更に詳細に説
明するが、この発明は係る実施例に限定されるものでは
ない。Next, the present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples.

【０１０９】実施例１ 成形型を構成する２つの金型のうちの一方の金型を雌型
とし、且つ、他方の金型を雄型とした。前記一方の金型
には、エアーの通気孔を確保するために多孔質の焼結金
属を使用し、その表面には、あらかじめ化学エッチング
処理により微細な凹凸を形成した。この微細な凹凸の表
面粗さは、触針式表面粗さ測定器（東京精密社製，商品
名：サーフコム５７０Ａ，触針先端５μｍＲ）を用いて
測定した表面粗さ波形において、振幅２０乃至３０μ
ｍ、波長１５０乃至２００μｍであった。また、前記他
方の金型は、成形型内へ水蒸気を供給するための蒸気孔
を有しており、更に発泡ビーズを充填するためのフィー
ダーも設けられている。Example 1 One of the two molds constituting the molding die was a female mold, and the other mold was a male mold. For the one mold, a porous sintered metal was used to secure air vents, and fine irregularities were previously formed on its surface by a chemical etching process. The surface roughness of the fine unevenness is measured by using a stylus type surface roughness measuring device (trade name: Surfcom 570A, manufactured by Tokyo Seimitsu Co., Ltd., tracing stylus tip: 5 μmR) in an amplitude of 20 to 30 μm
m, and the wavelength was 150 to 200 μm. Further, the other mold has a steam hole for supplying steam into the mold, and further has a feeder for filling foam beads.

【０１１０】熱可塑性樹脂表皮材として、ポリオレフィ
ン系熱可塑性樹脂シート（ＴＰＯシート）を用い、これ
を加熱軟化後、前記一方の金型に配置し、真空ポンプを
用いて賦形した。[0110] As a thermoplastic resin skin material, a polyolefin-based thermoplastic resin sheet (TPO sheet) was used, which was softened by heating, placed in the above one mold, and shaped using a vacuum pump.

【０１１１】発泡ビーズとして、エペランＰＰ（鐘淵化
学工業社製，商品名，発泡倍率１５倍，あらかじめ耐圧
容器内で空気圧により内圧２kg/cm2・Ｇを付与したも
の）を用い、型締めした後、この発泡ビーズを前記フィ
ーダーを介して成形型内へ充填した。As the expanded beads, Eperan PP (manufactured by Kaneka Chemical Industry Co., Ltd., trade name, expansion ratio: 15 times, with an internal pressure of 2 kg / cm 2 · G previously applied by air pressure in a pressure vessel) and clamped. Thereafter, the foamed beads were filled into the mold through the feeder.

【０１１２】次に、他方の金型に形成した蒸気孔から水
蒸気（蒸気圧１．５kg/cm2・Ｇ）を成形型内へ供給して
予備加熱を行い、発泡ビーズの蒸らしを行った後、真空
ポンプを用いてドレイン及び水蒸気を吸引、除去した。Next, water vapor (vapor pressure 1.5 kg / cm 2 · G) is supplied from a vapor hole formed in the other mold into the molding die, pre-heated, and the foamed beads are steamed. The drain and water vapor were sucked and removed using a vacuum pump.

【０１１３】その後、再び前記蒸気孔から水蒸気（蒸気
圧３．２〜３．７kg/cm2・Ｇ）を成形型内へ供給して本
加熱した後、水冷し、次いで型開きして表皮付き合成樹
脂型内発泡成形体を得た。Thereafter, water vapor (vapor pressure 3.2 to 3.7 kg / cm 2 · G) was again supplied from the vapor hole into the molding die, and the mold was fully heated. A synthetic molded in-mold foam was obtained.

【０１１４】実施例２ 前記一方の金型の表面に、あらかじめ化学エッチング処
理により製品意匠模様用凹凸を形成した後、更に実施例
１と同様にして微細な凹凸を形成した。この金型を使用
する他は、実施例１と同様にして表皮付き合成樹脂型内
発泡成形体を得た。Example 2 After forming irregularities for a product design pattern on the surface of the one mold in advance by a chemical etching process, fine irregularities were formed in the same manner as in Example 1. Except for using this mold, a foamed synthetic resin mold with a skin was obtained in the same manner as in Example 1.

【０１１５】実施例３ 一方の金型に適合するようにあらかじめ賦形した熱可塑
性樹脂表皮材を配置する他は、実施例１と同様にして表
皮付き合成樹脂型内発泡成形体を得た。Example 3 A foamed synthetic resin mold with a skin was obtained in the same manner as in Example 1 except that a thermoplastic resin skin material preliminarily shaped so as to fit one of the molds was arranged.

【０１１６】実施例４ 本加熱の際に、他方の金型の蒸気孔から水蒸気（蒸気圧
３．２〜３．７kg/cm2・Ｇ）を成形型内へ供給すると共
に、一方の金型側からも蒸気加熱を行う他は、実施例１
と同様にして表皮付き合成樹脂型内発泡成形体を得た。Example 4 At the time of the main heating, steam (vapor pressure 3.2 to 3.7 kg / cm 2 · G) was supplied from the steam hole of the other mold to the inside of the molding die. Example 1 except that steam was also heated from the side.
In the same manner as in Example 1, a foamed synthetic resin mold with a skin was obtained.

【０１１７】実施例５ 凹凸転写用部材として、表面に微細な凹凸が形成された
♯６００（６００番）のサンドペーパーを用い、これを
一方の金型の表面にあらかじめ貼付けておく他は、実施
例１と同様にして表皮付き合成樹脂型内発泡成形体を得
た。なお、サンドペーパーの微細な凹凸の表面粗さは、
実施例１と同じ触針式表面粗さ測定器を用いて測定した
表面粗さ波形において、振幅１０乃至３０μｍ、波長１
００乃至３００μｍであった。また、サンドペーパーに
は、あらかじめ０．２ｍｍ程度以下の微細な通気孔を複
数個設けておいた。Example 5 As a member for transferring irregularities, a sandpaper of # 600 (# 600) having fine irregularities formed on the surface was used, and this was previously adhered to the surface of one of the molds. In the same manner as in Example 1, a foamed synthetic resin mold with a skin was obtained. In addition, the surface roughness of the fine irregularities of the sandpaper is
In the surface roughness waveform measured using the same stylus-type surface roughness measuring device as in Example 1, an amplitude of 10 to 30 μm and a wavelength of 1
It was from 00 to 300 μm. In addition, a plurality of fine ventilation holes of about 0.2 mm or less were previously provided in the sandpaper.

【０１１８】実施例６ 一方の金型の表面に、ブラスト加工（♯１２０，ショッ
ト圧１０kg/cm2）により微細な凹凸を形成した他は、実
施例１と同様にして表皮付き合成樹脂型内発泡成形体を
得た。なお、前記ブラスト加工による微細な凹凸の表面
粗さは、実施例１と同じ触針式表面粗さ測定器を用いて
測定した表面粗さ波形において、振幅１０乃至２０μ
ｍ、波長８０乃至２００μｍであった。Example 6 A synthetic resin mold with a skin was formed in the same manner as in Example 1 except that fine irregularities were formed on the surface of one mold by blasting (# 120, shot pressure 10 kg / cm 2 ). A foam molded article was obtained. The surface roughness of the fine irregularities due to the blast processing was measured by using the same stylus-type surface roughness measuring device as in Example 1 and measuring an amplitude of 10 to 20 μm in the surface roughness waveform.
m, and the wavelength was 80 to 200 μm.

【０１１９】実施例７ 発泡ビーズとして、実施例１と同じエペランＰＰ（鐘淵
化学工業社製，商品名，発泡倍率１５倍，あらかじめ耐
圧容器内で空気圧により内圧２kg/cm2・Ｇを付与したも
の）を用い、これを型内発泡させてあらかじめ所定形状
の合成樹脂型内発泡成形体を成形した。また、熱可塑性
樹脂表皮材として、実施例１と同じポリオレフィン系熱
可塑性樹脂シート（ＴＰＯシート）を用い、この一方の
面にあらかじめ接着剤を塗布した。Example 7 The same beads as Eperan PP (manufactured by Kanegabuchi Chemical Industry Co., Ltd., trade name, expansion ratio: 15 times) as in Example 1 were previously applied with an internal pressure of 2 kg / cm 2 · G by air pressure in a pressure vessel. Was molded and foamed in a mold to form a synthetic resin foam molded article in a predetermined shape in advance. In addition, the same polyolefin-based thermoplastic resin sheet (TPO sheet) as in Example 1 was used as the thermoplastic resin skin material, and an adhesive was applied to one surface of the sheet in advance.

【０１２０】２つの金型のうち、表面にあらかじめ化学
エッチング処理により実施例１と同じ表面粗さの微細な
凹凸を形成した一方の金型を上型とし、且つ、他方の金
型を下型とした。そして、他方の金型の上に前記合成樹
脂型内発泡成形体を配置し、更にその上に、前記接着剤
を塗布した面が合成樹脂型内発泡成形体に接するように
熱可塑性樹脂表皮材を加熱して軟化させた状態で載置し
た。Of the two dies, one having the same surface roughness as in Example 1 formed in advance by chemical etching on the surface was used as the upper die, and the other die was used as the lower die. And Then, the synthetic resin mold foam is disposed on the other mold, and the thermoplastic resin skin material is further disposed thereon such that the surface coated with the adhesive is in contact with the synthetic resin mold foam. Was placed in a state of being heated and softened.

【０１２１】次に、一方の金型を加熱しながら型締め、
２kg/cm2の加圧力で加圧して表皮付き合成樹脂型内発泡
成形体を得た。Next, the mold is clamped while heating one of the molds.
By applying a pressure of 2 kg / cm 2 , a foamed synthetic resin mold with a skin was obtained.

【０１２２】比較例１ 一方の金型の表面に微細な凹凸を形成せずに平滑とした
他は、実施例１と同様にして表皮付き合成樹脂型内発泡
成形体を得た。Comparative Example 1 A foamed synthetic resin mold with a skin was obtained in the same manner as in Example 1 except that one mold was smoothed without forming fine irregularities on the surface.

【０１２３】比較例２ 一方の金型の表面に微細な凹凸を形成せずに平滑とした
他は、実施例７と同様にして表皮付き合成樹脂型内発泡
成形体を得た。Comparative Example 2 A foamed synthetic resin mold with a skin was obtained in the same manner as in Example 7, except that one mold was smoothed without forming fine irregularities on the surface.

【０１２４】以上、実施例１乃至７と、比較例１及び２
で得られた表皮付き合成樹脂型内発泡成形体の表面性を
観察し、下記の評価基準に基づいてそれぞれ評価を行っ
た。その結果を表１に示す。As described above, Examples 1 to 7 and Comparative Examples 1 and 2
The surface property of the foamed synthetic resin mold with skin obtained in the above was observed, and each was evaluated based on the following evaluation criteria. Table 1 shows the results.

【０１２５】〔評価基準〕 ○：熱可塑性樹脂表皮材の表面にビーズ模様は現れなか
った。 ×：熱可塑性樹脂表皮材の表面にビーズ模様が現れた。[Evaluation Criteria] A: No bead pattern appeared on the surface of the thermoplastic resin skin material. ×: A bead pattern appeared on the surface of the thermoplastic resin skin material.

【０１２６】[0126]

【表１】 [Table 1]

【０１２７】[0127]

【発明の効果】以上のように、請求項１及び２の表皮付
き合成樹脂型内発泡成形体の製造に使用する金型の発明
によれば、前記一方の金型の表面に、所定粗さの微細な
凹凸を形成しているので、いわゆる同時一体成形又は後
貼り成形においてこの金型を使用すれば、前記熱可塑性
樹脂表皮材の表面の所定範囲とその他の範囲には、前記
一方の金型の表面にあらかじめ形成した前記微細な凹凸
が転写されて、それぞれ微細な凹凸が形成される。この
場合、前記一方の金型の微細な凹凸を適宜の粗さとして
おけば、前記熱可塑性樹脂表皮材の表面にそれぞれ形成
された微細な凹凸の粗さが略同程度となり、前記熱可塑
性樹脂表皮材の表面粗さが略一様に保持されるので、従
来のようなビーズ模様が現れていない外観が美麗な表皮
付き合成樹脂型内発泡成形体を製造することができる。As described above, according to the invention of the mold used for producing the foamed molded article in the synthetic resin mold having the skin according to claims 1 and 2, the surface of the one mold has a predetermined roughness. Since this mold is used in the so-called simultaneous integral molding or post-paste molding, the predetermined area on the surface of the thermoplastic resin skin material and the other area have the one metal mold. The fine irregularities formed in advance on the surface of the mold are transferred to form fine irregularities respectively. In this case, if the fine unevenness of the one mold is set to an appropriate roughness, the roughness of the fine unevenness formed on the surface of the thermoplastic resin skin material becomes substantially the same, and the thermoplastic resin Since the surface roughness of the skin material is kept substantially uniform, it is possible to produce a synthetic resin-in-mold foam having a beautiful appearance without a bead pattern as in the related art.

【０１２８】請求項３の発明によれば、前記微細な凹凸
の粗さが、表面粗さ測定器を用いて測定した表面粗さ波
形において、振幅５乃至１５０μｍ、波長３０乃至６０
０μｍの範囲であるので、前記一方の金型の微細な凹凸
が転写されることによって前記熱可塑性樹脂表皮材の表
面にそれぞれ形成される微細な凹凸の粗さを確実に略同
程度とできるため、外観の見栄えをより効果的に良好に
できるという利点がある。According to the third aspect of the present invention, the roughness of the fine irregularities is 5 to 150 μm in amplitude and 30 to 60 in wavelength in a surface roughness waveform measured using a surface roughness measuring device.
Since it is in the range of 0 μm, the roughness of the fine irregularities respectively formed on the surface of the thermoplastic resin skin material by transferring the fine irregularities of the one mold can be made substantially the same. This has the advantage that the appearance can be improved more effectively.

【０１２９】請求項４の発明によれば、前記微細な凹凸
に加えて製品意匠模様用凹凸を形成しているので、この
金型を使用すれば、ビーズ模様が現れないと共に、製品
意匠模様用凹凸をも有する表皮付き合成樹脂型内発泡成
形体を製造でき、そのため当該表皮付き合成樹脂型内発
泡成形体に高級感等を付与することができる。According to the fourth aspect of the present invention, since the irregularities for the product design pattern are formed in addition to the fine irregularities, the use of this mold prevents the appearance of the bead pattern and the product design pattern. It is possible to produce a foamed synthetic resin-molded body with a skin that also has irregularities, so that it is possible to impart a sense of quality and the like to the foamed synthetic resin-molded mold with a skin.

【０１３０】請求項５の表皮付き合成樹脂型内発泡成形
体の製造方法の発明によれば、前記一方の金型の表面
に、所定粗さの微細な凹凸をあらかじめ形成しておき、
前記発泡ビーズ相互の融着及びこれら発泡ビーズと前記
熱可塑性樹脂表皮材の融着一体化と共に、該熱可塑性樹
脂表皮材の表面に前記微細な凹凸を転写することによっ
て、この熱可塑性樹脂表皮材の表面粗さを略一様に保持
するので、上記請求項１の効果と同様、いわゆる同時一
体成形において、従来のようなビーズ模様が現れていな
い外観が美麗な表皮付き合成樹脂型内発泡成形体を製造
することができる。[0130] According to the invention of the method for producing a foamed synthetic resin mold with a skin according to claim 5, fine irregularities having a predetermined roughness are previously formed on the surface of the one mold.
By transferring the fine irregularities to the surface of the thermoplastic resin skin material together with the fusion of the foam beads to each other and the fusion and integration of the foam beads and the thermoplastic resin skin material, Since the surface roughness is maintained substantially uniform, in the so-called simultaneous integral molding, as in the case of the above-mentioned simultaneous molding, foam molding in a synthetic resin mold with a beautiful skin without the appearance of a bead pattern as in the prior art. The body can be manufactured.

【０１３１】請求項６の発明によれば、前記一方の金型
の表面に、凹凸転写用部材をあらかじめ接合しておき、
前記発泡ビーズ相互の融着及びこれら発泡ビーズと前記
熱可塑性樹脂表皮材の融着一体化と共に、該熱可塑性樹
脂表皮材の表面に、前記凹凸転写用部材の表面に形成し
た微細な凹凸を転写することによって、この熱可塑性樹
脂表皮材の表面粗さを略一様に保持するので、いわゆる
同時一体成形において、上記と同様の外観が美麗な表皮
付き合成樹脂型内発泡成形体を製造できると共に、既存
の設備をそのまま利用することができる。また、この凹
凸転写用部材を前記一方の金型に対して着脱自在として
おけば付け替え可能であるので、多種類の設備に利用で
きるという利点がある。According to the invention of claim 6, an uneven transfer member is previously bonded to the surface of the one mold,
Along with the fusion of the foam beads to each other and the fusion of the foam beads and the thermoplastic resin skin material, the fine irregularities formed on the surface of the irregularity transfer member are transferred to the surface of the thermoplastic resin skin material. By doing so, the surface roughness of the thermoplastic resin skin material is kept substantially uniform, so that in the so-called simultaneous integral molding, it is possible to produce a synthetic resin mold foam with a beautiful skin having the same appearance as described above. The existing equipment can be used as it is. In addition, since this uneven transfer member can be replaced by being detachable from the one mold, there is an advantage that it can be used for various types of equipment.

【０１３２】請求項７の発明によれば、前記一方の金型
の表面に、凹凸転写用粒子状物を付着させて所定粗さの
微細な凹凸をあらかじめ形成しておき、前記発泡ビーズ
相互の融着及びこれら発泡ビーズと前記熱可塑性樹脂表
皮材の融着一体化と共に、該熱可塑性樹脂表皮材の表面
に前記微細な凹凸を転写することによって、この熱可塑
性樹脂表皮材の表面粗さを略一様に保持するので、いわ
ゆる同時一体成形において、上記と同様の外観が美麗な
表皮付き合成樹脂型内発泡成形体を製造できると共に、
既存の設備をそのまま利用できるという利点がある。According to the seventh aspect of the present invention, fine irregularities having a predetermined roughness are previously formed on the surface of the one mold by adhering fine particles for irregularity transfer, so that the foamed beads can be mutually formed. By transferring the fine irregularities to the surface of the thermoplastic resin skin material together with fusion and fusion bonding of these foam beads and the thermoplastic resin skin material, the surface roughness of the thermoplastic resin skin material is reduced. Since it is held substantially uniformly, in the so-called simultaneous integral molding, it is possible to produce a synthetic resin mold foamed body with a beautiful skin having the same appearance as above,
There is an advantage that existing equipment can be used as it is.

【０１３３】請求項８の発明によれば、前記成形型内に
発泡ビーズを充填した後、他方の金型に形成した蒸気孔
から水蒸気を供給して前記発泡ビーズが互いに融着する
温度より低い温度でこれら発泡ビーズを予備加熱し、そ
の状態で所定時間保持して前記発泡ビーズを水蒸気で蒸
らし、次いで前記発泡ビーズが互いに融着する温度以上
の温度でこれら発泡ビーズを本加熱するので、いわゆる
同時一体成形において、前記予備加熱により、発泡ビー
ズが互いに融着することなく充分に加熱された状態とす
ることができる。また、前記水蒸気による蒸らしによ
り、前記発泡ビーズ間に供給された水蒸気の潜熱を有効
に利用できるので、特に厚さが大きい合成樹脂型内発泡
成形体を成形する場合等、前記発泡ビーズをより均一に
加熱できるという利点がある。According to the eighth aspect of the present invention, after the foaming beads are filled in the mold, steam is supplied from the steam holes formed in the other mold to lower the temperature than the temperature at which the foaming beads fuse to each other. The foamed beads are pre-heated at a temperature, and the foamed beads are steamed while maintaining the state for a predetermined time, and then the foamed beads are fully heated at a temperature equal to or higher than a temperature at which the foamed beads are fused to each other. In the simultaneous integral molding, the preheating allows the expanded beads to be in a sufficiently heated state without fusing to each other. In addition, since the latent heat of the steam supplied between the foamed beads can be effectively used by steaming with the steam, the foamed beads can be made more uniform, particularly when a foamed article in a synthetic resin mold having a large thickness is formed. There is an advantage that it can be heated.

【０１３４】請求項９の発明によれば、前記発泡ビーズ
を水蒸気で蒸らした後、前記成形型内に残留するドレイ
ンを除去してから本加熱するので、前記合成樹脂型内発
泡成形体には発泡ビーズの融着不良の発生がない表皮付
き合成樹脂型内発泡成形体を製造することができる。ま
た、前記ドレインを除去するために、前記成形型内を真
空引きしていた場合には、前記本加熱のための水蒸気を
よりスムーズに成形型内へ供給できるという利点があ
る。According to the ninth aspect of the present invention, after the foam beads are steamed, the main body is heated after the drain remaining in the mold is removed. It is possible to produce a foamed molded article in a synthetic resin mold having a skin without occurrence of defective fusion of the foamed beads. In addition, when the inside of the mold is evacuated to remove the drain, there is an advantage that the steam for the main heating can be more smoothly supplied into the mold.

【０１３５】請求項１０の発明によれば、前記熱可塑性
樹脂表皮材と当接する一方の金型の表面に、所定粗さの
微細な凹凸をあらかじめ形成しておき、前記合成樹脂型
内発泡成形体と熱可塑性樹脂表皮材の一体化と共に、該
熱可塑性樹脂表皮材の表面に前記微細な凹凸を転写する
ことによって、この熱可塑性樹脂表皮材の表面粗さを略
一様に保持するので、上記請求項２の効果と同様、いわ
ゆる後貼り成形において、従来のようなビーズ模様が現
れていない外観が美麗な表皮付き合成樹脂型内発泡成形
体を製造することができる。According to the tenth aspect of the present invention, fine irregularities having a predetermined roughness are previously formed on the surface of one of the molds in contact with the skin material of the thermoplastic resin, and the mold is formed in the synthetic resin mold. With the integration of the body and the thermoplastic resin skin material, by transferring the fine irregularities to the surface of the thermoplastic resin skin material, the surface roughness of the thermoplastic resin skin material is maintained substantially uniformly, Similar to the effect of the second aspect, in the so-called post-paste molding, it is possible to produce a synthetic resin molded foam having a beautiful skin without a bead pattern as in the related art.

【０１３６】請求項１１の発明によれば、前記熱可塑性
樹脂表皮材と当接する一方の金型の表面に、凹凸転写用
部材をあらかじめ接合しておき、前記合成樹脂型内発泡
成形体と熱可塑性樹脂表皮材の一体化と共に、該熱可塑
性樹脂表皮材の表面に、前記凹凸転写用部材の表面に形
成した微細な凹凸を転写することによって、この熱可塑
性樹脂表皮材の表面粗さを略一様に保持するので、いわ
ゆる後貼り成形において、上記と同様の外観が美麗な表
皮付き合成樹脂型内発泡成形体を製造できると共に、既
存の設備をそのまま利用することができる。また、この
凹凸転写用部材を前記一方の金型に対して着脱自在とし
ておけば付け替え可能であるので、多種類の設備に利用
できるという利点がある。According to the eleventh aspect of the present invention, a member for transferring an unevenness is previously bonded to the surface of one of the molds that comes into contact with the skin material of the thermoplastic resin, so that the foamed article in the synthetic resin mold is thermally bonded to the surface. The surface roughness of the thermoplastic resin skin material is substantially reduced by transferring the fine irregularities formed on the surface of the irregularity transfer member to the surface of the thermoplastic resin skin material together with the integration of the thermoplastic resin skin material. Since it is held uniformly, in the so-called post-paste molding, it is possible to produce a foamed molded article in a synthetic resin mold having a beautiful appearance similar to that described above, and the existing equipment can be used as it is. In addition, since this uneven transfer member can be replaced by being detachable from the one mold, there is an advantage that it can be used for various types of equipment.

【０１３７】請求項１２の発明によれば、前記熱可塑性
樹脂表皮材と当接する一方の金型の表面に、凹凸転写用
粒子状物を付着させて所定粗さの微細な凹凸をあらかじ
め形成しておき、前記合成樹脂型内発泡成形体と熱可塑
性樹脂表皮材の一体化と共に、該熱可塑性樹脂表皮材の
表面に前記微細な凹凸を転写することによって、この熱
可塑性樹脂表皮材の表面粗さを略一様に保持するので、
いわゆる後貼り成形において、上記と同様の外観が美麗
な表皮付き合成樹脂型内発泡成形体を製造できると共
に、既存の設備をそのまま利用できるという利点があ
る。According to the twelfth aspect of the present invention, fine irregularities having a predetermined roughness are previously formed by adhering irregularity transfer particles on the surface of one of the molds in contact with the thermoplastic resin skin material. The surface roughness of the thermoplastic resin skin material is transferred by transferring the fine irregularities onto the surface of the thermoplastic resin skin material together with the integration of the synthetic resin mold foam molded article and the thermoplastic resin skin material. Is held almost uniformly,
In so-called post-paste molding, there is an advantage that a synthetic resin mold foam with a beautiful skin having the same appearance as described above can be produced and existing equipment can be used as it is.

【０１３８】請求項１３の発明によれば、前記微細な凹
凸の粗さが、表面粗さ測定器を用いて測定した表面粗さ
波形において、振幅５乃至１５０μｍ、波長３０乃至６
００μｍの範囲であるので、上記請求項３の効果と同
様、前記一方の金型の微細な凹凸が転写されることによ
って前記熱可塑性樹脂表皮材の表面にそれぞれ形成され
る微細な凹凸の粗さを確実に略同程度とすることができ
るため、外観の見栄えをより効果的に良好にできるとい
う利点がある。According to the thirteenth aspect of the present invention, the roughness of the fine irregularities is 5 to 150 μm in amplitude and 30 to 6 in wavelength in the surface roughness waveform measured using a surface roughness measuring device.
Since it is in the range of 00 μm, the roughness of the fine irregularities respectively formed on the surface of the thermoplastic resin skin material by transferring the fine irregularities of the one mold as in the effect of the third aspect Can be made substantially the same, and there is an advantage that the appearance can be more effectively improved.

【０１３９】請求項１４の発明によれば、前記一方の金
型の表面に、前記微細な凹凸に加えて製品意匠模様用凹
凸をあらかじめ形成しておき、前記熱可塑性樹脂表皮材
の表面に前記微細な凹凸を転写する際に、前記製品意匠
模様用凹凸をも転写するので、いわゆる同時一体成形又
は後貼り成形において、ビーズ模様が現れないと共に、
製品意匠模様用凹凸をも有する表皮付き合成樹脂型内発
泡成形体を製造でき、そのため当該表皮付き合成樹脂型
内発泡成形体に高級感等を付与することができる。According to the fourteenth aspect, in addition to the fine irregularities, irregularities for a product design pattern are previously formed on the surface of the one mold, and the surface of the thermoplastic resin skin material is formed in advance. When transferring the fine irregularities, since the product design pattern irregularities are also transferred, in so-called simultaneous integral molding or post-paste molding, bead patterns do not appear,
It is possible to manufacture a synthetic resin-molded inner foamed product with a skin that also has irregularities for a product design pattern, so that the synthetic foamed product with a skin can have a sense of quality and the like.

【０１４０】請求項１５の発明によれば、前記凹凸転写
用部材の表面に、前記微細な凹凸に加えて製品意匠模様
用凹凸をあらかじめ形成しておき、前記熱可塑性樹脂表
皮材の表面に前記微細な凹凸を転写する際に、前記製品
意匠模様用凹凸をも転写するので、いわゆる同時一体成
形又は後貼り成形において、ビーズ模様が現れないと共
に、製品意匠模様用凹凸をも有する表皮付き合成樹脂型
内発泡成形体を製造でき、そのため当該表皮付き合成樹
脂型内発泡成形体に高級感等を付与することができる。According to the fifteenth aspect of the present invention, in addition to the fine irregularities, irregularities for a product design pattern are previously formed on the surface of the irregularities transferring member, and the irregularities are formed on the surface of the thermoplastic resin skin material. When transferring fine irregularities, since the irregularities for the product design pattern are also transferred, in the so-called simultaneous integral molding or post-paste molding, the bead pattern does not appear, and the synthetic resin with a skin also has the irregularities for the product design pattern. The in-mold foam molded article can be manufactured, and therefore, the sense of quality and the like can be imparted to the synthetic resin in-mold foam molded article with a skin.

【０１４１】請求項１６の発明によれば、前記熱可塑性
樹脂表皮材を配置する前に、該熱可塑性樹脂表皮材の表
面に製品意匠模様用凹凸をあらかじめ形成しておくの
で、いわゆる同時一体成形又は後貼り成形において、得
られる表皮付き合成樹脂型内発泡成形体にビーズ模様が
現れずに外観が美麗であると共に、前記製品意匠模様用
凹凸により高級感等を付与できるという利点がある。ま
た、前記一方の金型の表面に製品意匠模様用凹凸を形成
しておかなくてもよいので、コストダウンを図ることも
できる。According to the sixteenth aspect of the present invention, before arranging the thermoplastic resin skin material, the irregularities for the product design pattern are formed in advance on the surface of the thermoplastic resin skin material. Alternatively, in the post-paste molding, there is an advantage that a bead pattern does not appear on the resulting foamed synthetic resin mold with a skin, the appearance is beautiful, and a high-grade feeling or the like can be imparted by the unevenness for the product design pattern. Further, since it is not necessary to form the product design pattern irregularities on the surface of the one mold, the cost can be reduced.

【図面の簡単な説明】[Brief description of the drawings]

【図１】実施形態に係る表皮付き合成樹脂型内発泡成形
体の側断面図。FIG. 1 is a side sectional view of a foamed synthetic resin mold with a skin according to an embodiment.

【図２】第１実施形態に係る表皮付き合成樹脂型内発泡
成形体の製造方法において、一方の金型の表面に熱可塑
性樹脂表皮材を配置して型締めした状態を示す側断面説
明図。FIG. 2 is an explanatory side sectional view showing a state in which a thermoplastic resin skin material is arranged on the surface of one of the molds and the mold is clamped in the method for producing a foamed synthetic resin mold with a skin according to the first embodiment. .

【図３】図２の熱可塑性樹脂表皮材の配置状態を示す要
部拡大側断面図。FIG. 3 is an enlarged side sectional view of an essential part showing an arrangement state of a thermoplastic resin skin material of FIG. 2;

【図４】成形型内へ発泡ビーズを充填する様子を示す側
断面説明図。FIG. 4 is an explanatory side sectional view showing a state in which foamed beads are filled into a molding die.

【図５】発泡ビーズを充填した後、成形型内へ水蒸気を
供給する様子を示す側断面説明図。FIG. 5 is an explanatory side sectional view showing a state in which steam is supplied into a mold after filling with foam beads.

【図６】成形型内を真空引きする様子を示す側断面説明
図。FIG. 6 is an explanatory side sectional view showing a state in which the inside of the mold is evacuated.

【図７】成形型内へ水蒸気を供給して発泡ビーズを型内
発泡させた状態を示す側断面説明図。FIG. 7 is an explanatory side sectional view showing a state in which steam is supplied into a molding die to expand foam beads in the die.

【図８】成形型内から脱型された耳部を有する表皮付き
合成樹脂型内発泡成形体の側断面図。FIG. 8 is a side cross-sectional view of a foamed molded article in a synthetic resin mold with a skin having ears removed from the mold.

【図９】発泡ビーズが型内発泡する状態を示す要部拡大
側断面図。FIG. 9 is an enlarged side sectional view of a main part showing a state in which foam beads are foamed in a mold.

【図１０】得られた表皮付き合成樹脂型内発泡成形体の
表面付近の要部拡大側断面図。FIG. 10 is an enlarged side cross-sectional view of a main part near the surface of the obtained synthetic resin mold foam with a skin.

【図１１】第２実施形態に係る表皮付き合成樹脂型内発
泡成形体の製造方法において、発泡ビーズが型内発泡す
る状態を示す要部拡大側断面図。FIG. 11 is an enlarged side sectional view of a main part showing a state in which foam beads are foamed in the mold in the method for producing a foamed synthetic resin mold in the second embodiment.

【図１２】得られた表皮付き合成樹脂型内発泡成形体の
表面付近の要部拡大側断面図。FIG. 12 is an enlarged side sectional view of a main portion near the surface of the obtained synthetic resin mold-in-foam molded product with a skin.

【図１３】第３実施形態に係る表皮付き合成樹脂型内発
泡成形体の製造方法において、発泡ビーズが型内発泡す
る状態を示す要部拡大側断面図。FIG. 13 is an enlarged side sectional view of a main part showing a state in which foam beads are foamed in the mold in the method of manufacturing a foamed synthetic resin molded article with a skin according to the third embodiment.

【図１４】第４実施形態に係る表皮付き合成樹脂型内発
泡成形体の製造方法において、発泡ビーズが型内発泡す
る状態を示す要部拡大側断面図。FIG. 14 is an enlarged side sectional view of a main part showing a state in which foam beads are foamed in the mold in the method for producing a foamed synthetic resin mold with a skin according to the fourth embodiment.

【図１５】第５実施形態に係る表皮付き合成樹脂型内発
泡成形体の製造方法において、発泡ビーズが型内発泡す
る状態を示す要部拡大側断面図。FIG. 15 is an enlarged side sectional view of a main part showing a state in which foam beads are foamed in the mold in the method for producing a foamed synthetic resin mold in the fifth embodiment according to the present invention.

【図１６】図１５の製品意匠模様用凹凸の表面を平滑に
形成した状態を示す要部拡大側断面図。FIG. 16 is an enlarged side sectional view of a main part showing a state where the surface of the product design pattern unevenness of FIG. 15 is formed smoothly.

【図１７】第６実施形態に係る表皮付き合成樹脂型内発
泡成形体の製造方法において、２つの金型の間に合成樹
脂型内発泡成形体と熱可塑性樹脂表皮材を配置して型締
めする様子を示す側断面図。FIG. 17 is a cross-sectional view illustrating a method of manufacturing a foamed molded article in a synthetic resin mold with a skin according to a sixth embodiment, in which a molded foamed article in a synthetic resin mold and a thermoplastic resin skin material are arranged between two dies; FIG.

【図１８】型締め後の状態を示す要部拡大側断面図。FIG. 18 is an enlarged side sectional view of a main part showing a state after mold clamping.

【図１９】一方の金型を上型とし、且つ、他方の金型を
下型として、これら２つの金型の間に熱可塑性樹脂表皮
材を合成樹脂型内発泡成形体に載置するように配置して
型締めする様子を示す側断面図。FIG. 19 is a diagram in which one mold is used as an upper mold and the other mold is used as a lower mold so that a thermoplastic resin skin material is placed between the two molds on the foamed molded article in the synthetic resin mold. Sectional drawing which shows a mode that it arrange | positions at a mold and clamps.

【図２０】型締め後の状態を示す要部拡大側断面図。FIG. 20 is an enlarged side sectional view of a main part showing a state after mold clamping.

【図２１】図１８の状態において加圧する際、熱で合成
樹脂型内発泡成形体と熱可塑性樹脂表皮材を融着一体化
させる様子を示す要部拡大側断面図。FIG. 21 is an enlarged side sectional view of a main part showing a state in which, when pressure is applied in the state shown in FIG. 18, the foamed molded article in the synthetic resin mold and the thermoplastic resin skin material are fused and integrated by heat.

【図２２】得られた表皮付き合成樹脂型内発泡成形体の
側断面図。FIG. 22 is a side cross-sectional view of the obtained foamed molded article in a synthetic resin mold with a skin.

【図２３】図２２の表皮付き合成樹脂型内発泡成形体の
表面付近の要部拡大側断面図。FIG. 23 is an enlarged side sectional view of a main part near the surface of the foamed synthetic resin mold inside skin of FIG. 22;

【図２４】第７実施形態に係る表皮付き合成樹脂型内発
泡成形体の製造方法において、熱と接着剤を併用して合
成樹脂型内発泡成形体と熱可塑性樹脂表皮材を融着一体
化させる様子を示す要部拡大側断面図。FIG. 24 is a view showing a method for producing a foamed synthetic resin-molded body with a skin according to the seventh embodiment, in which a foamed molded article in a synthetic resin mold and a thermoplastic resin skin material are integrated by fusion using heat and an adhesive. The principal part expanded side sectional view which shows a mode that it makes it.

【図２５】得られた表皮付き合成樹脂型内発泡成形体の
表面付近の要部拡大側断面図。FIG. 25 is an enlarged side cross-sectional view of a main part near the surface of the obtained foamed synthetic resin mold with a skin.

【図２６】第１の従来例に係る表皮付き合成樹脂型内発
泡成形体の製造方法において、発泡ビーズが型内発泡す
る状態を示す要部拡大側断面図。FIG. 26 is an enlarged side sectional view showing a state where foam beads are foamed in a mold in a method of manufacturing a foamed synthetic resin mold within a skin according to a first conventional example.

【図２７】得られた表皮付き合成樹脂型内発泡成形体の
表面にビーズ模様が形成された状態を示す要部拡大側断
面図。FIG. 27 is an enlarged side sectional view of a main part showing a state in which a bead pattern is formed on the surface of the obtained synthetic resin mold inner foam with skin.

【図２８】第２の従来例に係る表皮付き合成樹脂型内発
泡成形体の製造方法において、発泡ビーズが型内発泡す
る状態を示す要部拡大側断面図。FIG. 28 is an enlarged side sectional view of a main part showing a state in which foam beads are foamed in the mold in the method of manufacturing the foamed synthetic resin mold in the second conventional example.

【図２９】第３の従来例に係る表皮付き合成樹脂型内発
泡成形体の製造方法において、型締め、加圧する際、熱
で合成樹脂型内発泡成形体と熱可塑性樹脂表皮材を融着
一体化させる様子を示す要部拡大側断面図。FIG. 29 shows a third conventional example of a method for manufacturing a molded article in a synthetic resin mold with a skin, wherein when the mold is clamped and pressed, the molded article in a synthetic resin mold and a thermoplastic resin skin material are fused by heat. The principal part expanded side sectional view which shows a mode that it unifies.

【符号の説明】[Explanation of symbols]

１，２１，３１，４１ 表皮付き合成樹脂型内発泡成形
体 ２ 合成樹脂型内発泡成形体 ３ 熱可塑性樹脂表皮材 ３ａ 表面 ４ 成形型 ５，１５ 一方の金型 ５ａ，１５ａ 表面 ６，１６ 他方の金型 ６ｃ 蒸気孔 ７ 成形型内 ８ 発泡ビーズ Ｓ 水蒸気 ９ 微細な凹凸 １２ 製品意匠模様用凹凸 １３ 凹凸転写用部材 １４ 凹凸転写用粒子状物1, 21, 31, 41 Foamed synthetic resin mold inside skin 2 Foam molded inside synthetic resin mold 3 Thermoplastic resin skin material 3a Surface 4 Mold 5,15 One mold 5a, 15a Surface 6,16 The other Mold 6c Vapor hole 7 Inside mold 8 Foam beads S Steam 9 Fine irregularities 12 Irregularities for product design 13 Irregularities transfer member 14 Particles for irregularities transfer

Claims (16)

【特許請求の範囲】[Claims] 【請求項１】 成形型を構成する２つの金型のいずれか
一方の金型に熱可塑性樹脂表皮材を配置して型締め後、
この成形型内に発泡ビーズを充填し、蒸気加熱によりこ
れら発泡ビーズを発泡させて互いに融着させると共に、
これら発泡ビーズと前記熱可塑性樹脂表皮材を融着一体
化させる表皮付き合成樹脂型内発泡成形体の製造に使用
する金型において、 前記一方の金型の表面に、所定粗さの微細な凹凸を形成
したことを特徴とする表皮付き合成樹脂型内発泡成形体
の製造に使用する金型。Claims: 1. A thermoplastic resin skin material is placed in one of two molds constituting a molding die, and after clamping,
Filling the molding beads with foam beads, foaming these foam beads by steam heating and fusing them together,
In a mold used for manufacturing a foamed molded article in a synthetic resin mold with a skin that fuses and integrates these foam beads and the thermoplastic resin skin material, fine irregularities having a predetermined roughness are formed on the surface of the one mold. A mold used for producing a foamed molded article in a synthetic resin mold with a skin, characterized in that a molded article is formed. 【請求項２】 ２つの金型の間に合成樹脂型内発泡成形
体と熱可塑性樹脂表皮材を配置して型締め、加圧する
際、熱及び／又は接着剤でこれら合成樹脂型内発泡成形
体と熱可塑性樹脂表皮材を一体化させる表皮付き合成樹
脂型内発泡成形体の製造に使用する金型において、 前記熱可塑性樹脂表皮材と当接する一方の金型の表面
に、所定粗さの微細な凹凸を形成したことを特徴とする
表皮付き合成樹脂型内発泡成形体の製造に使用する金
型。2. A plastic molded article in a synthetic resin mold and a thermoplastic resin skin material are placed between two molds, and when the mold is clamped and pressurized, foam molding in the synthetic resin mold is performed using heat and / or an adhesive. In a mold used for manufacturing a foamed molded article in a synthetic resin mold with a skin that integrates a body and a thermoplastic resin skin material, the surface of one of the molds in contact with the thermoplastic resin skin material has a predetermined roughness. A mold used for manufacturing a foamed molded article in a synthetic resin mold having a skin, characterized by forming fine irregularities. 【請求項３】 前記微細な凹凸の粗さが、表面粗さ測定
器を用いて測定した表面粗さ波形において、振幅５乃至
１５０μｍ、波長３０乃至６００μｍの範囲である請求
項１又は２記載の表皮付き合成樹脂型内発泡成形体の製
造に使用する金型。3. The method according to claim 1, wherein the roughness of the fine unevenness is in a range of 5 to 150 μm and a wavelength of 30 to 600 μm in a surface roughness waveform measured using a surface roughness measuring device. A mold used for manufacturing foamed molded articles in synthetic resin molds with skins. 【請求項４】 前記微細な凹凸に加えて製品意匠模様用
凹凸を形成した請求項１乃至３のいずれか記載の表皮付
き合成樹脂型内発泡成形体の製造に使用する金型。4. The mold for use in manufacturing a foamed molded article in a synthetic resin mold having a skin according to claim 1, wherein irregularities for a product design pattern are formed in addition to the fine irregularities. 【請求項５】 成形型を構成する２つの金型のいずれか
一方の金型に熱可塑性樹脂表皮材を配置して型締め後、
この成形型内に発泡ビーズを充填し、蒸気加熱によりこ
れら発泡ビーズを発泡させて互いに融着させると共に、
これら発泡ビーズと前記熱可塑性樹脂表皮材を融着一体
化させる表皮付き合成樹脂型内発泡成形体の製造方法に
おいて、 前記一方の金型の表面に、所定粗さの微細な凹凸をあら
かじめ形成しておき、前記発泡ビーズ相互の融着及びこ
れら発泡ビーズと前記熱可塑性樹脂表皮材の融着一体化
と共に、該熱可塑性樹脂表皮材の表面に前記微細な凹凸
を転写することによって、この熱可塑性樹脂表皮材の表
面粗さを略一様に保持することを特徴とする表皮付き合
成樹脂型内発泡成形体の製造方法。5. A thermoplastic resin skin material is placed on one of two molds constituting a molding die and the mold is clamped.
Filling the molding beads with foam beads, foaming these foam beads by steam heating and fusing them together,
In the method for producing a foamed molded article in a synthetic resin mold having a skin in which the foamed beads and the thermoplastic resin skin material are fused and integrated, fine irregularities having a predetermined roughness are previously formed on the surface of the one mold. In addition, by transferring the fine irregularities to the surface of the thermoplastic resin skin material together with the fusion between the foam beads and the fusion and integration of the foam beads and the thermoplastic resin skin material, A method for producing a foamed synthetic resin in-mold with a skin, characterized in that the surface roughness of the resin skin material is kept substantially uniform. 【請求項６】 成形型を構成する２つの金型のいずれか
一方の金型に熱可塑性樹脂表皮材を配置して型締め後、
この成形型内に発泡ビーズを充填し、蒸気加熱によりこ
れら発泡ビーズを発泡させて互いに融着させると共に、
これら発泡ビーズと前記熱可塑性樹脂表皮材を融着一体
化させる表皮付き合成樹脂型内発泡成形体の製造方法に
おいて、 前記一方の金型の表面に、凹凸転写用部材をあらかじめ
接合しておき、前記発泡ビーズ相互の融着及びこれら発
泡ビーズと前記熱可塑性樹脂表皮材の融着一体化と共
に、該熱可塑性樹脂表皮材の表面に、前記凹凸転写用部
材の表面に形成した微細な凹凸を転写することによっ
て、この熱可塑性樹脂表皮材の表面粗さを略一様に保持
することを特徴とする表皮付き合成樹脂型内発泡成形体
の製造方法。6. A thermoplastic resin skin material is placed on one of two molds constituting a molding die and the mold is clamped.
Filling the molding beads with foam beads, foaming these foam beads by steam heating and fusing them together,
In the method for producing a foamed synthetic resin-in-mold molded article having a skin that fuses and integrates these foam beads and the thermoplastic resin skin material, a surface of one of the molds is joined in advance with a member for transferring irregularities, Along with the fusion of the foam beads to each other and the fusion of the foam beads and the thermoplastic resin skin material, the fine irregularities formed on the surface of the irregularity transfer member are transferred to the surface of the thermoplastic resin skin material. A method for producing a foamed synthetic resin mold with a skin, wherein the surface roughness of the thermoplastic resin skin material is maintained substantially uniform. 【請求項７】 成形型を構成する２つの金型のいずれか
一方の金型に熱可塑性樹脂表皮材を配置して型締め後、
この成形型内に発泡ビーズを充填し、蒸気加熱によりこ
れら発泡ビーズを発泡させて互いに融着させると共に、
これら発泡ビーズと前記熱可塑性樹脂表皮材を融着一体
化させる表皮付き合成樹脂型内発泡成形体の製造方法に
おいて、 前記一方の金型の表面に、凹凸転写用粒子状物を付着さ
せて所定粗さの微細な凹凸をあらかじめ形成しておき、
前記発泡ビーズ相互の融着及びこれら発泡ビーズと前記
熱可塑性樹脂表皮材の融着一体化と共に、該熱可塑性樹
脂表皮材の表面に前記微細な凹凸を転写することによっ
て、この熱可塑性樹脂表皮材の表面粗さを略一様に保持
することを特徴とする表皮付き合成樹脂型内発泡成形体
の製造方法。7. A thermoplastic resin skin material is placed on one of two molds constituting a molding die and the mold is clamped.
Filling the molding beads with foam beads, foaming these foam beads by steam heating and fusing them together,
In the method for producing a foamed synthetic resin-in-mold molded product with a skin in which the foamed beads and the thermoplastic resin skin material are fused and integrated, the method includes the steps of: adhering particles for irregularity transfer to the surface of the one mold; Fine irregularities of roughness are formed in advance,
By transferring the fine irregularities to the surface of the thermoplastic resin skin material together with the fusion of the foam beads to each other and the fusion and integration of the foam beads and the thermoplastic resin skin material, A method for producing a foamed molded article in a synthetic resin mold with a skin, characterized in that the surface roughness of the molded article is kept substantially uniform. 【請求項８】 前記成形型内に発泡ビーズを充填した
後、他方の金型に形成した蒸気孔から水蒸気を供給して
前記発泡ビーズが互いに融着する温度より低い温度でこ
れら発泡ビーズを予備加熱し、その状態で所定時間保持
して前記発泡ビーズを水蒸気で蒸らし、次いで前記発泡
ビーズが互いに融着する温度以上の温度でこれら発泡ビ
ーズを本加熱することを特徴とする請求項５乃至７のい
ずれか記載の表皮付き合成樹脂型内発泡成形体の製造方
法。8. After the foaming beads are filled in the mold, steam is supplied from a vapor hole formed in the other mold to pre-press the foaming beads at a temperature lower than a temperature at which the foaming beads fuse together. 8. Heating, holding the foamed beads for a predetermined time in that state, and steaming the foamed beads with steam, and then fully heating these foamed beads at a temperature higher than a temperature at which the foamed beads are fused to each other. The method for producing a foamed molded article in a synthetic resin mold with a skin according to any one of the above. 【請求項９】 前記発泡ビーズを水蒸気で蒸らした後、
前記成形型内に残留するドレインを除去してから本加熱
することを特徴とする請求項８記載の表皮付き合成樹脂
型内発泡成形体の製造方法。9. After steaming the foam beads with steam,
9. The method for producing a foamed molded article in a synthetic resin mold with a skin according to claim 8, wherein the main heating is performed after removing a drain remaining in the molding die. 【請求項１０】 ２つの金型の間に合成樹脂型内発泡成
形体と熱可塑性樹脂表皮材を配置して型締め、加圧する
際、熱及び／又は接着剤でこれら合成樹脂型内発泡成形
体と熱可塑性樹脂表皮材を一体化させる表皮付き合成樹
脂型内発泡成形体の製造方法において、 前記熱可塑性樹脂表皮材と当接する一方の金型の表面
に、所定粗さの微細な凹凸をあらかじめ形成しておき、
前記合成樹脂型内発泡成形体と熱可塑性樹脂表皮材の一
体化と共に、該熱可塑性樹脂表皮材の表面に前記微細な
凹凸を転写することによって、この熱可塑性樹脂表皮材
の表面粗さを略一様に保持することを特徴とする表皮付
き合成樹脂型内発泡成形体の製造方法。10. A plastic molded article in a synthetic resin mold and a thermoplastic resin skin material are placed between two molds, and when the mold is clamped and pressurized, these synthetic resin molded foams are molded with heat and / or an adhesive. In a method for producing a foamed molded article in a synthetic resin mold with a skin that integrates a body and a thermoplastic resin skin material, fine irregularities of a predetermined roughness are formed on the surface of one of the molds in contact with the thermoplastic resin skin material. Pre-formed,
The surface roughness of the thermoplastic resin skin material is substantially reduced by transferring the fine irregularities on the surface of the thermoplastic resin skin material together with the integration of the synthetic resin mold foam molded body and the thermoplastic resin skin material. A method for producing a foamed molded article in a synthetic resin mold with a skin, characterized in that the molded article is held uniformly. 【請求項１１】 ２つの金型の間に合成樹脂型内発泡成
形体と熱可塑性樹脂表皮材を配置して型締め、加圧する
際、熱及び／又は接着剤でこれら合成樹脂型内発泡成形
体と熱可塑性樹脂表皮材を一体化させる表皮付き合成樹
脂型内発泡成形体の製造方法において、 前記熱可塑性樹脂表皮材と当接する一方の金型の表面
に、凹凸転写用部材をあらかじめ接合しておき、前記合
成樹脂型内発泡成形体と熱可塑性樹脂表皮材の一体化と
共に、該熱可塑性樹脂表皮材の表面に、前記凹凸転写用
部材の表面に形成した微細な凹凸を転写することによっ
て、この熱可塑性樹脂表皮材の表面粗さを略一様に保持
することを特徴とする表皮付き合成樹脂型内発泡成形体
の製造方法。11. A plastic molded article in a synthetic resin mold and a thermoplastic resin skin material are placed between two molds, and when the mold is clamped and pressurized, these synthetic resin molded foams are molded with heat and / or an adhesive. In a method of manufacturing a foamed molded article in a synthetic resin mold with a skin that integrates a body and a thermoplastic resin skin material, an uneven transfer member is preliminarily joined to a surface of one of the molds in contact with the thermoplastic resin skin material. In advance, together with the integration of the synthetic resin molded foam and the thermoplastic resin skin material, by transferring fine irregularities formed on the surface of the irregularity transfer member to the surface of the thermoplastic resin skin material. And a method for producing a foamed synthetic resin mold with a skin, wherein the surface roughness of the thermoplastic resin skin material is kept substantially uniform. 【請求項１２】 ２つの金型の間に合成樹脂型内発泡成
形体と熱可塑性樹脂表皮材を配置して型締め、加圧する
際、熱及び／又は接着剤でこれら合成樹脂型内発泡成形
体と熱可塑性樹脂表皮材を一体化させる表皮付き合成樹
脂型内発泡成形体の製造方法において、 前記熱可塑性樹脂表皮材と当接する一方の金型の表面
に、凹凸転写用粒子状物を付着させて所定粗さの微細な
凹凸をあらかじめ形成しておき、前記合成樹脂型内発泡
成形体と熱可塑性樹脂表皮材の一体化と共に、該熱可塑
性樹脂表皮材の表面に前記微細な凹凸を転写することに
よって、この熱可塑性樹脂表皮材の表面粗さを略一様に
保持することを特徴とする表皮付き合成樹脂型内発泡成
形体の製造方法。12. A plastic molded article in a synthetic resin mold and a thermoplastic resin skin material are arranged between two molds, and when the mold is clamped and pressurized, these synthetic resin molded foams are molded with heat and / or an adhesive. In a method for producing a foamed molded article in a synthetic resin mold with a skin for integrating a body and a thermoplastic resin skin material, the irregularity transfer particulate matter is attached to the surface of one of the molds in contact with the thermoplastic resin skin material. In this way, fine irregularities having a predetermined roughness are formed in advance, and the fine irregularities are transferred to the surface of the thermoplastic resin skin material together with the integration of the foamed molded article in the synthetic resin mold and the thermoplastic resin skin material. A method for producing a foamed synthetic resin mold with a skin, wherein the surface roughness of the thermoplastic resin skin material is maintained substantially uniform. 【請求項１３】 前記微細な凹凸の粗さが、表面粗さ測
定器を用いて測定した表面粗さ波形において、振幅５乃
至１５０μｍ、波長３０乃至６００μｍの範囲である請
求項５乃至１２のいずれか記載の表皮付き合成樹脂型内
発泡成形体の製造方法。13. The surface roughness waveform measured using a surface roughness measuring instrument, wherein the roughness of the fine unevenness is in the range of 5 to 150 μm in amplitude and 30 to 600 μm in wavelength. The method for producing a foamed article in a synthetic resin mold with a skin according to the above. 【請求項１４】 前記一方の金型の表面に、前記微細な
凹凸に加えて製品意匠模様用凹凸をあらかじめ形成して
おき、前記熱可塑性樹脂表皮材の表面に前記微細な凹凸
を転写する際に、前記製品意匠模様用凹凸をも転写する
ことを特徴とする請求項５、７、８、９、１０、１２、
又は１３記載の表皮付き合成樹脂型内発泡成形体の製造
方法。14. The method according to claim 1, further comprising the step of forming in advance the irregularities for a product design pattern on the surface of the one mold in addition to the minute irregularities, and transferring the minute irregularities to the surface of the thermoplastic resin skin material. Wherein the irregularities for the product design pattern are also transferred.
Or a method for producing a foamed molded article in a synthetic resin mold having a skin according to item 13. 【請求項１５】 前記凹凸転写用部材の表面に、前記微
細な凹凸に加えて製品意匠模様用凹凸をあらかじめ形成
しておき、前記熱可塑性樹脂表皮材の表面に前記微細な
凹凸を転写する際に、前記製品意匠模様用凹凸をも転写
することを特徴とする請求項６、８、９、１１、又は１
３記載の表皮付き合成樹脂型内発泡成形体の製造方法。15. The method according to claim 1, further comprising: forming in advance the irregularities for the product design pattern on the surface of the member for transferring irregularities, in addition to the minute irregularities, to transfer the minute irregularities to the surface of the thermoplastic resin skin material. Wherein the irregularities for product design pattern are also transferred.
4. The method for producing a foamed molded article in a synthetic resin mold with a skin according to 3. 【請求項１６】 前記熱可塑性樹脂表皮材を配置する前
に、該熱可塑性樹脂表皮材の表面に製品意匠模様用凹凸
をあらかじめ形成しておくことを特徴とする請求項５乃
至１３のいずれか記載の表皮付き合成樹脂型内発泡成形
体の製造方法。16. The irregularities for a product design pattern are formed on the surface of the thermoplastic resin skin material in advance before the thermoplastic resin skin material is arranged. A method for producing a foamed molded article in a synthetic resin mold with a skin according to the above.
JP8182355A 1996-06-28 1996-07-11 Manufacture of synthetic resin in-mold foamed molded object fitted with skin and mold used therein Pending JPH1024435A (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
JP8182355A JPH1024435A (en) 1996-07-11 1996-07-11 Manufacture of synthetic resin in-mold foamed molded object fitted with skin and mold used therein
PCT/JP1997/002272 WO1998000287A1 (en) 1996-06-28 1997-06-27 Method of manufacturing skin-carrying internal-mold expansion molded body of synthetic resin and metal mold used for the same method
CNB971943273A CN1157283C (en) 1996-06-28 1997-06-27 Method for manufacturing skin-carrying internal-mold expansion molded body of synthetic resin and mold used for same
EP97928530A EP0960719B1 (en) 1996-06-28 1997-06-27 Method of manufacturing skin-carrying internal-mold expansion molded body of synthetic resin, and metal mold used for the same method
DE69730526T DE69730526T2 (en) 1996-06-28 1997-06-27 METHOD FOR PRODUCING A COATED, SYNTHETIC RESIN EXPRESSED IN A TOOL TOOL, AND METAL FORMING TOOL USED IN THIS METHOD
US09/142,210 US6261489B1 (en) 1996-06-28 1997-06-27 Method of manufacturing skin-carrying internal-mold expansion molded body of synthetic resin and metal mold used for the same method

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP8182355A JPH1024435A (en) 1996-07-11 1996-07-11 Manufacture of synthetic resin in-mold foamed molded object fitted with skin and mold used therein

Publications (1)

Publication Number Publication Date
JPH1024435A true JPH1024435A (en) 1998-01-27

Family

ID=16116872

Family Applications (1)

Application Number Title Priority Date Filing Date
JP8182355A Pending JPH1024435A (en) 1996-06-28 1996-07-11 Manufacture of synthetic resin in-mold foamed molded object fitted with skin and mold used therein

Country Status (1)

Country Link
JP (1) JPH1024435A (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1704978A1 (en) * 2005-03-22 2006-09-27 ArvinMeritor GmbH Thermoforming or sheet foaming mould, its manufacturing method and process for the production of a composite part

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1704978A1 (en) * 2005-03-22 2006-09-27 ArvinMeritor GmbH Thermoforming or sheet foaming mould, its manufacturing method and process for the production of a composite part

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