、發明說明： 【發明所屬之技領域】 本發明係涉及發泡產品的製造方法，尤其涉及如何製 造具有熱可塑性塑膠表皮之發泡產品的技術。 【先前技術】 在US 5, 658,179及US 4, 850, 913號專利案中，係揭 露一種運動用的板子’它具有一發泡核心及包覆住該發泡 核心的上表皮及下表皮。該發泡核心用是發泡原料發泡形 成後’再切割成預定的形狀’然後再將該上表皮及下表皮 以熱壓貼合方式結合至該發泡心板的上、下表面與週邊。 -在US 5, 211，593號專利案中，係揭露一種具有壓印圖 案的發泡核心結構，它的結構及製造方法比上述專利案還 要複雜一些。 在US 2003/0224675號專利案中，係揭露一種滑板， 它使用具有圖案的表皮及PE材料的發泡核心。然而，它的 製造方法一樣是要先切割形成該發泡核心，然後，再貼上 表皮。 US 2004/0176001號專利案中，係揭露一種滑板，它 使用PS材料的發泡核心，亦即保麗龍板。此一專利案的發 泡核心仍然是要預先成形’然後再貼上表皮。 、 US 4, 693, 856號專利案中，係揭露一種熱塑性物件的 製造方法，它提供多量第一次發泡的合成樹脂顆粒，並引 進一膨脹劑而形成第二次發泡的顆粒，然後，將第二次發 ，使得 ，的顆粒置於一模具内’並引入熱氣體至該模具内 第二次發泡的顆粒膨脹並相互黏結。 【發明内容】 、本發明主要描述一種製造具有表皮之發泡產品的方 法。此方法係先將一熱可塑性塑膠表皮或其它種類的熱可 塑性表皮固定於一模具内，接著將一些發泡顆粒及具有壓 力之熱氣體一起灌送入該模具内。由於該熱氣體的溫度係 足以使該些發泡顆軚的表面及該熱可塑性塑膠表皮的内 面發生熱熔。因此，經過前述過程所獲得的發泡產品係包 括該熱可塑性塑膠表皮及—核心，該核心係藉由該些發泡 ，粒以沒有_之方式相互黏結形成，且該核心㈣面也 疋沒有間㈣㈣熱可塑性塑膠表皮的内面相互黏結在 時形發=品㈣狀及表皮是同 具有不易分離的優=。皮與核心係形成良好結合而 【實施方式】 在第一圖中係_示本發 子所揭示的方法可Mu 佳實關。此-例 該第一發泡產品（3〇〇 。、\發泡產品（3〇〇)。 成品。此容後再述。 )可以視為成品，也可以視為半 1323216 請參閱第一圖，製造該第一發泡產品（3 〇 〇)之方 法如下述： a)提供一模具（1 ◦)。 該模具（1 0)係以可合模之上模（i i)與下模（工 2 )組成。該上模（1【）與下模（i 2 )中分別具有上 成型模穴（1 3 0)及下成型模穴（工3丄）供組成一成 型模穴（1 3 )，該成型模穴（丄3 )係對應一第一發泡產 品（3 0 0 )之形狀。此外，該上模（工工）另連接有一 • 射出管（1 4 )，並藉由該第射出管（1 4 )與一射出裝置 (3 )連接。 t 該射出裝置（3 )包括-料筒（3工）及一供氣設備 (33)該料rt(31)供裝填隨後步驟中戶斤需要的保麗 龍發泡顆粒（3 0)或其它種類的發泡顆粒。這些發泡顆 粒是呈現珠狀。又該料筒（3丄）的底端設置有—閥門（3 2 )’用以控制該些發泡顆粒（3 Q )的輸出量。至於該供 氣設備（3 3 )制以供應該模具（i Q )具有—定壓力' 鲁及溫度之熱氣體，例如蒸氣。 、b)將ϋ可魏轉表皮（2Q)以足夠涵蓋該 成型模穴（1 3)之方式固定於該模具（工〇)β，例如， ”所示地先將該第-熱可塑性塑膠表皮（2Q)固定於 該下模（1 2)上，然後將上模（1 1)與下模（1 2) 合模而將該第-熱可塑性塑膠表皮（2Q)四周定位。 Ο驅動該射岐置（3 )，以使數量足触·成型模 穴（1 3)的發泡顆粒（3 〇)與熱氣一起灌入該模具（工 0 )内。 7 由於該熱氣體之溫度係會使該些發泡顆粒（3 Ο)的 表面產生熱熔而導致具備黏性，以及使該熱可塑性塑膠表 皮（2 0)本身軟化及内面產生熱熔而導致具備黏性。且 該熱氣體的壓力會使該些發泡顆粒（3 0)相互擠壓，並 推擠該第一熱可塑性塑膠表皮（2 〇)促其延展成對應該 下模（1 2)内之成型模穴（1 3)的形狀。當溫度降低 時’該些發泡顆粒（3 〇)便會沒有間隙地相互黏結在一 起，且位在最外面的發泡顆粒（3 0)也會沒有間隙地與 該第一熱可塑性塑膠表皮（2 0)的内面相互黏結在二 起。接著，打開該模具（10)後，就可取得該第一發泡 產（3 ◦〇)要注思的是，圖中所不的第一發泡產品（3 0 0)是已藉由修剪程序去除多餘的邊料後的結果。 依上述方法所形成之第一發泡產品（3 0 0 )包括該 第熱可塑性塑膠表皮（2 0)及藉由該些發泡顆粒（3 0 )而开v成之一第一核心（3 〇 a )。且由於該熱可塑性 2膠表皮（2 0 )只覆蓋住該第__核心、（3 ◦ a )的頂面 J周邊二所以’該第-發泡產品（300)的底面會因為 覆蓋龍第—熱可塑性歸表皮（20)而裸露出-弟一面（3 0 1 )。在此例子中，該第—發泡產品（3 〇 〇) ^一滑板的半成品’它尚f要另—個半成品來組成一個 二正的,板成品’例如沖浪板及滑雪板。然而，若該第一 ，產αα ( 3 〇 Q )的形狀是自行車椅塾的形狀，那麼， Γ— *發/包產(3 ◦ ◦)就可視為-個成品，這是因為 自灯車椅墊的底面有沒有表皮覆蓋並不重要。 此外，必需指出的是，只要該下成型模穴（1 3 1) 的表面形成凹部或凸部，所形成的第一發泡產品（3 Ο Ο ) 的表面就會對應產生凹陷部（302)或凸出部，一如第 二圖所示。更進一步地說，如果這些凹部或凸部係構成一 圖案’那麼，所形成的第-發泡產品（3 0 0 )的表面就 會對應產生一立體圖案。 在第三圖中係顯示本發明另一個較佳實施例。此一例 子所揭示的方法可以用來製造一第二發泡產品（4 〇 〇 )。 該第二發泡產品（4 ο 〇)可以視為成品，也可以視為半 成品。在此例子中，其所有的步驟都與第一圖所示的步驟 相同，容不贅述。不同之處在於，其使用之模具（丄〇 a ) 的成形模穴（1 3 a )。藉由此一成形模穴（i 3 a )所形 成的第二發泡產品（4 0 〇 )係包括一第二熱可塑性塑膠 表皮（2 0 a )及藉由該些發泡顆粒（3 〇)而形成之一 第一核心（4 0 a )。該第二核心（4〇 a)的底面會因為 沒有覆蓋到該第二熱可塑性塑膠表皮（2 〇 a )而裸露出 一第二面（4〇 1 )。在此例子中，該第二面（4〇 1)的 ，狀被安排成可楔合於該第一面（3〇1)。因此，藉由該 第一面（3 0 1)對應楔合該第二面（3 〇 2 )之方式， 即可使該第一發泡產品（3 〇 〇)與該第二發泡產品（4 〇 0)以黏膠結合成一體而形成一個發泡產品，一如第四 圖所示。此一發泡產品的核心都是由該些顆粒（3 〇)組 構形成的，且所有表面都具有該熱可塑性塑膠表皮，即該 ，—'二熱可塑性塑膠表皮（2 0 )( 2 0 a )。需指出的 ，該第一、二熱可塑性塑膠表皮（2 〇 )( 2 0 a )可以 疋相同的結構，也可以是不相同的結構。 至中係指出該第一、二熱可塑性塑膠表皮 0 a )的幾種做法。為了方便說明起見，以下 僅以該第—熱可塑性塑膠表皮（20)為例。 在第五圖中係指出該第—熱可塑性塑膠表皮（2〇) 的第種I成方法。該方法是先提供—張塑膠膜（2丄）， 膜（21)内部具有一圖案（21〇)，該圖案（2 1⑸可從外面看到。接著’於該塑膠膜（2 1)的内面 以淋膜方式形成-層結合膜（2 2 )，該結合膜（2 2 )係 為:種可使由PE材料製成之塑膠膜（21)能與由_ ;製成之發泡齡（3 〇 )作良縣合之㈣，像是混合 有一些PE材料及Ps#料之多重物性共聚物（卿咖的。 在第八圖中係指出該第一熱可塑性塑膠表皮（2 〇) 的第二種形成方法。該方法是先提供-聚乙烯發泡皮（2 3 )，其發泡密度為h 5〜12pcF，厚度為卜6顏。再將上 述的塑膠膜（2 1 )結合到該聚乙烯發泡皮（2 3)的一 面。然後，於該聚乙婦發泡皮（2 3)的另面以淋膜方式 形成上述的結合膜（2 2 )。藉由該結合膜（2 2 )就能使 該聚乙烯發泡皮（2 3)與該發泡顆粒（3 〇)作良好结 合。 在第七圖中係係指出該第一熱可塑性塑膠表皮（2 0)的第三種形成方法。該方法是先提供—塊如上述的聚 乙烯發泡皮（2 3 )。然後於該聚乙烯發泡皮（2 3 )的一 面以淋膜方式形成—歸板（2 4 )該塑膠板（2 4 )具 備耐磨性。接著，於該聚乙烯發泡皮（2 3)的另一面二 淋膜方式形成上述的結合膜（2 2 )。 1323216 Π、3八圖中係係指出該第一熱可塑性塑膠表皮（2 ==)形3法。該方法是先1如上述的聚乙埽 該聚上二塑一^ (2 1 )外面以淋膜方式形成上述的塑膠二，2於二塑^ t)係較厚於該塑膠膜(21)。最後，於該； /皮（23)的另一面形成上述的結合膜 根攄指出的是’該結合膜（2 2 )的材料特性是 料而決定。如果，發泡顆粒是㈣材料 3二=上述的塑膠膜(2 1 )及聚乙稀發泡皮(2 ，，並 第一声』，膜（2 2 )的形成方法是先提供一 荦（“οΓΐ 膜上以彩色印刷方式形成該圖 產二上 等成品。無論如何，這些產 運動**具. 成的，所以具有重量輕的好處σ。$者核：：是發泡顆粒所構 =塑膠表皮可與其核心形成良好，= 延些產品的市場競爭力。更，圖案的呈現更能提昇 y簡翠、快速。例如1用本‘二，的製造過程 板’遠比傳統方式簡單、快速、月fa滑雪板或沖浪 1323216 綜上所述，本發明之生產流程完全突破改革習用製法 生產效率低、品質不良率劣化的問題，是一技術理念上的 高度發明，應符專利申請要件，爰依法提出申請。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a foamed product, and more particularly to a technique for producing a foamed product having a thermoplastic plastic skin. [Prior Art] In the U.S. Patent No. 5,658,179 and U. The foaming core is formed by foaming a foamed raw material and then 'cutting into a predetermined shape', and then bonding the upper and lower skins to the upper and lower surfaces and the periphery of the foamed core sheet by thermocompression bonding. . - In the patent US 5,211,593, a foamed core structure having an embossed pattern is disclosed, the structure and manufacturing method of which is more complicated than the above-mentioned patents. In the patent US 2003/0224675, a type of slide is disclosed which uses a patterned core and a foamed core of PE material. However, it is manufactured in the same way that the foamed core is first cut and then the skin is applied. In the case of US 2004/0176001, a type of skateboard is disclosed which uses a foamed core of PS material, namely a styrofoam board. The foaming core of this patent is still pre-formed' and then attached to the skin. In US Pat. No. 4,693,856, the disclosure of the entire disclosure of the entire disclosure of the entire disclosure of the disclosure of the entire disclosure of the entire disclosure of The second time, the particles are placed in a mold and the hot gas is introduced into the mold. The second foamed particles expand and bond to each other. SUMMARY OF THE INVENTION The present invention mainly describes a method of manufacturing a foamed product having a skin. In this method, a thermoplastic plastic skin or other kind of thermoplastic skin is first fixed in a mold, and then some foamed particles and a hot gas having pressure are poured into the mold together. The temperature of the hot gas is sufficient to cause heat fusion of the surface of the foamed crucible and the inner surface of the thermoplastic plastic skin. Therefore, the foamed product obtained through the foregoing process includes the thermoplastic plastic skin and the core, and the core is formed by the foaming, the particles are bonded to each other in a manner of no, and the core (four) surface is also absent. (4) (4) The inner surface of the thermoplastic plastic skin is bonded to each other in the shape of the hair = the shape of the product (four) and the skin is the same as the easy to separate. The skin forms a good combination with the core system. [Embodiment] In the first figure, the method disclosed in the present invention is shown to be good. This example of the first foamed product (3〇〇., \foaming product (3〇〇). Finished product. This content will be described later.) can be regarded as the finished product, can also be regarded as half 1332316 See the first figure The method of manufacturing the first foamed product (3 〇〇) is as follows: a) A mold (1 ◦) is provided. The mold (10) is composed of a moldable upper mold (i i) and a lower mold (work 2). The upper mold (1 [) and the lower mold (i 2 ) respectively have an upper molding cavity (1 30) and a lower molding cavity (3 3) for forming a molding cavity (13), the molding die The hole (丄3) corresponds to the shape of a first foamed product (300). Further, the upper mold (worker) is additionally connected to an injection tube (14), and is connected to an injection device (3) by the first injection tube (14). t The injection device (3) comprises a barrel (3 work) and a gas supply device (33). The material rt (31) is used for filling the styrofoam foam particles (30) or other required in the subsequent step. Kinds of foamed granules. These foamed granules are in the form of beads. Further, the bottom end of the barrel (3 丄) is provided with a valve (3 2 ) for controlling the output of the foamed particles (3 Q ). As for the gas supply device (3 3 ), the mold (i Q ) is supplied with a hot gas such as steam having a constant pressure and temperature. b) fixing the 转可魏转皮皮 (2Q) to the mold (work) β in a manner sufficient to cover the molding cavity (13), for example, the first thermoplastic plastic skin is first shown (2Q) is fixed on the lower mold (12), and then the upper mold (1 1) is clamped with the lower mold (1 2) to position the first thermoplastic plastic skin (2Q) around the 。. The device (3) is arranged such that the foamed particles (3 〇) of the number of full-touch molding holes (13) are poured into the mold together with the hot gas. 7 Since the temperature of the hot gas is The surface of the foamed particles (3 Ο) is thermally fused to cause stickiness, and the thermoplastic plastic skin (20) itself is softened and the inner surface is thermally fused to cause stickiness, and the pressure of the hot gas The foamed particles (30) are pressed against each other, and the first thermoplastic plastic skin (2 〇) is pushed to promote the formation of the molding cavity (1 3) corresponding to the lower mold (12). The shape of the foamed particles (3 〇) will stick to each other without gaps, and the outermost foamed particles (30) The inner surface of the first thermoplastic plastic skin (20) is bonded to each other without any gap. Then, after the mold (10) is opened, the first foaming product (3 ◦〇) can be obtained. The first foamed product (300) which is not shown in the figure is the result of having removed the excess edge material by the trimming process. The first foamed product (300) formed by the above method includes The first thermoplastic plastic skin (20) and the foamed particles (30) are opened to form a first core (3 〇a), and because of the thermoplastic 2 rubber skin (20) Covering the top surface J of the first __core, (3 ◦ a ), so the bottom surface of the first foaming product (300) will be exposed because of covering the dragon-thermoplasticity to the skin (20). One side (3 0 1 ). In this example, the first foaming product (3 〇〇) ^ a semi-finished product of a skateboard 'it's still another half-finished product to form a two-positive, finished sheet' such as a surfboard And snowboard. However, if the first, αα (3 〇Q) shape is the shape of a bicycle chair, then, Γ - * hair / package (3 ◦ It can be regarded as a finished product, because it is not important that there is no skin covering from the bottom surface of the lamp cushion. In addition, it must be pointed out that as long as the surface of the lower molding cavity (1 3 1) forms a concave or convex surface The surface of the first foamed product (3 Ο 形成 ) formed correspondingly produces a recess (302) or a projection, as shown in the second figure. Further, if these recesses or projections By constituting a pattern 'then, the surface of the formed first foamed product (300) will correspondingly produce a three-dimensional pattern. In the third figure, another preferred embodiment of the present invention is shown. The method disclosed in this example can be used to make a second foamed product (4 〇 〇 ). The second foamed product (4 ο 〇) can be regarded as a finished product or as a semi-finished product. In this example, all the steps are the same as those shown in the first figure, and are not described here. The difference is in the forming cavity (1 3 a ) of the mold (丄〇 a ) it uses. The second foamed product (40 〇) formed by the forming cavity (i 3 a ) comprises a second thermoplastic plastic skin (20 a ) and by the foamed particles (3 〇) ) forming one of the first cores (40 a). The bottom surface of the second core (4〇 a) exposes a second side (4〇 1 ) because it does not cover the second thermoplastic plastic skin (2 〇 a ). In this example, the second face (4〇 1) is arranged to be wedged to the first face (3〇1). Therefore, the first foamed product (3 〇〇) and the second foamed product can be obtained by the first surface (300) corresponding to the second surface (3 〇2). 4 〇0) A foamed product is formed by combining the adhesives, as shown in the fourth figure. The core of the foamed product is formed by the granules (3 〇), and all the surfaces have the thermoplastic plastic skin, that is, the 'two thermoplastic plastic skin (20) (20) a). It should be noted that the first and second thermoplastic plastic skins (2 〇 ) ( 20 a ) may have the same structure or different structures. To the middle of the system pointed out the first and second thermoplastic plastic skin 0 a) several practices. For convenience of explanation, the following only the thermoplastic plastic skin (20) is taken as an example. In the fifth figure, the first method of forming the first thermoplastic plastic skin (2〇) is indicated. The method first provides a plastic film (2 丄), and the film (21) has a pattern (21 〇) inside, the pattern (2 1 (5) can be seen from the outside. Then 'on the inner surface of the plastic film (2 1) Forming a layer-bonding film (2 2 ) by lamination, the bonding film (2 2 ) is: a plastic film (21) made of a PE material can be made with a foaming age made of 3 〇) as a good county (4), like a mixture of some PE materials and Ps# material of multiple physical copolymers (Qingca. In the eighth figure points out the first thermoplastic plastic skin (2 〇) The second method of forming is to first provide a polyethylene foam skin (2 3 ) having a foaming density of h 5 to 12 pcF and a thickness of 6 colors. The plastic film (2 1 ) is then bonded to the plastic film (2 1 ). One side of the polyethylene foam (23). Then, the above-mentioned bonding film (2 2 ) is formed on the other side of the polyethylene foam (23) by a coating method. 2 2 ) The polyethylene foam skin (23) can be well combined with the foamed particles (3 。). In the seventh figure, the first thermoplastic plastic skin (20) is indicated. Three The method comprises the following steps: providing a polyethylene foam skin (2 3 ) as described above, and then forming a film on one side of the polyethylene foam skin (23) by a lamination method (2 4 ) The plastic plate (24) has wear resistance. Then, the above-mentioned bonding film (2 2 ) is formed on the other side of the polyethylene foam skin (23). 1323216 Π, 八八图Pointing out the first thermoplastic plastic skin (2 ==) shape 3 method. The method is as follows: 1. The above-mentioned plastic bismuth is formed on the outside of the plastic film. 2 于二塑^t) is thicker than the plastic film (21). Finally, on the other side of the skin / 23 (23) forms the above-mentioned bonding film, the root is pointed out that 'the bonding film (2 2) The material properties are determined by the material. If the foamed particles are (4) material 3 2 = the above plastic film (2 1 ) and the polyethylene foam skin (2, and the first sound), the formation of the film (2 2 ) The method is to provide a 荦 (" ο 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜 膜σ.$者核:: It is the structure of foamed granules = the plastic skin can form well with its core, = the market competitiveness of some products. Moreover, the presentation of the pattern can improve y, simple and fast. For example, 1 'Second, the manufacturing process board' is much simpler and faster than the traditional method, and the monthly fa snowboard or surfing 1332316. In summary, the production process of the present invention completely breaks through the reforming conventional method, and the production efficiency is low and the quality defect rate is degraded. The high-invention of the technical concept should be in accordance with the requirements of the patent application, and the application should be made according to law.
12 1323216 【圖式簡單說明】 第一圖’係顯示本發明方法 立θ 之—較佳貫施例的流程示 製造形成之第一發泡 第二圖，係顯示藉由本發明方法 產品。 較佳實施例的流程 弟二圖’係顯不本發明方法之另一 示意圖。12 1323216 [Brief Description of the Drawings] The first drawing shows the method of the present invention. The flow of the preferred embodiment shows the first foaming of the manufacturing. The second drawing shows the product by the method of the present invention. The flow of the preferred embodiment shows another schematic diagram of the method of the present invention.
第四圖’係顯示—種藉由本發明方法所 品。 之發泡產 第五至八圖’係用以指出形成本發明熱可塑性塑膠表 皮的各種方法。 ν 【主要元件符號說明】The fourth figure is shown by the method of the present invention. The foaming products 5 to 8 are used to indicate various methods of forming the thermoplastic skin of the present invention. ν [Main component symbol description]
(1 0 a)模具 (12)下模 (13a)成形模穴 (1 3 1)上成型模穴 (1 〇)模具 (11)上模 (13) 成型模穴 (1 3 0)上成型模穴 (14) 射出管 (20) 第一熱可塑性塑膠表皮 (21) 塑膠膜 (2 2)結合膜 (2 0 a)第二熱可塑性塑膠表皮 (2 1 0 )圖案 13 1323216 (2 3)聚乙烯發泡皮 (2 4)塑膠板 (3 )射出裝置 (3 0)發泡顆粒 (3 0 a )第一核心 (3 0 0 )第一發泡產品 (3 0 1 )第一面 (3 0 2)凹陷部 (31)料筒 (3 3)供氣設備 (3 2)閥門 (4 0 0 )第二發泡產品 (4 0 a)第二核心 (4 0 1)第二面 14(1 0 a) mold (12) lower mold (13a) forming cavity (1 3 1) molding cavity (1 〇) mold (11) upper mold (13) molding cavity (1 30) molding die Hole (14) Injection tube (20) First thermoplastic plastic skin (21) Plastic film (2 2) Bonding film (20 a) Second thermoplastic plastic skin (2 1 0) pattern 13 1323216 (2 3) Ethylene foam skin (2 4) plastic plate (3) injection device (30) foamed particles (30 a) first core (300) first foam product (3 0 1) first side (3 0 2) recessed part (31) barrel (3 3) gas supply equipment (3 2) valve (400) second foamed product (40 a) second core (4 0 1) second side 14