JP2000043060A - Bead foamed molded product and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a bead foamed molded product having good and constant quality wherein resin beads are sufficiently fused and integrated up to the interior of the molded product and a foamed layer formed by the fusion and integration of resin beads is sufficiently fused to and integrated with a base material and a skin material. SOLUTION: The projected part 20 bent to one side of a base material 11 is preformed to the base material 11 and the heating medium supply ports 21, 22 opened to the side surface and leading end surface of the projected part are preliminarily provided and the base material 11 and a skin material 12 are arranged to a mold so that the projected part 20 is provided on the side of the skin material 12 and the space between the base material 11 and the skin material 12 is filled with resin beads B and a heating medium 39 is supplied to the space between the base material 11 and the skin material 12 from the heating medium supply ports 21, 22 through the projected part 20.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed molded article obtained by fusing a large number of resin beads filled between a base material and a skin material, and a method for producing the same.

[0002]

2. Description of the Related Art In some cases, bead foam moldings are used as foam moldings. Fig. 8
As shown in FIG. 2, there is a type that includes a base material 41, a skin material 42, and a foam layer 43 in which resin beads filled between the two members are fused and integrated. As a method for manufacturing the bead foam molded article 40, for example, a through hole 5
0, and the base material 41 is, as shown in FIG.
The base material 41 and the skin material are arranged on a mold surface 61a of one of two molds 61 constituting a molding die, and a skin material 42 formed by vacuum molding or the like is arranged on a mold surface 62a of the other mold 62. After filling the gaps 66 between the resin beads with the resin beads, the heat medium 69 such as steam supplied from the heat medium ejection port 65 of the molding die is
By supplying the resin layer between the base material 41 and the skin material 42 through the ventilation hole 50, the foamed layer 43 in which the resin beads are fused and integrated is formed.
And a method of fusing and integrating with the skin material 42.

However, in the above-described molding method, the heat medium 69 supplied between the base material 41 and the skin material 42 from the ventilation holes 50 is obstructed by the resin beads existing near the ventilation holes 50. There is a problem in that the resin beads are not efficiently supplied to the central portion between the base material 41 and the skin material 42 and to the skin material 42 side portion, and the heating of the resin beads tends to be insufficient particularly near the skin material 42. That is, the resin beads in the vicinity of the ventilation hole 50 are quickly heated and fused by the heat medium 69 supplied from the ventilation hole 50 of the base material 41, whereby the vicinity of the ventilation hole 50 in the base material 41 is fused. And the heat medium passage formed between the resin beads becomes narrower.
This is because the supply of the heat medium 69 between the two is hindered. As a result, the foam layer 43 formed by fusion of the resin beads is formed.
In the case, the fusion of the resin beads between the base material 41 and the skin material 42 and the vicinity of the skin material 42 become insufficient, and the fusion between the foamed layer 43 and the skin material 41 is not sufficiently performed.
Therefore, the obtained bead foam molded article 40 does not have the expected quality and the quality is not constant.

The resin beads include foam beads which are foamed in advance and are fused without foaming at the time of heating, and foamable beads which are foamed and fused at the time of heating at the time of heating. The above problem also occurs when resin beads are used.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and the resin beads are sufficiently fused and integrated even inside the molded article, and the foamed layer formed by the fusion and integration is formed. An object of the present invention is to provide a bead foam molded product having good and constant quality, which is sufficiently fused and integrated with a base material and a skin material, and a simple production method thereof.

[0006]

That is, according to the first aspect of the present invention, a base material and a skin material are fused and integrated by a heat medium supplied between the two members and supplied from a heat medium supply port of the base material. In the bead foam molded article composed of a foamed layer made of resin beads formed, a convex portion bent toward the skin material side is provided on the base material, and a heat medium supply port opened on the side surface and the distal end surface of the convex portion is formed. The present invention relates to a bead foam molded product characterized in that:

According to a second aspect of the present invention, a convex portion bent in advance to one side of the base material is formed on the base material, and a heat medium supply opening is provided on a side surface and a tip end surface of the convex portion. The base material and the skin material are arranged in a molding die such that the protrusions face the skin material side, and after filling the resin beads between the base material and the skin material, from the heat medium supply port through the protrusion. By supplying a heat medium between the base material and the skin material, a foamed layer is formed by fusing and integrating the resin beads, and the foamed layer is fused and integrated with the skin material and the base material. The present invention relates to a method for producing a bead foam molded article.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a sectional view showing a bead foam molded product according to one embodiment of the first aspect of the present invention, FIG. 2 is an enlarged perspective view of a base material convex portion, and FIG. 3 is an enlarged view of a base material convex portion according to another embodiment. FIG. 4 is a cross-sectional view showing a state in which a base material and a skin material are arranged in a molding die in a method for manufacturing a bead foam molded product according to an embodiment of the present invention, and FIG. FIG. 6 is a cross-sectional view showing a state in which the heating medium is supplied, and FIG.

First, a bead foam molded product according to an embodiment of the present invention will be described. The bead foam molded article 10 shown in FIG. 1 includes a base material 11, a skin material 12, and the base material 11.
And a foam layer 13 formed between the skin material 12 and the foam layer 13 and the base material 11 and the skin material 12 are fused and integrated.

The base material 11 is for maintaining the shape of the bead foam molded article 10, improving the strength, or attaching it.
It is made of rigid plastic or metal such as BS resin or glass fiber reinforced polypropylene, and is formed by injection molding or the like.

The base material 11 is provided with a plurality of convex portions 20 having a concave cross section which are bent toward the skin material 12 side, and a resin bead supply port 23 is formed at the center. The size of the convex portion 20 may be appropriately determined, but if it is too close to the inner surface of the skin material 12, the foam layer 13 in that portion becomes too thin and the feel of the surface of the molded product 10 may be partially different, On the other hand, if it is too small (away from the inner surface of the skin material 12), the effects of the present invention described later will not be sufficiently obtained, and therefore, a dimension in which the tip is located at a substantially middle position of the thickness of the molded product 10 is preferable.

As shown in FIG. 2, the projection 20 has a plurality of heat medium supply ports 21 and 22 formed on the side surface 20s and the front end surface 20e as heat medium supply holes when the foam layer 13 is formed. The inside and outside of the convex portion 20 communicate with each other through the heat medium supply ports 21 and 22. The size of the heat medium supply ports 21 and 22 may be any size as long as the resin beads do not pass through when heating the beads. In addition, the shape of the heat medium supply ports 21 and 22 is not limited to the elongated hole shape as shown in FIG. 2, but may be any other appropriate shape, for example, a round shape like the heat medium supply port 22a at the tip end surface shown in FIG. It may have a hole shape. Reference numeral 11a in FIG.
The convex portion 21a is a heat medium supply port on the side surface of the convex portion 20a. Further, the heat medium supply ports 21 and 22 on the side surface and the distal end surface of the convex portion 20 may be formed continuously, for example, by a slit extending from the side surface of the convex portion 20 to the distal end surface. Further, the shape of the projection 20 is not limited to the illustrated one. The protrusions 20 and the heat medium supply ports 21 and 22
Is preferably formed at the same time as the injection molding of the base material 11.

The resin bead supply port 23 is used for filling the resin beads for forming the foamed layer 13 between the base material 11 and the skin material 12 when the bead foam molded article 10 is formed. And at one or a plurality of locations as in this example.

The skin material 12 is made of the bead foam molded article 10.
Of the base material 11
And protects the foam layer 13 located between the cover material 12 and the cover layer 12. The cover layer 12 is made of vinyl chloride resin, thermoplastic polyurethane, polyolefin-based thermoplastic elastomer (TPO) resin, or the like, and is formed by vacuum molding or powder slush molding. A molded product having a surface shape is used.

The foam layer 13 includes the base material 11 and the skin material 12.
The resin beads filled in between are fused and integrated with a heat medium such as steam supplied from the heat medium supply ports 21 and 22 of the base material 11 to form a layer. It is used for imparting characteristics, that is, elasticity, cushioning property, heat insulation property, and the like to the bead foam molded article 10.

The resin beads include foam beads which do not foam by heating as described above and foam beads which foam by heating, and both can be used in the present invention. In other words, foamed beads are particles of a thermoplastic resin containing a foaming agent, which have already been foamed at a predetermined magnification, for example, several times to several tens times, and the surface is melted by being heated to a predetermined temperature. And has the property of exhibiting fusibility. In contrast, foamable beads are thermoplastic resin particles containing a foaming agent, and when heated to a predetermined temperature, the surface is melted to exhibit fusibility and foam to a predetermined magnification. It is. Examples of such resin beads include trade name: Eperan PP (manufactured by Kanegafuchi Chemical Industry Co., Ltd., expansion ratio: 15), trade name: EP Pole (manufactured by Mitsubishi Chemical BASF). The foam layer 13 is fused and integrated with the base material 11 and the skin material 12 simultaneously with the formation of the foam layer.

Next, an embodiment of a method of manufacturing the above-mentioned bead foam molded article 10 will be described. Forming device 3 shown in FIG.
Reference numeral 0 denotes a molding device for the bead foam molded article 10 and includes two molds 31 and 32 constituting a molding die. The molds 31 and 32 have a mold surface 3 having the shape of the bead foam molded product 10.
1a and 32a are provided inside.

Of the two dies 31, 32, one of the dies 31 has a heat medium space 31b formed therein, and the mold surface 31a has a plurality of heat medium spaces 31b communicating therewith. The heat medium outlet 35 is formed so as to be aligned with the projection 20 of the base material 11. Also, the mold surface 3 of the mold 31
The distal end of the resin bead filling gun 33 is inserted into 1 a so as to be aligned with the resin bead supply port 23 of the base material 11. The resin bead filling gun 33 is provided in the heat medium space 3.
1b is connected to a resin bead supply device (not shown) outside the mold. Further, a heat medium supply pipe 34 connected to a heat medium supply device (not shown) is connected to an end of the heat medium space 31b and the heat medium space 3b is connected to the mold 31.
A heat medium discharge pipe 37 is connected to the opposite end of 1b, and can be opened and closed by a valve 38.

First, on the mold surface 31a of the one mold 31, the base material 1 described in the bead foam molded article 10 is applied.
The surface material 12 is disposed on the mold surface 32a of the other 32, and the mold is clamped. At this time, the convex portion 20 of the base material 11 is directed to the skin material 12 side, and the convex portion 20 and the heat medium ejection port 35 of the mold surface 31a, and the resin bead supply port 23 and the resin bead filling gun The skin material 12 is arranged such that the design surface is on the mold surface 32a side. In addition,
The holding of the base material 11 on the mold surface 31a is performed by a known locking means such as a clip attached to the base material 11 or the mold surface 31a.

Next, as shown in FIG. 5, resin beads B are filled into the gap 36 between the base material 11 and the skin material 12 via the resin bead filling gun 33. At this time, since the heat medium supply port 21 on the side surface of the convex portion 20 and the heat medium supply port 22 on the front end surface of the convex portion 20 are smaller than the size of the resin beads B, the resin beads B are connected to the heat medium supply ports 21 and 22. Does not jump out of the substrate 11 through the substrate.

Subsequently, as shown in FIG. 6, a heat medium 39 such as steam is supplied from a heat medium supply device (not shown) to the heat medium supply pipe 34.
The heat medium is supplied between the base material 11 and the skin material 12 through the heat medium supply ports 21 and 22 on the side surface and the tip end surface of the protrusion 20 through the space 31 b for the heat medium, the heat medium outlet 35, and the inside of the protrusion 20 of the base material 11. I do.

When the heating medium is supplied, as shown in an enlarged view in FIG. 7, the convex portion 20 of the base material 11 projects to the center between the base material 11 and the skin material 12 or near the inner surface of the skin material 12, and Since the heat medium 39 is supplied between the base material 11 and the skin material 12 from the heat medium supply ports 21 and 22 formed on the side surface and the tip end surface of the portion 20, the skin material 12 which has conventionally been difficult for the heat medium to reach is provided.
The heating medium is also sufficiently supplied to the nearby resin beads B. Further, the side surface 20s and the tip end surface 2 of the convex portion 20
Since 0e constitutes a kind of heat medium supply surface, the heat medium supply area increases and the supply amount of the heat medium increases as compared with the case of the conventional through-hole formed in the flat surface of the base material. As a result, the heat medium 39 is efficiently applied to the resin beads B between the base material 11 and the skin material 12.
Can be dispersed and supplied, so that the resin beads B are reliably heated not only in the vicinity of the base material 11 but also in the vicinity of the skin material 12 and integrated by fusion or foam fusion to form the uniform foam layer 13. Is formed, and the foam layer 13 and the base material 11 and the skin material 12 are fused and integrated to obtain a desired bead foam molded article. The heat medium 39 supplied between the base material 11 and the skin material 12 is dispersed between the resin beads B between the base material 11 and the skin material 12, and then outside the mold via the heat medium discharge pipe 37 and the valve 38. Reach.

Thereafter, the supply of the heat medium 39 is stopped, and the molded product is released from the mold by cooling. Thus, the desired bead foam molded product 10 shown in FIG. 1 can be obtained.

[0024]

As shown and described above, according to the expanded bead product and the method of manufacturing the same of the present invention, a convex portion protruding toward the skin material side is formed on the base material, and the side and tip of the convex portion are formed. Since the heat medium supply port opening is formed on the surface, the resin beads filled between the base material and the skin material are sufficiently heated not only near the base material but also near the skin material to be fused and integrated, or foamed and fused. A uniform bead foam molded product is obtained.
In addition, since the substrate only needs to have the above structure, a bead foam molded article having a constant and good quality can be obtained very simply and economically.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a bead foam molded product according to an embodiment of the present invention.

FIG. 2 is an enlarged perspective view of a base member convex portion.

FIG. 3 is an enlarged perspective view of a base protrusion according to another embodiment.

FIG. 4 is a cross-sectional view showing a state in which a base material and a skin material are arranged in a molding die in the method for producing a bead foam molded product according to one embodiment of the second invention.

FIG. 5 is a cross-sectional view showing a state at the time of filling with resin beads.

FIG. 6 is a cross-sectional view showing when a heating medium is supplied.

FIG. 7 is an enlarged cross-sectional view of the vicinity of a base material protrusion when a heating medium is supplied.

FIG. 8 is a cross-sectional view showing an example of a conventional bead foam molded product.

FIG. 9 is an enlarged cross-sectional view of the vicinity of a ventilation hole when a heat medium is supplied in the related art.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Bead foam molded article 11 Base material 12 Skin material 13 Foam layer 20 Convex part 21, 22 Heat medium supply port 30 Molding apparatus 31, 32 Die B Resin beads

 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Hiroaki Suzuki 3-1-36 Imaikecho, Anjo-shi, Aichi F-term (reference) in INOAC Corporation Anjo Office 4F202 AB02 AD03 AD05 AD24 AD35 AG03 AG20 AJ08 AM32 CA01 CB01 CB13 CB22 CN21 CN27 CQ05 4F204 AB02 AD03 AD05 AD24 AD35 AG03 AG20 AJ08 AM32 EA01 EB01 EB13 EB22 EK24 EL17 4F212 AB02 AD03 AD05 AD24 AD35 AG03 AG20 AJ08 AM32 UA01 UB01 UB13 UB22 UL01 UN10

Claims (2)

[Claims] 1. Beads comprising a base material, a skin material, and a resin foam layer formed by resin beads which are filled between the two members and fused and integrated by a heat medium supplied from a heat medium supply port of the base material. A bead foam molded product, characterized in that a convex portion bent toward the skin material side is provided on the base material, and a heat medium supply port is opened at a side surface and a front end surface of the convex portion. 2. A method according to claim 1, wherein a convex portion bent to one side of the base material is formed in advance on the base material, and a heat medium supply port opened on a side surface and a tip end surface of the convex portion is provided in advance. The convex portion is arranged in a mold so as to face the skin material side, and after filling the resin beads between the base material and the skin material, between the base material and the skin material from the heat medium supply port through the convex portion. A method for producing a bead foam molded article, comprising: forming a foam layer in which the resin beads are fused and integrated by supplying a heat medium; and bonding the foam layer to a skin material and a substrate by fusion. .