JP2001347532A - Core-filled foamed molding and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for easily and efficiently manufacturing a core- filled foamed molding having good appearance and good touch feeling without exposing a cut edge of the core on its surface. SOLUTION: The method for manufacturing the core-filled foamed molding comprises the steps of bending many wire strands 1 made of plastics so as to entangle with each other, filing a plurality of cores 2 of a stereoscopic net- like structure formed by gathering contact points while fusion bonding in a mold 6 in a state in which core bars 4 are inserted into holes 3 provided at the cores, supporting the cores 2 by the bars 4 so as to align at a suitable interval so as not to contact with each other, filling a foamed composition 7 in the mold 6, foaming the composition 7 in a state in which the composition 7 encloses the core 2, then setting a cutting surface 8 at a position where only the foam 5 exists between the cores 2, and slicing the foam 5 at the same place.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed product with a core which can be used as a cushioning material for beds and chairs, a cushioning material for packing and the like, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, for example, JP-A-2000-12725
According to Japanese Patent Publication No. 3 (1994), a three-dimensional structure having voids formed by randomly entangled continuous filaments and the like of a thermoplastic resin, a foamed resin composition, and the like are placed in a mold and foamed to form a fiber-reinforced resin. Articles are known.

[0003] By the way, since the production efficiency is low when producing the above fiber-reinforced resin molded products one by one, a production method capable of mass production at one time is desired.

As a manufacturing method, for example, there is a method in which a plurality of the above-described three-dimensional structures are stacked and placed in a molding die, a foamed resin composition or the like is foamed, and then sliced into a plurality of pieces. . According to this method, a plurality of fiber-reinforced resin molded products can be manufactured at one time, so that production efficiency is improved. However, the cut surface of the fiber of the three-dimensional structure is exposed on the cut surface, so that the appearance is poor, and when the hand or the like is touched to the surface, the cut surface of the exposed fiber hits the hand or the like and the touch is bad. There are evils.

[0005]

Therefore, the present invention solves the above-mentioned problems, that is, it can be manufactured efficiently, and the cutout of the core is not exposed on the surface so that the appearance is good and the touch feeling is improved. It is another object of the present invention to provide a foamed molded product with a good core and to provide a production method capable of easily and efficiently producing such a foamed molded product with a core.

[0006]

In order to solve the above-mentioned problems, a foamed molded article with a core according to the present invention has a large number of plastic filaments 1 bent so as to be entangled with each other, and a contact point of the filaments is formed. A core 2 having a three-dimensional net-like structure formed by being assembled while being fused, a core rod 4 inserted through a hole 3 provided in the core 2, and the core 2 so that the core 2 is not exposed on the surface. And a foam body 5 covering the outer peripheral portion.

[0007] In order to solve the above-mentioned problems, a method of manufacturing a cored foam molded article of the present invention comprises bending a plurality of plastic filaments 1 so as to be entangled with each other;
A plurality of cores 2 having a three-dimensional net-like structure formed by assembling the contacts while being fused are put into a molding die 6 with a core rod 4 inserted through a hole 3 provided therein. Core rod 4
In addition to supporting the respective cores 2 so as not to be in contact with each other so as to be arranged in parallel at an appropriate interval, the foam composition 7 is also placed inside the molding die 6, and the foam composition 7 After the foam composition 7 is foamed in the encapsulated state, the cut surface 8 is set at a position where only the foam 5 exists between the respective cores 2 and sliced at the same place. Things.

[0008]

Embodiments of the present invention will be described below with reference to the drawings. First, FIG. 1 shows a cored foam molded article of the present invention as a so-called fiber-reinforced resin molded article. This core-containing foamed molded product includes a core 2 and
It is composed of a core rod 4 and a foam 5.

As shown in FIG. 2, the core body 2 is formed by bending a large number of plastic filaments 1 so as to be entangled with each other, and assembling them into a plate shape while fusing their contacts. It has a net-like structure, and is provided with holes 3 which are opened at both end surfaces at substantially the center in the thickness direction.

The filament 1 constituting the core 2 can be made of a thermoplastic resin such as polypropylene, and its wire diameter is preferably about 0.1 to several mm.

The thickness of the core 2 is preferably about 5 to 200 mm, and the width and length can be freely set according to the purpose of use.

The inner diameter of the hole 3 provided in the core 2 is 3 to 150.
mm is preferable.

The above-mentioned core 2 can be manufactured, for example, by the following method. The manufacturing method will be described with reference to FIG.
First, a die 9 in which a plurality of orifices that open downward are arranged at appropriate intervals in a planar manner so that a blank portion exists at a required position is attached to an extruder, and the thermoplastic resin melted by the extruder is attached. Is continuously extruded from each orifice to produce a large number of filaments.
Lower while forming. Then, while the respective filaments 1 are still hardened and viscous, the respective filaments 1 are taken at a lower speed at a lower speed than the descending speed of the respective filaments 1.
In the drawing, reference numeral 12 is the take-off roller. As a result, the filaments 1 are bent in a loop or a curl and entangled with each other, and are accumulated at a location other than the position below the orifice blank portion 10 in the die 9 while fusing the contacts thereof to form a continuous plate. A three-dimensional net-like aggregate 11 is formed.
The three-dimensional net-like assembly 11 is provided with the orifice blank portion 1 described above.
A hole 3 will be formed at a position below 0. Next, the core body 2 as shown in FIG. 2 is manufactured by cooling and solidifying the three-dimensional net-like aggregate 11 by immersing it in cooling water 13 and then pulling it up and cutting it into an appropriate size.

Next, the core rod 4 is inserted into the hole 3 in the core body 2.
, And both ends thereof are slightly projected from both end surfaces of the core body 2. Although the material and the structure of the core rod 4 are free, it is also possible to use the same material as the core body 2 and a three-dimensional net-like structure like the core body 2.

The foam 5 covers the outer periphery of the core 2 so that the core 2 is not exposed. Note that the foam 5 is also filled into the internal space of the core 2. The material of the foam 5 is free, such as polyurethane, polyethylene, polystyrene, and polypropylene.

Next, a method for manufacturing the above-mentioned core-formed foam molded article will be described with reference to FIGS. First, the core 2
A plurality of core rods 4 are inserted into the holes 3 of FIG. 3, and they are put in a molding die 6 as shown in FIG. It is supported so as to be juxtaposed at appropriate intervals. In addition, the foam composition 7 is also placed inside the mold 6 so that the foam composition 7 covers all the cores 2. In addition, the foam composition 7 not only includes the above-mentioned foaming resin such as polyurethane, polyethylene, polystyrene, and polypropylene, but also includes additives such as a foaming agent and a catalyst necessary for foaming, , Pre-foamed material and the like. Then, the foam composition 7 is foamed by performing an appropriate physical or chemical foaming treatment.

Next, when the foaming of the foamed composition 7 is completed, as shown in FIG. 5, the foamed composition 7 is taken out of the molding die 6 and cut at a position where only the foamed body 5 exists between the cores 2. Is set, and slice is performed at the same place. As a result, FIG.
Are manufactured at the same time.

[0018]

According to the core-formed foam molded article of the present invention, the outer periphery of the core 2 is covered with the foam 5 so that the cuts of the fibers constituting the core 2 are not exposed on the surface. There is an effect that the appearance is good, and the cut end of the fiber constituting the core body does not touch the hand or the like at the time of use, so that the touch feeling is good. In addition, the insertion of the core rod 4 into the hole 3 of the core body 2 also has the effect of increasing the overall bending strength and the like.

Further, the method for producing a cored foamed molded article of the present invention comprises the above-described cored foamed molded article of the present invention, that is, a cored foamed molded article in which the cuts of the fibers constituting the core 2 are not exposed on the surface. There is an effect that the product can be easily and efficiently manufactured.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a cored foam molded article.

FIG. 2 is a perspective view of a core.

FIG. 3 is a cross-sectional view illustrating a manufacturing process of the core body.

FIG. 4 is a cross-sectional view showing a state where a core and a foam composition are placed in a molding die.

FIG. 5 is a cross-sectional view showing a state where the foam composition is foamed and taken out of a mold.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Filament 2 Core 3 Hole 4 Core rod 5 Foam 6 Mold 7 Foam composition 8 Cutting surface 9 Die 10 Orifice blank part 11 Solid net-like assembly 12 Take-off roller 13 Cooling water

Claims (2)

[Claims] 1. A core 2 having a three-dimensional net-like structure formed by bending a large number of plastic filaments 1 so as to be entangled with each other and fusing their contacts together. A core-formed foam molded product comprising a core rod 4 inserted through the provided hole 3 and a foam 5 covering the outer peripheral portion of the core 2 so that the core 2 is not exposed on the surface. 2. A plurality of cores 2 having a three-dimensional net-like structure formed by bending a large number of plastic filaments 1 so as to be entangled with each other and assembling them while fusing their contacts.
Are inserted into the molding die 6 with the core rods 4 inserted through the holes 3 provided therein, and the cores 2 are juxtaposed at appropriate intervals so that the cores 2 do not come into contact with each other. While supporting, the foam composition 7 is also put into the inside of the mold 6, and the foam composition 7 is foamed in a state where the foam composition 7 covers the core 2, and then each core 2. A method for producing a cored foam molded product, comprising setting a cut surface 8 at a position where only the foam 5 exists between the two, and slicing at the same location.