JP2006068930A - Manufacturing method of composite molded product - Google Patents

Manufacturing method of composite molded product Download PDF

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JP2006068930A
JP2006068930A JP2004252062A JP2004252062A JP2006068930A JP 2006068930 A JP2006068930 A JP 2006068930A JP 2004252062 A JP2004252062 A JP 2004252062A JP 2004252062 A JP2004252062 A JP 2004252062A JP 2006068930 A JP2006068930 A JP 2006068930A
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mold
thermoplastic resin
resin sheet
composite molded
extruded
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JP4689213B2 (en
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Haruhiro Endo
治弘 遠藤
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Kyoraku Co Ltd
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Kyoraku Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/266—Auxiliary operations after the thermoforming operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/001—Shaping in several steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a composite molded product capable of shortening a molding cycle as compared with a method for filling a hollow double wall structure with foam and capable of obtaining the composite molded product having lightweight properties, high strength and high rigidity. <P>SOLUTION: The thermoplastic resin sheet 4 extruded from an extrusion head 3 is arranged in a pair of split molds 1 and 1 and air is introduced into the molds by the vacuum suction from the cavity surfaces of the molds not only to mold the thermoplastic resin sheet 4 into the shape conformed to the cavities 2 and 2 of the molds but also to fill the molds with prefoamed resin particles. The prefoamed resin particles are mutually welded by blowing heated steam into the molds. The thermoplastic resin sheet 4 is extruded in a molten state and molded by the vacuum suction from the cavity surfaces of the molds and the introduction of air into the molds. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、溶融状態で押出した熱可塑性樹脂シートと発泡体を一体に成形することにより、高い強度と剛性を備えた断熱性および遮音性に優れた複合成形品を得る複合成形品の製造方法に関するものである。   The present invention relates to a method for producing a composite molded product, in which a thermoplastic resin sheet extruded in a molten state and a foam are integrally molded to obtain a composite molded product with high strength and rigidity and excellent heat insulation and sound insulation. It is about.

体表皮を有する発泡成形体の製造方法であって、表皮として布と熱可塑性樹脂シートの貼り合せ体を金型にインサートして予備発泡樹脂粒子を型内充填により成形したものは、特開昭５５−７３５３３号公報に、筒状のパリソンの中に予備発泡樹脂粒子を型内充填した中空二重壁構造体の製造方法は、特開平０６−３３９９７９号公報に、また、溶融押出しした熱可塑性樹脂シートを成形し、予め成形した発泡体を充填（インサート）する中空二重壁構造体の製造方法は、特開２０００−２１８６８２公報にそれぞれ記載されている。
特開昭５５−７３５３３号公報 特開平０６−３３９９７９号公報 特開２０００−２１８６８２公報 A method for producing a foamed molded article having a body skin, in which a laminate of a cloth and a thermoplastic resin sheet is inserted as a skin into a mold and pre-foamed resin particles are molded by in-mold filling, is disclosed in No. 55-73333 discloses a method for producing a hollow double wall structure in which pre-expanded resin particles are filled in a mold in a cylindrical parison, as disclosed in Japanese Patent Application Laid-Open No. 06-339979, and melt extruded thermoplastic. The manufacturing method of the hollow double wall structure which shape | molds a resin sheet and fills (inserts) the preformed foam is described in Unexamined-Japanese-Patent No. 2000-218682, respectively.
JP-A-55-73533 Japanese Patent Application Laid-Open No. 06-339979 JP 2000-218682 A

前掲の特許文献１，２および３に記載されている複合成形体の製造方法によれば、いずれも成形工程で表皮が成形された状態で型内に発泡樹脂を充填することができるが、溶融状態で押出した熱可塑性樹脂シートと発泡体を一体に成形するものでないところから、軽量であるとともに高い強度と剛性を備えた断熱性および遮音性に優れた複合成形品を得ることができないという問題があった。   According to the method for producing a composite molded body described in the above-mentioned Patent Documents 1, 2, and 3, the mold can be filled with a foamed resin in a state where the skin is molded in the molding process. The problem is that it is not possible to obtain a composite molded product that is lightweight and has high strength and rigidity and is excellent in heat insulation and sound insulation, since it is not integrally molded with the extruded thermoplastic resin sheet and foam. was there.

そこで、本発明は、中空二重壁構造体内に発泡体を充填するものと比べ、成形サイクルの短縮することができ、軽量化、低コストの成形品を得ることができるとともに、さらに装飾シートを貼着する場合、装飾シートと熱可塑性樹脂シートの間にエア溜りが生じることがなく、エア溜りによる外観の低下が発生することがないうえ、筒状のパリソンを２分割した熱可塑性樹脂シートとすることで装飾シートなどを容易に貼着することができるとともに、中枠型を用いることで同時に２つの成形品を製造することができる複合成形品の製造方法を提供することを目的とするものである。   Therefore, the present invention can shorten the molding cycle, obtain a lightweight, low-cost molded product, and further provide a decorative sheet, as compared with a case where a hollow double-wall structure is filled with foam. When sticking, there is no air accumulation between the decorative sheet and the thermoplastic resin sheet, no deterioration of the appearance due to the air accumulation occurs, and the thermoplastic resin sheet obtained by dividing the cylindrical parison into two parts An object of the present invention is to provide a method for manufacturing a composite molded product that can easily attach a decorative sheet and the like and can simultaneously manufacture two molded products by using an inner frame mold. It is.

上記目的を達成する本発明の請求項１に係る複合成形品の製造方法は、押出ヘッドから押し出した熱可塑性樹脂シートを金型内に配置し、熱可塑性樹脂シートを金型のキャビティに沿った形状に成形するとともに、金型内に予備発泡樹脂粒子を充填し、加熱水蒸気の吹込みにより該粒子を互いに融着させる複合成形品の製造方法において、前記熱可塑性樹脂シートを溶融状態で押し出して、金型のキャビティ面から真空吸引するとともに、金型内にエアを導入して熱可塑性樹脂シートを成形することを特徴とするものである。   The method for producing a composite molded article according to claim 1 of the present invention that achieves the above object includes arranging a thermoplastic resin sheet extruded from an extrusion head in a mold, and placing the thermoplastic resin sheet along a cavity of the mold. In a method for producing a composite molded product, in which a pre-foamed resin particle is filled in a mold and the particles are fused to each other by blowing heated steam, the thermoplastic resin sheet is extruded in a molten state. In addition, vacuum suction is performed from the cavity surface of the mold, and air is introduced into the mold to mold the thermoplastic resin sheet.

請求項２に係る複合成形品の製造方法は、請求項１記載の方法において、溶融状態で押し出された熱可塑性樹脂シートは金型に挟持され、金型のキャビティ面と熱可塑性樹脂シートとの間に閉鎖空間を形成し、閉鎖空間内の空気を真空吸引することにより熱可塑性樹脂シートを金型のキャビティ面に沿って吸着させるとともに吹込手段を介して加圧流体を導入して熱可塑性樹脂シートを金型のキャビティ面に密着させ、ついで、金型内に予備発泡樹脂粒子を充填して加熱水蒸気を吹込むことを特徴とするものである。   The method for producing a composite molded article according to claim 2 is the method according to claim 1, wherein the thermoplastic resin sheet extruded in a molten state is sandwiched between molds, and the cavity surface of the mold and the thermoplastic resin sheet A thermoplastic resin sheet is adsorbed along the cavity surface of the mold by forming a closed space between them and vacuuming the air in the closed space, and a pressurized fluid is introduced through the blowing means to introduce the thermoplastic resin. The sheet is brought into close contact with the cavity surface of the mold, and then pre-expanded resin particles are filled into the mold and heated steam is blown into the mold.

また、請求項３に係る複合成形品の製造方法は、一方の金型と他方の金型と型開きした状態の前記一方の金型と前記他方の金型の間に配置される中枠型を用い、押出ヘッドから押し出した熱可塑性樹脂シートを一方の金型と中枠型および他方の金型と中枠型の間に配置し、熱可塑性樹脂シートを一方の金型および他方の金型のキャビティに沿った形状に成形するとともに、型内に予備発泡樹脂粒子を充填し、加熱水蒸気の吹込みにより該粒子を互いに融着させる複合成形品の製造方法において、前記熱可塑性樹脂シートを溶融状態で押し出して、金型のキャビティ面から真空吸引するとともに、型内にエアを導入して熱可塑性樹脂シートを成形することを特徴とするものである。   According to a third aspect of the present invention, there is provided a method for producing a composite molded product, comprising: a middle frame mold disposed between one mold and the other mold in a state where the mold is opened with the other mold. The thermoplastic resin sheet extruded from the extrusion head is placed between one mold and the middle frame mold and between the other mold and the middle frame mold, and the thermoplastic resin sheet is placed between the one mold and the other mold. In the method of manufacturing a composite molded product, the thermoplastic resin sheet is melted in a method of forming a shape along the cavity of the mold, filling pre-foamed resin particles in a mold, and fusing the particles together by blowing heated steam. The thermoplastic resin sheet is formed by extruding in a state and vacuum-sucking from the cavity surface of the mold and introducing air into the mold.

請求項４に係る複合成形品の製造方法は、請求項３記載の方法において、溶融状態で押し出された熱可塑性樹脂シートは金型のキャビティ面から真空吸引されることにより一方の金型および他方の金型の金型のキャビティ面に沿って吸着されるとともに、中枠に設けられた吹込手段を介して加圧流体を導入して熱可塑性樹脂シートを金型のキャビティ面に密着させ、ついで、中枠より予備発泡粒子充填手段を介して型内に予備発泡樹脂粒子を充填して加熱水蒸気を吹込むことを特徴とするものである。   The method for producing a composite molded article according to claim 4 is the method according to claim 3, wherein the thermoplastic resin sheet extruded in a molten state is vacuum-sucked from the cavity surface of the mold, whereby one mold and the other are molded. In addition to being adsorbed along the cavity surface of the mold of the mold, a pressurized fluid is introduced through the blowing means provided in the inner frame to bring the thermoplastic resin sheet into close contact with the cavity surface of the mold. The pre-expanded resin particles are filled into the mold through the pre-expanded particle filling means from the middle frame, and heated steam is blown into the mold.

さらに、請求項５に係る複合成形品の製造方法は、一方の金型と他方の金型と型開きした状態の前記一方の金型と前記他方の金型の間に配置される中枠型を用い、押出ヘッドから押し出した熱可塑性樹脂シートを一方の金型と中枠型および他方の金型と中枠型の間に配置し、熱可塑性樹脂シートを中枠型のキャビティに沿った形状に成形するとともに、型内に予備発泡樹脂粒子を充填し、加熱水蒸気の吹込みにより該粒子を互いに融着させる複合成形品の製造方法において、前記熱可塑性樹脂シートを溶融状態で押し出して、中枠型のキャビティ面から真空吸引するとともに、加圧流体を導入して熱可塑性樹脂シートを中枠型のキャビティ面に密着させることを特徴とするものである。   Furthermore, the manufacturing method of the composite molded product which concerns on Claim 5 is the middle frame type | mold arrange | positioned between the said one metal mold | die and the said other metal mold | die in the state where one metal mold | die and the other metal mold | die opened. The thermoplastic resin sheet extruded from the extrusion head is placed between one mold and the middle frame mold and between the other mold and the middle frame mold, and the thermoplastic resin sheet is shaped along the cavity of the middle frame mold In the method of manufacturing a composite molded product, in which pre-foamed resin particles are filled into a mold and the particles are fused to each other by blowing heated steam, the thermoplastic resin sheet is extruded in a molten state, In addition to vacuum suction from the cavity surface of the frame mold, a pressurized fluid is introduced to closely contact the thermoplastic resin sheet to the cavity surface of the middle frame mold.

請求項６に係る複合成形品の製造方法は、請求項１、２、３、４または５記載の方法において、熱可塑性樹脂シートは引張弾性率が７０００Ｋｇ／ｃｍ2以上の剛性を有する樹脂よりなり、成形されることにより複合成形品の表面壁を構成することを特徴とするものである。 The method for producing a composite molded article according to claim 6 is the method according to claim 1, 2, 3, 4 or 5, wherein the thermoplastic resin sheet is made of a resin having a rigidity with a tensile modulus of elasticity of 7000 kg / cm 2 or more. The surface wall of the composite molded product is formed by molding.

請求項７に係る複合成形品の製造方法は、請求項１、２、３、４、５または６記載の方法において、熱可塑性樹脂シートは環状樹脂路を有する押出ヘッドから押し出され、環状樹脂路は吐出部付近で２分割されていることにより、筒状のパリソンが切り開かれたシート状パリソンとして押出されることを特徴とするものである。   The method for producing a composite molded article according to claim 7 is the method according to claim 1, 2, 3, 4, 5 or 6, wherein the thermoplastic resin sheet is extruded from an extrusion head having an annular resin path, and the annular resin path is formed. Is characterized by being extruded as a sheet-like parison in which a cylindrical parison is cut open by being divided into two near the discharge portion.

請求項８に係る複合成形品の製造方法は、請求項１、２、３、４、５、または６記載の方法において、熱可塑性樹脂シートはＴダイ押出ヘッドから押出されることを特徴とするものである。   The method for producing a composite molded article according to claim 8 is the method according to claim 1, 2, 3, 4, 5, or 6, wherein the thermoplastic resin sheet is extruded from a T-die extrusion head. Is.

請求項９に係る複合成形品の製造方法は、請求項１、２、３、４、５、６、７または８記載の方法において、押出ヘッドから押し出した熱可塑性樹脂シートに装飾シートを密着させ金型内に配置することを特徴とするものである。   The method for producing a composite molded article according to claim 9 is the method according to claim 1, 2, 3, 4, 5, 6, 7 or 8, wherein the decorative sheet is brought into close contact with the thermoplastic resin sheet extruded from the extrusion head. It arrange | positions in a metal mold | die, It is characterized by the above-mentioned.

本発明によれば、中空二重壁構造体内に発泡体を充填するものと比べ、成形サイクルの短縮することができ、軽量化、低コストの成形品を得ることができるとともに、さらに装飾シートを貼着する場合、装飾シートと熱可塑性樹脂シートの間にエア溜りが生じることがなく、エア溜りによる外観の低下が発生することがないうえ、一枚状または筒状のパリソンを２分割した熱可塑性樹脂シートとすることで装飾シートなどを容易に貼着することができるとともに、中枠型を用いることで同時に２つの成形品を製造することができる効果が得られるものである。   According to the present invention, the molding cycle can be shortened as compared with the case where the hollow double-wall structure is filled with foam, and a molded product with reduced weight and cost can be obtained. When sticking, there is no air accumulation between the decorative sheet and the thermoplastic resin sheet, no deterioration of the appearance due to the air accumulation, and the heat obtained by dividing the single or cylindrical parison into two parts. By using a plastic resin sheet, a decorative sheet or the like can be easily attached, and by using an intermediate frame mold, two molded products can be produced at the same time.

本発明に係る複合成形品は、図１ないし図４に示す態様でブロー成形されるものである。１、１は一対の分割金型、２、２はキャビティ、３は押出ヘッド、４は熱可塑性樹脂シート、５は発泡樹脂充填ノズル、６は真空吸引孔、７は外気導入孔または吹込手段である。   The composite molded product according to the present invention is blow-molded in the manner shown in FIGS. 1, 1 is a pair of split molds, 2 is a cavity, 3 is an extrusion head, 4 is a thermoplastic resin sheet, 5 is a foamed resin filling nozzle, 6 is a vacuum suction hole, 7 is an outside air introduction hole or blowing means is there.

押出ヘッド３より溶融状態で押し出された熱可塑性樹脂シート４をローラー１８等により肉厚を調整しながら平面状として分割金型１、１間に配置し（図１）、型締めを行うとともに一方の分割金型１のキャビティ２面と熱可塑性樹脂シート４との間の閉鎖空間内の空気をキャビティ２面に形成した真空吸引孔６より排除して熱可塑性樹脂シート４をキャビティ２面に沿って吸着させる。この際、真空吸引に伴って金型内に負圧が生じるのを防止するため金型内に外気導入孔または吹込手段７より外気が導入される（図２）。さらに、金型内には吹込手段である吹込ノズル（図示せず）よりエア等の加圧流体を導入して熱可塑性樹脂シート４を一方の分割金型１のキャビティ２に密着させ（図３）、そのキャビティ２に沿った形状に成形する。ついで、型締め状態のまま金型内に、発泡樹脂充填ノズル５から予備発泡樹脂粒子充填手段より予備発泡樹脂粒子である発泡ビーズを充填し、加熱水蒸気を吹込み、発泡ビーズを互いに融着させるとともに発泡ビーズと熱可塑性樹脂シートの内面とを融着させる（図４）。   The thermoplastic resin sheet 4 extruded in a molten state from the extrusion head 3 is placed between the divided molds 1 and 1 in a flat shape while adjusting the thickness by a roller 18 or the like (FIG. 1), and the mold is clamped. The air in the closed space between the cavity 2 surface of the split mold 1 and the thermoplastic resin sheet 4 is excluded from the vacuum suction hole 6 formed in the cavity 2 surface, and the thermoplastic resin sheet 4 is moved along the cavity 2 surface. Adsorb. At this time, outside air is introduced into the mold through the outside air introduction hole or the blowing means 7 in order to prevent negative pressure from being generated in the mold due to vacuum suction (FIG. 2). Further, a pressurized fluid such as air is introduced into a mold from a blowing nozzle (not shown) which is a blowing means, and the thermoplastic resin sheet 4 is brought into close contact with the cavity 2 of one divided mold 1 (FIG. 3). ), And shaped into a shape along the cavity 2. Next, the expanded beads filled with the pre-expanded resin particles are filled from the expanded resin filling nozzle 5 into the mold in the mold-clamped state from the pre-expanded resin particle filling means, and heated steam is blown to fuse the expanded beads together. At the same time, the foam beads and the inner surface of the thermoplastic resin sheet are fused (FIG. 4).

図５ないし図８は本発明の他の実施の形態を示す。この実施の形態においては、熱可塑性樹脂シートは環状樹脂路を有する押出ヘッド８から押し出され、環状樹脂路が吐出部付近で２分割されていることにより、筒状のパリソンが切り開かれたシート状パリソン９、９として押し出される（図５）。熱可塑性樹脂シート９、９は一方および他方の金型１０、１０と中枠型１１の間に配置され、一方の金型１０および他方の金型１０の型締めを開始し、中枠型１１に設けた移動枠１２に接触させた状態とし、キャビティ１３、１３の周囲との間に熱可塑性樹脂シート９、９を挟持した状態とする。ここで、キャビティ１３、１３と熱可塑性樹脂シート９、９との間に形成された閉鎖空間内の空気を真空吸引孔１４、１４から真空吸引し、熱可塑性樹脂シート９、９をキャビティ１３、１３面に吸着させる（図６）。この際、移動枠１２に設けたエア導入孔１５より外気が金型内に導入され、金型内が負圧となるのを防止する。その後、さらに型締めを進めて、一方の金型１０および他方の金型１０を中枠型１１に接触させ、型締めを完了させる。そして、中枠型１１に設けた吹込手段である吹込ノズル１６より加圧流体を導入して熱可塑性樹脂シート９、９を金型のキャビティ１３、１３面に密着させる（図７）。ついで、型締め状態のまま金型内に予備発泡樹脂粒子である発泡ビーズを発泡樹脂充填孔１７から予備発泡樹脂粒子充填手段を介して充填して加熱水蒸気を吹込み、発泡ビーズを互いに融着させるとともに発泡ビーズと熱可塑性樹脂シート９、９の内面とを融着させる（図８）。   5 to 8 show another embodiment of the present invention. In this embodiment, the thermoplastic resin sheet is extruded from the extrusion head 8 having an annular resin path, and the annular resin path is divided into two near the discharge portion, whereby a cylindrical parison is cut open. Extruded as parison 9, 9 (Fig. 5). The thermoplastic resin sheets 9 and 9 are disposed between the one and the other molds 10 and 10 and the middle frame mold 11, and the mold clamping of the one mold 10 and the other mold 10 is started. In this state, the thermoplastic resin sheets 9 and 9 are sandwiched between the cavities 13 and 13. Here, the air in the closed space formed between the cavities 13 and 13 and the thermoplastic resin sheets 9 and 9 is vacuum-sucked from the vacuum suction holes 14 and 14, and the thermoplastic resin sheets 9 and 9 are evacuated to the cavities 13, Adsorbed on the 13th surface (FIG. 6). At this time, outside air is introduced into the mold through the air introduction hole 15 provided in the moving frame 12 to prevent the inside of the mold from becoming negative pressure. Thereafter, the mold clamping is further advanced, and the one mold 10 and the other mold 10 are brought into contact with the middle frame mold 11 to complete the mold clamping. And a pressurized fluid is introduce | transduced from the blowing nozzle 16 which is the blowing means provided in the inner frame type | mold 11, and the thermoplastic resin sheets 9 and 9 are closely_contact | adhered to the cavity 13 and 13 surface of a metal mold | die (FIG. 7). Next, the expanded beads, which are pre-expanded resin particles, are filled in the mold through the pre-expanded resin particle filling means 17 while the mold is clamped, and heated steam is blown to fuse the expanded beads together. At the same time, the foam beads and the inner surfaces of the thermoplastic resin sheets 9 and 9 are fused (FIG. 8).

図１０および図１１は、図５ないし図８に示す実施の形態により同時に製造された２つの複合成形品のうちの一方の複合成形品１９（パネル）を例示する。２０は表面壁、２１は発泡体である。   10 and 11 illustrate one composite molded product 19 (panel) of two composite molded products manufactured simultaneously according to the embodiment shown in FIGS. 5 to 8. 20 is a surface wall and 21 is a foam.

複合成形品１９の表皮または表壁となる基材樹脂は押出ヘッドよりシート状または筒状のパリソンを２分割にして押出し、ローラー１８等により肉厚を調整しながら平面のシート状パリソンである熱可塑性樹脂シートとして金型内に配置される。さらに装飾シート２２を貼着する場合にあっては、熱可塑性樹脂シートを垂下させるとともに装飾シート２２を沿わせて圧着ローラー２３により互いに圧着させて多層状態にて金型内に配置される（図９）。熱可塑性樹脂シートは筒状のパリソンと異なりシート状で装飾シートと一体に圧着されるため、熱可塑性樹脂シートと装飾シートの間にエア溜りが生じることがなく、気泡等による外観の低下が生じることがない。またエア溜りを防止するために装飾シートに予め通気孔等を設ける必要がなく装飾シートの選択を大きく広げることができる。   The base resin used as the skin or front wall of the composite molded product 19 is extruded as a flat sheet-like parison while the sheet-like or cylindrical parison is extruded into two parts from an extrusion head and the thickness is adjusted by a roller 18 or the like. It arrange | positions in a metal mold | die as a plastic resin sheet. Further, when the decorative sheet 22 is pasted, the thermoplastic resin sheet is suspended, and the decorative sheet 22 is placed along the decorative sheet 22 so as to be pressed against each other by the pressure roller 23 and arranged in the mold in a multilayer state (see FIG. 9). Unlike the cylindrical parison, the thermoplastic resin sheet is in the form of a sheet and is bonded together with the decorative sheet. Therefore, there is no air accumulation between the thermoplastic resin sheet and the decorative sheet, and the appearance is deteriorated due to bubbles or the like. There is nothing. In addition, it is not necessary to provide a vent or the like in advance in the decorative sheet in order to prevent air accumulation, and the selection of the decorative sheet can be greatly expanded.

本発明に係る熱可塑性樹脂シートを構成する樹脂は、引張弾性率が７０００Ｋｇ／ｃｍ2以上の剛性を有するプラスチックであって、耐衝撃性ポリスチレン樹脂のほか、高密度ポリエチレン樹脂、中密度ポリエチレン樹脂、ポリプロピレン樹脂、ポリアミド樹脂、ポリエチレンテレフタート樹脂、ポリブチレンテレフタート樹脂、ポリスチレン樹脂、ＡＢＳ樹脂、ポリカーボネート樹脂、変性ポリフェニレンオキサイド樹脂あるいはこれらのブレンド物など、剛性にすぐれた真空・圧空またはブロー成形可能な熱可塑性樹脂である。本発明にかかる製造方法により形成される複合成形品において、熱可塑性樹脂シートは複合成形品の表面壁を構成するものであり、熱可塑性樹脂シートは押出ヘッドより押し出されるとともにローラー等により１．５ｍｍ以上の任意の肉厚に調整させて金型内に配置され、これにより複合成形品の表面壁の最大肉厚は１．５ｍｍ以上に形成される。本発明に係る予備発泡樹脂粒子は予備発泡させた直径１〜５ｍｍ程度の発泡ビーズが好適である。発泡ビーズを構成する樹脂は熱可塑性樹脂シートを構成する樹脂と同材質のものが好適であり、特にポリエチレン系またはポリスチレン系のものが好ましい。 The resin constituting the thermoplastic resin sheet according to the present invention is a plastic having a tensile modulus of rigidity of 7000 kg / cm 2 or more, and in addition to an impact-resistant polystyrene resin, a high-density polyethylene resin, a medium-density polyethylene resin, Polypropylene resin, polyamide resin, polyethylene terephthalate resin, polybutylene terephthalate resin, polystyrene resin, ABS resin, polycarbonate resin, modified polyphenylene oxide resin or blends thereof, etc. It is a plastic resin. In the composite molded product formed by the manufacturing method according to the present invention, the thermoplastic resin sheet constitutes the surface wall of the composite molded product, and the thermoplastic resin sheet is extruded from the extrusion head and 1.5 mm by a roller or the like. It adjusts to the above arbitrary wall thickness, and it arrange | positions in a metal mold | die, and, thereby, the maximum wall thickness of the surface wall of a composite molded product is formed in 1.5 mm or more. The pre-expanded resin particles according to the present invention are preferably pre-expanded expanded beads having a diameter of about 1 to 5 mm. The resin constituting the foam beads is preferably made of the same material as that of the resin constituting the thermoplastic resin sheet, and particularly preferably a polyethylene or polystyrene resin.

本発明に係る装飾シートは熱可塑性樹脂シートに一体に貼着され、成形される際に伸びが良く、成形を阻害しないものであればよく、熱可塑性樹脂シートと同材質の熱可塑性樹脂で構成したりあるいはホットメルトタイプの接着剤を介したり接着した布を介した異質な熱可塑性樹脂または布などの装飾材で構成される。装飾シートは、熱可塑性樹脂の場合はその表面に木目模様、大理石模様、石目模様または光沢面を有する。装飾シートと熱可塑性樹脂シートとの接合は、装飾シートが同材質の熱可塑性樹脂の場合はそれらの溶着により発現し、ホットメルトタイプの接着剤を介した異質な熱可塑性樹脂の場合は接着剤の接着により発現するものであり、さらに接着した布を介した異質な熱可塑性樹脂の場合あるいは布等の装飾材の場合は布の目の中に熱可塑性樹脂が入り込むことにより物理的に接合されるものである。装飾シートの表面に木目模様、大理石模様、石目模様、あるいは光沢面を形成するには、その表面に印刷を施したり表面処理をするなど適宜の手段によることができる。   The decorative sheet according to the present invention is integrally bonded to the thermoplastic resin sheet, and may be any material that has good elongation when molded and does not hinder molding, and is composed of the same thermoplastic resin as the thermoplastic resin sheet. Or a decorative material such as a heterogeneous thermoplastic resin or cloth via a hot melt type adhesive or a bonded cloth. In the case of a thermoplastic resin, the decorative sheet has a wood grain pattern, marble pattern, stone pattern or glossy surface on the surface thereof. Bonding between the decorative sheet and the thermoplastic resin sheet is manifested by welding when the decorative sheet is made of the same thermoplastic resin, and in the case of a heterogeneous thermoplastic resin via a hot melt adhesive. In the case of a heterogeneous thermoplastic resin through a bonded fabric or a decorative material such as a fabric, the material is physically joined by the thermoplastic resin entering the fabric eyes. Is. In order to form a wood grain pattern, marble pattern, stone pattern, or glossy surface on the surface of the decorative sheet, an appropriate means such as printing or surface treatment can be used.

本発明の一実施の形態に係る複合成形品の成形態様を示す断面図である。It is sectional drawing which shows the shaping | molding aspect of the composite molded product which concerns on one embodiment of this invention. 同上型締めした態様を示す断面図である。It is sectional drawing which shows the aspect clamped same as the above. 同上つぎの成形工程を示す断面図である。It is sectional drawing which shows the next formation process same as the above. 成形が完了した態様を示す断面図である。It is sectional drawing which shows the aspect which shaping | molding completed. 本発明の他の実施の形態に係る複合成形品の成形態様を示す断面図である。It is sectional drawing which shows the shaping | molding aspect of the composite molded product which concerns on other embodiment of this invention. 同上型締め過程の態様を示す断面図である。It is sectional drawing which shows the aspect of a mold clamping process same as the above. 同上型締めした態様を示す断面図である。It is sectional drawing which shows the aspect clamped same as the above. 成形が完了した態様を示す断面図である。It is sectional drawing which shows the aspect which shaping | molding completed. 装飾シートを貼着する態様を示す図である。It is a figure which shows the aspect which sticks a decoration sheet. 本発明に係る方法で製造された複合成形品の一例を示す斜視図である。It is a perspective view which shows an example of the composite molded product manufactured by the method which concerns on this invention. 同上Ａ−Ａ断面図である。It is AA sectional drawing same as the above.

符号の説明Explanation of symbols

１、１ 一対の分割金型
２、２ キャビティ
３ 押出ヘッド
４ 熱可塑性樹脂シート
５ 発泡樹脂充填ノズル
６ 真空吸引孔
７ 外気導入孔または吹込手段
８ 押出ヘッド
９、９ シート状パリソン
１０、１０ 一方および他方の金型
１１、１１ 中枠型
１２ 移動枠
１３、１３ キャビティ
１４、１４ 真空吸引孔
１５ エア導入孔
１６ 吹込ノズル
１７ 発泡体樹脂充填孔
１８ ローラー
１９ 複合成形品
２０ 表面壁
２１ 発泡体
２２ 装飾シート
２３ 圧着ローラー DESCRIPTION OF SYMBOLS 1, 1 Pair of split molds 2, 2 Cavity 3 Extrusion head 4 Thermoplastic resin sheet 5 Foamed resin filling nozzle 6 Vacuum suction hole 7 Outside air introduction hole or blowing means 8 Extrusion head 9, 9 Sheet-like parison 10, 10 One and The other mold 11, 11 Middle frame mold 12 Moving frame 13, 13 Cavity 14, 14 Vacuum suction hole 15 Air introduction hole 16 Blowing nozzle 17 Foam resin filling hole 18 Roller 19 Composite molded product 20 Surface wall 21 Foam 22 Decoration Sheet 23 Pressure roller

Claims (9)

押出ヘッドから押し出した熱可塑性樹脂シートを金型内に配置し、
熱可塑性樹脂シートを金型のキャビティに沿った形状に成形するとともに、
金型内に予備発泡樹脂粒子を充填し、
加熱水蒸気の吹込みにより該粒子を互いに融着させる複合成形品の製造方法において、
前記熱可塑性樹脂シートを溶融状態で押し出して、
金型のキャビティ面から真空吸引するとともに、金型内にエアを導入して熱可塑性樹脂シートを成形する
ことを特徴とする複合成形品の製造方法。 Place the thermoplastic resin sheet extruded from the extrusion head in the mold,
While molding the thermoplastic resin sheet into a shape along the mold cavity,
Fill the mold with pre-expanded resin particles,
In the method for producing a composite molded article in which the particles are fused to each other by blowing heated steam,
Extruding the thermoplastic resin sheet in a molten state,
A method for producing a composite molded article, wherein vacuum suction is performed from a cavity surface of a mold, and air is introduced into the mold to mold a thermoplastic resin sheet. 溶融状態で押し出された熱可塑性樹脂シートは金型に挟持され、
金型のキャビティ面と熱可塑性樹脂シートとの間に閉鎖空間を形成し、
閉鎖空間内の空気を真空吸引することにより熱可塑性樹脂シートを金型のキャビティ面に沿って吸着させるとともに
吹込手段を介して加圧流体を導入して熱可塑性樹脂シートを金型のキャビティ面に密着させ、
ついで、金型内に予備発泡樹脂粒子を充填して加熱水蒸気を吹込む
ことを特徴とする請求項１記載の複合成形品の製造方法。 The thermoplastic resin sheet extruded in a molten state is sandwiched between molds,
A closed space is formed between the cavity surface of the mold and the thermoplastic resin sheet,
By sucking the air in the closed space by vacuum suction, the thermoplastic resin sheet is adsorbed along the cavity surface of the mold, and a pressurized fluid is introduced through the blowing means to place the thermoplastic resin sheet on the cavity surface of the mold. Close contact
Next, the pre-foamed resin particles are filled into the mold and heated steam is blown into the mold. 一方の金型と他方の金型と型開きした状態の前記一方の金型と前記他方の金型の間に配置される中枠型を用い、
押出ヘッドから押し出した熱可塑性樹脂シートを一方の金型と中枠型および他方の金型と中枠型の間に配置し、
熱可塑性樹脂シートを一方の金型および他方の金型のキャビティに沿った形状に成形するとともに、
型内に予備発泡樹脂粒子を充填し、
加熱水蒸気の吹込みにより該粒子を互いに融着させる複合成形品の製造方法において、
前記熱可塑性樹脂シートを溶融状態で押し出して、
金型のキャビティ面から真空吸引するとともに、型内にエアを導入して熱可塑性樹脂シートを成形する
ことを特徴とする複合成形品の製造方法。 Using an intermediate frame mold disposed between the one mold and the other mold, and the one mold and the other mold,
Place the thermoplastic resin sheet extruded from the extrusion head between one mold and the middle frame mold and the other mold and the middle frame mold,
While molding the thermoplastic resin sheet into a shape along the cavity of one mold and the other mold,
Fill the mold with pre-expanded resin particles,
In the method for producing a composite molded article in which the particles are fused to each other by blowing heated steam,
Extruding the thermoplastic resin sheet in a molten state,
A method for producing a composite molded product, comprising vacuum suction from a cavity surface of a mold and molding a thermoplastic resin sheet by introducing air into the mold. 溶融状態で押し出された熱可塑性樹脂シートは金型のキャビティ面から真空吸引されることにより一方の金型および他方の金型の金型のキャビティ面に沿って吸着されるとともに、
中枠に設けられた吹込手段を介して加圧流体を導入して熱可塑性樹脂シートを金型のキャビティ面に密着させ、
ついで、中枠より予備発泡粒子充填手段を介して型内に予備発泡樹脂粒子を充填して加熱水蒸気を吹込む
ことを特徴とする請求項３記載の複合成形品の製造方法。 The thermoplastic resin sheet extruded in a molten state is adsorbed along the cavity surface of the mold of one mold and the other mold by being vacuumed from the cavity surface of the mold,
Introducing a pressurized fluid through the blowing means provided in the inner frame to closely adhere the thermoplastic resin sheet to the cavity surface of the mold,
4. The method for producing a composite molded product according to claim 3, wherein the pre-expanded resin particles are filled into the mold through the pre-expanded particle filling means from the middle frame and heated steam is blown. 一方の金型と他方の金型と型開きした状態の前記一方の金型と前記他方の金型の間に配置される中枠型を用い、
押出ヘッドから押し出した熱可塑性樹脂シートを一方の金型と中枠型および他方の金型と中枠型の間に配置し、
熱可塑性樹脂シートを中枠型のキャビティに沿った形状に成形するとともに、
型内に予備発泡樹脂粒子を充填し、
加熱水蒸気の吹込みにより該粒子を互いに融着させる複合成形品の製造方法において、
前記熱可塑性樹脂シートを溶融状態で押し出して、
中枠型のキャビティ面から真空吸引するとともに、加圧流体を導入して熱可塑性樹脂シートを中枠型のキャビティ面に密着させる
ことを特徴とする複合成形品の製造方法。 Using an intermediate frame mold disposed between the one mold and the other mold, and the one mold and the other mold,
Place the thermoplastic resin sheet extruded from the extrusion head between one mold and the middle frame mold and the other mold and the middle frame mold,
While molding the thermoplastic resin sheet into a shape along the cavity of the middle frame mold,
Fill the mold with pre-expanded resin particles,
In the method for producing a composite molded article in which the particles are fused to each other by blowing heated steam,
Extruding the thermoplastic resin sheet in a molten state,
A method for producing a composite molded article, wherein vacuum suction is performed from a cavity surface of an intermediate frame mold, and a pressurized fluid is introduced to closely adhere a thermoplastic resin sheet to the cavity surface of the intermediate frame mold. 熱可塑性樹脂シートは引張弾性率が７０００Ｋｇ／ｃｍ2以上の剛性を有する樹脂よりなり、
成形されることにより複合成形品の表面壁を構成する
ことを特徴とする請求項１、２、３、４または５記載の複合成形品の製造方法。 The thermoplastic resin sheet is made of a resin having a rigidity with a tensile elastic modulus of 7000 kg / cm 2 or more,
6. The method for producing a composite molded product according to claim 1, wherein a surface wall of the composite molded product is formed by molding. 熱可塑性樹脂シートは環状樹脂路を有する押出ヘッドから押し出され、
環状樹脂路は吐出部付近で２分割されていることにより、
筒状のパリソンが切り開かれたシート状パリソンとして押出される
ことを特徴とする請求項１、２、３、４、５または６記載の複合成形品の製造方法。 The thermoplastic resin sheet is extruded from an extrusion head having an annular resin path,
The annular resin path is divided into two near the discharge part,
7. The method for producing a composite molded article according to claim 1, wherein the cylindrical parison is extruded as a sheet-shaped parison which is cut open. 熱可塑性樹脂シートはＴダイ押出ヘッドから押出される
ことを特徴とする請求項１、２、３、４、５または６記載の複合成形品の製造方法。 The method for producing a composite molded article according to claim 1, 2, 3, 4, 5, or 6, wherein the thermoplastic resin sheet is extruded from a T-die extrusion head. 押出ヘッドから押し出した熱可塑性樹脂シートに装飾シートを密着させ金型内に配置する
ことを特徴とする請求項１、２、３、４、５、６、７または８記載の複合成形品の製造方法。 The composite molded article according to claim 1, 2, 3, 4, 5, 6, 7 or 8, wherein a decorative sheet is brought into close contact with a thermoplastic resin sheet extruded from an extrusion head and placed in a mold. Method.
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WO2007140880A1 (en) * 2006-06-09 2007-12-13 Kautex Textron Gmbh & Co. Kg Method for producing hollow bodies from thermoplastic material by extrusion blow moulding with continuous die gap adjustment
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JP2011106727A (en) * 2009-11-17 2011-06-02 Kyoraku Co Ltd Method for manufacturing floor heating panel unit
JP2012030551A (en) * 2010-08-02 2012-02-16 Meiwa Ind Co Ltd Laminated sheet with double-sided designability
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WO2020071215A1 (en) * 2018-10-03 2020-04-09 キョーラク株式会社 Molding method
JP2020055295A (en) * 2018-10-03 2020-04-09 キョーラク株式会社 Molding method
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