JP2006315235A - Composite molding and its production method - Google Patents

Composite molding and its production method Download PDF

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JP2006315235A
JP2006315235A JP2005138420A JP2005138420A JP2006315235A JP 2006315235 A JP2006315235 A JP 2006315235A JP 2005138420 A JP2005138420 A JP 2005138420A JP 2005138420 A JP2005138420 A JP 2005138420A JP 2006315235 A JP2006315235 A JP 2006315235A
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core material
thermoplastic resin
composite molded
hole
intermediate material
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JP4811989B2 (en
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Shoichi Koide
昭一 小出
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Showa Denko Materials Co Ltd
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Hitachi Chemical Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a composite molding which has high strength and is excellent in heat resistance and in which the unevenness of its appearance is reduced and a method for producing the molding. <P>SOLUTION: In the method for producing the composite molding 60, a core material 20 of a foamed thermoplastic resin is formed by foaming the thermoplastic resin, an intermediate material 40 of a non-foamed thermoplastic resin is formed by vacuum-forming the thermoplastic resin, a combined body 50 is formed by combining the core material 20 and the intermediate material 40 together, the combined body 50 is used as a vacuum forming mold, and a thermoplastic resin is molded integrally on the combined body 50 to form a skin material 6 of the non-foamed thermoplastic resin. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

本発明は、浴槽ユニット等に使用される、複合成形品及びその製造方法に関する。   The present invention relates to a composite molded product used for a bathtub unit or the like and a method for manufacturing the same.

近年、樹脂製の浴槽ユニットが広く使用され、その材料として繊維補強熱硬化製樹脂（ＦＲＰ）が使用されている。一方、繊維補強熱可塑性樹脂（ＦＲＴＰ）によるユニットもあるが、一般には、ポリプロピレンの射出成形品やアクリルシ−ト真空成形品等に、ＦＲＰや木型をバックアップ材として用いたユニット等が知られている。しかし、これらは、保温のためウレタン吹きつけによる断熱工程を施している場合が多く、多くの作業工数を要する問題を有している。また、ＦＲＰタイプのユニットは、リサイクルが困難であり、埋立による廃棄処理が主な処理法である。   In recent years, resin bathtub units are widely used, and fiber reinforced thermosetting resin (FRP) is used as the material thereof. On the other hand, there is a unit made of fiber reinforced thermoplastic resin (FRTP), but generally a unit using FRP or a wooden mold as a backup material is known for polypropylene injection molded products or acrylic sheet vacuum molded products. Yes. However, these are often subjected to a heat insulation process by blowing urethane for heat retention, and have a problem that requires a large number of work steps. In addition, the FRP type unit is difficult to recycle, and disposal processing by landfill is the main processing method.

ＦＲＴＰ製のユニットは、バックアップとしてＦＲＰ材を使用する場合が多いが、この場合には、バックアップ材がＦＲＰであるために、生産性の低さ、リサイクルの難しさが伴い、さらには、この両者の界面の接着性が悪く、接着方法が適当でないと樹脂のフクレ等の問題が生じる欠点があった（特許文献１）。
特開平０５−１７６８５５号公報 FRTP units often use FRP material as a backup, but in this case, the backup material is FRP, which results in low productivity and difficulty in recycling. There was a drawback that problems such as resin blistering occurred if the adhesion at the interface was poor and the bonding method was not appropriate (Patent Document 1).
JP 05-176855 A

本発明は、以上の問題を鑑みてなされたものであり、高強度で、断熱性に優れた、さらに外観の凸凹が少ない複合成形品とその製造方法を提供することを目的とする。   The present invention has been made in view of the above problems, and an object of the present invention is to provide a composite molded article having high strength, excellent heat insulation, and less appearance unevenness, and a method for producing the same.

本発明によれば、以下の複合成形品の製造方法及びその製造方法により得られる複合成形品が提供される。
１．熱可塑性樹脂を発泡成形して発泡熱可塑性樹脂からなるコア材を形成し、
熱可塑性樹脂を成形して非発泡熱可塑性樹脂からなる中間材を形成し、
前記コア材と前記中間材を勘合させて、勘合体を形成し、
前記勘合体を真空成形の型として、前記中間材の上に、熱可塑性樹脂を一体成形して、非発泡熱可塑性樹脂からなる表皮材を形成する、
複合成形品の製造方法。
２．前記コア材が突起を有し、
前記中間材が孔を有し、
前記突起と前記孔が勘合して、前記突起が前記表皮層と接する１記載の複合成形品の製造方法。
３．前記コア材の突起に、前記表皮材を真空成形するための空気の出入りが可能な孔を開ける２記載の複合成形品の製造方法。
４．前記コア材と前記中間材に孔を開け、コア材の孔と中間材の孔が連通する１〜３のいずれか記載の複合成形品の製造方法。
５．前記中間材を真空成形して形成する１〜４のいずれか記載の複合成形品の製造方法。
６．前記コア材の密度が０．２ｇ／ｃｍ３以下である１〜５のいずれか記載の複合成形品の製造方法。
７．前記コア材を構成する熱可塑性樹脂と、前記表皮材及び前記中間材を構成する熱可塑性樹脂が、相溶性である１〜６のいずれか記載の複合成形品の製造方法。
８．前記コア材を構成する熱可塑性樹脂と、前記表皮材及び前記中間材を構成する熱可塑性樹脂が、下記（１）〜（４）のいずれか一つの組み合わせである１〜７のいずれか記載の複合成形品の製造方法。
（１）コア材：発泡ポリスチレン
表皮材・中間材：ハイインパクトポリスチレン
（２）コア材：発泡スチレン・アクリロニトリル共重合体
表皮材・中間材：スチレン・アクリロニトリル共重合体、又はゴム成分によって変性されたスチレン・アクリロニトリル共重合体
（３）コア材：発泡ポリオレフィン
表皮材・中間材：ポリオレフィン
（４）コア材：メタクリル酸メチル・アクリロニトリル共重合体の発泡体
表皮材・中間材：アクリル系樹脂
９．１〜８のいずれか記載の製造方法により製造した複合成形品。
１０．発泡熱可塑性樹脂からなるコア材と、
前記コア材と勘合している、非発泡性樹脂からなる中間材と、
前記中間材の上にある、非発泡熱可塑性樹脂からなる表皮材とを有する、複合成形品。
１１．前記中間材が、第１の孔と第２の孔を有し、
前記コア材が、前記第１の孔と勘合して前記表面層と接する突起と、前記第２の孔と連通する孔を有する、１０記載の複合成形品。 According to the present invention, the following composite molded product manufacturing method and a composite molded product obtained by the manufacturing method are provided.
1. Forming a core material made of foamed thermoplastic resin by foaming thermoplastic resin,
Forming an intermediate material made of non-foamed thermoplastic resin by molding a thermoplastic resin,
The core material and the intermediate material are mated to form a mated body,
Using the fitting body as a vacuum forming mold, a thermoplastic resin is integrally formed on the intermediate material to form a skin material made of a non-foamed thermoplastic resin.
A method for producing a composite molded product.
2. The core material has protrusions;
The intermediate material has holes;
2. The method for producing a composite molded article according to 1, wherein the projection and the hole are fitted to each other so that the projection is in contact with the skin layer.
3. 3. The method for producing a composite molded article according to 2, wherein a hole for allowing air to enter and exit for vacuum forming the skin material is formed in the protrusion of the core material.
4). The method for producing a composite molded article according to any one of 1 to 3, wherein a hole is formed in the core material and the intermediate material, and the hole of the core material and the hole of the intermediate material communicate with each other.
5. The method for producing a composite molded product according to any one of 1 to 4, wherein the intermediate material is formed by vacuum molding.
6). The manufacturing method of the composite molded article in any one of 1-5 whose density of the said core material is 0.2 g / cm < 3 > or less.
7). The method for producing a composite molded article according to any one of 1 to 6, wherein the thermoplastic resin constituting the core material and the thermoplastic resin constituting the skin material and the intermediate material are compatible.
8). The thermoplastic resin that constitutes the core material and the thermoplastic resin that constitutes the skin material and the intermediate material are any one combination of the following (1) to (4): A method for producing a composite molded product.
(1) Core material: expanded polystyrene Skin material / intermediate material: high impact polystyrene (2) Core material: expanded styrene / acrylonitrile copolymer Skin material / intermediate material: modified by styrene / acrylonitrile copolymer or rubber component Styrene / Acrylonitrile Copolymer (3) Core Material: Polyolefin Foam Skin Material / Intermediate Material: Polyolefin (4) Core Material: Methyl Methacrylate / Acrylonitrile Copolymer Foam Skin Material / Intermediate Material: Acrylic Resin 9.1 A composite molded article produced by the production method according to any one of -8.
10. A core material made of foamed thermoplastic resin;
An intermediate material made of non-foamable resin, which is combined with the core material,
A composite molded article having a skin material made of a non-foamed thermoplastic resin on the intermediate material.
11. The intermediate member has a first hole and a second hole;
11. The composite molded article according to 10, wherein the core material has a protrusion that fits into the first hole and contacts the surface layer, and a hole that communicates with the second hole.

本発明によれば、コア材の発泡熱可塑性成形体に中間材として熱可塑性樹脂真空成形体を勘合させ、これを真空成形の型として、表皮材である熱可塑性樹脂を真空成形する。従って、表皮材を真空成形する際の熱が、中間材により、コア材へ伝導することが阻害され、コア材の残存発泡剤が膨張したり、表面が溶融することを防ぐことができ、凸凹の少ない外観を得ることができる。   According to the present invention, the thermoplastic resin vacuum molded body is fitted as an intermediate material to the foamed thermoplastic molded body of the core material, and the thermoplastic resin as the skin material is vacuum molded using this as a mold for vacuum molding. Therefore, the heat at the time of vacuum forming the skin material can be prevented from being conducted to the core material by the intermediate material, and the remaining foaming agent of the core material can be prevented from expanding and the surface from being melted. Can be obtained.

本発明の複合成形品は、発泡熱可塑性樹脂からなるコア材と、非発泡熱可塑性樹脂からなる中間材と、これらの上に一体成形した非発泡熱可塑性樹脂からなる表皮材からなる。   The composite molded article of the present invention comprises a core material made of foamed thermoplastic resin, an intermediate material made of non-foamed thermoplastic resin, and a skin material made of non-foamed thermoplastic resin integrally molded thereon.

本発明に用いられるコア材の熱可塑性樹脂は、発泡成形の成形加工性を有するものならば特に限定されない。例えば、発泡ポリスチレン、発泡スチレン・アクリロニトリル共重合体、発泡ポリエチレンや発泡ポリプロピレン等の発泡ポリオレフィン等を使用できる。尚、発泡ウレタンは、リサイクル性に劣る場合があり好ましくない。   The thermoplastic resin of the core material used in the present invention is not particularly limited as long as it has the moldability of foam molding. For example, foamed polystyrene, foamed styrene / acrylonitrile copolymer, foamed polyolefin such as foamed polyethylene and foamed polypropylene can be used. Note that urethane foam is not preferable because it may be inferior in recyclability.

コア材となる発泡熱可塑性成形体は、密度がコストに直接的に影響することから低密度であることが好ましい。密度は好ましくは０．２ｇ／ｃｍ３以下、より好ましくは０．１ｇ／ｃｍ３以下、さらに好ましくは０．０５ｇ／ｃｍ３以下であり、好ましくは０．０１ｇ／ｃｍ３以上である。
密度が０．０１ｇ／ｃｍ３未満では、発泡成形による形状維持の精度が困難な場合がある。逆に、０．２ｇ／ｃｍ３を超えるとコストアップの要因となる。 The foamed thermoplastic molded body as the core material preferably has a low density because the density directly affects the cost. Density is preferably 0.2 g / cm 3 or less, more preferably 0.1 g / cm 3 or less, still more preferably 0.05 g / cm 3 or less, preferably 0.01 g / cm 3 or more.
If the density is less than 0.01 g / cm 3 , the accuracy of shape maintenance by foam molding may be difficult. On the contrary, if it exceeds 0.2 g / cm 3 , it causes an increase in cost.

表皮材は真空成形可能な樹脂から選択される。尚、中間材も真空成形可能な樹脂から選択することができる。
真空成形可能性な樹脂として、例えば、ポリメチルメタクリレート等のアクリル系樹脂、ポリプロピレン（ＰＰ）、アクリロニトリル・ブタジエン・スチレン（ＡＢＳ）、ポリカーボネイト（ＰＣ）が挙げられる。
中間材と表皮材の熱可塑性樹脂は、同じでも異なってもよいが、リサイクル性、相溶性の観点から同じであることが好ましい。 The skin material is selected from resins that can be vacuum formed. The intermediate material can also be selected from resins that can be vacuum formed.
Examples of the resin that can be vacuum formed include acrylic resins such as polymethyl methacrylate, polypropylene (PP), acrylonitrile / butadiene / styrene (ABS), and polycarbonate (PC).
The thermoplastic resin of the intermediate material and the skin material may be the same or different, but is preferably the same from the viewpoint of recyclability and compatibility.

好ましくは、コア材と中間材及び／又は表皮材の密着性を高め、リサイクル性を向上させるために、コア材の熱可塑性樹脂と、中間材と表皮材の熱可塑性樹脂の少なくとも一方、より好ましくは両方とは、互いに相溶する性質を有する。また、中間材と表皮材の熱可塑性樹脂も同様に、好ましくは互いに相溶する性質を有する。   Preferably, in order to increase the adhesion between the core material and the intermediate material and / or the skin material and improve the recyclability, at least one of the thermoplastic resin of the core material and the thermoplastic resin of the intermediate material and the skin material is more preferable. Both are compatible with each other. Similarly, the thermoplastic resin of the intermediate material and the skin material is preferably compatible with each other.

本発明において、「相溶する性質を有する」とは、二つの種類の樹脂が互いに混和可能な性質をいい、類似の化学構造を有することで達成可能である。相溶する性質を有するコア材と、中間材及び／又は表皮材の樹脂の組み合わせとして、発泡ポリスチレン−ハイインパクトポリスチレン、発泡アクリロニトリル・スチレンコポリマー−アクリロニトリル、発泡アクリロニトリル・スチレンコポリマー−ブタジエンゴム、発泡アクリロニトリル・スチレンコポリマー−スチレン共重合体（ＡＢＳ）、発泡アクリロニトリル・スチレンコポリマー−ゴムを変性したＡＢＳ樹脂、発泡ポリオレフィン類−ポリエチレン、発泡ポリオレフィン類−ポリプロピレン樹脂、メタクリル酸メチル・アクリロニトリル共重合体の発泡体−アクリル系樹脂等が挙げられる。アクリル系樹脂の好適例としては、ポリメチルメタクリル酸メチル等のポリメチルメタクリレートが挙げられる。   In the present invention, “having compatible properties” refers to properties in which two types of resins are miscible with each other, and can be achieved by having similar chemical structures. As a combination of a core material having compatible properties and a resin of an intermediate material and / or a skin material, expanded polystyrene-high impact polystyrene, expanded acrylonitrile / styrene copolymer / acrylonitrile, expanded acrylonitrile / styrene copolymer / butadiene rubber, expanded acrylonitrile / Styrene copolymer-Styrene copolymer (ABS), Foamed acrylonitrile / styrene copolymer-Rubber modified ABS resin, Foamed polyolefin-Polyethylene, Foamed polyolefin-Polypropylene resin, Methyl methacrylate / acrylonitrile copolymer foam-Acrylic Based resins and the like. Preferable examples of the acrylic resin include polymethyl methacrylate such as polymethyl methyl methacrylate.

より好適なコア材と中間材、表皮材の組み合わせとして、以下の樹脂の組み合わせ（１）〜（４）を特性とコストの兼ね合いから選ぶことができる。
（１）コア材：発泡ポリスチレン
表皮材・中間材：ハイインパクトポリスチレン
（２）コア材：発泡スチレン・アクリロニトリル共重合体
表皮材・中間材：アクリロニトリル・スチレン共重合体、又はゴム成分によって強化されたスチレン・アクリロニトリル共重合体
（３）コア材：発泡ポリオレフィン
表皮材・中間材：ポリオレフィン
（４）コア材：メタクリル酸メチル・アクリロニトリル共重合体の発泡体
表皮材・中間材：アクリル系樹脂
アクリル系樹脂としては、単量体として、アクリル酸アルキルエステル、メタクリル酸アルキルエステル等の（メタ）アクリル酸アルキルエステルを主成分として重合した樹脂が例示され、中でもポリメチルメタクリル酸メチル等のポリメチルメタクリレートが好ましい。
ポリオレフィンとしては、ポリエチレンやポリプロピレン樹脂が例示される。ゴム成分として、ブタジエンゴムやアクリルゴム等が例示される。 As a more suitable combination of the core material, the intermediate material, and the skin material, the following resin combinations (1) to (4) can be selected from the balance of characteristics and cost.
(1) Core material: Expanded polystyrene Surface material / intermediate material: High impact polystyrene (2) Core material: Expanded styrene / acrylonitrile copolymer Surface material / intermediate material: Reinforced by acrylonitrile / styrene copolymer or rubber component Styrene / acrylonitrile copolymer (3) Core material: Foamed polyolefin Skin / intermediate material: Polyolefin (4) Core material: Methyl methacrylate / acrylonitrile copolymer foam Skin / intermediate material: Acrylic resin Acrylic resin Examples of the monomer include a resin obtained by polymerizing, as a main component, a (meth) acrylic acid alkyl ester such as an alkyl acrylate or alkyl methacrylate, and polymethyl methacrylate such as polymethyl methacrylate is preferable. .
Examples of the polyolefin include polyethylene and polypropylene resin. Examples of the rubber component include butadiene rubber and acrylic rubber.

コア材となる熱可塑性樹脂の発泡成形は、従来公知の発泡性樹脂粒子の熱融着成形方法をそのまま適用することができる。かかる成形方法は、当該樹脂を予備（一次）発泡することで密度を調整したのち、熟成工程を経て金型に充填し、スチーム等で加熱する。   For the foam molding of the thermoplastic resin used as the core material, a conventionally known heat fusion molding method for foamable resin particles can be applied as it is. In this molding method, the density is adjusted by preliminary (primary) foaming of the resin, and then the mold is filled through a aging step and heated with steam or the like.

中間材・表皮材となる熱可塑性樹脂の真空成形も、従来公知の真空成形方法をそのまま適用することができる。例えば、スチレン・ブタジエンゴム・アクリロニトリル共重合体樹脂を板状にシーティングして、得られたシートを電熱ヒータで加熱軟化させた後、型を押し当てシート樹脂と型の空気を真空状態になるまで吸引し、冷却することで行われる。
尚、中間体の成形方法は真空成形に限定されない。例えば、バスダブ用中間体等、形成する中間体が大きい場合は、射出成形は一般に困難であるが、射出成形可能な中間体は射出成形で成形してもよい。 A conventionally known vacuum forming method can also be applied as it is to vacuum forming of a thermoplastic resin as an intermediate material / skin material. For example, a sheet of styrene / butadiene rubber / acrylonitrile copolymer resin is sheeted and the resulting sheet is heated and softened with an electric heater, and then the mold is pressed until the sheet resin and mold air are in a vacuum state. This is done by sucking and cooling.
The method for forming the intermediate is not limited to vacuum forming. For example, when an intermediate to be formed such as an intermediate for bath dub is large, injection molding is generally difficult, but an intermediate that can be injection molded may be formed by injection molding.

本発明においては、コア材と中間材は別々に成形した後、勘合して勘合体を形成する。即ち、コア材と中間材が互いに凸部と凹部を有し、これらが勘合する。勘合することにより、強度と密着性を高めることができる。   In the present invention, the core material and the intermediate material are separately molded and then fitted to form a fitting. That is, the core material and the intermediate material have a convex portion and a concave portion, and these are fitted. By fitting, strength and adhesion can be increased.

好ましくは、コア材が突起を有し、中間材が孔を有し、突起と孔が勘合する。さらに好ましくは、突起が中間材を貫通して表皮材と接する。孔は、エンドミル、ドリル等の機械的切削手段を用いて形成できる。
このような孔と突起を形成して表皮材とコア材が直接触れると、表皮材を真空成形するときの熱及び成形時の真空吸引で、表皮材とコア材を密着させることができる。 Preferably, the core material has a protrusion, the intermediate material has a hole, and the protrusion and the hole are fitted together. More preferably, the protrusion penetrates the intermediate material and contacts the skin material. The hole can be formed using a mechanical cutting means such as an end mill or a drill.
When the skin material and the core material are in direct contact with each other by forming such holes and protrusions, the skin material and the core material can be brought into close contact with each other by heat when vacuum forming the skin material and vacuum suction during molding.

また、コア材には、好ましくは、真空成形する際に空気の出入りが可能な孔を形成する。孔は、前記した機械的切削手段、又は金型での成形時に、金型に針状の突起物を設けることにより、形成できる。
孔を表皮材に達する突起に形成すれば、表皮材の真空成形時に表皮材とコア材の間の空気の吸引が可能でこれらが密着した一体成形体が形成できる。
また、中間材にも孔を形成して、コア材の孔と中間材の孔が連通するようにすれば、表皮材と勘合体の間の空気の吸引が可能で、これらが密着した一体成形体が形成できる。
その結果、高強度で、断熱性に優れた複合成形品を得ることができる。 The core material is preferably formed with holes through which air can enter and exit when vacuum forming. The hole can be formed by providing a needle-like protrusion on the mold when the above-described mechanical cutting means or the mold is used.
If the hole is formed in the protrusion reaching the skin material, air can be sucked between the skin material and the core material at the time of vacuum molding of the skin material, and an integrally molded body in which these are in close contact can be formed.
Also, if holes are formed in the intermediate material so that the holes in the core material and the holes in the intermediate material communicate with each other, air can be sucked between the skin material and the mating body, and these are closely integrated. The body can form.
As a result, a composite molded product having high strength and excellent heat insulation can be obtained.

表皮材を設けることにより、より外部からの応力に耐えうる構造となる。表皮材の肉厚としては、０．３〜５ｍｍが好ましく、１〜４ｍｍがより好ましい。
０．３ｍｍ未満では、十分な強度を得られない恐れがあり、５ｍｍを超えると重量の増加やコストアップの要因となる。 By providing the skin material, the structure can withstand more external stress. As thickness of a skin material, 0.3-5 mm is preferable and 1-4 mm is more preferable.
If the thickness is less than 0.3 mm, sufficient strength may not be obtained. If the thickness exceeds 5 mm, the weight increases and the cost increases.

中間材の樹脂は、表皮材の樹脂を真空成形する時の熱をコア材に伝導しづらくする役割を有する。中間材の肉厚としては、０．３〜５ｍｍが好ましく、１〜４ｍｍがより好ましい。
０．３ｍｍ未満では、コア材に熱が伝導し表面が凸凹になる可能性があり、５ｍｍを超えると必要ないばかりでなく重量の増加やコストアップの要因となる。 The intermediate resin has a role of making it difficult to conduct heat to the core material when vacuum forming the skin resin. The thickness of the intermediate material is preferably 0.3 to 5 mm, and more preferably 1 to 4 mm.
If it is less than 0.3 mm, heat may be conducted to the core material and the surface may be uneven. If it exceeds 5 mm, it is not necessary, but it causes an increase in weight and cost.

本発明の複合成形品は、必要に応じ、その他の部材を形成／取り付けてもよいし、加工してもよい。   In the composite molded article of the present invention, other members may be formed / attached or processed as necessary.

以下実施例によって本発明をさらに詳細に説明するが、本発明はこれに限定されるものではない。
実施例１
１．コア材の製造
＜予備発泡＞
発泡性スチレン・アクリロニトリル共重合体（ＡＳ）樹脂粒子（日立化成工業製：ハイビーズＧＲ）を、発泡スチロール用のバッチ式発泡機（日化設備エンジニアリング製：ＨＢＰ−５００ＬＷ）を用い、嵩密度０．０３ｇ／ｃｍ３に予備発泡したのち、成形までの１８時間、通気性の良い袋に保管した。 Hereinafter, the present invention will be described in more detail by way of examples, but the present invention is not limited thereto.
Example 1
1. Manufacture of core material <pre-foaming>
Expandable styrene / acrylonitrile copolymer (AS) resin particles (manufactured by Hitachi Chemical Co., Ltd .: High Beads GR) using a batch type foaming machine for foamed polystyrene (manufactured by Nikka Equipment Engineering Co., Ltd .: HBP-500LW), and a bulk density of 0.03 g. After pre-foaming to / cm 3, it was stored in a bag with good air permeability for 18 hours until molding.

＜成形＞
発泡スチロール用成形機（日立化成工業製：モルデックスＣ１０ＶＳ）に、おおよその外寸４００×１５０×１５０ｍｍ厚さ１０ｍｍのバスタブ状の成形品を得るための発泡スチロール用金型を取り付けた。引き続き、型締めしたのち、上記の一次発泡粒子を金型に充填した。さらに０．０８ＭＰａのゲージ圧を有する水蒸気で２５秒加熱し、水冷工程、真空冷却工程を経て、金型より取り出した。その後、５０℃の雰囲気下に２４時間放置して乾燥することにより、図１に示すバスタブ状のコア材本体１０を得た。図１において、コア材本体１０の内壁には、等間隔に突起１が４７ヶ所設けられている。
コア材本体１０の密度は、０．０３ｇ／ｃｍ３であった。尚、密度は、コア材本体１０を水没させ上昇した水位をコア材本体１０の体積として、コア材本体１０の重量で除することにより求めた。 <Molding>
A foamed polystyrene mold for obtaining a bathtub-shaped molded product having an approximate outer size of 400 × 150 × 150 mm and a thickness of 10 mm was attached to a foamed polystyrene molding machine (manufactured by Hitachi Chemical Co., Ltd .: Moldex C10VS). Subsequently, after the mold was clamped, the primary foamed particles were filled in the mold. Furthermore, it heated with the water vapor | steam which has a gauge pressure of 0.08 MPa for 25 seconds, and took out from the metal mold | die through the water cooling process and the vacuum cooling process. Then, it was left to dry in an atmosphere of 50 ° C. for 24 hours to obtain a bathtub-shaped core material body 10 shown in FIG. In FIG. 1, 47 protrusions 1 are provided at equal intervals on the inner wall of the core material body 10.
The density of the core material body 10 was 0.03 g / cm 3 . In addition, the density was calculated | required by remove | dividing by the weight of the core material main body 10 by making the water level which submerged the core material main body 10 into the volume of the core material main body 10, and raised.

＜加工＞
図２に示すように、コア材本体１０にφ１の錐を用いドリルでコア材本体１０の内壁の突起１を含む７１ヶ所に孔２をまんべんなく開け、コア材２０を得た。 <Processing>
As shown in FIG. 2, the core material 20 was obtained by uniformly drilling holes 2 at 71 locations including the protrusions 1 on the inner wall of the core material body 10 using a φ1 cone in the core material body 10.

２．中間材の製造
＜成形＞
アクリロニトリル・アクリルゴム・スチレン共重合体（ＡＡＳ）樹脂（日立化成工業製：バイタックス６７００Ｂ）を、５２０×２７０×３．５ｍｍのシートにシーティングした。真空成形機（布施真空製：ＣＵＶＦ １２２１
ＰＷＢ）におおよそ４００×１５０×１５０ｍｍのバスタブ状の成形品を得るための真空成型用金型を取り付けた。シートをセットし、３５０℃のヒータ設定温度でシートの上下を１００秒間加熱後、真空成形、冷却工程を経て、図３に示す中間材本体３０を得た。 2. Production of intermediate materials <Molding>
An acrylonitrile / acrylic rubber / styrene copolymer (AAS) resin (manufactured by Hitachi Chemical Co., Ltd .: Vitax 6700B) was sheeted on a 520 × 270 × 3.5 mm sheet. Vacuum forming machine (cloth vacuum: CUVF 1221
PWB) was fitted with a vacuum molding die for obtaining a bathtub-shaped molded product of approximately 400 × 150 × 150 mm. The sheet was set, and the upper and lower sides of the sheet were heated for 100 seconds at a heater set temperature of 350 ° C., and then subjected to vacuum forming and cooling steps to obtain an intermediate material body 30 shown in FIG.

＜トリミング及び加工＞
トリミングマシーン（布施真空製：ＣＵＴＭ−１２１６）の刃物をφ６エンドミルにして、中間材本体３０について、孔４と端部をＮＣ制御にてカットした。さらに刃物をφ１の錐に交換して、コア材２０の孔２と合う位置に孔３を開け、図４に示す中間材４０を得た。 <Trimming and processing>
The cutting tool (manufactured by Vacuums for Fabrication: CUTM-1216) was made into a φ6 end mill, and the hole 4 and the end of the intermediate material body 30 were cut by NC control. Further, the blade was replaced with a φ1 cone, and a hole 3 was formed at a position that matched with the hole 2 of the core material 20 to obtain an intermediate material 40 shown in FIG.

３．バスタブ（複合成形品）の製造
アクリロニトリル・アクリルゴム・スチレン共重合体（ＡＡＳ）樹脂（日立化成工業製：バイタックス６７００Ｂ）を、５２０×２７０×３．５ｍｍのシートにシーティングした。真空成形機（布施真空製：ＣＵＶＦ １２２１ ＰＷＢ）に、６００×３５０×３００ｍｍの真空台を固定した。その中央部に、コア材２０と中間材４０を、コア材２０の内壁の突起１と中間材４０の孔４が勘合するように勘合させ、図５に示す勘合体５０を得た。シートをセットし、３５０℃のヒータ設定温度でシートの上下を１００秒間加熱後、真空成形、冷却工程を経て、表皮材６が勘合体５０上に形成された図６に示すバスタブ（複合成形品）６０を得た。
複合成形品６０は表皮材６と中間材４０からなる複数層の非発泡樹脂層を有している。
この複合成形品は、真空成形時に熱を加えたにも係わらず表面の凸凹が非常に少なかった。
尚、実施例１の複合成形品６０において、突起、孔の形、大きさ及び数は適宜変えることができる。 3. Production of Bathtub (Composite Molded Product) Acrylonitrile / acrylic rubber / styrene copolymer (AAS) resin (manufactured by Hitachi Chemical Co., Ltd .: Vitax 6700B) was sheeted on a sheet of 520 × 270 × 3.5 mm. A vacuum stand of 600 × 350 × 300 mm was fixed to a vacuum forming machine (manufactured by Vacuum for Fabrication: CUVF 1221 PWB). In the center part, the core material 20 and the intermediate material 40 were fitted so that the protrusion 1 of the inner wall of the core material 20 and the hole 4 of the intermediate material 40 were fitted, and the fitting body 50 shown in FIG. 5 was obtained. After setting the sheet and heating the upper and lower sides of the sheet at a heater set temperature of 350 ° C. for 100 seconds, through the vacuum forming and cooling process, the skin material 6 is formed on the mating body 50 as shown in FIG. ) 60 was obtained.
The composite molded product 60 has a plurality of non-foamed resin layers composed of the skin material 6 and the intermediate material 40.
This composite molded product had very few surface irregularities despite the application of heat during vacuum forming.
In the composite molded product 60 of Example 1, the shape, size, and number of protrusions and holes can be changed as appropriate.

本発明の複合成形品は、浴槽ユニット、ユニット天井材、ユニットバス壁面等のユニットバス構造部材等の断熱性及び美粧性さらに軽量性が求められるものに用いることができる。
本発明の複合成形品は、コア材が発泡成形体であり、中間材・表皮材が非発泡成形体であるため、軽量かつ高強度、さらに表面の凸凹が非常に少なく、断熱性に優れるため浴槽ユニット等に特に好適に使用される。 The composite molded article of the present invention can be used for those requiring heat insulation, cosmetics, and light weight such as a unit bath structural member such as a bathtub unit, a unit ceiling material, and a unit bath wall surface.
In the composite molded product of the present invention, the core material is a foamed molded body, and the intermediate material / skin material is a non-foamed molded body. Therefore, it is lightweight and high in strength, and has very little surface irregularity and excellent heat insulation. It is particularly preferably used for a bathtub unit or the like.

実施例１で製造したコア材本体の上面図及び断面図である。2 is a top view and a cross-sectional view of a core material body manufactured in Example 1. FIG. 実施例１で製造した孔を設けたコア材の上面図及び断面図である。It is the top view and sectional drawing of the core material which provided the hole manufactured in Example 1. FIG. 実施例１で製造した中間材本体の上面図及び断面図である。2 is a top view and a cross-sectional view of an intermediate material body manufactured in Example 1. FIG. 実施例１で製造した孔を設けた中間材の上面図及び断面図である。It is the upper side figure and sectional drawing of the intermediate material which provided the hole manufactured in Example 1. FIG. 実施例１で製造した勘合体の断面図である。1 is a cross-sectional view of a fitting manufactured in Example 1. FIG. 実施例１で製造したバスタブの断面図である。1 is a cross-sectional view of a bathtub manufactured in Example 1. FIG.

符号の説明Explanation of symbols

１ 突起
２，３，４ 孔
６ 表皮材
１０ コア材本体
２０ コア材
３０ 中間材本体
４０ 中間材
５０ 勘合体
６０ バスタブ（複合成形品） 1 Protrusion 2, 3, 4 Hole 6 Skin material 10 Core material main body 20 Core material 30 Intermediate material main body 40 Intermediate material 50 Fitting body 60 Bathtub (composite molded product)

Claims (11)

熱可塑性樹脂を発泡成形して発泡熱可塑性樹脂からなるコア材を形成し、
熱可塑性樹脂を成形して非発泡熱可塑性樹脂からなる中間材を形成し、
前記コア材と前記中間材を勘合させて、勘合体を形成し、
前記勘合体を真空成形の型として、前記中間材の上に、熱可塑性樹脂を一体成形して、非発泡熱可塑性樹脂からなる表皮材を形成する、
複合成形品の製造方法。 Forming a core material made of foamed thermoplastic resin by foaming thermoplastic resin,
Forming an intermediate material made of non-foamed thermoplastic resin by molding a thermoplastic resin,
The core material and the intermediate material are mated to form a mated body,
Using the fitting body as a vacuum forming mold, a thermoplastic resin is integrally formed on the intermediate material to form a skin material made of a non-foamed thermoplastic resin.
A method for producing a composite molded product. 前記コア材が突起を有し、
前記中間材が孔を有し、
前記突起と前記孔が勘合して、前記突起が前記表皮層と接する請求項１記載の複合成形品の製造方法。 The core material has protrusions;
The intermediate material has holes;
The method for manufacturing a composite molded article according to claim 1, wherein the protrusion and the hole are fitted to each other so that the protrusion is in contact with the skin layer. 前記コア材の突起に、前記表皮材を真空成形するための空気の出入りが可能な孔を開ける請求項２記載の複合成形品の製造方法。   The manufacturing method of the composite molded product of Claim 2 which opens the hole in which the entrance and exit of the air for vacuum-molding the said skin material is opened in the protrusion of the said core material. 前記コア材と前記中間材に孔を開け、コア材の孔と中間材の孔が連通する請求項１〜３のいずれか一項記載の複合成形品の製造方法。   The method for producing a composite molded product according to any one of claims 1 to 3, wherein a hole is formed in the core material and the intermediate material, and the hole of the core material and the hole of the intermediate material communicate with each other. 前記中間材を真空成形して形成する請求項１〜４のいずれか一項記載の複合成形品の製造方法。   The method for producing a composite molded article according to any one of claims 1 to 4, wherein the intermediate material is formed by vacuum forming. 前記コア材の密度が０．２ｇ／ｃｍ３以下である請求項１〜５のいずれか一項記載の複合成形品の製造方法。 The density of the said core material is 0.2 g / cm < 3 > or less, The manufacturing method of the composite molded product as described in any one of Claims 1-5. 前記コア材を構成する熱可塑性樹脂と、前記表皮材及び前記中間材を構成する熱可塑性樹脂が、相溶性である請求項１〜６のいずれか一項記載の複合成形品の製造方法。   The method for producing a composite molded article according to any one of claims 1 to 6, wherein the thermoplastic resin constituting the core material and the thermoplastic resin constituting the skin material and the intermediate material are compatible. 前記コア材を構成する熱可塑性樹脂と、前記表皮材及び前記中間材を構成する熱可塑性樹脂が、下記（１）〜（４）のいずれか一つの組み合わせである請求項１〜７のいずれか一項記載の複合成形品の製造方法。
（１）コア材：発泡ポリスチレン
表皮材・中間材：ハイインパクトポリスチレン
（２）コア材：発泡スチレン・アクリロニトリル共重合体
表皮材・中間材：スチレン・アクリロニトリル共重合体、又はゴム成分によって変性されたスチレン・アクリロニトリル共重合体
（３）コア材：発泡ポリオレフィン
表皮材・中間材：ポリオレフィン
（４）コア材：メタクリル酸メチル・アクリロニトリル共重合体の発泡体
表皮材・中間材：アクリル系樹脂 The thermoplastic resin constituting the core material and the thermoplastic resin constituting the skin material and the intermediate material are any one combination of the following (1) to (4). A method for producing a composite molded article according to one item.
(1) Core material: expanded polystyrene Skin material / intermediate material: high impact polystyrene (2) Core material: expanded styrene / acrylonitrile copolymer Skin material / intermediate material: modified by styrene / acrylonitrile copolymer or rubber component Styrene / Acrylonitrile Copolymer (3) Core Material: Polyolefin Foam Skin Material / Intermediate Material: Polyolefin (4) Core Material: Methyl Methacrylate / Acrylonitrile Copolymer Foam Skin Material / Intermediate Material: Acrylic Resin 請求項１〜８のいずれか一項記載の製造方法により製造した複合成形品。   A composite molded article produced by the production method according to claim 1. 発泡熱可塑性樹脂からなるコア材と、
前記コア材と勘合している、非発泡性樹脂からなる中間材と、
前記中間材の上にある、非発泡熱可塑性樹脂からなる表皮材とを有する、複合成形品。 A core material made of foamed thermoplastic resin;
An intermediate material made of non-foamable resin, which is combined with the core material,
A composite molded article having a skin material made of a non-foamed thermoplastic resin on the intermediate material. 前記中間材が、第１の孔と第２の孔を有し、
前記コア材が、前記第１の孔と勘合して前記表面層と接する突起と、前記第２の孔と連通する孔を有する、請求項１０記載の複合成形品。
The intermediate member has a first hole and a second hole;
The composite molded product according to claim 10, wherein the core material has a protrusion that fits into the first hole and contacts the surface layer, and a hole that communicates with the second hole.
JP2005138420A 2005-05-11 2005-05-11 Manufacturing method of composite molded product Expired - Fee Related JP4811989B2 (en)

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JPS56111645A (en) * 1980-02-08 1981-09-03 Meiwa Sangyo Kk Preparation of composite molding
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JPS55124627A (en) * 1979-03-20 1980-09-25 Sekisui Plastics Co Ltd Production of compound molded body
JPS56111645A (en) * 1980-02-08 1981-09-03 Meiwa Sangyo Kk Preparation of composite molding
JPH0327925A (en) * 1989-06-27 1991-02-06 Sekisui Plastics Co Ltd Manufacture of composite molding
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2020196142A (en) * 2019-05-31 2020-12-10 キョーラク株式会社 Structure and method of manufacturing structure
JP7328512B2 (en) 2019-05-31 2023-08-17 キョーラク株式会社 Structure and method for manufacturing structure

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