JP2015006772A - Net-stretched resin molding and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a net-stretched resin molding in which the whole of a fabric can be tightly stretched to the surface of a resin base material, further capable of imparting a unique touch feeling or design to the surface of a product and further having high productivity, and a method for producing the same.SOLUTION: Provided is a net-stretched resin molding N including: a resin base material 1 produced from a thermoplastic resin; and a net-shaped fabric 2 pasted on the surface of the resin base material 1 and in which the opening area of each mesh is 1 mmor higher, and further, the inside of each net 21, 21...of the above net-shaped fabric 2 is filled with each resin projection 11, 11...

Description

The present invention is an improvement of a method for producing a resin-reinforced resin-molded product. Specifically, the fabric can be firmly attached to the surface of the resin base material, and a unique tactile sensation and design can be imparted to the surface of the product. In addition, the present invention relates to a net-clad resin molded product having a very high manufacturing efficiency and a manufacturing method thereof.

  As is well known, various plastic products (for example, containers for food and cosmetics, detergents, hot water bottles, building materials, figurines, etc.) are available in the market. In addition, among these products, there are already cloth-reinforced plastic products in which a cloth is attached to the surface of a resin base material in order to impart the design and touch of the cloth to the product.

  However, when a method of applying an adhesive or the like and applying a fabric is applied during the manufacture of the above-mentioned fabric-reinforced plastic product, the manufacturing process is complicated because the fabric attaching process must be added after the plastic product forming process. Manufacturing efficiency deteriorates, making it difficult to reduce costs when mass-producing cloth-reinforced plastic products.

  Thus, conventionally, when blow molding the plastic product, a technique has been proposed in which a cloth is inserted inside the mold and integrated with the resin base material (see Patent Documents 1 to 3). Since the product manufactured by this technique had insufficient adhesive strength between the fabric and the resin substrate, the fabric was easily peeled off due to external load or resin deterioration.

  Further, conventionally, a technique for increasing the adhesive strength between a fabric and a resin base material by inserting a cloth having a raised surface on the back surface and causing the softened resin to bite at the time of the blow molding is also known. In this technique, since raising and falling of the raised portions were liable to occur at the time of molding, it was difficult to increase the adhesive strength of the entire fabric.

  In addition, a technique for increasing the strength of a resin molded product by inserting a net-like cloth and sticking it to the surface during blow molding is also known (see Patent Document 5). Since the net-like fabric was used as a reinforcing material to the last, the properties of the net-like fabric were not fully utilized for the appearance and feel of the resin molded product.

JP-A-3-69335 JP-A-9-57826 JP-A-10-217320 JP-A-1-105723 JP-A-5-138723

  The present invention has been made in view of the above-described problems, and the object of the present invention is to firmly attach the entire fabric to the surface of the resin base material and to provide a unique tactile sensation on the surface of the product. Another object of the present invention is to provide a net-clad resin molded product that can be given a design and a high manufacturing efficiency and a manufacturing method thereof.

  Means adopted by the present inventor for solving the above-described problems will be described as follows.

That is, the present invention includes a resin base material 1 made of a thermoplastic resin; and a net-like fabric 2 having an opening area of each mesh attached to the surface of the resin base material 1 of 1 mm ² or more. The resin molded product N is formed, and the meshes 21, 21... Of the net fabric 2 are filled with resin protrusions 11, 11. In the present specification, the “net-like fabric” includes not only a knitted fabric and a woven fabric but also a nonwoven fabric having innumerable small holes.

Further, as a method for producing the net-clad resin molded product N, a net-like fabric having an opening area of each mesh of 1 mm ² or more and heat resistance equal to or higher than a molding temperature when a thermoplastic resin is blow-molded. Insert it so that it is placed between the mold and the parison, then perform clamping and blowing in compressed air to blow up the melt-softened resin and blow it up into the mesh of the net fabric. It is possible to employ a method for allowing the melt-softening resin to enter.

  Furthermore, at the time of the blow molding, a mold having a movable pin is used, and a net-like fabric is hooked on the movable pin protruding from the inside of the mold to perform mold clamping. Later, the movable pin is housed inside the mold and compressed air is blown. After the mold is further opened, the movable pin is protruded inside the mold again to remove the resin molded product from the mold. By adopting the method, efficient production can be performed.

  In addition, at the time of the blow molding, the net cloth is irradiated with an electron beam for several seconds in order to enhance the adhesion with the melt softening resin, and then the net cloth and the melt softening resin whose surface is modified by the electron beam irradiation. Can also be integrated.

  In the present invention, the net-clad resin molded article N includes a resin base material 1 made of a thermoplastic resin; and a non-stretchable net-like fabric 2 attached to the surface of the resin base material 1. The net-like fabric 2 is filled with resin protrusions inside the mesh-like fabric 2 and part or all of the net-like fabric 2 is filled with resin protrusions larger than the thickness of the fabric from the inside of the mesh-like cloth 21.21. Innumerable 11/11 ... can be raised. This makes it possible to use the resin protrusions 11, 11... For pressing a massage point, and to manufacture a resin molded product having a unique appearance and touch.

  In addition, as a method for producing the net-clad resin molded product N, when a thermoplastic resin is blow-molded, a non-stretchable net-like fabric having a heat resistance equal to or higher than the molding temperature is used as a mold and a parison. The melt-softening resin was inserted so as to be disposed between the two, and then the mold was clamped and compressed air was blown in to blow up the melt-softened resin and blow up into the mesh of the net-like fabric And a soft resin that has entered the mesh is raised to the outside of the fabric, and a method of forming innumerable resin protrusions on a part of or the entire surface of the resin molded product to which the net-like fabric is attached is adopted. Can do.

  Furthermore, in the present invention, as the non-stretchable net-like fabric 2, a multiaxial fabric excellent in shape stability can be suitably used. In the present specification, the term “non-stretchable fabric” means a fabric having such a rigidity that the fabric does not follow unevenness of a mold or the like during blow molding. The “mold” includes not only a metal such as iron or aluminum but also a non-metal such as synthetic resin or wood.

  On the other hand, in the present invention, the net-clad resin molded product N is made of a resin base material 1 having irregularities made from a thermoplastic resin; and a net-like fabric 2 having stretchability attached to the surface of the resin base material 1. Are further filled with resin protrusions 11, 11, and the like, and the mesh 21 of the net fabric 2 attached to the concavo-convex portion of the resin base material 1.・ 21 ... can be non-uniform. Thereby, since a mesh shape changes according to the unevenness | corrugation of a resin molded product, a unique design effect can be provided.

  In addition, as a method of manufacturing the above-mentioned net-clad resin molded article N, when blow molding a thermoplastic resin, a net-like fabric having heat resistance equal to or higher than the molding temperature and having stretchability is provided with unevenness. Inserted so as to be placed between the mold and the parison, and then blown in with compressed air to blow up the resin in a melt-softened state, while making the net fabric follow the unevenness of the mold. A method of causing the melt softened resin blown up into the mesh to be deformed non-uniformly according to the stretch of the fabric can be employed.

  In the present invention, the net fabric 2 impregnated with a functional agent having an antibacterial effect, a deodorizing effect, an anti-aging effect, or the like, or made of functional fibers, is used according to the use of the net-clad resin molded product N. Can be used. In that case, nanoporous fibers that can carry a functional agent by crazing treatment can be suitably used for the thread material of the net-like fabric.

  In addition, when the net-like fabric 2 is touched to the net tension portion of the resin molded product N by using a fabric having lower thermal conductivity than the resin base material 1 (thermoplastic resin used for blow molding). Since the heat transfer generated between the human body and the resin base material 1 can be suppressed by the net fabric 2, even when the resin molded product N is used as a hot water bottle or a coolant, an adverse effect on the body due to a sudden temperature change (low temperature) The effect which reduces a burn, myocardial infarction, etc.) can be expected.

  In the present invention, a net-like cloth is inserted at the time of blow molding, and the resin base material and the cloth are integrally formed, so that the softening resin can be inserted into the mesh and the mesh can be filled with resin protrusions. Lateral misalignment can be suppressed by resin protrusions. This also makes it difficult for the fabric to peel off from the resin base material even when a load is applied from the outside or the resin is deteriorated.

  Moreover, in the present invention, a design effect utilizing the fabric can be imparted by attaching a net-like fabric to the surface of the resin base material, and design variations can be achieved by changing the material of the net-like fabric, the mesh shape, etc. Can be diversified. Moreover, the unique tactile sensation which has an unevenness | corrugation feeling can also be provided with the net-like cloth stuck on the surface and the resin protrusion.

  Further, in the present invention, the resin base material is molded at the same time as blow molding, and at the same time, the net-like fabric and the resin base material are integrated. Therefore, it is necessary to attach the fabric using an adhesive after blow molding. There is no concern that the production efficiency will be significantly reduced. Further, if the net-like fabric insert is automated, it can be manufactured with the same efficiency as a normal plastic product.

  Therefore, according to the present invention, even when the product is used for a long period of time, it is difficult for the fabric to peel off, and the unique design and tactile sensation are applied to various uses (for example, chairs, health appliances, interior materials, various containers, etc.) Since the net-clad resin molded product that can be applied to (uses) can be provided at low cost, the practical utility value of the present invention is very high.

It is a whole perspective view showing the net-clad resin molded product in Example 1 of this invention. It is an expanded sectional view showing the section structure of the net-clad resin molded product in Example 1 of the present invention. It is a state explanatory drawing showing the manufacturing method of the net-clad resin molded product in Example 1 of this invention. It is a whole perspective view showing the net-clad resin molded product in Example 2 of this invention.

“Example 1”
First, a first embodiment of the present invention will be described with reference to FIGS. In the figure, what is indicated by reference numeral 1 is a resin base material, and what is indicated by reference numeral 2 is a net-like fabric. Also, what is indicated by the symbol N is a net-clad resin molded product.

[Configuration of net-clad resin molded product]
In Example 1, a net-like resin molded product N is configured by attaching a net-like fabric 2 having an opening area of each mesh of 1 mm ² or more to the surface of a resin substrate 1 made of a thermoplastic resin ( In this embodiment, as shown in FIG. 2, the inside of each mesh 21, 21... Of the net fabric 2 is filled with the resin protrusions 11. .

  Thereby, the net-like fabric 2 attached to the resin base material 1 is hardly peeled off. In this embodiment, polyethylene resin is used for the resin base material 1. However, other thermoplastic resins such as polypropylene, polystyrene, and ABS resin can be used as long as it is a thermoplastic resin depending on the use of the net-clad resin molded product N. And engineering plastics such as polyamide resin can be used.

In addition, regarding the net fabric 2, the non-stretchable knitted fabric is used in this example.
A multiaxial fabric excellent in shape stability can also be used suitably. Further, regarding the material of the net-like fabric 2, polyester fibers are employed in this embodiment, but natural fibers such as cotton and silk can be used as long as the materials have heat resistance higher than the molding temperature of the resin base material 1. It can be appropriately selected from chemical fibers such as rayon and polyamide fibers, glass fibers, carbon fibers, metal wires, inorganic fibers, and the like. In addition, when using metal net-like fabric 2, the preform goods which shape-processed according to the metal mold | die shape beforehand can also be used.

  Further, in this embodiment, as shown in the partially enlarged view of FIG. 1, a recess 12 is provided in the resin substrate 1, and the fabric 21 is formed from the inside of the meshes 21, 21 of the net fabric 2 around the recess 12. Innumerable resin protrusions 11, 11... Thereby, the resin protrusions 11, 11... Of the resin substrate 1 raised from the meshes 21, 21.

  Of course, the resin protrusions 11, 11... May be projected not only from a part of the meshes 21, 21... Of the net fabric 2 but also from the entire meshes 21, 21. it can. Further, the resin protrusions 11, 11... Can be protruded not on the periphery of the recesses 12, 12.

[Method of manufacturing net-clad resin molded product]
Next, a method for producing the net-clad resin molded product N of the present embodiment will be described. As a first step, as shown in FIG. 3A, when the thermoplastic resin is blow-molded, the net-like fabric 2 is inserted and arranged between the mold M and the parison P. In the present embodiment, the mold M provided with the movable pin Q is used, and the net-like fabric 2 is hooked and temporarily fixed to the movable pin Q protruding to the inside of the mold M.

  Thereafter, as a second step, as shown in FIG. 3 (b), the mold is clamped and compressed air is blown to blow up the melt-softened resin and blow up into the mesh of the net fabric 2. The melted softening resin is allowed to enter. Further, at this time, the net fabric 2 and the resin are molded so that the depressions 12, 12... Are formed following the shape of the concavo-convex parts A, A. Furthermore, in this embodiment, when the compressed air is blown in, the movable pin Q is retracted and housed inside the mold M so that the movable pin Q does not affect the shape of the resin molded product.

  Then, after blowing in the compressed air, as a third step, the softened resin that has entered the meshes 21, 21... Of the net fabric 2 is raised to the outside of the fabric to form innumerable resin protrusions 11, 11. At the same time (not shown), the net-like cloth 2 is fixed and integrated in a state where the net-like cloth 2 is stuck to the surface of the resin base material 1 to produce a net-like resin molded article N. Further, in this embodiment, after the mold is opened, the movable pin Q is projected again inside the mold M so that the resin molded product can be easily detached from the mold M (not shown). )

“Example 2”
Next, a second embodiment of the present invention will be described with reference to FIG. In Example 2, the net-clad resin molded product N is pasted on the surface of the resin base material 1 and the resin base material 1 having recesses 12, 12... Made of the same thermoplastic resin as in Example 1. And a net-like fabric 2 having stretchability.

  In the present embodiment, the meshes 21, 21... Of the net fabric 2 are filled with the resin protrusions 11, 11. The nets 21, 21... Of the net-like fabric 2 are formed in a non-uniform shape. Thereby, the mesh shape of the net-like fabric 2 can be freely deformed according to the unevenness of the resin base material 1.

[Method of manufacturing net-clad resin molded product]
Next, a method for producing the net-clad resin molded product N of the present embodiment will be described. In the first step, the net fabric 2 is inserted between the mold M provided with the concavo-convex portions A, A... And the parison P as in the first embodiment. In the present embodiment, unlike the first embodiment, it is an essential condition that the mold M is provided with the uneven portion A.

  Then, as a second step, compressed air is blown to blow up the melt-softened resin so that the net fabric 2 follows the concave and convex portions A, A,. Are deformed non-uniformly in accordance with the stretch of the fabric, and the melt-softened resin blown up into the meshes 21, 21.

  As a third step, the soft resin is cured while the meshes 21, 21... Of the net cloth 2 are deformed to form the resin base material 1, and the net cloth 2 and the resin base material 1. Complete the integration. This makes it possible to produce a net-clad resin molded product N having a unique mesh pattern formed on the surface.

  The present invention is generally configured as described above. However, the present invention is not limited to the illustrated embodiment, and various modifications can be made within the scope of the claims. For example, Further, instead of providing the recess 12 in the resin base material 1, it is also possible to provide a convex portion. In that case, blow molding is performed using a mold M in which a concave portion is formed inside.

  Furthermore, in the above embodiment, the net-like cloth 2 is attached only to one surface of the resin base material 1, but the net-like cloth 2 can also be attached to the entire surface of the resin base material 1. In that case, the net-like fabric 2 can be formed in a cylindrical shape so as to surround the outside of the parison P during blow molding, and the net-like fabric 2 can be automatically introduced.

  In addition, at the time of the blow molding, the net cloth is irradiated with an electron beam or the like for several seconds, and then the net cloth whose surface is modified by the electron beam irradiation and the melt softening resin are integrated to form a resin base. The adhesive strength between the material 1 and the net fabric 2 can also be increased.

  Moreover, according to the use of the net-clad resin molded product N, the net-like fabric 2 impregnated with a functional agent having an antibacterial effect, a deodorizing effect, an anti-aging effect, etc. can also be used. In this case, nanoporous fibers that can carry a functional agent by crazing treatment can be used for the thread material of the net-like fabric. In addition, a net-like fabric 2 made of functional fibers having a hygroscopic effect or the like due to structural features (such as a porous shape or a tube shape) can also be used.

  On the other hand, with respect to the net-like fabric 2, the resin substrate N is used in order to reduce adverse effects on the body (such as low-temperature burns and myocardial infarction) caused by a rapid temperature change even when the resin molded product N is used as a hot water bottle or coolant. It is preferable to use a fabric having lower thermal conductivity than the material 1. Moreover, if the net-like fabric 2 with low thermal conductivity is used, the effect of suppressing heat radiation and keeping the inside of the resin molded product N warm, and the effect of reducing the cooling sensation when touching the resin substrate 1 can be obtained. .

  In addition, the use of the net-clad resin molded product N of the present invention includes various containers, plastic planters, and interior materials whose appearance design is important, such as health appliances, chairs, hot water bottles, etc. that touch the human body during use. It can also be used for figurines and the like, and any of the above belongs to the technical scope of the present invention.

  In recent years, plastic products having unique characteristics in terms of function or appearance have been demanded in the market. Under such circumstances, since the technology related to the net-clad resin molded product and the manufacturing method thereof according to the present invention is a useful technology capable of imparting unprecedented characteristics to blow-molded products, its industrial application. The value is very high.

1 Resin base material
11 Resin protrusion
12 Indentation 2 Net-like fabric
21 Mesh N Net-molded resin molded product P Parison M Mold A Concavity and convexity

Claims (15)

When the thermoplastic resin is blow-molded, a net-like fabric having an opening area of each mesh of 1 mm ² or more and heat resistance equal to or higher than the molding temperature is inserted so as to be disposed between the mold and the parison. Thereafter, the mold is clamped and compressed air is blown to blow up the melt-softened resin, and the melt-softened resin blown up into the mesh of the net-like fabric is made to enter. Manufacturing method of molded products.   When the thermoplastic resin is blow-molded, it has a heat resistance equal to or higher than the molding temperature, and the net-like fabric is inserted so as to be disposed between the mold and the parison, and then the mold is clamped for compressed air. Blow up the melt-softened resin, let the melt-softened resin blown up into the mesh of the net-like fabric, and further raise the softened resin that entered the mesh to the outside of the fabric 2. A method for producing a net-clad resin molded product according to claim 1, wherein an infinite number of resin protrusions are formed on a part or the whole of the surface of the resin molded product with the net-like fabric attached thereto.   The method for producing a net-clad resin molded article according to claim 1 or 2, wherein a multiaxial woven fabric having excellent shape stability is used for the net-like fabric.   When blow molding a thermoplastic resin, insert a net-like fabric that has heat resistance equal to or higher than the molding temperature and that is stretchable so that it is placed between the mold with the unevenness and the parison. Then, compressed air is blown to melt and soften the resin in a melt-softened state, and the net-like fabric is deformed unevenly according to the stretch of the fabric while following the unevenness of the mold. 2. The method for producing a net-clad resin molded article according to claim 1, wherein the melt-softened resin blown up is inserted into the resin-molded product.   The method for producing a net-clad resin molded article according to any one of claims 1 to 4, wherein a net-like fabric impregnated with a functional agent or made of functional fibers is used.   The method for producing a net-clad resin molded article according to any one of claims 1 to 5, wherein a net-like fabric having a lower thermal conductivity than a thermoplastic resin used for blow molding is used.   Using a mold with a movable pin during blow molding, the net-like fabric is hooked on the movable pin protruding to the inside of the mold, and then the mold is clamped. The molded product is stored inside the mold, blown with compressed air, further opened, and then the movable pin is protruded again inside the mold to release the resin molded product from the mold. The manufacturing method of the net-clad resin molded product as described in any one of 1-6.   In blow molding, the net cloth is irradiated with an electron beam for several seconds in order to enhance the adhesion to the melt softening resin, and then the net cloth and the melt softening resin whose surface is modified by the electron beam irradiation are integrated. The method for producing a net-clad resin molded article according to any one of claims 1 to 7, wherein A resin base material (1) made from a thermoplastic resin; and a net-like fabric (2) having an opening area of each mesh pasted on the surface of the resin base material (1) of 1 mm ² or more, Further, the net-like resin molded product is characterized in that the meshes (21), (21),... Of the net-like fabric (2) are filled with resin protrusions (11), (11),. A resin base material (1) made from a thermoplastic resin; and a non-stretchable net fabric (2) attached to the surface of the resin base material;
Further, the inside of each mesh (21), (21),... Of the net fabric (2) is filled with resin protrusions (11), (11), and the mesh ( 21. The net-clad resin molded product according to claim 9, wherein resin protrusions (11), (11),.   11. The net-clad resin molded article according to claim 9, wherein a multiaxial woven fabric having excellent shape stability is used for the net-like fabric (2). A resin base material (1) having irregularities made from a thermoplastic resin; and a net-like fabric (2) having stretchability attached to the surface of the resin base material (1),
Further, the meshes (21), (21), etc. of the net-like fabric (2) are filled with resin protrusions (11), (11), and the net-like fabric adhered to the uneven portion of the resin base material (1). 10. The net-clad resin molded product according to claim 9, wherein the meshes (21), (21),... Of (2) have a non-uniform shape.   The net-like resin molded article according to any one of claims 9 to 12, wherein a net-like fabric (2) impregnated with a functional agent or made of functional fibers is used.   14. The net-clad resin molded article according to claim 13, wherein the thread material of the net-like fabric (2) is made of nanoporous fibers capable of supporting a functional agent by crazing treatment.   The net-like resin molded article according to any one of claims 9 to 14, wherein a net-like fabric (2) having a lower thermal conductivity than the resin base material (1) is used.