JP2015151695A - Method of manufacturing coating expanded material, and coating expanded material - Google Patents

Method of manufacturing coating expanded material, and coating expanded material Download PDF

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JP2015151695A
JP2015151695A JP2014024170A JP2014024170A JP2015151695A JP 2015151695 A JP2015151695 A JP 2015151695A JP 2014024170 A JP2014024170 A JP 2014024170A JP 2014024170 A JP2014024170 A JP 2014024170A JP 2015151695 A JP2015151695 A JP 2015151695A
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foam
plate
resin sheet
vent
hole
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JP6408225B2 (en
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義人 奥田
Yoshito Okuda
義人 奥田
直史 金子
Naofumi KANEKO
直史 金子
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KOTOBUKI KASEI KOGYO KK
Nagase and Co Ltd
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Nagase and Co Ltd
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Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a coating expanded material, which enables simple formation of a coating layer with sufficient strength, and the like.SOLUTION: A method of manufacturing a coating expanded material includes the steps of: arranging a foam plate 10 on a surface of a ventilation plate 40 with a vent hole 42; bringing a heated resin sheet 20a into contact with a surface of the foam plate 10 and a part 40p, around the foam plate 10, of the surface of the ventilation plate 40; and sucking out gas between the ventilation plate 40 and the resin sheet 20a to the other side of the ventilation plate 40 via the vent hole 42 to bring the resin sheet 20a into intimate contact with the foam plate 10.

Description

本発明は、被覆発泡体の製造方法、および、被覆発泡体に関する。   The present invention relates to a method for producing a coated foam and a coated foam.

従来より、いわゆる発泡スチロール等の発泡体は、緩衝材、断熱材、水耕栽培用の定植パネルなどに幅広く利用されている。このような発泡体は、その表面が柔らかくて傷がつきやすく、繰り返し利用に適さないことから、発泡体の表面を樹脂で被覆する技術が開示されている（例えば、特許文献１、２参照）。   Conventionally, foams such as so-called expanded polystyrene have been widely used for cushioning materials, heat insulating materials, fixed planting panels for hydroponics, and the like. Since such a foam has a soft surface and is easily scratched and is not suitable for repeated use, a technique for coating the surface of the foam with a resin is disclosed (for example, see Patent Documents 1 and 2). .

特開平９−１６８３３９号公報Japanese Patent Laid-Open No. 9-168339 特開平９−４０８５号公報Japanese Patent Laid-Open No. 9-4085

特許文献１では、金型内で発泡ポリスチレンの表面を溶融させて表面にポリスチレン膜を形成しているが、この方法では十分な強度の膜を形成することが困難であった。   In Patent Document 1, the surface of foamed polystyrene is melted in a mold to form a polystyrene film on the surface. However, it is difficult to form a film having sufficient strength by this method.

また、特許文献２では、発泡体に予め細溝を形成すると共に表面被覆材に予め凸条を設ける必要があり、工程が煩雑である。   Moreover, in patent document 2, it is necessary to form a narrow groove beforehand in a foam, and to provide a protruding item | line beforehand in a surface coating material, and a process is complicated.

本発明は、上記課題に鑑みてなされたものであり、十分な強度の被覆層を簡易に形成できる発泡被覆体の製造方法等を提供することを目的とする。   This invention is made | formed in view of the said subject, and it aims at providing the manufacturing method of the foaming coating body etc. which can form a coating layer of sufficient intensity | strength easily.

本発明に係る製造方法は、通気孔を有する通気板の表面上に発泡体を配置する第１配置工程、
加熱された樹脂シートを、前記発泡体の表面及び前記通気板の表面における前記発泡体の周囲の部分に接触させる第１接触工程、及び、
前記通気孔を介して前記通気板と前記樹脂シートとの間のガスを前記通気板の反対側に吸い出して、前記樹脂シートを前記発泡体に密着させる第１吸出工程と、を備える。 The manufacturing method according to the present invention includes a first disposing step of disposing a foam on the surface of a vent plate having a vent.
A first contact step in which the heated resin sheet is brought into contact with a portion of the surface of the foam and the surface of the vent plate around the foam; and
A first suction step of sucking gas between the vent plate and the resin sheet through the vent hole to the opposite side of the vent plate and bringing the resin sheet into close contact with the foam.

本発明によれば、任意の材質及び任意の厚みの樹脂シートを用いた被覆が出来るので、強度の高い被覆層を容易に得られる。また、被覆作業も簡単に行える。また、発泡体の形状が複雑でも、樹脂シートを発泡体の表面形状に沿わせることが容易である。   According to the present invention, since coating using a resin sheet having an arbitrary material and an arbitrary thickness can be performed, a high-strength coating layer can be easily obtained. Also, the covering operation can be easily performed. Moreover, even if the shape of the foam is complicated, it is easy to make the resin sheet conform to the surface shape of the foam.

ここで、前記発泡体は、前記通気板の表面と対向する面、及び、前記通気板の表面と対向しない面の間に貫通する貫通孔を有することができる。   Here, the foam may have a through-hole penetrating between a surface facing the surface of the vent plate and a surface not facing the surface of the vent plate.

このような発泡体は定植パネルに適し、本方法によれば貫通孔の内面にも樹脂シートを好適に被覆できる。   Such a foam is suitable for a fixed planting panel, and according to this method, the inner surface of the through hole can be suitably coated with a resin sheet.

また、前記第１接触工程において、前記発泡体と前記樹脂シートとの間に、中間シートを介在させることができる。   In the first contact step, an intermediate sheet can be interposed between the foam and the resin sheet.

これによれば、加熱された樹脂シートと発泡体との直接接触が妨げられるので、その部分において樹脂シートの表面を平滑に維持できるので、美観に優れた被覆発泡体を形成しやすい。   According to this, since direct contact between the heated resin sheet and the foam is hindered, the surface of the resin sheet can be kept smooth at that portion, so that it is easy to form a coated foam excellent in aesthetics.

また、前記第１吸引工程の後に、
前記発泡体を、前記樹脂シートで被覆されていない部分が露出するように前記通気板上に配置する第２配置工程、
加熱された樹脂シートを、前記発泡体の前記被覆されていない部分及び前記通気板の表面における前記発泡体の周囲の部分に接触させる第２接触工程、及び、
前記通気孔を介して前記通気板と前記樹脂シートとの間のガスを前記通気板の反対側に吸い出して、前記樹脂シートを前記発泡体に密着させる第２吸出工程を、更に備えることができる。これにより、発泡体の両面を被覆できる。 In addition, after the first suction step,
A second disposing step of disposing the foam on the vent plate so that a portion not covered with the resin sheet is exposed;
A second contact step of bringing the heated resin sheet into contact with the uncovered portion of the foam and the portion of the vent plate surrounding the foam; and
A second sucking step of sucking out the gas between the vent plate and the resin sheet to the opposite side of the vent plate through the vent hole and bringing the resin sheet into close contact with the foam can be further provided. . Thereby, both surfaces of a foam can be coat | covered.

本発明に掛かる被服発泡体は、上述の方法により製造された被覆発泡体である。   The clothing foam according to the present invention is a coated foam produced by the above-described method.

本発明に係る他の被覆発泡体は、複数の貫通孔を有する発泡板と、
前記発泡板の一方の主面、前記発泡板の側面、及び、各前記貫通孔の内面を被覆する第１の樹脂シートと、
前記発泡板の他方の主面、前記発泡板の側面、及び、各前記貫通孔の内面を被覆する第２の樹脂シートと、を備える。 Another coated foam according to the present invention includes a foam plate having a plurality of through holes,
A first resin sheet covering one main surface of the foam plate, a side surface of the foam plate, and an inner surface of each of the through holes;
A second resin sheet covering the other main surface of the foam plate, a side surface of the foam plate, and an inner surface of each through hole.

ここで、前記第１の樹脂シート及び前記第２の樹脂シートは、前記発泡板の側面及び前記各貫通孔の内面において互いに重なっていることができる。   Here, the first resin sheet and the second resin sheet may overlap each other on a side surface of the foamed plate and an inner surface of each through hole.

本発明によれば、十分な強度の被覆層を簡易に形成できる発泡被覆体の製造方法等が提供される。   ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the foaming coating body etc. which can form a coating layer of sufficient intensity | strength simply are provided.

図１の（ａ）は被覆前の発泡板（発泡体）１０の斜視図、図１の（ｂ）は（ａ）のＩａ−Ｉａ断面図である。1A is a perspective view of a foam plate (foam) 10 before coating, and FIG. 1B is a cross-sectional view taken along line Ia-Ia in FIG. 図２の（ａ）は、本発明の第１実施形態に係る被覆発泡体の製造方法を説明する模式断面図であり、図２の（ｂ）は、図２の（ａ）の後工程を示す模式断面図である。(A) of FIG. 2 is a schematic cross-sectional view illustrating a method for producing a coated foam according to the first embodiment of the present invention, and (b) of FIG. 2 illustrates a post-process of (a) of FIG. It is a schematic cross section shown. 図３の（ａ）は、図２の（ｂ）の後工程を示す模式断面図であり、図３の（ｂ）は、図３の（ａ）の後工程を示す模式断面図である。3A is a schematic cross-sectional view showing a post-process of FIG. 2B, and FIG. 3B is a schematic cross-sectional view showing a post-process of FIG. 3A. 図４の（ａ）は、図３の（ｂ）の後工程を示す模式断面図であり、図４の（ｂ）は、図４の（ａ）の後工程を示す模式断面図である。4A is a schematic cross-sectional view showing a post-process of FIG. 3B, and FIG. 4B is a schematic cross-sectional view showing a post-process of FIG. 4A. 図５の（ａ）は、本発明の第２実施形態に係る発泡被覆体の製造方法に用いる中間シート３０の斜視図であり、図５の（ｂ）は、本発明の第２実施形態に係る被覆発泡体の製造方法を説明する模式断面図である。(A) of FIG. 5 is a perspective view of the intermediate sheet 30 used for the manufacturing method of the foaming covering which concerns on 2nd Embodiment of this invention, (b) of FIG. 5 is in 2nd Embodiment of this invention. It is a schematic cross section explaining the manufacturing method of the covering foam which concerns. 図６の（ａ）は、図５の（ｂ）の後工程を説明する模式断面図であり、図６の（ｂ）は、図６の（ａ）の後工程を示す模式断面図である。6A is a schematic cross-sectional view for explaining a post-process of FIG. 5B, and FIG. 6B is a schematic cross-sectional view showing a post-process of FIG. 6A. . 図７は、更に他の実施形態に係る被覆発泡体の製造方法を説明する模式断面図である。FIG. 7 is a schematic cross-sectional view illustrating a method for manufacturing a coated foam according to still another embodiment.

図面を参照して、本発明の第１実施形態に係る被覆発泡体の製造方法を説明する。   With reference to drawings, the manufacturing method of the covering foam which concerns on 1st Embodiment of this invention is demonstrated.

（第１実施形態）   (First embodiment)

まず、発泡体を用意する。本実施形態では、図１の（ａ）及び（ｂ）に示すように、一例として多数の貫通孔を有する板状の発泡体（発泡板１０）について説明する。この発泡板１０は、板状の形状を有する。発泡板１０の２つの主面は、例えば、正方形又は矩形であることができる。主面の一辺の長さは、１００〜９００ｍｍとすることが出来る。また、発泡板１０の厚みは、例えば、２０〜５０ｍｍとすることが出来る。   First, a foam is prepared. In the present embodiment, as shown in FIGS. 1A and 1B, a plate-like foam (foamed plate 10) having a large number of through holes will be described as an example. The foam plate 10 has a plate shape. The two main surfaces of the foam plate 10 can be, for example, square or rectangular. The length of one side of the main surface can be 100 to 900 mm. Moreover, the thickness of the foam board 10 can be 20-50 mm, for example.

発泡板１０の材質は、発泡樹脂であれば特に限定されない。樹脂の例は、ポリウレタン、ポリスチレン、ポリオレフィン（例えば、ポリプロピレン、ポリエチレン）、ポリエステル（Ａ−ＰＥＴ（アモルファスポリエチレンテレフタレート）など）、フェノール樹脂、ポリ塩化ビニル、ユリア樹脂、シリコーン樹脂、ポリイミド、メラミン樹脂である。発泡板１０は、例えば、ビース法発泡スチロール（EPS）、ビーズ法発泡ポリプロピレン(EPP)であることができる。また、ビーズ法発泡以外でも、注型発泡、溶融発泡などによる発泡材料でも良い。   The material of the foam board 10 will not be specifically limited if it is foam resin. Examples of the resin are polyurethane, polystyrene, polyolefin (for example, polypropylene, polyethylene), polyester (A-PET (amorphous polyethylene terephthalate), etc.), phenol resin, polyvinyl chloride, urea resin, silicone resin, polyimide, melamine resin. . The foam plate 10 can be, for example, bead method foamed polystyrene (EPS) or bead method foamed polypropylene (EPP). In addition to foaming by the bead method, foaming material such as cast foaming or melt foaming may be used.

発泡倍率も特に限定されないが、例えば、１倍を超えればよく、例えば、１．５〜１００倍とすることが出来る。定植パネルの場合には、２０〜４０倍が好ましい。   The expansion ratio is not particularly limited, but may be, for example, more than 1 time, for example, 1.5 to 100 times. In the case of a fixed planting panel, 20 to 40 times is preferable.

また、気泡の形態は、連続気泡でもよく、独立気泡でも良い。発泡体の耐久性をより高いものとする観点から、気泡の形態は、独立気泡の方が好ましい。   The form of the bubbles may be open cells or closed cells. From the viewpoint of enhancing the durability of the foam, the form of the bubbles is preferably closed cells.

貫通孔１２は発泡板１０の両主面間を貫通している。貫通孔１２の最狭部の径は、例えば、５〜５０ｍｍとすることが出来る。また、貫通孔１２の軸方向両端部は、貫通孔の出口に近づくにつれて径が広くなるように面取されていることができる。   The through hole 12 penetrates between both main surfaces of the foamed plate 10. The diameter of the narrowest part of the through-hole 12 can be 5-50 mm, for example. Moreover, the axial direction both ends of the through-hole 12 can be chamfered so that a diameter may become large as it approaches the exit of a through-hole.

貫通孔１２の数や配置は特に限定されない。例えば、貫通孔１２間の間隔は、中心軸間間隔として、例えば、５０ｍｍ以上とすることが出来る。   The number and arrangement of the through holes 12 are not particularly limited. For example, the distance between the through holes 12 can be set to, for example, 50 mm or more as the distance between the central axes.

このような発泡板１０は、公知の方法により製造できる。   Such a foam board 10 can be manufactured by a well-known method.

続いて、図２の（ａ）に示すように、発泡板１０を、通気板４０の上に配置する（第１配置工程）。通気板４０は、表裏を貫通する多数の通気孔４２を有する。通気板４０の表面（上面）は、発泡板１０の下面（主面）よりも大きな面積を有する。発泡板１０を例えば通気板４０の略中央部に配置することにより、発泡板１０の周囲に通気板４０の一部（発泡体の周囲の部分）４０ｐが露出するように発泡板１０を配置する。   Then, as shown to (a) of FIG. 2, the foam board 10 is arrange | positioned on the ventilation board 40 (1st arrangement | positioning process). The ventilation plate 40 has a large number of ventilation holes 42 penetrating the front and back. The surface (upper surface) of the ventilation plate 40 has a larger area than the lower surface (main surface) of the foam plate 10. For example, by disposing the foam plate 10 at a substantially central portion of the vent plate 40, the foam plate 10 is disposed so that a part of the vent plate 40 (portion around the foam) 40 p is exposed around the foam plate 10. .

通気板４０の通気孔４２の孔径は、例えば、１〜５ｍｍとすることが出来る。通気板４０の材質は、後述する樹脂シート２０ａ，２０ｂと熱融着しない材料であることが好ましい。   The hole diameter of the ventilation hole 42 of the ventilation board 40 can be 1-5 mm, for example. The material of the ventilation plate 40 is preferably a material that is not thermally fused to resin sheets 20a and 20b described later.

通気板４０の下方には、チャンバ４４ａを形成するチャンバ形成部４４が設けられ、チャンバ形成部４４には、真空ポンプ５０が接続されている。   Below the ventilation plate 40, a chamber forming portion 44 that forms a chamber 44 a is provided, and a vacuum pump 50 is connected to the chamber forming portion 44.

続いて、図２の（ａ）に示すように、発泡板１０の上に、樹脂シート２０ａを配置する。樹脂シートの材質は特に限定されないが、熱可塑性シートであることができる。樹脂の例は、発泡体の例で挙げたものと同一であることができるが、発泡板１０と同種の樹脂、言い換えると、発泡板１０と熱融着可能な材料であると、発泡板１０と熱融着できるので好ましい。   Subsequently, as illustrated in FIG. 2A, the resin sheet 20 a is disposed on the foamed plate 10. The material of the resin sheet is not particularly limited, but can be a thermoplastic sheet. Examples of the resin may be the same as those given in the example of the foam, but if the resin is the same type of resin as the foam plate 10, in other words, a material that can be heat-sealed with the foam plate 10, the foam plate 10 And can be heat-sealed.

その後、樹脂シート２０ａの上に配置したヒータ５などで、樹脂シート２０ａを加熱して、樹脂シートを軟化させる。加熱温度は、樹脂が容易に変形できる温度であればよく、例えば、ガラス転位温度Ｔｇ以上又は融点Ｔｍ以上であることが出来る。   Then, the resin sheet 20a is heated with the heater 5 etc. which were arrange | positioned on the resin sheet 20a, and a resin sheet is softened. The heating temperature may be a temperature at which the resin can be easily deformed, and can be, for example, a glass transition temperature Tg or higher or a melting point Tm or higher.

続いて、樹脂シート２０ａを発泡板１０及び通気板４０に向かって移動させる、及び／又は、通気板４０を発泡板１０と共に樹脂シート２０ａに向かって移動させ、図２の（ｂ）に示すように、樹脂シート２０ａを発泡板１０及び発泡板１０の周りを取り囲むように露出する通気板４０の一部４０ｐに接触させる（第１接触工程）。   Subsequently, the resin sheet 20a is moved toward the foam plate 10 and the vent plate 40 and / or the vent plate 40 is moved together with the foam plate 10 toward the resin sheet 20a, as shown in FIG. Next, the resin sheet 20a is brought into contact with the foam plate 10 and a portion 40p of the ventilation plate 40 exposed so as to surround the foam plate 10 (first contact step).

次に、真空ポンプ５０を作動させて、チャンバ４４ａ内のガスを排気する（第１吸出工程）。これにより、樹脂シート２０ａと通気板４０との間にあるガスが通気孔４２を介して通気板４０の反対側にあるチャンバ４４ａに排気され、樹脂シート２０ａが変形しつつ、発泡板１０に密着する。これにより、発泡板１０の一方主面１０ｍ１、側面１０ｓ、及び貫通孔１２の内面が樹脂シート２０ａで被覆される。なお、ガスの排気は、樹脂シート２０ａが、発泡板１０及び通気板４０に接触する前から始めても良い。   Next, the vacuum pump 50 is operated to exhaust the gas in the chamber 44a (first suction step). As a result, the gas between the resin sheet 20a and the vent plate 40 is exhausted to the chamber 44a on the opposite side of the vent plate 40 through the vent holes 42, and the resin sheet 20a is deformed and is in close contact with the foam plate 10. To do. Accordingly, the one main surface 10m1, the side surface 10s, and the inner surface of the through hole 12 of the foam plate 10 are covered with the resin sheet 20a. The gas exhaust may be started before the resin sheet 20a comes into contact with the foam plate 10 and the ventilation plate 40.

続いて、図３の（ａ）に示すように、トリミング装置などで、樹脂シート２０ａの不要部分、例えば、発泡板１０と密着していない部分を除去する。なお、不要部分の除去は、通気板４０上で行っても良いし、真空ポンプ５０の動作を止め、樹脂シート２０ａで被覆された発泡板１０を通気板４０から離して行っても良い。特に、貫通孔１２内をガスが通り抜けるように、貫通孔１２を閉鎖する膜を除去することが好適である。   Subsequently, as shown in FIG. 3A, an unnecessary portion of the resin sheet 20 a, for example, a portion not in close contact with the foamed plate 10 is removed with a trimming apparatus or the like. The unnecessary portion may be removed on the ventilation plate 40, or the operation of the vacuum pump 50 may be stopped and the foamed plate 10 covered with the resin sheet 20a may be separated from the ventilation plate 40. In particular, it is preferable to remove the film that closes the through hole 12 so that the gas passes through the through hole 12.

続いて、図３の（ｂ）に示すように、発泡板１０を、その非被覆部である他方主面１０ｍ２が露出し、被覆された一方主面１０ｍ１が通気板４０と対向するように、天地をひっくり返した上で、発泡板１０の周囲に通気板４０の一部４０ｐが露出するように通気板４０上に配置する（第２配置工程）。   Subsequently, as shown in FIG. 3 (b), the foam plate 10 is exposed so that the other main surface 10 m 2 which is the non-covered portion is exposed, and the covered one main surface 10 m 1 faces the ventilation plate 40. After turning upside down, it is arranged on the ventilation plate 40 so that a part 40p of the ventilation plate 40 is exposed around the foam plate 10 (second arrangement step).

続いて、前回と同様に、樹脂シート２０ａと同様の樹脂シート２０ｂを発泡板１０の上方に配置し、ヒータ５でこの樹脂シート２０ｂを加熱し、発泡板１０及び発泡板１０の周りに露出する通気板４０の一部４０ｐに接触させ（第２接触工程）、さらに、真空ポンプ５０によりチャンバ４４ａ内のガスを排気する（第２吸出工程）。この場合も、ガスの排気は、樹脂シート２０ｂが、発泡板１０及び通気板４０に接触する前から始めても良い。   Subsequently, as in the previous time, a resin sheet 20b similar to the resin sheet 20a is disposed above the foam plate 10, and the resin sheet 20b is heated by the heater 5 to be exposed around the foam plate 10 and the foam plate 10. A part 40p of the ventilation plate 40 is brought into contact (second contact step), and the gas in the chamber 44a is exhausted by the vacuum pump 50 (second suction step). Also in this case, the exhaust of gas may be started before the resin sheet 20 b comes into contact with the foamed plate 10 and the ventilation plate 40.

これにより、図４の（ａ）に示すように、樹脂シート２０ｂが変形しつつ、発泡板１０に密着し、発泡板１０の他方主面１０ｍ２と側面１０ｓ及び貫通孔１２の内面が樹脂シート２０ｂで被覆される。   As a result, as shown in FIG. 4A, the resin sheet 20b is deformed and is in close contact with the foam plate 10, and the other main surface 10m2, the side surface 10s of the foam plate 10 and the inner surfaces of the through holes 12 are the resin sheet 20b. Covered with.

その後、図４の（ｂ）に示すように、トリミング装置などで、樹脂シート２０ｂの不要部分を除去する。なお、不要部分の除去は、通気板４０上で行っても良いし、真空ポンプ５０の動作を止め、樹脂シート２０ｂで被覆された発泡板１０を通気板４０から離して行っても良い。   Thereafter, as shown in FIG. 4B, unnecessary portions of the resin sheet 20b are removed by a trimming apparatus or the like. The removal of unnecessary portions may be performed on the ventilation plate 40, or the operation of the vacuum pump 50 may be stopped and the foamed plate 10 covered with the resin sheet 20b may be separated from the ventilation plate 40.

これにより、図４の（ｂ）に示す、被覆発泡板（被覆発泡体）１０Ａが完成する。このような発泡体は、その表面が樹脂シートにより被覆されているので、被覆のない発泡体と比べて、表面が劣化しにくくなり、寿命を延ばすことが出来る。   Thereby, the covering foam board (covering foam) 10A shown in FIG. 4B is completed. Since the surface of such a foam is coated with a resin sheet, the surface is less likely to be deteriorated and the life can be extended as compared with a foam without a coating.

図４の（ｂ）に示す被覆発泡板１０Ａは、水耕栽培用の定植パネルとして好適に使用することが出来る。本実施形態では、被覆発泡板１０Ａは、複数の貫通孔１２を有する発泡板１０と、発泡板１０の一方主面１０ｍ１、発泡板１０の側面１０ｓ、及び、各貫通孔１２の内面を被覆する樹脂シート２０ａと、発泡板１０の他方主面１０ｍ２、発泡板１０の側面１０ｓ、及び、各貫通孔１２の内面を被覆する樹脂シート２０ｂと、を備える。特に、本実施形態では、樹脂シート２０ａ及び樹脂シート２０ｂは、発泡板１０の側面１０ｓ及び各貫通孔１２の内面において互いに重なっている。なお、樹脂シート２０ａ及び樹脂シート２０ｂが、各貫通孔１２の内面において互いに重ならない態様でも実施は可能である。   The coated foam plate 10A shown in FIG. 4B can be suitably used as a fixed planting panel for hydroponics. In the present embodiment, the coated foam plate 10 </ b> A covers the foam plate 10 having a plurality of through holes 12, the one main surface 10 m 1 of the foam plate 10, the side surface 10 s of the foam plate 10, and the inner surface of each through hole 12. The resin sheet 20a, the other main surface 10m2 of the foam plate 10, the side surface 10s of the foam plate 10, and the resin sheet 20b that covers the inner surface of each through hole 12 are provided. In particular, in the present embodiment, the resin sheet 20 a and the resin sheet 20 b overlap each other on the side surface 10 s of the foamed plate 10 and the inner surface of each through hole 12. In addition, implementation is also possible in an embodiment in which the resin sheet 20a and the resin sheet 20b do not overlap each other on the inner surface of each through-hole 12.

本実施形態によれば、発泡体の材料や発泡率とは関係なく、任意の材質及び任意の厚みの樹脂シートを用いて発泡体の被覆が出来るので、強度の高い被覆層を容易に得ることができる。また、発泡体の形状が、例えば、多数の貫通孔を有するような複雑な形状であっても、樹脂シートを発泡体の表面形状に沿わせて密着させることが容易である。さらに、発泡体と樹脂シートの材質を互いに熱融着できる材質の組合せとすることにより、発泡体と樹脂シートとを融着して高い接着力を発揮させることも出来る。   According to the present embodiment, since the foam can be coated using a resin sheet of any material and any thickness regardless of the foam material and the foaming rate, a high-strength coating layer can be easily obtained. Can do. Moreover, even if the shape of a foam is a complicated shape which has many through-holes, for example, it is easy to adhere | attach a resin sheet along the surface shape of a foam. Furthermore, by using a combination of materials that can be heat-sealed to each other, the foam and the resin sheet can be fused to exhibit a high adhesive force.

なお、発泡体が連続気泡構造であれば、発泡体の内部を通ってガスを排気することができるが、発泡体が独立気泡構造であっても、樹脂シートと発泡体との隙間、あるいは、樹脂シート間の隙間等を介してガスを十分に排気することができる。   If the foam has an open cell structure, gas can be exhausted through the inside of the foam, but even if the foam has a closed cell structure, the gap between the resin sheet and the foam, or The gas can be sufficiently exhausted through a gap between the resin sheets.

（第２実施形態）
続いて、本発明の第２実施形態について説明する。なお、第１実施形態と同一の内容については説明を省略し，異なる点についてのみ説明する。 (Second Embodiment)
Subsequently, a second embodiment of the present invention will be described. In addition, description is abbreviate | omitted about the content same as 1st Embodiment, and only a different point is demonstrated.

本実施形態では、図５の（ａ）に示すような、中間シート３０を用意する。中間シートの材料は、特に限定されないが、ポリエステル（ＰＥＴ等）やＡＢＳ等の樹脂、紙であることができる。中間シートの厚さは、０．０５〜１．０ｍｍとすることが出来る。   In the present embodiment, an intermediate sheet 30 as shown in FIG. The material of the intermediate sheet is not particularly limited, but can be a resin such as polyester (PET or the like) or ABS, or paper. The thickness of the intermediate sheet can be 0.05 to 1.0 mm.

中間シート３０は、発泡板１０の一方主面１０ｍ１、他方主面１０ｍ２とほぼ同一の外形形状を有することができ、また、発泡板１０の貫通孔１２の最狭部の径に対応する径を有する貫通孔３０ａを有することができる。   The intermediate sheet 30 can have substantially the same outer shape as the one main surface 10m1 and the other main surface 10m2 of the foam plate 10, and has a diameter corresponding to the diameter of the narrowest portion of the through hole 12 of the foam plate 10. The through hole 30a can be included.

そして、図５の（ｂ）に示すように、加熱した樹脂シート２０ａを発泡板１０及び通気板４０の一部４０ｐに接触させる前に、発泡板１０の上に予め中間シート３０を配置しておく。中間シート３０を、加熱する必要はない。そして、第１実施形態と同様に、図６の（ａ）に示すように、樹脂シート２０ａで発泡板１０を被覆する。また、第１実施形態と同様に発泡板１０の他面を樹脂シート２０ｂで被覆する際も、樹脂シート２０ｂと発泡板１０との間に、別の中間シート３０を介在させる。   Then, as shown in FIG. 5B, before the heated resin sheet 20a is brought into contact with the foam plate 10 and a part 40p of the vent plate 40, the intermediate sheet 30 is arranged on the foam plate 10 in advance. deep. The intermediate sheet 30 does not need to be heated. And like 1st Embodiment, as shown to (a) of FIG. 6, the foam board 10 is coat | covered with the resin sheet 20a. Similarly to the first embodiment, when the other surface of the foam plate 10 is covered with the resin sheet 20 b, another intermediate sheet 30 is interposed between the resin sheet 20 b and the foam plate 10.

これにより、図６の（ｂ）に示すような被覆発泡板（被覆発泡体）１０Ｂを得ることができる。   Thereby, the covering foam board (covering foam) 10B as shown to (b) of FIG. 6 can be obtained.

本実施形態でも、吸引により樹脂シート２０ａ、２０ｂを発泡板１０に容易に密着させることができる。加熱された樹脂シート２０ａ，２０ｂは、発泡板１０の側面１０ｓや貫通孔１２の軸方向中央部の内面に対して熱融着することができる。一方、加熱された樹脂シートは２０ａ、２０ｂは、中間シート３０が存在するので、発泡板１０の両方の主面や、貫通孔の軸方向両端の面取部の表面に対して直接接触しない。例えば、ビーズ成形された発泡体など、発泡構造によっては、加熱した樹脂シートが高い圧力で発泡体に密着すると、樹脂シートの表面に発泡セル構造に由来する凹凸模様が転写され、表面の美観を損なう場合がある。中間シート３０を介在させると、中間シート３０が介在した部分では発泡セル構造に基づく凹凸模様の発生を抑制できるため、美観を向上させることができる。なお、中間シートの材料が発泡体及び樹脂シートと熱融着可能な材料であっても、中間シートが加熱されていなければ、美観向上の効果を奏することができる。   Also in this embodiment, the resin sheets 20a and 20b can be easily adhered to the foamed plate 10 by suction. The heated resin sheets 20 a and 20 b can be heat-sealed to the side surface 10 s of the foamed plate 10 and the inner surface of the central portion in the axial direction of the through hole 12. On the other hand, the heated resin sheets 20a and 20b are not in direct contact with both the main surfaces of the foamed plate 10 and the surfaces of the chamfered portions at both ends in the axial direction of the through holes because the intermediate sheet 30 exists. For example, depending on the foam structure, such as a bead-molded foam, when the heated resin sheet adheres to the foam at a high pressure, the uneven pattern derived from the foam cell structure is transferred to the surface of the resin sheet, and the appearance of the surface is improved. It may be damaged. When the intermediate sheet 30 is interposed, the appearance of the uneven pattern based on the foamed cell structure can be suppressed at the portion where the intermediate sheet 30 is interposed, so that the appearance can be improved. In addition, even if the material of the intermediate sheet is a material that can be heat-sealed with the foam and the resin sheet, if the intermediate sheet is not heated, an effect of improving aesthetics can be achieved.

本発明は、上記実施形態に限定されず、様々な変形態様が可能である。例えば、上記実施形態では、発泡体として発泡板１０を採用しているが、板以外の形状、例えば箱状でもよい。また、発泡体の表面形状は、平面でなく波状などでもよいし、リブなどの凹凸があっても良い。発泡体の表面が平面ではなく曲面形状を有する場合には、図７に示すように、通気板４０上に、発泡体１０’の曲面に対応する曲面を有する表面形状変更用の追加通気板７０を配置して、通気板の表面の形状を調節すればよい。追加通気板７０は、通気板４０と連通する貫通孔７２を有することができる。また、発泡体が貫通孔を有さなくても良いのは言うまでもない。   The present invention is not limited to the above embodiment, and various modifications can be made. For example, in the said embodiment, although the foam board 10 is employ | adopted as a foam, shapes other than a board, for example, a box shape, may be sufficient. Further, the surface shape of the foam may be a wave shape instead of a flat surface, or may have irregularities such as ribs. When the surface of the foam has a curved shape instead of a flat surface, as shown in FIG. 7, an additional ventilation plate 70 for changing the surface shape has a curved surface corresponding to the curved surface of the foam 10 ′ on the ventilation plate 40. And the shape of the surface of the ventilation plate may be adjusted. The additional vent plate 70 may have a through hole 72 that communicates with the vent plate 40. Needless to say, the foam does not have to have through holes.

また、上記実施形態では、１枚目の樹脂シートを接触及び吸引した後に、２枚目の樹脂シートを接触及び吸引させて、発泡体の両面を被覆しているが、２枚目の樹脂シートを接触及び吸引を行わずに、一方面のみを被覆することもできる。   In the above embodiment, the first resin sheet is contacted and sucked, and then the second resin sheet is contacted and sucked to cover both surfaces of the foam. It is also possible to cover only one surface without contacting and suctioning.

また、上記実施形態では、大気圧によって樹脂シートを発泡体に密着させているが、例えば、通気板４０の上部に加圧用のチャンバを設け、樹脂シートを、大気圧を超える圧力で発泡体に押しつけることもできる。   Moreover, in the said embodiment, although the resin sheet is closely_contact | adhered to the foam by atmospheric pressure, the chamber for pressurization is provided in the upper part of the ventilation board 40, for example, a resin sheet is made into a foam by the pressure exceeding atmospheric pressure. It can also be pressed.

１０…発泡板（発泡体）、１０’…発泡体、１０Ａ，１０Ｂ…被覆発泡板（被覆発泡体）、１２…貫通孔、２０ａ、２０ｂ…樹脂シート、４０…通気板、４０ｐ…通気板の一部（発泡体の周囲の部分）、４２…通気孔。   DESCRIPTION OF SYMBOLS 10 ... Foam board (foam), 10 '... Foam, 10A, 10B ... Covering foam board (coating foam), 12 ... Through-hole, 20a, 20b ... Resin sheet, 40 ... Ventilation board, 40p ... Ventilation board Part (portion around the foam), 42 ... vent.

Claims (7)

通気孔を有する通気板の表面上に発泡体を配置する第１配置工程、
加熱された樹脂シートを、前記発泡体の表面及び前記通気板の表面における前記発泡体の周囲の部分に接触させる第１接触工程、及び、
前記通気孔を介して前記通気板と前記樹脂シートとの間のガスを前記通気板の反対側に吸い出して、前記樹脂シートを前記発泡体に密着させる第１吸出工程と、を備える、被覆発泡体の製造方法。 A first disposing step of disposing a foam on a surface of a vent plate having a vent;
A first contact step in which the heated resin sheet is brought into contact with a portion of the surface of the foam and the surface of the vent plate around the foam; and
A first foaming step of sucking gas between the vent plate and the resin sheet to the opposite side of the vent plate through the vent hole, and bringing the resin sheet into close contact with the foam. Body manufacturing method. 前記発泡体は、前記通気板の表面と対向する面、及び、前記通気板の表面と対向しない面の間に貫通する貫通孔を有する、請求項１記載の方法。   The method according to claim 1, wherein the foam has a through-hole penetrating between a surface facing the surface of the vent plate and a surface not facing the surface of the vent plate. 前記第１接触工程において、前記発泡体と前記樹脂シートとの間に、中間シートを介在させる、請求項１又は２に記載の方法。   The method according to claim 1, wherein an intermediate sheet is interposed between the foam and the resin sheet in the first contact step. 前記第１吸出工程の後に、
前記発泡体を、前記樹脂シートで被覆されていない部分が露出するように前記通気板上に配置する第２配置工程、
加熱された樹脂シートを、前記発泡体の前記被覆されていない部分及び前記通気板の表面における前記発泡体の周囲の部分に接触させる第２接触工程、及び、
前記通気孔を介して前記通気板と前記樹脂シートとの間のガスを前記通気板の反対側に吸い出して、前記樹脂シートを前記発泡体に密着させる第２吸出工程を、更に備える、請求項１〜３のいずれか１項に記載の方法。 After the first suction step,
A second disposing step of disposing the foam on the vent plate so that a portion not covered with the resin sheet is exposed;
A second contact step of bringing the heated resin sheet into contact with the uncovered portion of the foam and the portion of the vent plate surrounding the foam; and
The method further comprises a second sucking step of sucking gas between the vent plate and the resin sheet through the vent hole to the opposite side of the vent plate and bringing the resin sheet into close contact with the foam. The method of any one of 1-3. 請求項１〜４のいずれか１項に記載の方法により製造された被覆発泡体。   The coated foam manufactured by the method of any one of Claims 1-4. 複数の貫通孔を有する発泡板と、
前記発泡板の一方の主面、前記発泡板の側面、及び、各前記貫通孔の内面を被覆する第１の樹脂シートと、
前記発泡板の他方の主面、前記発泡板の側面、及び、各前記貫通孔の内面を被覆する第２の樹脂シートと、を備える、被覆発泡体。 A foam plate having a plurality of through holes;
A first resin sheet covering one main surface of the foam plate, a side surface of the foam plate, and an inner surface of each of the through holes;
A coated foam comprising: the other main surface of the foam plate, a side surface of the foam plate, and a second resin sheet that covers the inner surface of each through hole. 前記第１の樹脂シート及び前記第２の樹脂シートは、前記発泡板の側面及び各前記貫通孔の内面において互いに重なっている、請求項６に記載の被覆発泡体。   The coated foam according to claim 6, wherein the first resin sheet and the second resin sheet overlap each other on a side surface of the foam plate and an inner surface of each through hole.
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