JP2016086918A - Side rail and manufacturing method of side rail - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a side rail and a manufacturing method of a side rail excellent in rigidity, lightness and hygiene.SOLUTION: A side rail 20 attached to the lateral side of a bed includes a body part, and the body part is configured by a sandwich structure including a plate-like core material 21, a resin surface material 22A bonded to the surface of the core material 21, and a resin reverse surface material 22B bonded to the reverse surface of the core material 21.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a side rail and a method for manufacturing the side rail.

  2. Description of the Related Art Conventionally, in a bed, particularly a medical or nursing care bed, a pipe-like frame structure is known regarding a side rail, that is, a protective fence provided on the side of a bed so that a user or bedding does not fall from the bed ( For example, see Patent Document 1).

  In Patent Document 1, the outer peripheral frame of the bed frame is a metal frame, a headboard (head-side partition plate) and footboard (foot-side partition plate) are attached to the metal frame, and side rails are attached to both sides. Further, a decorative frame covering a metal surface or a metal frame having a decorative finish, a headboard, a footboard, and a side rail are disclosed.

  When such a metal pipe-shaped frame is used for a side rail, it is difficult to wipe off the image of the iron lattice even if a decorative cover or a decorative finish covering the metal surface is applied. I cannot deny that. Therefore, in recent years, there is a demand for using a bed including a side rail excellent in lightness and hygiene while maintaining high rigidity for ensuring safety without feeling of pressure.

Japanese Patent Laid-Open No. 2001-258685

  This invention is made | formed in view of such a situation, The objective is to provide the manufacturing method of the side rail and the side rail excellent in high rigidity, lightweight property, and hygiene.

The present invention is grasped by the following composition.
(1) The present invention is a side rail attached to the side of a bed, and includes a main body, and the main body includes a plate-shaped core material and a resin surface material bonded to the surface of the core material. And a resin-made back surface material adhered to the back surface of the core material.

(2) In the configuration of (1), the present invention is characterized by further including a leg portion that extends from a lower portion of the main body portion and can be inserted into the frame of the bed.

(3) In the configuration of the above (1), the present invention provides an arm attached to the first side frame of the bed, which is rotatably provided at the first end of the main body via a hinge. In addition, the main body is pivoted on the arm and placed sideways so as to bridge the second side of the bed.

(4) In the configuration according to any one of (1) to (3) described above, the outer peripheral portion of the front surface member and the outer peripheral portion of the rear surface member are joined to the outer peripheral portion of the core member. Opposing peripheral wall portions are formed, and the entire core material is covered with a front surface material and a back surface material.

(5) In the configuration of (4), the present invention is characterized in that a gap is formed between the outer peripheral portion and the peripheral wall portion of the core material.

(6) In the configuration of (5), the present invention is characterized in that the gap is located in the vicinity of a parting line that is a joint between the front surface material and the back surface material.

(7) According to the present invention, in any one of the above configurations (4) to (6), a through hole that penetrates the surface material and the back surface material in the thickness direction is formed in the vicinity of the peripheral wall portion. A grip portion that can be gripped by the user's hand is formed from the edge portion to the peripheral wall portion.

(8) The present invention is characterized in that, in any one of the constitutions (1) to (7), the core material is a foamed molding formed by foaming a resin.

(9) The present invention is characterized in that, in any one of the constitutions (1) to (8), the surface material and the back surface material are bonded to the front surface and the back surface of the core material by welding.

(10) The present invention is characterized in that, in any one of the configurations (1) to (9), the core material is divided into a plurality of parts.

(11) The present invention is a method for manufacturing a side rail attached to the side of a bed, and includes an arrangement step of arranging a core material between the first resin sheet and the second resin sheet, and an outer side of the first resin sheet. The first resin sheet, the core material, and the second resin sheet are sandwiched between the first resin mold, the second resin sheet, and the second resin mold disposed outside the second resin sheet. And a molding step of bonding each of the core material to the front and back surfaces of the core material to obtain a molded article of the side rail.

(12) In the present invention, in the molding step according to the configuration of (11), the first split-type first annular pinch-off portion and the second split-type second annular pinch-off portion are butted outside the outer peripheral portion of the core material. Thus, the first resin sheet and the second resin sheet are joined.

(13) In the molding step according to the configuration of (12), the present invention provides a first annular pinch-off portion so that the joint between the first resin sheet and the second resin sheet has a gap with respect to the outer peripheral portion of the core material. And the second annular pinch-off portion is abutted against each other.

(14) In the arrangement step according to any one of (11) to (13), the present invention is a molten first resin sheet extruded from the first extrusion device and extruded from the second extrusion device. A core material is disposed between the molten second resin sheet.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the side rail and side rail excellent in high rigidity, lightweight property, and hygiene can be provided.

It is a perspective view of a bed provided with a side rail concerning an embodiment of the present invention. It is the longitudinal cross-sectional view of a side rail, Comprising: (a) is the sectional view on the AA line of FIG. 1, (b) is an enlarged view of the edge part of (a). It is an enlarged view of a side rail, (a) is a perspective view, (b) is a front view, (c) is sectional drawing of the aa line of (b). It is a bottom view of a side rail, and (a) is a perspective view, (b) is a sectional view showing one example of arrangement of a leg, and (c) is a sectional view showing another example of arrangement of a leg. It is a figure explaining the structure and process (1) of the shaping | molding apparatus which concern on embodiment. Similarly, it is a figure explaining a process (2). Similarly, it is a figure explaining a process (3). Similarly, it is a figure explaining a process (4) (arrangement process). Similarly, it is a figure explaining a process (5) (molding process). Similarly, it is a figure explaining a process (6). It is a figure explaining the modification of a side rail, and is a figure corresponding to FIG.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention (hereinafter referred to as “embodiments”) will be described in detail with reference to the accompanying drawings. The same number is attached | subjected to the same element through the whole description of embodiment. The drawings are viewed in the direction of the reference numerals.

(Composition of bed 10)
First, the whole structure of the bed 10 according to the embodiment will be described with reference to FIG.

  As shown in FIG. 1, the bed 10 is a furniture and a medical device that allows a healthy person to sleep, and to carry a sick patient or a person in need of care lying down or carrying it on the bed. There is one. FIG. 1 shows a bed 10 having a simple structure (excluding bedding), a horizontal bed bottom (bed) 11, side rails 20 provided on the sides, and the longitudinal direction of the bed bottom 11. It is comprised from the two bed boards 15 attached to the front-and-rear ends. At the lower part of the side rail 20, a leg part 200 disposed therein extends, and the leg part 200 is inserted into the insertion hole 111 </ b> A of the bed frame 111 disposed around the bed bottom 11. The side rail 20 is erected. In addition, although the case where the side rail 20 is arrange | positioned 1 each on each side of the bed 10 is shown, it is not restricted to such an aspect so that it may mention later, and it arrange | positions 2 each on each side. May be. As for the bedboard 15, the front end, that is, the headboard side of the human head is called a headboard 15A, and the rear end, that is, the footboard side, is called the footboard 15B.

  Of course, in the present embodiment, the configuration of the bed 10 is not limited to this. For example, a movable frame with wheels (not shown) is attached to the bed bottom 11, and the frame can be moved up and down. May be. For example, the wheeled frame includes a base formed by combining a plurality of frame members made of metal pipes in a substantially rectangular shape, at least four casters provided at the lower ends of the four corners of the base, and a base And a pantograph-type link interposed between the bed bottom 11 and moving the bed bottom 11 up and down, and an operation handle for operating the bed bottom 11 up and down.

  As described above, the bed 10 having the wheeled frame can travel in any direction by a caster, and the height of the bed bottom 11 can be adjusted by a link by operating an operation handle. In addition, since the structure which attaches the bed bottom 11 to a wheeled frame is arbitrary and can use a well-known attachment structure, description is abbreviate | omitted.

(Configuration of side rail 20)
Next, the structure of the side rail 20 is demonstrated based on FIGS. 1-3B. As shown in FIG. 1, the side rail 20 is a member provided on the side upper limb side of the bed 10 (may be provided on the side lower limb side as will be described later). Functions as a protective fence to prevent bedding and bedding from falling. In FIG. 1, a side rail 20 having a horizontally long and irregular rectangular shape (the height on the abdomen side is lower than the head side) is shown, but the shape takes into consideration the purpose of use and the decorativeness of the bed 10. Can be anything. However, from the viewpoint of ensuring the safety of the user of the bed 10, it must exhibit a predetermined strength.

  The side rail 20 shown here is formed with a through hole 26 on the abdomen side of the upper part thereof, and is gripped by a user or a staff member of a medical or care facility from the edge of the through hole 26 to the peripheral wall 23. A possible handle 28 is formed. The shape of the through hole 26 that forms the handle portion 28 is arbitrary as long as it is a size and shape that can be inserted by a user's hand. In this example, an elongated oval through hole 26 is formed along the peripheral wall portion 23. In addition, an opening window 27 is formed on the upper head side so as not to cause a feeling of blockage, so that a user lying on the bed 10 looks at the outside of the bed 10 or a medical or care worker is in bed. It is possible to quickly see the facial expression of the user lying on the 10.

  Next, the cross-sectional structure of the side rail 20 will be described with reference to FIG. As shown in FIG. 2, in this embodiment, the side rail 20 is gently curved in a cross-sectional view in the longitudinal direction, and the user feels pressure and tightness when the inside of the curve faces the bed 10 side. It is made wide so as not to receive it. Of course, in order to correspond to the use of the bed 10 and the environment in which it is used, it may be linear, or only the inside may be curved concavely. The side rail 20 includes a plate-shaped core material 21, a resin surface material 22A that is welded over the entire surface of the core material 21 (upper surface in this example), and a rear surface of the core material 21 (in this example). Then, it is comprised by the sandwich structure provided with resin-made back material 22B welded over the whole surface of a lower surface. The means for adhering the front surface material 22A and the back surface material 22B to the core material 21 can be selected from various means according to the manufacturing method of the side rail 20 in addition to welding. For example, the surface material 22A and the back surface material 22B may be bonded to the core material 21 using an adhesive. The aforementioned through hole 26 is provided so as to penetrate the front surface material 22A and the back surface material 22B in the thickness direction.

  The outer peripheral portion of the surface material 22A and the outer peripheral portion of the back surface material 22B are abutted and joined over the entire circumference. In this example, a parting line PL that is a joint portion between the front surface material 22A and the back surface material 22B is set near the corner portion 33 on the back surface side of the side rail 20. For this reason, the outer peripheral portion of the surface material 22 </ b> A is formed in a shape that bends to the back side of the core material 21. With the outer peripheral portion of the surface material 22A bent in this manner, the peripheral wall portion 23 is formed to face the outer peripheral portion 21a of the core material 21, and the entire outer surface of the core material 21 including the outer peripheral portion 21a is the surface material 22A and the back surface. Covered by material 22B.

  A gap portion 35 is formed between the outer peripheral portion 21 a of the core material 21 and the peripheral wall portion 23. The gap 35 is a space formed near the inside of the parting line PL. Even if the gap portion 35 is formed in such a manner that the outer dimension of the core member 21 is the largest and the inner dimension of the peripheral wall portion 23 is the smallest due to dimensional errors, the peripheral wall portion 23 and the core member 21 Is set to a size that at least separates.

  The core material 21 is interposed between the facing surfaces of the front surface material 22A and the back surface material 22B with no gap except for the gap portion 35. For the core material 21, it is preferable to use a foam molded body formed by foaming a resin.

  In addition, in FIG. 1, although the structure which has arrange | positioned one core material 21 between the opposing surfaces of 22 A of surface materials and back surface material 22B was illustrated, in addition to this, the several core material 36 divided | segmented is surface material 22A. You may arrange in the length direction of the side rail 20 between the opposing surfaces with the back material 22B (refer FIG. 3). The dividing direction of the plurality of core members 36 can be set in any direction such as the width direction of the side rail 20 in addition to the length direction of the side rail 20.

  Next, FIG. 3A is an enlarged view of the side rail 20 (main body portion). As shown in FIG. 3A (a), as described above, a through hole 26 and an opening window 27 are formed in the upper portion. And the leg part 200 arrange | positioned in the inside is extended in the lower part of the side rail 20 (main-body part). A method of providing the leg 200 on the side rail 20 (main body) will be described later. 3A (c) is a diagram showing a cross section taken along line aa in FIG. 3A (b). As shown in the figure, the side rail 20 has a thickness W2 at the central portion thinner than a thickness W1 at the outer peripheral portion. be able to. This is because, as described above, the side rail 20 has a sandwich structure in which the core material 21 is covered with the front surface material 22A and the back surface material 22B, and further weight reduction can be achieved while exhibiting a desired strength. .

  A method of providing the leg portion 200 on the side rail 20 (main body portion) will be described with reference to FIG. 3B. FIG. 3B (a) is a perspective view of the side rail 20 as seen from the bottom surface side. The core material 21 is provided with a notch 211 for placing the leg 200. As shown in FIG. 3B (b), the leg portion 200 is disposed in the notch portion 211 from the outside of the back surface material 22B (from the direction of the arrow). That is, at the position where the core material 21 is cut out, the leg portion 200 is disposed inside the side rail 20 so as to press the back surface material 22B against the surface material 22A side. The leg part 200 is surrounded and fixed by the back material 22B. Of course, the leg portion 200 may be arranged not from the outside of the back material 22B but from the outside of the surface material 22A. FIG. 3B (c) shows a modified example different from this, in which the core material 21 is divided into the front surface material 22A and the back surface material 22B side, and cuts corresponding to the leg portions 200 are respectively provided at corresponding positions. A notch is provided, and the leg portion 200 is disposed at the position and sandwiched between the two core members 21.

(Side rail manufacturing method)
Next, the manufacturing method of a side rail is demonstrated based on FIGS. The manufacturing method of the side rail includes steps (1) to (6). Prior to the description of each step (1) to (6), the molding material and apparatus used in steps (1) to (6) will be described. Of the steps (1) to (6), the step (4) corresponds to the “arrangement step” in the present invention, and the step (5) corresponds to the “molding step” in the present invention.

(Molding material)
As shown in FIG. 4, in this manufacturing method, the first resin sheet 41A that is a molding material of the surface material 22A (see FIG. 2) and the second resin sheet 41B that is a molding material of the back surface material 22B (see FIG. 2). And are used.

  The first and second resin sheets 41A and 41B are made of a sheet made of polypropylene, engineering plastics, olefin resin, or the like. More specifically, the first and second resin sheets 41A and 41B are preferably made of a resin material having a high melt tension from the viewpoint of preventing a variation in thickness due to drawdown, neck-in, etc. Therefore, it is preferable to use a resin material having high fluidity in order to improve transferability to the mold and followability.

  Specifically, it is a polyolefin (for example, polypropylene, high density polyethylene) which is a homopolymer or copolymer of an olefin such as ethylene, propylene, butene, isoprene pentene, methyl pentene, etc., and has an MFR (JIS) at 230 ° C. According to K-7210, measured at a test temperature of 230 ° C. and a test load of 2.16 kg) of 3.0 g / 10 min or less, more preferably 0.3 to 1.5 g / 10 min, or acrylonitrile butadiene Amorphous resin such as styrene copolymer, polystyrene, high-impact polystyrene (HIPS resin), acrylonitrile / styrene copolymer (AS resin), and MFR at 200 ° C. (test temperature according to JIS K-7210) Measured at 200 ° C. and a test load of 2.16 kg) is 3.0 to 60 g / 10 min. More preferably, the melt tension at 30 to 50 g / 10 min and at 230 ° C. (using a melt tension tester manufactured by Toyo Seiki Seisakusho Co., Ltd., preheating temperature 230 ° C., extrusion speed 5.7 mm / min, diameter 2.095 mm, long A strand is extruded from an orifice having a length of 8 mm, and the tension when the strand is wound around a roller having a diameter of 50 mm at a winding speed of 100 rpm is 50 mN or more, preferably 120 mN or more. Resin sheets 41A and 41B are formed.

  Further, the first and second resin sheets 41A and 41B are added with a hydrogenated styrene-based thermoplastic elastomer in an amount of less than 30 wt%, preferably less than 15 wt%, in order to prevent cracking due to impact. It is preferable. Specifically, styrene-ethylene / butylene-styrene block copolymer, styrene-ethylene / propylene-styrene block copolymer, hydrogenated styrene-butadiene rubber and mixtures thereof are suitable as hydrogenated styrene-based thermoplastic elastomers, The styrene content is less than 30 wt%, preferably less than 20 wt%, and the MFR at 230 ° C. (measured at a test temperature of 230 ° C. and a test load of 2.16 kg according to JIS K-7210) is 1.0 to 10 g / 10. Minute, preferably 5.0 g / 10 min or less and 1.0 g / 10 min or more.

  Furthermore, the first and second resin sheets 41A and 41B may contain an additive. Examples of the additive include silica, mica, talc, calcium carbonate, glass fiber, carbon fiber and other inorganic fillers, Examples include plasticizers, stabilizers, colorants, antistatic agents, flame retardants, and foaming agents. Specifically, silica, mica, glass fiber or the like is added in an amount of 50 wt% or less, preferably 30 to 40 wt%, based on the molding resin.

(Configuration of molding apparatus 40)
Next, the structure of the shaping | molding apparatus 40 is demonstrated by process (1)-(6). As shown in FIG. 4, the molding apparatus 40 includes first and second extrusion apparatuses 42A and 42B, and a mold clamping apparatus 43 disposed below the first and second extrusion apparatuses 42A and 42B. In the molding apparatus 40, the melted first and second resin sheets 41 A and 41 B made of thermoplastic resin extruded from the first and second extrusion apparatuses 42 A and 42 B are sent to the mold clamping apparatus 43. Thus, the molten first and second resin sheets 41A and 41B are formed into a predetermined shape.

  In addition, since the 1st extrusion apparatus 42A and the 2nd extrusion apparatus 42B are the same, in the following description, only the 1st extrusion apparatus 42A corresponding to the 1st resin sheet 41A is demonstrated, and it respond | corresponds to the 2nd resin sheet 41B. The description of the second extruding device 42B is omitted. Further, in the molding apparatus 40, “A” is followed by the symbol of the element corresponding to the first resin sheet 41A, and “B” is followed by the symbol of the element corresponding to the second resin sheet 41B.

  The first extruding device 42A is a well-known extruding device, and a detailed description thereof is omitted. However, a cylinder 46A provided with a hopper 45A, a screw (not shown) provided in the cylinder 46A, and a connection to this screw The hydraulic motor 47A, an accumulator 48A communicating with the inside of the cylinder 46A, and a plunger 51A provided in the accumulator 48A. In the first extrusion device 42A, the resin pellets introduced from the hopper 45A are melted and kneaded by rotation of the screw by the hydraulic motor 47A in the cylinder 46A, and the molten resin is transferred to the accumulator 48A and stored in a certain amount. Then, the molten resin in the accumulator 48A is sent to the T-die 52A by driving the plunger 51A, and extruded as a continuous first resin sheet 41A having a predetermined length through the extrusion slit 53A. The extruded first resin sheet 41A is sent downward while being pinched by a pair of rollers 55A arranged at intervals, and is suspended between first and second split dies 57A and 57B (described later). Accordingly, the first resin sheet 41A is disposed between the first and second split molds 57A and 57B in a state having a uniform thickness in the vertical direction (extrusion direction).

The extrusion capability of the first extrusion device 42A is appropriately determined from the viewpoint of the size of the first resin sheet 41A, the draw-down of the first resin sheet 41A, or the prevention of neck-in occurrence. More specifically, from a practical point of view, the extrusion rate of one shot in intermittent extrusion is preferably 1 to 10 kg, and the extrusion rate of the resin from the extrusion slit 53A is several hundred kg / hour or more, more preferably 700 kg / hour or more. Further, from the viewpoint of preventing the first resin sheet 41A from being drawn down or neck-in occurrence, the extrusion process of the first resin sheet 41A is preferably as short as possible, depending on the type of resin, MFR value, and melt tension value. Generally, the extrusion process should be completed within 40 seconds, more preferably within 10-20 seconds. For this reason, the extrusion area per unit time and unit time from the extrusion slit 53A of the thermoplastic resin is 50 kg / hour / cm ² or more, more preferably 150 kg / hour / cm ² or more.

  The first resin sheet 41A can be stretched and thinned by feeding the first resin sheet 41A sandwiched between the pair of rollers 55A downward. By adjusting the relationship between the extrusion speed of the extruded first resin sheet 41A and the delivery speed of the first resin sheet 41A by the pair of rollers 55A, it is possible to prevent the occurrence of drawdown or neck-in. The restriction on the type of resin, particularly the MFR value and melt tension value, or the extrusion rate per unit time can be reduced.

  The extrusion slit 53A provided in the T die 52A is arranged vertically downward, and the first resin sheet 41A extruded from the extrusion slit 53A is sent vertically downward in a form that hangs down from the extrusion slit 53A. Yes. The extrusion slit 53A can change the thickness of the first resin sheet 41A by making the interval variable.

  The pair of rollers 55A is arranged below the extrusion slit 53A in a state in which the respective rotation axes are substantially horizontal and are arranged in parallel to each other. One of the pair of rollers 55A is a rotation driving roller, and the other is a rotation driven roller. More specifically, the pair of rollers 55 </ b> A are arranged to be line-symmetric with respect to the first resin sheet 41 </ b> A extruded in a form that hangs downward from the extrusion slit 53 </ b> A.

  The diameter of the roller 55A and the axial length of the roller 55A depend on the extrusion speed of the first resin sheet 41A to be formed, the length of the first resin sheet 41A in the extrusion direction, the width of the first resin sheet 41A, the type of resin, and the like. It is set accordingly. However, from the viewpoint of smoothly feeding the first resin sheet 41A downward by the rotation of the roller 55A in a state where the first resin sheet 41A is sandwiched between the pair of rollers 55A, the diameter of the rotation drive roller is set to the rotation drive roller. It is preferable to set it slightly larger than the diameter. In addition, if the curvature of the roller 55A is too large or too small, the first resin sheet 41A is wound around the roller 55A. Therefore, the diameter of the roller 55A is preferably in the range of 50 to 300 mm.

  On the other hand, the mold clamping device 43 is a well-known mold clamping device and has a mold driving device (not shown) and a molding die 56, although detailed explanation thereof is omitted. The molding die 56 is a split type, and includes a first split die 57A and a second split die 57B that fits the first split die 57A. The first and second split dies 57A and 57B are arranged with the molding surfaces 58A and 58B facing each other, and the molding surfaces 58A and 58B are arranged along a substantially vertical direction.

  The mold driving device is a device that moves the first and second split dies 57A and 57B in a direction substantially orthogonal to the supply direction of the molten first and second resin sheets 41A and 41B. The second split molds 57A and 57B are moved between the open position and the closed position.

  A first annular pinch-off portion 61A and a second annular pinch-off portion 61B are formed around the molding surfaces 58A and 58B of the first and second split dies 57A and 57B. The first and second annular pinch-off portions 61A and 61B are formed in an annular shape so as to surround the molding surfaces 58A and 58B, and project toward the opposed first and second split dies 57A and 57B. Thus, when the first and second split dies 57A and 57B are clamped, the tip portions of the first and second annular pinch-off portions 61A and 61B come into contact with each other, and the two first and second resin sheets 41A are brought into contact with each other. , 41B are thermally welded so that a parting line PL (see FIG. 2) is formed on the periphery thereof. Thereby, the surrounding wall part 23 (refer FIG. 2) of the side rail 20 is formed.

  Form frames 62A and 62B are slidably fitted in close contact with the outer peripheral portions of the first and second split dies 57A and 57B. The molds 62A and 62B can be moved relative to the first and second split molds 57A and 57B by a mold moving device (not shown). More specifically, the molds 62A and 62B project inwardly from the first and second split molds 57A and 57B, so that the first and second split molds 57A and 57B are disposed between the first and second split molds 57A and 57B. It can contact | abut on the outer surface 63A, 63B of 2nd resin sheet 41A, 41B.

  The first and second split dies 57A and 57B are respectively driven by a mold driving device, and the first and second resin sheets 41A and 41B are disposed between the first and second split dies 57A and 57B in the open position. On the other hand, in the closed position, the first and second annular pinch-off portions 61A and 61B of the first and second split molds 57A and 57B come into contact with each other, so that a sealed space is formed in the first and second split molds 57A and 57B. Form. The closed position is set to a substantially intermediate position between the first and second resin sheets 41A and 41B (a position approximately equidistant from the first and second resin sheets 41A and 41B). Note that the first extrusion device 42A and the pair of rollers 55A, and the second extrusion device 42B and the pair of rollers 55B are disposed symmetrically with respect to the closed position.

  In addition, vacuum suction chambers 65A and 65B are provided in the first and second split dies 57A and 57B, respectively. The vacuum suction chambers 65A and 65B communicate with the molding surfaces 58A and 58B through the suction holes 66A and 66B. By suctioning from the vacuum suction chambers 65A and 65B through the suction holes 66A and 66B, the first The second resin sheets 41A and 41B are adsorbed on the molding surfaces 58A and 58B. Thus, the first and second resin sheets 41A and 41B are shaped into shapes along the surfaces of the molding surfaces 58A and 58B.

(Process (1))
As shown in FIG. 4, in the step (1), a predetermined amount of the melted and kneaded thermoplastic resin is stored in the accumulators 48A and 48B, and from the extrusion slits 53A and 53B provided at predetermined intervals on the T dies 52A and 52B. The stored thermoplastic resin is intermittently extruded at a predetermined extrusion rate per unit time. Thereby, the thermoplastic resin swells and hangs downward in a molten sheet shape, and is extruded at a predetermined extrusion speed with a predetermined thickness. Next, the rollers 55A and 55B are moved to the open position, and the distance between the pair of rollers 55A and the distance between the pair of rollers 55B is made wider than the thickness of the first and second resin sheets 41A and 41B, so that the melt is extruded downward. The lowermost portions of the first and second resin sheets 41A and 41B in a state are smoothly supplied between the pair of rollers 55A and the pair of rollers 55B. In addition, the timing which makes the space | interval of a pair of rollers 55A and the space | interval of a pair of roller 55B larger than the thickness of 1st, 2nd resin sheet 41A, 41B is not after an extrusion start, but the time when secondary shaping | molding was completed for every one shot. You may go on. Next, the pair of rollers 55A and the pair of rollers 55B are moved close to each other, moved between the first and second resin sheets 41A and 41B, and the first and second resins are rotated by the rotation of the rollers 55A and 55B. The sheets 41A and 41B are sent out downward.

  Further, the first and second resin sheets 41A and 41B formed to have a uniform thickness in the extrusion direction are disposed between the first and second split molds 57A and 57B. At this time, the first and second resin sheets 41 </ b> A and 41 </ b> B are positioned in a form that protrudes from around the first and second annular pinch-off portions 61 </ b> A and 61 </ b> B. As described above, the first resin sheet 41A, which is the material of the surface material 22A (see FIG. 2), and the second resin sheet 41B, which is the material of the back surface material 22B (see FIG. 2), are spaced apart from each other. Therefore, it arrange | positions between 1st, 2nd division | segmentation type | mold 57A, 57B. The first and second split molds 57A, 57A, 57B can be obtained by individually adjusting the intervals between the extrusion slits 53A, 53B or the rotation speeds of the rollers 55A, 55B with respect to the first and second resin sheets 41A, 41B. The thicknesses of the first and second resin sheets 41A and 41B disposed between 57B can be individually adjusted.

(Process (2))
As shown in FIG. 5, in the step (B), the molds 62A and 62B are moved from the first and second split molds 57A and 57B until they contact the outer surfaces 63A and 63B of the first and second resin sheets 41A and 41B. . Then, sealed spaces 67A and 67B surrounded by the molding surfaces 58A and 58B, the inner peripheral surfaces of the molds 62A and 62B, and the outer surfaces 63A and 63B of the first and second resin sheets 41A and 41B are formed.

(Process (3))
As shown in FIG. 6, in the step (3), the first and second sealed spaces 67A and 67B (see FIG. 5) are sucked through the suction holes 66A and 66B communicating with the vacuum suction chambers 65A and 65B. The two resin sheets 41A and 41B are pressed against the molding surfaces 58A and 58B to form the first and second resin sheets 41A and 41B in a shape along the surfaces of the molding surfaces 58A and 58B. Thereby, the front surface material 22A and the back surface material 22B are formed.

(Process (4))
As shown in FIG. 7, in the step (4), the core material 21 formed in a predetermined shape is disposed between the front surface material 22A and the back surface material 22B (between the first and second resin sheets 41A and 41B). Then, the core material 21 is pressed against the front surface material 22A or the back surface material 22B (in this example, the back surface material 22B).

  The material of the core material 21 can be selected from various synthetic resin materials, various metal materials, or a combination of these materials. The core material 21 may include a paper honeycomb that is a structure in which hexagonal cylindrical cells are continuously formed. Here, it is made of a foam molded body such as a styrene resin foam (for example, expanded polystyrene) or a polyolefin resin foam (for example, expanded polypropylene), and can be welded to the first and second resin sheets 41A and 41B. The core material 21 is used in a compact.

  As the means 68 for disposing the core material 21 between the front surface material 22A and the back surface material 22B, for example, a well-known adsorption manipulator can be used. That is, after the core material 21 is pressed and held against the front surface material 22A or the back surface material 22B by the suction type manipulator, the suction type manipulator is detached from the core material 21 and pulled out between the first and second split molds 57A and 57B. Like that.

(Process (5))
As shown in FIG. 8, in the step (5), the first and second resin sheets 41A and 41B are held with the molds 62A and 62B contacting the first and second resin sheets 41A and 41B held in their positions. The first and second split molds 57A and 57B are moved toward each other until the first and second annular pinch-off portions 61A and 61B come into contact with each other, and the first and second split molds 57A are held. , 57B are closed. That is, the first resin sheet 41A, the core material 21, and the second resin are provided by the first split mold 57A and the second split mold 57B that are disposed outside the first resin sheet 41A and the second resin sheet 41B. The sheet 41B is sandwiched. Accordingly, the first resin sheet 41A and the second resin sheet 41B are bonded to the front surface and the back surface of the core member 21 by heat welding.

  In addition, the first and second annular pinch-off portions 61A and 61B are abutted on the outer side of the outer peripheral portion 21a of the core member 21, so that the peripheral edges of the first and second resin sheets 41A and 41B are thermally welded to each other. Be joined. As a result, the peripheral wall portion 23 is formed, and a side rail molded body 71 is formed in which the entire core material 21 is covered with the front surface material 22A and the back surface material 22B.

  Further, in the step (5), the first and second resin sheets 41 </ b> A and 41 </ b> B have a gap 72 with respect to the outer peripheral portion 21 a of the core material 21. When the annular pinch-off portions 61A and 61B are brought into contact with each other, a gap portion 35 (see FIG. 9) is formed between the peripheral wall portion 23 and the outer peripheral portion 21a of the core member 21 in the side rail molded body 71.

(Process (6))
As shown in FIG. 9, in step (6), the first and second split dies 57A and 57B are opened, the side rail molded body 71 is taken out, and the first and second annular pinch-off portions 61A and 61B are removed. The outer burr portion 73 is cut. Thereby, the side rail 20 (refer FIG. 2) is obtained.

  As described above, the side rails 20 can be manufactured one after another by repeating the steps (1) to (6) each time the molten resin is extruded intermittently.

(Other examples of side rail manufacturing methods)
In the manufacturing method described above, the core material 21 is disposed between the extruded first and second resin sheets 41A and 41B in a molten state, and the first resin sheet 41A, the core material 21 and the second resin sheet 41B are disposed in the first. An example is shown in which the side rail molded body 71 is obtained so as to be sandwiched between the first and second split dies 57A and 57B. However, the manufacturing method of the side rail of the present invention is not particularly limited to that by extrusion molding or vacuum molding. For example, a side rail molded body can be obtained by so-called twin composite molding. That is, a core material is disposed between first and second resin sheets that are pre-formed in a predetermined shape, and the first resin sheet, the core material, and the second resin sheet can be heated by heating means, and can be divided vertically. A side rail molded body may be formed by sandwiching between the first and second split molds.

(Effect of embodiment)
The effects of the embodiment described above will be described. According to the present embodiment, since the side rail 20 is formed by the sandwich structure in which the core material 21 is disposed between the resin surface material 22A and the resin back material 22B, the following effects can be obtained. Can do.

  In general blow-molded side rails, it was necessary to have a reinforcing rib structure in order to increase the strength, but in this embodiment, the reinforcing rib is no longer necessary. A rigid side rail can be provided. In addition, since there are no reinforcing ribs, both outer surfaces of the side rail 20 can be made into a flat design. As a result, dirt at home or blood, for example, in a medical facility adheres to the outer surface of the side rail 20. However, the deposits can be easily washed away. For this reason, the hygiene of the side rail 20 can be easily maintained. Furthermore, the function by the core material 21 can be added, for example, by making the side rail 20 have heat insulation performance by using, for example, a heat insulating material as the material of the core material 21.

  Further, by joining the outer peripheral portions of the front surface material 22A and the back surface material 22B, it is possible to provide a good-looking side rail 20 in which the core material 21 is completely covered with the front surface material 22A and the back surface material 22B. Further, since the core material 21 is completely covered with the front surface material 22A and the back surface material 22B, the outer surface of the side rail 20 can be washed without wetting the core material 21, and the side rail 20 having good cleaning properties. Can be provided.

  Consider a panel in which the core material is not bonded to the surface material and the back material, but the core material is simply sandwiched between the surface material and the back material. In the case of such a panel, since the surface material and the back surface material move (displace) with respect to the front surface and the back surface of the core material, the entire panel is easily bent with respect to the load. That is, the thickness of the core material cannot be utilized effectively, and only rigidity corresponding to the thickness of the front surface material and the thickness of the back surface material can be obtained.

  In this respect, in the side rail 20, since the surface material 22A and the back material 22B are bonded to the front surface and the back surface of the core material 21, the core material 21 is integrated with the surface material 22A and the back material 22B. . For this reason, in addition to the thickness of each of the front surface material 22A and the back surface material 22B, the thickness of the core material 21 can be effectively utilized, and high rigidity corresponding to the total thickness of the side rail 20 is obtained. It becomes difficult to bend. As a result, the front surface material 22A and the back surface material 22B can be formed thinner, and the side rails 20 that are more lightweight can be obtained. Moreover, rigidity and light weight can be improved more by forming the core material 21 with a foaming molding.

  Further, in the present embodiment, the gap portion 35 is formed between the peripheral wall portion 23 and the outer peripheral portion 21a of the core member 21 and in the vicinity of the parting line PL.

  On the other hand, in a structure in which the core material is filled between the peripheral wall portion and the outer peripheral portion of the core material without gaps, the core material is sandwiched between the parting lines when the outer peripheral portions of the front surface material and the back surface material are joined together. In some cases, the outer peripheral portions of the front surface material and the back surface material cannot be satisfactorily joined. Further, when the side rail is manufactured, when the front surface material and the back surface material are cooled and contract, the front surface material and the back surface material may receive an unreasonable force from the core material depending on the amount of contraction.

  In this respect, in the side rail 20, since the gap portion 35 is formed between the peripheral wall portion 23 and the outer peripheral portion 21a of the core member 21 and in the vicinity of the parting line PL, the outer peripheral portion 21a of the core member 21 becomes the parting line PL. Can be prevented, and the outer peripheral portions of the front surface material 22A and the back surface material 22B can be satisfactorily bonded. In addition, even when the surface material 22A and the back surface material 22B are cooled and contracted when the side rail 20 is manufactured, it is possible to prevent an excessive force from being applied from the core material 21 to the surface material 22A and the back surface material 22B.

  In addition, since the side rail 20 can hold the handle portion 28 by inserting a hand into the through hole 26, if a means for fixing the side rail 20 to the frame of the bed 10 is provided, a frame with wheels (not shown) The bed 10 (bed bottom 11) can be easily attached to and detached from and the side rail 20 can be easily carried.

(Modified side rail)
Next, the modification of the side rail which concerns on this invention is demonstrated based on FIG.

  Although the above-described side rail 20 has been described as having an aspect that is detachably fixed to the bed 10 in a normal specification state, the present invention is not limited thereto, and may be a movable type. For example, as shown in FIG. 10 (a), side rails 20 are provided on both sides of the upper limb side of the bed 10, and the abdomen side of the right side rail 20 (main body) as viewed from the user lying on the bed 10. One end 202 </ b> A of the arm 202 is attached to the end 20 </ b> A (first end) of the arm 202 via a rotatable hinge 201. The other end 202B of the arm 202 is attached to a frame on the right side 10A (first side) of the bed 10. Then, as shown in FIG. 10B, the head 20 side end 20B (second end) of the side rail 20 is rotated in the direction of the arrow from the state set on the right side 10A of the bed 10. Move. Next, as shown in FIG. 10C, after the side rail 20 once stands upright, the head-side end 20 </ b> B is moved to another side on the left side 10 </ b> B (second side) of the bed 10. It is placed on the rail 20 and placed so that the bed 10 is cross-bridged.

  In this way, conventionally, when the user of the bed 10 eats or reads, for example, the table with casters is moved across the bed 10 and used, but it is difficult to place it. However, according to the present modification, the side rail 20 can be used as a table, and can be stored as the side rail 20 when not used. In addition, about this modification, various further deformation | transformation are possible. For example, even in the absence of the left side rail 20, the right side rail can be supported horizontally by the frame on the left side 10B of the bed 10 when the right side rail 20 is placed horizontally. An extended portion (either fixed or foldable) having a desired length that bends along the head board 15A from the head portion 20B on the head side of the head 20 and having a key shape (a shape of a dog) as a whole It may be. Further, a groove or rail is provided in the side rail 20 and the hinge 201 is slid along the groove or rail so that an appropriate distance from the user of the bed 10 can be maintained when the right side rail is placed horizontally. It may be possible.

  In this modification, since the side rail 20 is also used as a table, the back surface material 22B side of the side rail 20 that becomes the surface when the bed 10 is cross-bridged is at least flat without being curved. Will be formed. Further, the through hole 26 and the opening window 27 may not be provided, and when used as a table, the back member 22B side of the side rail 20 may be closed with another member.

  As mentioned above, although this invention was demonstrated using embodiment and a modification, it cannot be overemphasized that the technical scope of this invention is not limited to the range as described in the said embodiment. It will be apparent to those skilled in the art that various modifications or improvements can be added to the above embodiment. Further, it is apparent from the scope of the claims that the embodiments added with such changes or improvements can be included in the technical scope of the present invention.

10 Bed 11 Bed bottom 15 Bedboard 15A Headboard 15B Footboard 20 Side rail 200 Leg 201 Hinge 202 Arm 21 Core 21a Outer part 22A Surface material 22B Back material 23 Peripheral wall part 26 Through hole 27 Open window 28 Handle part 35 Gap Part 36 Core 41A First resin sheet 41B Second resin sheet 42A First extrusion device 42B Second extrusion device 57A First split mold 57B Second split mold 61A First annular pinch-off portion 61B Second annular pinch-off portion 71 Molded body 72 Clearance PL Parting line (joint)

Claims (14)

A side rail attached to the side of the bed,
With a body,
The main body is
A plate-shaped core material;
A resin surface material bonded to the surface of the core material;
A side rail comprising a sandwich structure comprising a resin back surface material bonded to the back surface of the core material.   The side rail according to claim 1, further comprising leg portions extending from a lower portion of the main body portion and insertable into a frame of the bed.   The arm further includes an arm attached to a first side frame of the bed so as to be pivotable at a first end of the main body through a hinge, and the main body is pivoted on the arm. The side rail according to claim 1, wherein the side rail is placed so as to bridge between the second side of the bed.   By joining the outer peripheral part of the surface material and the outer peripheral part of the back material over the entire periphery, a peripheral wall part facing the outer peripheral part of the core material is formed, and the whole of the core material is the surface material and The side rail according to any one of claims 1 to 3, wherein the side rail is covered with the back material.   The side rail according to claim 4, wherein a gap is formed between an outer peripheral portion of the core member and the peripheral wall portion.   The side rail according to claim 5, wherein the gap is located in the vicinity of a parting line that is a joint between the front surface material and the back surface material.   A grip portion that can be gripped by a user by hand from an edge portion of the through hole to the peripheral wall portion by forming a through hole penetrating the surface material and the back surface material in the thickness direction in the vicinity of the peripheral wall portion. The side rail according to claim 4, wherein the side rail is formed.   The side rail according to any one of claims 1 to 7, wherein the core material is a foam molded body formed by foaming a resin.   The side rail according to any one of claims 1 to 8, wherein each of the surface material and the back surface material is bonded to the front surface and the back surface of the core material by welding.   The side rail according to claim 1, wherein the core material is divided into a plurality of parts. A method of manufacturing a side rail attached to the side of a bed,
An arrangement step of arranging a core material between the first resin sheet and the second resin sheet;
The first resin sheet, the core material, and the second resin sheet are sandwiched between a first split mold disposed outside the first resin sheet and a second split mold disposed outside the second resin sheet. And a molding step of bonding each of the first resin sheet and the second resin sheet to the front surface and the back surface of the core material to obtain a molded body of the side rail.   In the molding step, the first resin sheet is formed by abutting the first annular pinch-off portion of the first split mold and the second annular pinch-off portion of the second split mold outside the outer peripheral portion of the core member. The method for manufacturing a side rail according to claim 11, wherein the second resin sheet is joined.   In the molding step, the first annular pinch-off portion and the second annular pinch-off portion are abutted so that a joint portion between the first resin sheet and the second resin sheet has a gap with respect to an outer peripheral portion of the core material. The method of manufacturing a side rail according to claim 12.   In the arranging step, the core material is arranged between the molten first resin sheet extruded from the first extrusion device and the molten second resin sheet extruded from the second extrusion device. The method for manufacturing a side rail according to claim 11, wherein:

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