JP2547188B2 - Bead-foam molded article having deep unevenness and complex shape having a fabric on the surface and method for producing the same - Google Patents

Description

Detailed Description of the Invention

INDUSTRIAL APPLICABILITY The present invention fills a space between a pair of male and female molds provided with a core vent with a thermoplastic resin encapsulating bead having a heat-expanding property, and heats and molds it with high-temperature steam introduced from the core vent. A bead foam-molded article having a fabric on the surface, the bead foam-molded article having a fabric laminated on the surface of the bead foam-molded article by fusion bonding and having a deep shape or a complicated shape Regarding the method.

[0001]

2. Description of the Related Art Conventionally, polypropylene (PP) / polyethylene having a heat-expanding property and beads made of a thermoplastic resin are filled in a space between molds provided with a core vent, that is, a cavity to form a core vent. It is impossible to use the bead foam molding molded by heating with high temperature steam from the above as it is as a cushioning material as it is on the part that requires designability. I wore it and used it. There may be a method of adhering the skin material with an adhesive, but it is convenient to adhere the same at the same time as molding of the bead foam type product. Therefore, a method of adhering the skin material at the same time when molding the beads has been proposed. (See, for example, Japanese Patent Application Laid-Open No. 61-116527) However, in all of the conventional ones, the bead foam molding with deep unevenness and complicated shape at the same time as molding which does not require an adhesive as in the present invention. The present invention does not relate to a product and a method for producing the same, but relates to a bead foam-molded product having a simple shape that requires an adhesive in order to prevent displacement of the skin material and to strengthen the adhesive force of the skin material.

However, due to the following problems, in particular, bead foam moldings having deep irregularities and complicated shapes are still manufactured by using an adhesive on the skin. That is, in order for the skin material such as the fabric to be adhered at the same time during foaming of the beads, it is necessary that the surface of the skin on the bead side is weakly melted and mutually welded with the filled beads in the same molten state. There is. But at this time,
Often, not only the back side of the skin but also the front side of the surface heats up and melts the fibers, impairing the appearance.The skin material does not conform to the deep irregularities and complex shapes of the product, causing wrinkles and tears, A sharp bead foam-molded product conforming to the space shape cannot be obtained.

[0003]

SUMMARY OF THE INVENTION The present invention has no coating step of applying an adhesive in order to solve the above-mentioned problems, and solves the above-mentioned problems to improve the appearance of the product. It does not damage, and the surface material has a deep unevenness shape and a complicated shape with a fabric on the surface, which has features such as wrinkles and tears, etc. It is an object of the present invention to provide a bead foam-molded article and a method for producing the same. Further, a bead foam molded article having a deep uneven shape and a complicated shape having a fabric on the surface, which is suitable for mass production, has a characteristic that the production process is simple and can be produced in a short time, and a method for producing the same. It is also intended to provide.

[0004]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, according to the first aspect of the present invention, two layers of high-melting point fiber and low-melting point fiber are provided between a pair of male and female molds provided with a core vent. A thermoplastic resin fiber fabric is stretched, then the thermoplastic resin fiber fabric is clamped, the space between the molds is filled with a thermoplastic resin encapsulating bead, and high temperature steam from the core vent is filled. In a bead foam molded article with a fabric integrally molded by heating with, the fabric is the low melting point fiber located on the thermoplastic resin foam bead side, the mold side, that is,
A high-melting-point fiber located on the surface side is integrally molded, which is a bead foam-molded product having deep unevenness and a complicated shape with a fabric on the surface, and a core vent is provided in the second invention. Between a pair of male and female molds, a fabric of thermoplastic resin fibers consisting of two layers of high melting point fibers and low melting point fibers is stretched, then the fabric of thermoplastic resin fibers is clamped, and the space between the molds is heated. Plastic resin foam beads
The thermoplastic resin foam beads are melted together with the low melting point fibers on the thermoplastic resin foam bead side by foaming the thermoplastic resin foam beads by press-filling them and heating them with a high temperature steam from the core vent. In a bead foam-molded article with a fabric molded into a fabric, the fabric comprises the low melting point fiber located on the thermoplastic resin foam bead side and the high melting point fiber located on the mold side, that is, the surface side. It is a method for producing a bead foam-molded article having a deep uneven shape or a complex shape having a fabric on the surface, which is characterized by being molded in a uniform manner.

[0005]

By constructing the first aspect of the invention as described above, it is possible to provide a bead foam molded article having a deep uneven shape and a complicated shape, which does not require an adhesive at all and has no problems as in the prior art. It has become possible and the application of bead foam molding has been expanded.
According to the production method of the second invention, a thermoplastic resin fiber fabric consisting of two layers of high melting point fiber and low melting point fiber is stretched between a pair of male and female molds without using an adhesive,
Thereafter, the fabric of the thermoplastic resin fiber is clamped, the space between the molds is filled with a thermoplastic resin foaming bead and press-fitted, and the thermoplastic resin is foamed by heating with a high temperature steam from the core vent. In a bead foam molded article with a fabric in which a low melting point fiber on the bead side is melted and a thermoplastic resin foam bead is foamed to be integrally molded, the fabric is a thermoplastic resin foam bead side. The low-melting point fiber located in the mold and the high-melting point fiber located on the mold side, that is, the surface side are integrally molded to form a bead foam molding having a deep uneven shape and a complicated shape having a fabric on the surface. Since it is a manufacturing method of a product, there is no need for an adhesive coating step and no exhaust equipment is required.

[0006]

EXAMPLE An example of a bead foam molded article having a deep uneven shape or a complex shape having a fabric on the surface of the present invention and a method for producing the same will be described below with respect to an automobile trunk part, that is, a tool holder 1. To explain, the tool holder 1 is shown in FIG.
As shown in FIG. 3, it is a bead foam-molded article having an uneven shape or a complicated shape having a fabric 3 on its surface 2. If the fabric 3 is a soft material having breathability such as synthetic fiber of thermoplastic resin, non-woven fabric, porous synthetic resin sheet, and relatively heat resistant and tension resistant, It can be used regardless of the material. In particular, the fabric 3 of the present invention has a high melting point fiber 31 and a low melting point fiber 32.
It is a thermoplastic resin fiber composed of two layers. Moreover,
The fabric 3 is characterized in that the low melting point fiber 32 located on the thermoplastic resin foam bead 91 side and the high melting point fiber 31 located on the mold side, that is, the surface side are integrally molded. is there. And fabric 3
The low melting point fiber 32 and the thermoplastic resin foam bead 91 are made of polyolefin resin, and the high melting point fiber 31 of the fabric 3 is made of polyamide or polyester (PET).
If a system-based one is used, it is suitable for a bead foam-molded article having a deep rugged shape or a complicated shape having a fabric on the surface and a method for producing the same.

The surface 2 of the tool holder 1 has a deep uneven shape 4, which is used as a tool holder. Moreover, the front surface side of the uneven shape 4 is a curved surface 42 that holds half of the tread curved surface of the tire. Therefore, the tire (not shown) is held by being sandwiched between the curved surfaces 42 of the two tool holders 1. Therefore, the structure is suitable as the tool holder 1 for the trunk of the automobile. Also, the uneven shape 4
A protrusion 41 is formed in the right front corner over approximately half the width of the top surface thereof, and has a thickness of approximately 1/3 of the thickness of the tool holder 1 from the top surface.

Polyolefin-based thermoplastic resin foam beads 91 such as polypropylene (PP) and polyethylene are used as the core material of the tool holder 1, and this is particularly useful as a foam-molded article for impact resistance and This is because it has excellent strength and is suitable. Next, a method of manufacturing the tool holder 1 will be described with reference to FIGS. First, core vent 8
A pair of male and female molds 5 and 6 provided with is prepared. This mold is composed of a movable mold 5 and a fixed mold 6. This mold 5,
A thermoplastic resin fiber fabric 3 composed of two layers of high melting point fibers 31 and low melting point fibers 32 having different melting points is stretched between 6 pieces. After trial and error, the inventor found that fabric 3 was
In the case of a dollar punched nonwoven fabric, the tensile expansion ratio is 200% or more in one direction of this nonwoven fabric, and 100% or more in the direction orthogonal to this direction, and the ratio of both expansion ratios is 0.5 to 3 ·.
It was found that the most stable molding can be performed when the value is 0. Then, this fabric 3 is set to 1 by the clampers 7 and 7.
It is arranged by giving a tension of not more than kgf. At this time, the fabric 3 has the low melting point fibers 32 located on the thermoplastic resin foam beads 91 side and the high melting point fibers 31 located on the mold side, that is, the surface side.

After that, the movable die 5 is brought close to the fixed die 6 and the fabric 3 is clamped between the dies. If the clamp tension of the fabric 3 at this time is 1 kgf or less, the fabric 3 is not well adapted to the die. It does not have high tension and does not cause wrinkles or breaks during molding. And
Thermoplastic resin foam beads provided on the fixed mold 6 in the clamped state
The space 91 is filled from the filling port 9 with the space 91. At this time, the filling pressure is 5 kgf / cm ² to 10 kg
If f / cm ^{2 is set} , the thermoplastic foam bead 91 has a space 101.
The inside of the fabric 3 is filled without any gap, and the fabric 3 does not have wrinkles or tears. It does not impair the appearance of the foamed molded product thereafter. Next, the paif 1 provided on the fixed die 6
0 valve v is opened to introduce a high temperature steam from the core vent 8 of the fixed die 6, and the valve v of the pipe 11 of the movable die 5 is opened via the core vent 8 of the movable die 5.
Try to discharge more. The high-temperature steam softens the thermoplastic resin foam beads 91 and promotes the foaming reaction to form the foam 3
3 is formed, and the temperature of the high temperature steam introduced at this time is set within the range of 10 degrees C above and below the melting point of the low melting point fiber and lower than the melting point of the high melting point fiber by 20 degrees C or more.
The skin, that is, the fibers of the low-melting point fibers 32 of the fabric 3 and the resin of the thermoplastic resin foam beads 91 cause a weak softening and melting and enter each other, so-called anchor adhesion occurs, and a strong adhesion is obtained. it can. Further, this temperature does not give any damage to the high melting point fiber 31, and the surface texture of the foam-molded article is improved. The comparative examples and examples of Table 1 below show the results of applying the examples of the present invention to the tool holder shown in FIGS. 3 and 4 having a depth of 50 mm and a width of 55 mm to 140 mm with deep concave and convex shapes.

[0010]

[Table 1] Therefore, by having the constitutional requirements of the present invention, the moldability of a bead foam molded article having a deep uneven shape or a complicated shape having a fabric on the surface, the surface skin, that is, the adhesiveness of the fabric, It was shown that each property such as surface texture was satisfied at the same time.

[0011]

As described above, in the method for manufacturing a bead foam-molded article having a deep uneven shape and a complex shape having a fabric on the surface of the second invention of the present invention, the conventionally required adhesive is required. Therefore, there is no application step for applying the adhesive, and the exhaust equipment required for using the adhesive is not required, so that the equipment cost associated therewith can be reduced. Moreover, since no adhesive is used, the adhesive does not exude to the skin, and there is no fear of impairing the external appearance of a bead foam molded product having a deep uneven shape having a fabric on the surface or a complicated shape. However, since a fabric of thermoplastic resin fiber consisting of two layers of high melting point fiber and low melting point fiber is stretched between a pair of male and female molds provided with core vents, that fabric can be easily obtained. Also, tension equipment can be easily equipped, and then the fabric of the thermoplastic resin fiber is clamped, the space between the molds is filled with thermoplastic resin foam beads and press-fitted, and the high temperature steam from the core vent is pressed. -In a bead foam-molded article with a fabric integrally formed by melting the low melting point fiber on the bead side by heating with a foam and foaming a thermoplastic resin foam bead, the fabric is , The low melting point fiber located on the thermoplastic resin foam beads side, and the mold side,
That is, since it is a method for producing a bead foam molded article having a deep uneven shape or a complex shape having a fabric on the surface integrally molded with high melting point fibers located on the surface side, a foam core material and a fabric That is, it is possible to adhere the epidermis at the same time. And, with a beautiful surface with an unprecedented appearance, a bead with deep unevenness and a complicated shape with a fabric on it.
It is possible to provide a foam molded article. And suitable for mass production,
A bead foam molding can be provided at low cost.

Further, in the bead foam-molded article having a deep uneven shape or a complicated shape having a fabric on the surface of the first invention of the present invention produced by this production method, fabrics of various materials are used, These various epidermis are adhered and soft,
It is possible to obtain bead foam molded products that are lightweight and have a high decorative value, and can be used in a wide range of applications such as the packaging field, household products field, and transportation field. A bead foam molding can be provided.

[Brief description of drawings]

FIG. 1 is a side sectional view showing an arrangement of one step for manufacturing a bead foam-molded article having a deep uneven shape and a complicated shape having a fabric on a surface according to the present invention.

FIG. 2 is a side sectional view showing a subsequent step of FIG.

FIG. 3 is a perspective view of a tool holder which is an embodiment of a bead foam-molded article having a deep uneven shape and a complex shape having a fabric on the surface according to the present invention.

4A is a sectional view taken along the line 4L-4L in FIG. 3, and FIG. 4B is a partially enlarged sectional view of FIG.

[Explanation of symbols]

 1 ... Tool holder 2 ... Surface 3 ... Fabric 31 ... High melting point fiber 32 ... Low melting point fiber 33 ... Foam 4 ... Concavo-convex shape 41 ... Projection 42. ..Curved surface 5 ... movable type 6 ... fixed type 7 ... clamper 8 ... core vent 9 ... filling port 91 ... thermoplastic resin foam beads 10 ... pipe 101 ...・ Space 11 ・ ・ ・ Pipe v ・ ・ ・ Valve.

Claims (8)

(57) [Claims] 1. Between a pair of male and female molds provided with a core vent,
A thermoplastic resin fiber fabric consisting of two layers of high-melting point fiber and low-melting point fiber is stretched, then the fabric of the thermoplastic resin fiber is clamped, and thermoplastic resin foam beads are provided in the space between the molds. In a bead foam molded article with a fabric integrally formed by filling and press-fitting and heating with high-temperature steam from a core vent, the fabric is the low melting point fiber located on the thermoplastic resin foam bead side. , The mold side, that is, the high-melting-point fibers located on the surface side are integrally molded, and a bead having a deep uneven shape or a complicated shape having a fabric on the surface is formed.
Foam molded products. 2. Between a pair of male and female molds provided with a core vent,
A thermoplastic resin fiber fabric consisting of two layers of high-melting point fiber and low-melting point fiber is stretched, then the fabric of the thermoplastic resin fiber is clamped, and thermoplastic resin foam beads are provided in the space between the molds. By filling and press-fitting and heating with a high temperature steam from the core vent, the low melting point fiber on the bead side is melted and the thermoplastic resin foam bead is foamed to form a bead with fabric integrally formed. -In the foamed molded article, the fabric is obtained by integrally molding the low melting point fiber located on the thermoplastic resin foam bead side and the mold side, that is, the high melting point fiber located on the surface side. A method for producing a bead foam-molded product having a deep uneven shape or a complicated shape having a fabric on a characteristic surface. 3. The low melting point fiber of the fabric and the thermoplastic resin foam beads are each made of a polyolefin resin,
The bead foam-molded article having a deep uneven shape or a complicated shape having a fabric on the surface according to claim 1, wherein the high melting point fiber of the fabric is mainly made of polyamide. 4. The low melting point fiber of the fabric and the thermoplastic resin encapsulating beads are polyolefin resins, respectively.
The bead foam-molded article having a deep uneven shape or a complex shape having a fabric on the surface according to claim 1, wherein the high melting point fiber of the fabric is mainly made of polyester. 5. A bead foam-molded article having a deep uneven shape or a complicated shape having a fabric on the surface, wherein the fabric of claim 1 is a 2-doll punch nonwoven fabric. 6. The fabric according to claim 4 is a needle punch nonwoven fabric, and the tensile extension ratio of the needle punch nonwoven fabric is 200% or more in at least one direction of the nonwoven fabric and 100% in a direction orthogonal to this direction. As described above, a bead foam-molded product having a deep uneven shape and a complicated shape having a fabric on the surface, characterized in that the ratio of both tensile elongation ratios is 0.5 to 3.0. 7. The temperature of the high temperature steam introduced from the covent according to claim 2 is set within a range of 10 ° C. above and below the melting point of the low melting point fiber and is set to be 20 ° C. or more lower than the melting point of the high melting point fiber. A method for producing a bead foam molded product having a deep uneven shape or a complicated shape having a fabric on the surface. 8. The fabric tension of claim 2 is 1.0.
KGf or less, the filling pressure of thermoplastic resin foam beads is 5 kg
A method for producing a foam-molded product having a deep uneven shape or a complicated shape having a surface ^two- fabric characterized by having f / cm ² to 10 kgf / cm ² . [0001]