JP3145424B2 - Foam molding method - Google Patents
Foam molding methodInfo
- Publication number
- JP3145424B2 JP3145424B2 JP10889191A JP10889191A JP3145424B2 JP 3145424 B2 JP3145424 B2 JP 3145424B2 JP 10889191 A JP10889191 A JP 10889191A JP 10889191 A JP10889191 A JP 10889191A JP 3145424 B2 JP3145424 B2 JP 3145424B2
- Authority
- JP
- Japan
- Prior art keywords
- mold
- skin
- thermoplastic resin
- foaming
- molding
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Description
【０００１】[0001]
【産業上の利用分野】本発明は熱可塑性樹脂発泡層と表
皮とからなる成形物を製造することを目的とした発泡成
形方法に関するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foam molding method for producing a molded article comprising a thermoplastic resin foam layer and a skin.
【０００２】[0002]
【従来の技術】従来、熱可塑性樹脂発泡層と表皮とから
なる成形物を製造する方法としては、射出成形でまず熱
可塑性樹脂発泡層を成形しておき、次いで該熱可塑性樹
脂発泡層に表皮を接着する方法、熱可塑性樹脂発泡層を
表皮とを接着しておいてから所定形状に真空成形し、そ
の後トリミング行なう方法等が提供されていた。2. Description of the Related Art Conventionally, as a method of manufacturing a molded article comprising a thermoplastic resin foam layer and a skin, a thermoplastic resin foam layer is first formed by injection molding, and then the thermoplastic resin foam layer is formed on the thermoplastic resin foam layer. And a method in which a thermoplastic resin foam layer is adhered to a skin, vacuum formed into a predetermined shape, and then trimmed.
【０００３】[0003]
【発明が解決しようとする課題】しかしながら、前者の
方法では熱可塑性樹脂発泡層の成形工程と、表皮の接着
工程との２つの工程を経なければならず、また後者の方
法ではトリミングの際に熱可塑性樹脂発泡層と表皮との
両方にスクラップを生じ、材料の歩留りが悪くなり、製
品のコストアップにつながる。However, in the former method, two steps must be performed: a molding step of a thermoplastic resin foam layer and a bonding step of a skin. In the latter method, trimming is performed at the time of trimming. Scrap is generated in both the thermoplastic resin foam layer and the skin, resulting in poor material yield and increased product cost.
【０００４】[0004]
【課題を解決するための手段】本発明は上記従来の課題
を解決する手段として、発泡剤を混合した熱可塑性樹脂
を加熱軟化させて外型と内型とからなるスタンピング成
形型内にセットし、スタンピング成形を行ない予備成形
体を得る工程１工程１の後該成形型を開いて該予備成形
体上に表皮を挿入し、再び該成形型を閉じて該熱可塑性
樹脂の発泡温度以上に加熱する工程２該成形型を若干開
いて該予備成形体を発泡させる工程３該成形型を冷却し
成形物を該成形型から取出し表皮をトリミングする工程
４以上の工程１，２，３，４からなることを特徴とする
発泡成形方法を提供するものである。According to the present invention, as a means for solving the above-mentioned conventional problems, a thermoplastic resin mixed with a foaming agent is heated and softened and set in a stamping mold comprising an outer mold and an inner mold. Step 1 of stamping and obtaining a preformed body 1 After step 1, the forming die is opened, a skin is inserted on the preformed body, and the forming die is closed again and heated to a temperature not lower than the foaming temperature of the thermoplastic resin. Step 2 of slightly opening the mold and foaming the preform 3 Step 3 of cooling the mold, removing the molded product from the mold, and trimming the skin From Steps 1, 2, 3, 4 and above The present invention provides a foam molding method characterized in that:
【０００５】本発明に用いられる熱可塑性樹脂はポリエ
チレン、ポリプロピレン、エチレン−プロピレン共重合
体、エチレン−酢酸ビニル共重合体等の主としてオレフ
ィン系樹脂であるが、ポリスチレン、ポリ塩化ビニル、
アクリロニトリル−ブタジエン−スチレン共重合体等の
他の熱可塑性樹脂が用いられてもよい。The thermoplastic resin used in the present invention is mainly an olefin resin such as polyethylene, polypropylene, ethylene-propylene copolymer and ethylene-vinyl acetate copolymer.
Other thermoplastic resins such as acrylonitrile-butadiene-styrene copolymer may be used.
【０００６】本発明に用いられる熱可塑性樹脂にはアゾ
ジカルボンアミド、アゾビスイソブチロニトリル等の発
泡剤が添加される。該発泡剤の分解温度（発泡温度）は
熱可塑性樹脂の軟化点よりも高いものを選ぶ。[0006] A blowing agent such as azodicarbonamide and azobisisobutyronitrile is added to the thermoplastic resin used in the present invention. The decomposition temperature (foaming temperature) of the foaming agent is selected to be higher than the softening point of the thermoplastic resin.
【０００７】工程１では該熱可塑性樹脂は該熱可塑性樹
脂の軟化点よりも高く、発泡温度よりも低い温度で加熱
されてスタンピング成形型内にセットし、スタンピング
成形が行なわれ予備成形体を得る。[0007] In step 1, the thermoplastic resin is heated at a temperature higher than the softening point of the thermoplastic resin and lower than the foaming temperature and set in a stamping mold, and stamping is performed to obtain a preformed body. .
【０００８】工程２では成形型を開いて工程１でスタン
ピング成形された該予備成形体上に表皮を挿入する。該
表皮は不織布、編織物、天然皮革、合成皮革等であり、
必要寸法よりも若干長めに設定しておく。そして再び成
形型を閉じて該熱可塑性樹脂の発泡温度以上に加熱すれ
ば、該予備成形体は軟化状態でかつ発泡して発泡圧によ
って表皮に接着する。また該発泡圧は成形型内の閉鎖空
間内に均一に行きわたる。[0008] In step 2, the mold is opened, and the skin is inserted on the preformed body stamped and formed in step 1. The skin is a non-woven fabric, knitted fabric, natural leather, synthetic leather, and the like,
Set slightly longer than required dimensions. Then, when the mold is closed again and heated to a temperature higher than the foaming temperature of the thermoplastic resin, the preform is foamed in a softened state and adheres to the skin by foaming pressure. The foaming pressure is evenly distributed in the closed space in the mold.
【０００９】工程３では該成形型を若干開けば該予備成
形体は発泡し所定形状の熱可塑性樹脂発泡層が成形され
る。この際、発泡圧は工程２で成形型内に均一に行きわ
たっているので、予備成形体の発泡は均一に行なわれ
る。In step 3, if the mold is slightly opened, the preform is foamed to form a thermoplastic resin foam layer having a predetermined shape. At this time, since the foaming pressure is evenly distributed in the molding die in Step 2, foaming of the preform is performed uniformly.
【００１０】工程４では成形型を冷却して成形物を取出
し、該熱可塑性樹脂発泡層からはみ出した表皮部分をト
リミングする。In step 4, the molding is cooled to take out the molded product, and the skin portion protruding from the thermoplastic resin foam layer is trimmed.
【００１１】[0011]
【作用】本発明ではスタンピング成形した熱可塑性樹脂
予備成形体を表皮を挿入した成形型内で規制しつゝ軟化
状態で発泡させるので、その発泡圧は成形型内で均一化
させ、該発泡圧によって該予備成形体は表皮に接着す
る。その後に成形型を若干開いて該予備成形体を発泡さ
せて所定形状の熱可塑性樹脂発泡層と表皮とからなる成
形物を得るのであるが、本発明では上記したように発泡
圧が均一化されているので均一な発泡が行なわれ、また
上記したように表皮接着工程と熱可塑性樹脂発泡成形工
程とが同時に行なわれる。According to the present invention, since the thermoplastic resin preform formed by stamping is foamed in a softened state while being regulated in the mold into which the skin is inserted, the foaming pressure is made uniform in the mold and the foaming pressure is made uniform. Thereby, the preform adheres to the skin. Thereafter, the mold is opened slightly to foam the preformed body to obtain a molded product comprising a thermoplastic resin foam layer and a skin of a predetermined shape.In the present invention, the foaming pressure is made uniform as described above. Therefore, uniform foaming is performed, and the skin bonding step and the thermoplastic resin foam molding step are performed simultaneously as described above.
【００１２】そして熱可塑性樹脂発泡層は成形型内で所
定形状に成形されるからトリミングが不要で、表皮のみ
トリミングを行なう。Since the thermoplastic resin foam layer is formed into a predetermined shape in a molding die, trimming is unnecessary, and only the skin is trimmed.
【００１３】[0013]
【実施例】本発明を図１〜図５に示す一実施例により具
体的に説明する。図１に示すように発泡剤を混合したポ
リプロピレンを１６０℃前後の成形適性温度に加熱軟化
させて同様に１６０℃に加熱した外型(21)と内型(22)と
からなるスタンピング成形型(2) 内にセットする。該内
型(22)にはスプリング(22)B によって下方に付勢されて
いる堰(22)Aが装備されている。該内型(22)を該外型(2
1)内に挿入して該ポリプロピレン加熱軟化物(1) を図２
に示すようにスタンピング成形して予備成形体(1)Aを得
る（工程１）。DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail with reference to one embodiment shown in FIGS. As shown in FIG. 1, a stamping mold (including an outer mold (21) and an inner mold (22) heated and softened to a molding suitable temperature of about 160 ° C. and heated to 160 ° C. to form a polypropylene mixed with a foaming agent. 2) Set in. The inner mold (22) is equipped with a weir (22) A urged downward by a spring (22) B. The inner mold (22) is connected to the outer mold (2
1) and heat-softened polypropylene (1)
As shown in (1), a preform (1) A is obtained by stamping (step 1).
【００１４】工程１の後成形型(2) を開いてポリエステ
ル繊維織物である表皮(3) を該予備成形体(1)A上に挿入
し、再び図３に示すように該成形型(2) を閉じて２００
℃前後の発泡温度に加熱すると該予備成形体(1)Aに含ま
れている発泡剤が分解し発泡が開始される。この際の発
泡圧は該成形型(2) の内部密閉空間内に均一に行きわた
り、該加熱軟化状態の予備成形体(1)Aを表皮(3) に押付
け接着させる（工程２）。After the step 1, the mold (2) is opened, a skin (3), which is a polyester fiber woven fabric, is inserted on the preform (1) A, and the mold (2) is again inserted as shown in FIG. ) And close 200
When heated to a foaming temperature of about ° C, the foaming agent contained in the preform (1) A is decomposed and foaming is started. The foaming pressure at this time uniformly spreads in the internal closed space of the molding die (2), or the pre-formed body (1) A in the heated and softened state is pressed and adhered to the skin (3) (step 2).
【００１５】工程２の後は図４に示すように該成形型
(2) を若干開いて該予備成形体(1)Aを発泡せしめてポリ
プロピレン発泡層(1)Bを成形する。この際内型(22)の堰
(22)Aはスプリング(22)B の付勢力によって下降して該
ポリプロピレン発泡層(1)Bが成形型(2) 外部へ漏出しな
いように規制する（工程３）。After the step 2, as shown in FIG.
(2) is slightly opened to foam the preform (1) A to form a foamed polypropylene layer (1) B. At this time, weir of inner type (22)
(22) A is lowered by the urging force of the spring (22) B to regulate the polypropylene foam layer (1) B from leaking out of the molding die (2) (step 3).
【００１６】このようにしてポリプロピレン発泡層(1)B
と表皮(3)とからなる成形物(4) が得られるが、該成形
物(4) は成形型(2) を介して冷却固化された後、該成形
型(2) から取出し図５に示すように切刃(5) によりポリ
プロピレン発泡層(1)Bからはみ出した表皮(3) をトリミ
ングする（工程４）。Thus, the foamed polypropylene layer (1) B
A molded product (4) composed of the molded product (4) and the skin (3) is obtained. After the molded product (4) is cooled and solidified through the molding die (2), it is removed from the molding die (2) and is shown in FIG. As shown, the skin (3) protruding from the foamed polypropylene layer (1) B is trimmed by the cutting blade (5) (step 4).
【００１７】[0017]
【発明の効果】したがって本発明では表皮と熱可塑性樹
脂発泡層との接着は発泡成形と同時に行なわれるから、
製造工程が簡略化され、また表皮のみトリミングするか
ら材料の歩留りが向上し、コストダウンにつながる。Therefore, in the present invention, since the bonding between the skin and the thermoplastic resin foam layer is performed simultaneously with the foam molding,
Since the manufacturing process is simplified and only the skin is trimmed, the yield of the material is improved, leading to a cost reduction.
【００１８】[0018]
図１〜図５は本発明の一実施例を示すものである。 1 to 5 show one embodiment of the present invention.
【図１】スタンピング成形前説明図FIG. 1 is an explanatory view before stamping molding.
【図２】スタンピング成形時説明図FIG. 2 is an explanatory view at the time of stamping molding.
【図３】表皮挿入状態説明図FIG. 3 is an explanatory view of an epidermal insertion state.
【図４】発泡成形状態説明図FIG. 4 is an explanatory diagram of a foam molding state.
【図５】トリミング状態説明図FIG. 5 is an explanatory diagram of a trimming state.
(1)・・・・・ポリプロピレン加熱軟化物 (2)・・・・・成形型 (21)・・・・外型 (22)・・・・内型 (3)・・・・・表皮 (4)・・・・・成形物 (5)・・・・・切刃 (1) ・ ・ ・ ・ ・ Polypropylene heat-softened product (2) ・ ・ ・ ・ ・ Molding mold (21) ・ ・ ・ ・ Outer mold (22) ・ ・ ・ ・ Inner mold (3) ・ ・ ・ ・ ・ Skin ( 4) ・ ・ ・ ・ ・ Molded product (5) ・ ・ ・ ・ ・ Cutting edge
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.7 識別記号 ＦＩ Ｂ２９Ｌ 9:00 (58)調査した分野(Int.Cl.7，ＤＢ名) B29C 43/02 - 43/20 B29C 43/32 - 43/42 B29C 39/02 - 39/12 B29C 39/22 - 39/34 B29C 44/00 B29C 69/00 - 69/02 B29D 9/00 ──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. 7 identification code FI B29L 9:00 (58) Fields surveyed (Int.Cl. 7 , DB name) B29C 43/02-43/20 B29C 43/32 -43/42 B29C 39/02-39/12 B29C 39/22-39/34 B29C 44/00 B29C 69/00-69/02 B29D 9/00
Claims (1)
させて外型と内型とからなるスタンピング成形型内にセ
ットし、スタンピング成形を行ない予備成形体を得る工
程１ 工程１の後該成形型を開いて該予備成形体上に表皮を挿
入し、再び該成形型を閉じて該熱可塑性樹脂の発泡温度
以上に加熱する工程２ 該成形型を若干開いて該予備成形体を発泡させる工程３ 該成形型を冷却し成形物を該成形型から取出し表皮をト
リミングする工程４ 以上の工程１，２，３，４からなることを特徴とする発
泡成形方法1. A step 1 of softening a thermoplastic resin mixed with a foaming agent by heating and setting it in a stamping mold comprising an outer mold and an inner mold, and performing stamping molding to obtain a preformed body. Step 2: Opening a mold, inserting a skin on the preformed body, closing the mold again and heating to a temperature equal to or higher than the foaming temperature of the thermoplastic resin. Step 2 Opening the mold slightly to foam the preformed body. Step 3 Cooling the mold, removing the molded product from the mold, and trimming the skin 4 A foam molding method comprising the above steps 1, 2, 3, and 4
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP10889191A JP3145424B2 (en) | 1991-04-12 | 1991-04-12 | Foam molding method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP10889191A JP3145424B2 (en) | 1991-04-12 | 1991-04-12 | Foam molding method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH04314530A JPH04314530A (en) | 1992-11-05 |
| JP3145424B2 true JP3145424B2 (en) | 2001-03-12 |
Family
ID=14496231
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP10889191A Expired - Fee Related JP3145424B2 (en) | 1991-04-12 | 1991-04-12 | Foam molding method |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3145424B2 (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5292465A (en) * | 1991-11-28 | 1994-03-08 | Mitsui Petrochemical Industries, Ltd. | Process for preparing composite foamed molded article |
| US5762842A (en) * | 1996-08-30 | 1998-06-09 | Burchi; Charles R. | Process for seat production |
| US5827546A (en) * | 1996-08-30 | 1998-10-27 | Woodbridge Foam Corporation | System for production of a passenger seat |
| US5827547A (en) * | 1996-08-30 | 1998-10-27 | Woodbridge Foam Corporation | Mold for production of a passenger seat |
| US5882073A (en) * | 1996-08-30 | 1999-03-16 | Woodbridge Foam Corporation | Foam passenger seat having trim cover attachment means |
| JP4539238B2 (en) * | 2004-08-31 | 2010-09-08 | 住友化学株式会社 | Vacuum forming method for thermoplastic resin foam sheet |
-
1991
- 1991-04-12 JP JP10889191A patent/JP3145424B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JPH04314530A (en) | 1992-11-05 |
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