JP3743924B2 - Method for producing foamed article in synthetic resin mold with skin - Google Patents

Description

【０１１２】
【発明の効果】
以上のように、請求項１の発明によれば、前記一方の金型の表面に、前記熱可塑性樹脂表皮材の表面粗さと同程度の粗さの微細な凹凸をあらかじめ形成しておき、前記発泡ビーズ相互の融着及びこれら発泡ビーズと前記熱可塑性樹脂表皮材の融着一体化と共に、該熱可塑性樹脂表皮材の表面に前記微細な凹凸を転写することによって、この熱可塑性樹脂表皮材の表面粗さを略一様に保持するので、いわゆる同時一体成形において、従来のようなビーズ模様が現れていない外観が美麗な表皮付き合成樹脂型内発泡成形体を製造することができる。しかも、前記熱可塑性樹脂表皮材の元の表面粗さが非常に粗い場合や非常に細かい場合でも同様に、ビーズ模様が現れないので、種々の熱可塑性樹脂表皮材を使用できるという利点がある。
【０１１３】
請求項２の発明によれば、前記熱可塑性樹脂表皮材と当接する一方の金型の表面に、前記熱可塑性樹脂表皮材の表面粗さと同程度の粗さの微細な凹凸をあらかじめ形成しておき、前記合成樹脂型内発泡成形体と熱可塑性樹脂表皮材の一体化と共に、該熱可塑性樹脂表皮材の表面に前記微細な凹凸を転写することによって、この熱可塑性樹脂表皮材の表面粗さを略一様に保持するので、いわゆる後貼り成形において、従来のようなビーズ模様が現れていない外観が美麗な表皮付き合成樹脂型内発泡成形体を製造することができる。しかも、前記熱可塑性樹脂表皮材の元の表面粗さが非常に粗い場合や非常に細かい場合でも同様に、ビーズ模様が現れないので、種々の熱可塑性樹脂表皮材を使用できるという利点がある。
【０１１５】
請求項３の発明によれば、前記一方の金型の表面に、前記微細な凹凸に加えて製品意匠模様用凹凸をあらかじめ形成しておき、前記熱可塑性樹脂表皮材の表面に前記微細な凹凸を転写する際に、前記製品意匠模様用凹凸をも転写するので、いわゆる同時一体成形又は後貼り成形において、ビーズ模様が現れないと共に、製品意匠模様用凹凸をも有する表皮付き合成樹脂型内発泡成形体を製造でき、そのため当該表皮付き合成樹脂型内発泡成形体に高級感等を付与することができる。
【０１１６】
請求項４の発明によれば、前記熱可塑性樹脂表皮材を配置する前に、該熱可塑性樹脂表皮材の表面に製品意匠模様用凹凸をあらかじめ形成しておくので、いわゆる同時一体成形又は後貼り成形において、得られる表皮付き合成樹脂型内発泡成形体にビーズ模様が現れずに外観が美麗であると共に、前記製品意匠模様用凹凸により高級感等を付与できるという利点がある。また、前記一方の金型の表面に製品意匠模様用凹凸を形成しておかなくてもよいので、コストダウンを図ることもできる。
【図面の簡単な説明】
【図１】実施形態に係る表皮付き合成樹脂型内発泡成形体の側断面図。
【図２】第１実施形態に係る表皮付き合成樹脂型内発泡成形体の製造方法において、一方の金型の表面に熱可塑性樹脂表皮材を配置して型締めした状態を示す側断面説明図。
【図３】図２の熱可塑性樹脂表皮材の配置状態を示す要部拡大側断面図。
【図４】成形型内へ発泡ビーズを充填する様子を示す側断面説明図。
【図５】発泡ビーズを充填した後、成形型内へ水蒸気を供給する様子を示す側断面説明図。
【図６】成形型内を真空引きする様子を示す側断面説明図。
【図７】成形型内へ水蒸気を供給して発泡ビーズを型内発泡させた状態を示す側断面説明図。
【図８】成形型内から脱型された耳部を有する表皮付き合成樹脂型内発泡成形体の側断面図。
【図９】発泡ビーズが型内発泡する状態を示す要部拡大側断面図。
【図１０】得られた表皮付き合成樹脂型内発泡成形体の表面付近の要部拡大側断面図。
【図１１】第２実施形態に係る表皮付き合成樹脂型内発泡成形体の製造方法において、発泡ビーズが型内発泡する状態を示す要部拡大側断面図。
【図１２】得られた表皮付き合成樹脂型内発泡成形体の表面付近の要部拡大側断面図。
【図１３】第３実施形態に係る表皮付き合成樹脂型内発泡成形体の製造方法において、発泡ビーズが型内発泡する状態を示す要部拡大側断面図。
【図１４】第４実施形態に係る表皮付き合成樹脂型内発泡成形体の製造方法において、発泡ビーズが型内発泡する状態を示す要部拡大側断面図。
【図１５】第５実施形態に係る表皮付き合成樹脂型内発泡成形体の製造方法において、発泡ビーズが型内発泡する状態を示す要部拡大側断面図。
【図１６】図１５の製品意匠模様用凹凸の表面を略平滑にした状態を示す要部拡大側断面図。
【図１７】第６実施形態に係る表皮付き合成樹脂型内発泡成形体の製造方法において、２つの金型の間に合成樹脂型内発泡成形体と熱可塑性樹脂表皮材を配置して型締めする様子を示す側断面図。
【図１８】型締め後の状態を示す要部拡大側断面図。
【図１９】一方の金型を上型とし、且つ、他方の金型を下型として、これら２つの金型の間に熱可塑性樹脂表皮材を合成樹脂型内発泡成形体に載置するように配置して型締めする様子を示す側断面図。
【図２０】型締め後の状態を示す要部拡大側断面図。
【図２１】図１８の状態において加圧する際、熱で合成樹脂型内発泡成形体と熱可塑性樹脂表皮材を融着一体化させる様子を示す要部拡大側断面図。
【図２２】得られた表皮付き合成樹脂型内発泡成形体の側断面図。
【図２３】図２２の表皮付き合成樹脂型内発泡成形体の表面付近の要部拡大側断面図。
【図２４】第７実施形態に係る表皮付き合成樹脂型内発泡成形体の製造方法において、熱と接着剤を併用して合成樹脂型内発泡成形体と熱可塑性樹脂表皮材を融着一体化させる様子を示す要部拡大側断面図。
【図２５】得られた表皮付き合成樹脂型内発泡成形体の表面付近の要部拡大側断面図。
【符号の説明】
１，２１，３１，４１ 表皮付き合成樹脂型内発泡成形体
２ 合成樹脂型内発泡成形体
３ 熱可塑性樹脂表皮材
３ａ 表面
４ 成形型
５，１５ 一方の金型
５ａ，１５ａ 表面
６，１６ 他方の金型
６ｃ 蒸気孔
７ 成形型内
８ 発泡ビーズ
Ｓ 水蒸気
９ 微細な凹凸
１２ 製品意匠模様用凹凸[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to the production of a foamed synthetic resin-molded body used for, for example, automotive interior materials.MethodAbout.
[0002]
[Prior art]
As a conventional method for producing a synthetic resin-molded foam-molded body with a skin of this type, for example, a thermoplastic resin skin material is placed in one of two molds constituting the mold and the mold is clamped. Then, the mold is filled with foam beads, the foam beads are foamed by steam heating and fused together, and the foam beads and the thermoplastic resin skin material are fused and integrated, so-called simultaneous integral molding. It has been known.
[0003]
In addition, when placing a synthetic resin in-mold foam molded article and a thermoplastic resin skin material between two molds, and clamping and pressurizing, these synthetic resin in-mold foam molded body and heat So-called post-bonding molding in which a plastic resin skin material is integrated is also known.
[0004]
However, in these simultaneous integral molding and post-bonding molding, the surface of one mold in contact with the thermoplastic resin skin material is formed smoothly, and the surface of the thermoplastic resin skin material is substantially rough with a predetermined roughness. Since it is often uniformly frosted, a so-called circular bead pattern appears in plan view on the surface of the thermoplastic resin skin material, and the appearance of the resulting synthetic resin-in-mold foam-molded article with skin is attractive. There was a problem that it was not good.
[0005]
Therefore, in order to solve the above problems, the inventors of this application disclosed in the patent application (Japanese Patent Application No. Hei 8-182355) filed in the past that the surface of the one mold has a fine roughness. By forming the irregularities in advance and transferring the fine irregularities to the surface of the thermoplastic resin skin material when the thermoplastic resin skin material and the synthetic resin mold-internally molded molded body are integrated, the bead pattern is formed. We have proposed a technology that can produce a synthetic resin-in-mold foam-molded article with a skin that does not appear and has a good appearance.
[0006]
[Problems to be solved by the invention]
However, the surface of the thermoplastic resin skin material is not necessarily matte with an appropriate roughness. Depending on the type and application, the surface roughness may be very rough, or conversely very fine. It may take. Therefore, in such a case, there is a problem that a bead pattern appears on the surface of the thermoplastic resin skin material even when the above technique is used.
[0007]
  The present invention has been made in view of the above problems, and the case where the surface roughness of the thermoplastic resin skin material integrated into the synthetic resin-molded foamed product is very rough or very fine. However, the production of a synthetic resin-in-mold foam-molded body with a skin that has a beautiful appearance without the appearance of beads on the surface of this thermoplastic resin skin material.MethodThe purpose is to provide.
[0012]
[Means for Solving the Problems]
  To achieve the above purposeClaim1As a means of the method for producing a synthetic resin-molded foam-molded body with a skin, a thermoplastic resin skin material is placed in one of the two molds constituting the mold, and the mold is clamped. Filling the molding die with foam beads, foaming these foam beads by steam heating and fusing them together, and foaming these foam beads and the thermoplastic resin skin material to fuse and integrate the foam inside the synthetic resin mold with a skin In the method for producing a molded body, fine irregularities having the same degree of roughness as the surface roughness of the thermoplastic resin skin material are formed in advance on the surface of the one mold, and the fusion between the foam beads and Together with the fusion integration of the foam beads and the thermoplastic resin skin material, the fine unevenness is transferred to the surface of the thermoplastic resin skin material, thereby making the surface roughness of the thermoplastic resin skin material substantially uniform. Hold on In the Rukoto.
[0013]
  Claim2The means of the above is that when a foamed body in a synthetic resin mold and a thermoplastic resin skin material are placed between two molds, and the mold is clamped and pressed, the inside of these synthetic resin molds is heated and / or adhesive. In the method for producing a synthetic resin-molded foam-molded body with a skin, in which the foamed molded body and the thermoplastic resin skin material are integrated, the thermoplastic resin skin material is provided on the surface of one mold that comes into contact with the thermoplastic resin skin material. A fine unevenness having the same degree of roughness as the surface roughness of the surface is formed in advance, and the fine foam is formed on the surface of the thermoplastic resin skin material together with the integration of the synthetic resin mold foam molding and the thermoplastic resin skin material. It is to keep the surface roughness of the thermoplastic resin skin material substantially uniform by transferring the unevenness.
[0015]
  Claim3In this case, in addition to the fine unevenness, a product design pattern unevenness is previously formed on the surface of the one mold, and the fine unevenness is transferred to the surface of the thermoplastic resin skin material. In doing so, the unevenness for the product design pattern is also transferred.
[0016]
  Claim4This means is that, prior to disposing the thermoplastic resin skin material, product design pattern irregularities are formed in advance on the surface of the thermoplastic resin skin material.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings. In the following first to fifth embodiments, so-called simultaneous integral molding will be described, and in the sixth and seventh embodiments, so-called post-bonding molding will be described.
[0018]
As shown in FIG. 1, the manufacturing method of the first embodiment has a synthetic resin in-mold foam molded body 2 and a surface roughness fused and integrated with the surface 2a of the synthetic resin in-mold foam molded body 2. This relates to the production of a synthetic resin-in-mold foam-molded body 1 with a skin comprising a uniform thermoplastic resin skin material 3.
[0019]
As shown in FIGS. 2 to 10, this manufacturing method is performed after the thermoplastic resin skin material 3 is placed in one mold 5 of the two molds 5 and 6 constituting the mold 4 and clamped. The inside of the mold 7 is filled with foam beads 8, and the foam beads 8 are foamed by steam heating and fused together, and the foam beads 8 and the thermoplastic resin skin material 3 are fused and integrated. In the manufacturing method of the foamed molded product 1 with a synthetic resin, fine irregularities 9 having the same roughness as the surface roughness of the thermoplastic resin skin material 3 are formed in advance on the surface 5a of the one mold 5. The fine irregularities 9 are transferred to the surface 3a of the thermoplastic resin skin material 3 together with the fusion of the foam beads 8 and the fusion integration of the foam beads 8 and the thermoplastic resin skin material 3. By this thermoplastic resin skin Surface roughness of 3 is substantially that uniformly held.
[0020]
That is, as shown in FIG. 2, first, the thermoplastic resin skin material 3 is placed in the one mold 5 and clamped.
[0021]
Here, the said shaping | molding die 4 is comprised by the two metal mold | dies 5 and 6, which can be clamped and opened in a horizontal direction, for example.
[0022]
The one mold 5 has, for example, a concave cross section and a chamber 5b formed therein, and a plurality of decompression holes 5c communicating with the chamber 5b are formed on the surface 5a side. A steam valve A1, a pressure reducing valve B1, and a drain valve C1 are connected to the chamber 5b. In addition, as this one metal mold | die 5, it is manufactured by nickel electroforming etc., for example, has the fine ventilation hole connected to the said chamber 5b in the whole surface 5a or arbitrary places, and has air permeability. A breathable electric mold (for example, porous denchu, trade name, manufactured by Gangnam Special Industrial Co., Ltd.), or a breathable metal in which fine vents are formed on the entire surface 5a by sintering metal or ceramic particles under predetermined conditions A mold or a breathable ceramic mold (for example, PORAX II, trade name, manufactured by Shinto Kogyo Co., Ltd.) may be used.
[0023]
The other mold 6 has, for example, a convex cross section and a chamber 6b formed therein, and a plurality of vapor holes 6c communicating with the chamber 6b are formed on the surface 6a side. A steam valve A2, a pressure reducing valve B2, and a drain valve C2 are connected to the chamber 6b, and a feeder 10 for filling the foam beads 8 into the mold 7 is provided.
[0024]
Examples of the thermoplastic resin skin material 3 include a thermoplastic resin sheet made of a vinyl chloride resin, or a polyolefin resin such as a polyethylene resin or a polypropylene resin. In addition, since this thermoplastic resin skin material 3 is used as the skin of the synthetic resin mold-in-mold foam-molded body 1 with the skin, it may be colored in a desired color with a colorant or the like according to its use.
[0025]
In order to dispose the thermoplastic resin skin material 3 on the surface 5a of one mold 5, for example, it is adapted to the shape of the surface 5a of the one mold 5 by vacuum forming or the like in advance with another mold or the like. What is necessary is just to arrange what was shape | molded.
[0026]
Here, as shown in FIG. 3, the surface 3 a of the thermoplastic resin skin material 3 is formed with fine irregularities 19 to have a predetermined surface roughness.
[0027]
Further, on the surface 5 a of the one mold 5, fine irregularities 9 having the same degree of roughness as the surface roughness of the thermoplastic resin skin material 3 are formed. In order to form the fine unevenness 9, various conventional techniques such as blasting and etching can be used.
[0028]
In addition, as long as the roughness of these fine unevenness | corrugations 9 and the surface roughness of the said thermoplastic resin skin material 3 are comparable, they may be very rough, or conversely, they may be very fine. Further, in the very fine case, the surface 5a of the one mold 5 and the surface 3a of the thermoplastic resin skin material 3 are both formed to be substantially smooth, and the fine irregularities 9, 19 are super The case where the roughness is fine is also included.
[0029]
Here, when the obtained synthetic resin-in-mold foam-molded body 1 with a skin requires a fixture or the like for attaching to another member, for example, the surface 6a of the other mold 6 has a predetermined shape in advance. An insert material (not shown) may be disposed, and the insert material and the synthetic resin in-mold foam molded body 2 may be integrated when the foam beads 8 are foamed in the mold.
[0030]
Next, as shown in FIG. 4, the foam beads 8 are filled into the mold 7 from the feeder 10. In this case, in order to make it easy to fill the foam beads 8, the filling may be performed in a state where the mold beads are slightly opened (cracked) so that the foam beads 8 do not fall.
[0031]
Examples of the synthetic resin constituting the foam beads 8 include polyolefin resins and polystyrene resins.
[0032]
Examples of the polyolefin resin include low density polyethylene, medium density polyethylene, high density polyethylene, linear low density polyethylene, ethylene-vinyl acetate copolymer, propylene homopolymer, ethylene-propylene random copolymer, ethylene- Such as propylene block copolymer, ethylene-propylene-butene random terpolymer, propylene-vinyl chloride copolymer, propylene-butene copolymer, propylene-maleic anhydride copolymer, poly (butene-1), etc. A polyethylene resin, a polypropylene resin, etc. are mentioned, These can be used individually or in mixture of 2 or more types.
[0033]
This polyolefin-based resin is preferably in a non-crosslinked state, but may be crosslinked by peroxide or radiation.
[0034]
Moreover, what mixed the other thermoplastic resin with this polyolefin resin can also be used. Examples of such thermoplastic resins include, when mixed with the polypropylene resin, low density polyethylene, linear low density polyethylene, vinyl aromatic polymer, polybutene, and ionomer. And when mixing with the said polyethylene-type resin, vinyl aromatic polymer, polybutene, an ionomer etc. are mentioned, for example. In these cases, the amount of the thermoplastic resin blended is preferably 20 parts by weight or less, more preferably 5 to 10 parts by weight with respect to 100 parts by weight of the polyolefin resin.
[0035]
The foam beads 8 are, for example, previously molded into a granular form of the above synthetic resin, containing a volatile foaming agent in the synthetic resin particles in a pressure vessel, and dispersed in water while stirring. After heating to a predetermined foaming temperature under pressure, the aqueous dispersion may be produced in a prefoamed state by a method such as discharging the aqueous dispersion to a low pressure region. As such foam beads 8, for example, Eperan PP (trade name, manufactured by Kaneka Chemical Co., Ltd., foaming magnification: 15 times) and the like can be suitably used.
[0036]
In order to improve the adhesiveness between the synthetic resin in-mold foamed product 2 obtained by in-mold foaming of the foamed beads 8 and the thermoplastic resin skin material 3, contact with the foamed beads 8 as necessary. An appropriate adhesive may be applied in advance to the back surface 3 b of the thermoplastic resin skin material 3. Examples of the adhesive include an organic solvent solution of a synthetic resin, a resin emulsion, and a resin powder.
[0037]
Thereafter, as shown in FIG. 5, the steam valve A2 connected to the chamber 6b of the other mold 6 is opened to supply the steam S from the steam hole 6c to the inside 7 of the mold, and the foam beads 8 are heated and foamed. Let
[0038]
At this time, before the main heating of the foam beads 8 at a temperature equal to or higher than the temperature at which the foam beads 8 are fused to each other, the foam beads 8 are pre-heated in advance at a temperature lower than the temperature at which the foam beads 8 are fused to each other. In this case, the foamed beads 8 can be sufficiently heated without being fused to each other.
[0039]
In addition, if the foamed beads 8 are steamed with the steam S after being preheated for a predetermined time, the latent heat of the steam S supplied between the foamed beads 8 can be used effectively. There is an advantage that the foamed beads 8 can be heated more uniformly, for example, when the synthetic resin in-mold foam molded product 2 having a large length is molded. This steaming may be performed in a state where the supply of the water vapor S is continued, or may be performed in a state where the supply of the water vapor S is stopped and the drain valve C2 is opened as necessary. Further, after steaming with steam S, there is a drain (moisture) between the foam beads 8, and if this heat is used in this state, poor fusion between the foam beads 8 may occur. The drain is removed by evacuating the inside of the mold 7 from the steam hole 6c as shown, or by ventilating high-temperature dry air from the steam hole 6c in a slightly opened state (cracking). Is desirable.
[0040]
Next, the main heating is performed at a temperature equal to or higher than the temperature at which the foam beads 8 are fused together. As shown in FIG. 7, the main heating is performed by opening the steam valve A2 and supplying the steam S through the steam hole 6c to the inside 7 of the mold. At this time, as described above, when the inside of the mold 7 is evacuated in order to remove the drain after steaming with the steam S, the steam S for the main heating is more smoothly performed. It can be supplied into the mold 7. Further, at the time of this main heating, in order to sufficiently transfer the heat due to the water vapor S to the foam beads 8, it is desirable to maintain the state for a predetermined time.
[0041]
Next, when the mold 4 is cooled and then opened, as shown in FIG. 8, the synthetic resin mold-in-mold foam 2 obtained by in-mold foaming of the foam beads 8 and the synthetic resin mold are obtained. A synthetic resin-type inner foamed molded body 1a with a skin having an ear portion 3c, for example, is obtained, which is composed of a thermoplastic resin skin material 3 fused and integrated with the surface 2a of the inner foamed molded body 2. The synthetic resin-in-mold foam-molded body 1a with skin is preferably cured and dried after being removed from the mold 4. In addition, as in this embodiment, when an unnecessary portion such as the ear portion 3c is formed due to an excess of the end portion of the thermoplastic resin skin material 3, if it is cut, FIG. The synthetic resin-in-mold foam-molded body 1 with a skin shown can be obtained.
[0042]
Here, at the time of the main heating, as shown in FIG. 9, due to the foaming force F of the foamed beads 8, the predetermined range D of the surface 3a of the thermoplastic resin skin material 3 is different from the back surface 3b. It is pressed more strongly than the range E and pressed more strongly by the surface 5 a of the one mold 5. In this state, since the thermoplastic resin skin material 3 is in a softened state by steam heating, as shown in FIG. The fine irregularities 9 formed in advance on the surface 5a of the mold 5 are transferred to form fine irregularities 9d.
[0043]
Further, the other range E is also pressed against the surface 5a of the one mold 5 although the force is weaker than the range D. Therefore, the fine unevenness 9 is transferred to the other range E, and the fine range 9 is fine. Unevenness 9e is formed.
[0044]
In this case, since the force pressed against the surface 5a of the one mold 5 is different between the range D and the other range E, the roughness of the fine irregularities 9d and 9e formed on the respective ranges may be different. As in this embodiment, if the roughness of the fine irregularities 9 is set to be approximately the same as the original surface roughness of the thermoplastic resin skin material 3, the roughness of these fine irregularities 9d and 9e is substantially the same. It can be roughness. That is, the surface roughness of the thermoplastic resin skin material 3 is kept substantially uniform, and a conventional bead pattern does not appear. In addition, even when the original surface roughness of the thermoplastic resin skin material 3 is very rough or very fine, the bead pattern does not appear in the same manner, so that there is an advantage that various thermoplastic resin skin materials 3 can be used. is there.
[0045]
Here, it is most desirable that the roughness of the fine unevenness 9 and the surface roughness of the thermoplastic resin skin material 3 are the same roughness, but when these are different, the difference between them is determined by the surface roughness measuring instrument. In the surface roughness waveform measured by using, it is desirable that the amplitude is 50 μm or less, the wavelength is 200 μm or less, preferably the amplitude is 40 μm or less, the wavelength is 150 μm or less, more preferably the amplitude is 30 μm or less, and the wavelength is 100 μm or less. In this case, any of them may be rough.
[0046]
Note that the difference here refers to the maximum value calculated so that the amplitude and wavelength in the surface roughness waveform are compared and the amplitude difference and the wavelength difference are both maximized.
[0047]
When the difference is within the above range, the fine irregularities 9d and 9e formed on the surface 3a of the thermoplastic resin skin material 3 are surely roughened by transferring the fine irregularities 9. Since the roughness can be substantially the same, there is an advantage that the appearance can be more effectively improved. Here, when the surface roughness of the one mold 5 and the thermoplastic resin skin material 3 is the same or very close, the bead pattern does not appear even if the transfer of the fine irregularities 9 is not necessarily required. It is natural to achieve the above-mentioned purpose of doing so. Therefore, in this case, for example, when the surface 5a of the one mold 5 has unevenness for the product design pattern such as a skin texture, even if it is essential to transfer the unevenness for the product design pattern, The manufacture of the foam molded body 1 includes a case where the transfer of the fine irregularities 9 is not necessarily essential.
[0048]
Examples of the surface roughness measuring instrument include a stylus type surface roughness measuring instrument (for example, manufactured by Tokyo Seimitsu Co., Ltd., trade name: Surfcom 570A, stylus tip 5 μmR), or a non-contact type surface roughness measuring instrument ( For example, the product made by Pelten, amplifier part model: Peltometer S3P, sensor part model: non-contact probe, phocodin), etc. are mentioned.
[0049]
Here, the difference between the roughness of the fine unevenness 9 and the surface roughness of the thermoplastic resin skin material 3 exceeds the amplitude of 50 μm and the wavelength of 200 μm in the surface roughness waveform, and the thermoplasticity When the surface roughness of the resin skin material 3 is rougher, the roughness of the fine unevenness 9d in the range D is finer than the roughness of the fine unevenness 9e in the other range E, and a bead pattern appears. Absent. On the contrary, when the surface roughness of the thermoplastic resin skin material 3 is finer, the roughness of the fine unevenness 9d becomes rougher than the roughness of the fine unevenness 9e, and the contrast is opposite to the above. Since a pattern appears, it is not preferable.
[0050]
As described above, the roughness is not particularly limited as long as the roughness of the fine unevenness 9 and the surface roughness of the thermoplastic resin skin material 3 are approximately the same, and the roughness is very rough. Or, conversely, it may be very fine, but if the above-mentioned very rough case is expressed by the above-mentioned surface roughness waveform, it corresponds to a roughness exceeding both an amplitude of about 150 μm and a wavelength of about 600 μm. Similarly, the very fine case corresponds to a roughness with an amplitude of less than about 5 μm and a wavelength of less than about 30 μm in the surface roughness waveform. When this is compared with the surface roughness of, for example, abrasive paper (sandpaper), the very rough case corresponds to the case where it is coarser than # 100 (100th), and the very fine case corresponds to # 1000 (1000th). Corresponds to the case of finer than degree. In short, any roughness may be used as long as both have the same roughness.
[0051]
As shown in FIG.11 and FIG.12, the manufacturing method of the synthetic resin type in-mold foam-molded body 21 with a skin which concerns on 2nd Embodiment is the above-mentioned 1st Embodiment. In addition to the fine unevenness 9, the product design pattern unevenness 12 is formed in advance, and when transferring the fine unevenness 9 to the surface 3a of the thermoplastic resin skin material 3, the product design pattern unevenness 12 is formed. Is also transferred.
[0052]
Examples of the product design pattern irregularities 12 include a leather texture, and the fine irregularities 9 may be formed on the surface of the product design pattern irregularities 12. The product design pattern irregularities 12 can be formed using various conventional techniques. When the product design pattern irregularities 12 and the fine irregularities 9 are formed by etching, the product design pattern irregularities 12 are formed. In order to make it appear clearly, it is desirable to form the fine irregularities 9 after the irregularities 12 for the product design pattern are formed.
[0053]
When the product design pattern irregularities 12 are formed, the thermoplastic resin skin material 3 is arranged with a gap H with respect to the surface 5a of one mold 5 as shown in FIG. However, if the same operation as in the first embodiment is performed, the thermoplastic resin skin material 3 is entirely pressed against the one mold 5 when the foam beads 8 are foamed in the mold. As shown in FIG. 3, the product design pattern unevenness 12 is transferred to the surface 3a of the thermoplastic resin skin material 3, and the fine unevenness 9 is transferred to form fine unevenness 9d (9e). Therefore, as in the first embodiment, if the roughness of the fine unevenness 9 is set to be approximately the same as the surface roughness of the thermoplastic resin skin material 3, the thermoplastic resin skin material including the product design pattern unevenness 12 is used. 3 has a substantially uniform surface roughness.
[0054]
In this way, if the product design pattern irregularities 12 are formed in advance in addition to the fine irregularities 9 on the surface 5 a of the one mold 5, the bead pattern does not appear and the product design pattern irregularities 12. Since the synthetic resin-in-mold foam-molded product 21 with a skin having a surface can be produced, it is possible to impart a high-grade feeling to the synthetic-mold-in-mold foam-molded product 21 with a skin.
[0055]
As shown in FIG. 13, the method for producing a synthetic resin-in-mold foam-molded body 1 with a skin according to the third embodiment is the above-mentioned thermoplastic resin on the surface 5 a of the one mold 5 in the first embodiment. A concave / convex transfer member 13 in which fine irregularities 9 having the same degree of roughness as the surface roughness of the skin material 3 are formed on the surface 13a is bonded in advance, and the foam beads 8 are fused together and the foam beads 8 And the thermoplastic resin skin material 3 are fused and integrated, and the fine unevenness 9 is transferred to the surface 3a of the thermoplastic resin skin material 3, so that the surface roughness of the thermoplastic resin skin material 3 is substantially reduced. It keeps uniformly.
[0056]
Examples of the uneven transfer member 13 include a metal plate, a synthetic resin plate, an abrasive cloth, an abrasive paper or a water-resistant abrasive paper (sand paper), a metallic or synthetic resin mesh surface material, and the like. The surface 5a of the mold 5 is formed in conformity with the shape of the surface 5a, and the surface roughness of the thermoplastic resin skin material 3 is the same as that of the surface 13a by etching, blasting, or attaching fine particles. What is necessary is just to form the fine unevenness | corrugation 9 of the roughness of a grade. Then, the fine unevenness 9 side is directed to the outside, and may be bonded in advance to the surface 5a of the one mold 5 by adhesion or magnetic adhesion with an adhesive or the like. The order in which the fine irregularities 9 are formed and the irregularity transfer member 13 is formed so as to conform to the shape of the surface 5a of the one mold 5 is not particularly limited. If necessary, a plurality of communication holes communicating with the decompression hole 5c of the one mold 5 may be formed.
[0057]
As described above, even when the uneven transfer member 13 is joined to the surface 5a of one mold 5, if the same operation as described above is performed, the synthetic resin in-mold foam-molded body with a skin similar to the first embodiment is used. 1 can be manufactured. For this reason, the existing equipment can be used as it is, and the uneven transfer member 13 can be attached and detached, so that it can be used for various kinds of equipment.
[0058]
In this embodiment, the case where the fine unevenness 9 is formed on the surface 13a of the uneven transfer member 13 is described. However, the present invention is not limited to this, and the unevenness as in the second embodiment. In addition to the fine irregularities 9, product design pattern irregularities 12 may be formed on the surface 13 a of the transfer member 13.
[0059]
As shown in FIG. 14, the method of manufacturing the synthetic resin-in-mold foam-molded body 1 with a skin according to the fourth embodiment is to form the surface 5 a of the one mold 5 smoothly in the first embodiment, The fine irregularities 9 having the same degree of roughness as the surface roughness of the thermoplastic resin skin material 3 are formed in advance by attaching the irregularity transfer particulate matter 14 to the smooth surface 5a, and the foam beads 8 This thermoplastic resin is formed by transferring the fine irregularities 9 onto the surface 3a of the thermoplastic resin skin material 3 together with mutual fusion and fusion integration of the foam beads 8 and the thermoplastic resin skin material 3. The surface roughness of the skin material 3 is maintained substantially uniformly.
[0060]
Examples of the irregularity transfer particulate matter 14 include metal powder and the like, and it may be adhered to the surface 5a of the one mold 5 by adhesion or magnetic adhesion with an adhesive or the like. Moreover, as the particle size, the roughness of the fine unevenness 9 formed by the particulate transfer material 14 is approximately the same as the surface roughness of the thermoplastic resin skin material 3, preferably the fine unevenness 9 It is desirable that the difference between the roughness and the surface roughness of the thermoplastic resin skin material 3 is in the range of the amplitude of 50 μm or less and the wavelength of 200 μm or less in the aforementioned surface roughness waveform.
[0061]
Thus, if the fine unevenness 9 is formed on the surface 5a of one mold 5 using the unevenness transfer particulate matter 14, the same as in the third embodiment, the same as in the first embodiment. A synthetic resin-in-mold foam-molded body 1 with a skin can be produced. Therefore, there is an advantage that the existing equipment can be used as it is.
[0062]
In this embodiment, the case where fine irregularities 9 are formed on the surface 5a of the one mold 5 by the irregularity transfer particulate matter 14 has been described. However, the present invention is not limited to this. As in the second embodiment, product design pattern irregularities 12 are formed on the surface 5 a of the one mold 5 in addition to the fine irregularities 9 formed by the irregularity transfer particulates 14. Also good.
[0063]
As shown in FIG. 15, the manufacturing method of the synthetic resin-in-mold foam-molded body 21 with a skin according to the fifth embodiment is the arrangement of the thermoplastic resin skin material 3 on the one mold 5 in the first embodiment. Before carrying out, the unevenness 12 for product design patterns is formed in advance on the surface 3a of the thermoplastic resin skin material 3.
[0064]
As a method for forming the product design pattern irregularities 12 on the surface 3 a of the thermoplastic resin skin material 3, various conventional techniques such as a method using a drawing machine or the like can be used. Note that the surface of the product design pattern irregularities 12 may have substantially the same roughness as the other portions as in this embodiment, or may be substantially smooth as shown in FIG. Good.
[0065]
As shown in FIG. 15, after the thermoplastic resin skin material 3 is arranged on the surface 5 a of the one mold 5, if the same operation as in the first embodiment is performed, the surface 3 a of the thermoplastic resin skin material 3. The fine unevenness 9 is transferred to form fine unevenness 9d (9e), and a synthetic resin-in-mold foam-molded body 21 with a skin similar to that of the second embodiment shown in FIG. 12 can be manufactured.
[0066]
In this way, even when the product design pattern irregularities 12 are formed in advance on the surface 3a of the thermoplastic resin skin material 3, as in the second embodiment, the obtained synthetic resin-in-mold foam-molded body with skin is obtained. 21 has an advantage that a bead pattern does not appear and the appearance is beautiful and the product design pattern irregularities 12 can give a high-class feeling and the like. Further, since the product design pattern irregularities 12 need not be formed on the surface 5a of the one mold 5, the cost can be reduced.
[0067]
In addition, in this embodiment, the case where the thermoplastic resin skin material 3 on which the product design pattern irregularities 12 had been formed in advance was disposed on the one mold 5 having the fine irregularities 9 formed on the surface 5a was described. However, the present invention is not limited to this, and as in the third or fourth embodiment, it is arranged on the uneven transfer member 13 bonded to the surface 5a of the one mold 5, or the uneven You may arrange | position on the surface 5a of one metal mold | die 5 in which the fine unevenness | corrugation 9 was formed with the particulate matter 14 for transcription | transfer.
[0068]
As described above, in the first to fifth embodiments, the case where the one mold 5 is a concave mold (female mold) having a concave cross section is described, but the present invention is not limited to this. The one mold 5 may be a convex mold (male mold) having a convex cross section, and the other mold 6 may be a concave mold (female mold) formed in a concave shape.
[0069]
Next, the case of so-called post-bonding will be described.
As shown in FIGS. 17 to 23, the synthetic resin-in-mold foam-molded body 31 with a skin according to the sixth embodiment includes a synthetic-resin-mold foam-molded body 2 between two molds 15, 16. When the thermoplastic resin skin material 3 is placed, clamped, and pressed, for example, the synthetic resin in-mold foamed product 2 and the thermoplastic resin skin material 3 are fused and integrated by heat, for example, with a synthetic resin in-mold foam molding with a skin. In the manufacturing method of the body 31, the fine unevenness 9 having the same roughness as the surface roughness of the thermoplastic resin skin material 3 is preliminarily formed on the surface 15 a of the mold 15 in contact with the thermoplastic resin skin material 3. By forming and transferring the fine irregularities 9 on the surface 3a of the thermoplastic resin skin material 3 together with the fusion integration of the synthetic resin mold foam 2 and the thermoplastic resin skin material 3, The surface roughness of the thermoplastic resin skin material 3 is approximately It is to hold as.
[0070]
That is, as shown in FIG. 17, first, the synthetic resin in-mold foam molded body 2 and the thermoplastic resin skin material 3 are disposed between the two molds 15 and 16, and the mold clamping is performed as shown in FIG. To do.
[0071]
The two molds 15 and 16 can be clamped and opened in the vertical direction, for example, one mold 15 that contacts the thermoplastic resin skin material 3 is a lower mold, and the composite The other mold 16 that comes into contact with the resin-molded foamed molded body 2 is an upper mold. Then, a concave portion 15d conforming to the shape of the surface 2a of the synthetic resin mold foam molded body 2 is formed on the surface 15a of the one mold 15, and the surface 16a of the other mold 16 is formed flat. ing. Furthermore, at least one of the molds 15 may be heated to a predetermined temperature by steam or heating wire.
[0072]
The synthetic resin in-mold foam molding 2 is manufactured in advance in a predetermined shape by foaming the above-mentioned foam beads 8 in the mold.
[0073]
The thermoplastic resin skin material 3 may be arranged, for example, by using another molding die or the like molded in advance so as to conform to the shape of the surface 15a of the one mold 15 by vacuum molding or the like, or In the case of arranging without molding or the like, for example, as shown in FIG. 19 and FIG. 20, the one mold 15 is an upper mold and the other mold 16 is a lower mold, and the thermoplastic resin is used. You may arrange | position the skin material 3 by mounting etc. on the synthetic resin in-mold foaming molding 2. In this case, when clamping and pressurizing as shown in FIG. 20, it is desirable to apply heat to facilitate shaping.
[0074]
Next, as shown in FIG. 21, in the state shown in FIG. 18, when pressurizing with the applied pressure G, the synthetic resin in-mold foamed product 2 and the thermoplastic resin skin material 3 are fused and integrated with heat. In this case, before placing the synthetic resin in-mold foamed product 2 and the thermoplastic resin skin material 3, after placing them, after mold clamping, or may be heated either after being pressurized, Or you may heat simultaneously with any of arrangement | positioning, mold clamping, or pressurization. Alternatively, it may be heated in advance to a predetermined temperature, and the temperature may be raised to a temperature at which the synthetic resin in-mold foamed molded product 2 and the thermoplastic resin skin material 3 are fused in a predetermined stage. Furthermore, it may be heated in advance at a temperature higher than the temperature at which the synthetic resin mold foam 2 and the thermoplastic resin skin material 3 are fused, and the heating may be stopped at a predetermined stage and the remaining heat may be fused. In any case, it is only necessary that the synthetic resin-in-mold foamed molded body 2 and the thermoplastic resin skin material 3 can be fused and integrated during pressurization.
[0075]
If the mold is opened after cooling or the like, as shown in FIG. 22, a synthetic resin-in-mold foam-molded body 31 with a skin is obtained.
[0076]
Incidentally, the surface 3a of the thermoplastic resin skin material 3 is formed with fine irregularities 19 and has a predetermined surface roughness as shown in FIG. Further, on the surface 15 a of the one mold 15, fine irregularities 9 having a roughness comparable to the surface roughness of the thermoplastic resin skin material 3 are formed in advance. Also in this case, as described above, the difference between the roughness of the fine unevenness 9 and the surface roughness of the thermoplastic resin skin material 3 is within the range of the amplitude of 50 μm or less and the wavelength of 200 μm or less in the aforementioned surface roughness waveform. It is desirable to be.
[0077]
At this time, since the surface 2a of the synthetic resin-molded foam-molded body 2 is not flat, the predetermined range D of the surface 3a of the thermoplastic resin skin material 3 is more than the other range E from the back surface 3b. It is strongly pressed and strongly pressed by the surface 15 a of the one mold 15. In this case, as in the first embodiment, in this state, the thermoplastic resin skin material 3 is in a softened state due to heat. Therefore, as shown in FIG. The fine irregularities 9 formed in advance on the surface 15a of the mold 15 are transferred to form fine irregularities 9d.
[0078]
Further, since the other range E is also weaker than the range D, it is pressed against the surface 15a of the one mold 15, so that the fine unevenness 9 is also transferred to the other range E, and the fine range 9 is fine. Unevenness 9e is formed.
[0079]
Also in this case, the roughness of the fine irregularities 9d and 9e can be made substantially the same if the roughness of the fine irregularities 9 is set to the same level as the surface roughness of the thermoplastic resin skin material 3 as described above. Therefore, the surface roughness of the thermoplastic resin skin material 3 is kept substantially uniform, and a conventional bead pattern does not appear. In addition, even when the original surface roughness of the thermoplastic resin skin material 3 is very rough or very fine, the bead pattern does not appear in the same manner, so that there is an advantage that various thermoplastic resin skin materials 3 can be used. is there. Here, as in the case of the simultaneous integral molding described above, when the surface roughness of the one mold 15 and the thermoplastic resin skin material 3 is the same or very close, the transfer of the fine unevenness 9 is not necessarily performed. Of course, the above-mentioned purpose of preventing the appearance of the bead pattern is achieved even if it is not essential. Therefore, also in this case, for example, when the surface 15a of the one mold 15 has the product design pattern unevenness 12 such as a skin texture, even if the transfer of the product design pattern unevenness 12 is essential, the composite with the skin is concerned. The production of the resin-molded foam-molded body 31 includes a case where the transfer of the fine unevenness 9 is not necessarily essential.
[0080]
As shown in FIGS. 24 and 25, the synthetic resin-in-mold foam-molded article 41 with a skin according to the seventh embodiment is the same as the synthetic resin-mold-in-mold foam-molded body 2 in the sixth embodiment. The adhesive 17 is interposed between the resin skin materials 3, and the heat and the adhesive 17 are used together to fuse and integrate them.
[0081]
Examples of the adhesive 17 include an organic solvent solution of a synthetic resin, a resin emulsion, and a resin powder, as in the case of the above-described simultaneous integral molding. This adhesive 17 may be applied in advance to the front surface 2a of the synthetic resin mold foam molding 2 or the back surface 3b of the thermoplastic resin skin material 3.
[0082]
When the synthetic resin in-mold foamed molded body 2 and the thermoplastic resin skin material 3 are placed between the two molds 15 and 16 and clamped and pressed, they are fused and integrated with heat and an adhesive. 24, as in the sixth embodiment, the surface 2a of the synthetic resin-in-mold foam-molded body 2 is not flat. Therefore, the surface 3a of the thermoplastic resin skin material 3 is applied by the pressure G. The predetermined range D is pressed more strongly than the other ranges E. Therefore, as in the sixth embodiment, as shown in FIG. 25, fine irregularities 9 are transferred to the surface 3a of the thermoplastic resin skin material 3 to form minute irregularities 9d and 9e. Therefore, if the roughness of the fine irregularities 9 is set to the same level as the surface roughness of the thermoplastic resin skin material 3, the roughness of the fine irregularities 9d and 9e can be made substantially the same, so that a bead pattern appears. There is no.
[0083]
As described above, when the adhesive 17 is used, the adhesiveness between the synthetic resin-molded foamed molded body 2 and the thermoplastic resin skin material 3 can be improved, and an appropriate adhesive 17 is used. If it does so, since it can adhere | attach at the temperature which the said synthetic resin internal foaming molding 2 does not fuse | melt, there exists an advantage that it is not necessary to heat to high temperature.
[0084]
In this embodiment, the synthetic resin in-mold foamed molded body 2 and the thermoplastic resin skin material 3 are fused and integrated using heat and the adhesive 17 together, but the present invention is not limited to this. Alternatively, the adhesive 17 may be integrated without applying heat. As the adhesive 17 in this case, an adhesive having an adhesive property at room temperature or a room temperature curing type may be used. Even in the case of integrating with the adhesive 17, the bead pattern appears because fine irregularities 9d and 9e are formed on the surface 3a of the thermoplastic resin skin material 3 by the pressure G as described above. There is nothing.
[0085]
As described above, in the sixth and seventh embodiments, the two molds 15 and 16 can be clamped and opened in the vertical direction. However, the present invention is not limited to this. And mold opening may be possible.
[0086]
Furthermore, although the case where the fine unevenness | corrugation 9 was formed in the surface 15a of said one metal mold | die 15 was demonstrated, it is not limited to this, Like said 2nd thru | or 5th Embodiment, said one metal mold | die In addition to the fine irregularities 9, product design pattern irregularities 12 are formed in advance on the surface 15 a of 15, or the product design pattern irregularities 12 are formed in advance on the surface 3 a of the thermoplastic resin skin material 3. You may keep it. Further, the above-described uneven transfer member 13 may be used, or the fine unevenness 9 may be formed by the uneven transfer particle 14.
[0087]
【Example】
EXAMPLES Next, although an Example demonstrates this invention still in detail, this invention is not limited to the Example which concerns.
[0088]
[Example 1]
One of the two molds constituting the mold was a female mold, and the other mold was a male mold. A porous sintered metal was used for the one mold in order to secure air vents, and fine irregularities were formed in advance on the surface by chemical etching. The roughness of this fine unevenness is measured by using a stylus type surface roughness measuring instrument (manufactured by Tokyo Seimitsu Co., Ltd., trade name: Surfcom 570A, stylus tip 5 μmR) with an amplitude of 20 to 30 μm, The wavelength was 150 to 250 μm. The other mold has a steam hole for supplying water vapor into the mold, and is further provided with a feeder for filling foam beads.
[0089]
As the thermoplastic resin skin material, a polyolefin-based thermoplastic resin sheet (TPO sheet) molded in advance so as to conform to the surface shape of the one mold was used, and this was placed in the one mold. The surface roughness of this thermoplastic resin skin material was 10 to 30 μm in amplitude and 100 to 300 μm in wavelength in the surface roughness waveform measured using the stylus type surface roughness measuring instrument. That is, the difference between the roughness of the fine irregularities and the surface roughness of the thermoplastic resin skin material was an amplitude of 20 μm and a wavelength of 150 μm in the surface roughness waveform.
[0090]
Eperan PP (manufactured by Kaneka Chemical Co., Ltd., product name, expansion ratio of 15 times, with an internal pressure of 2 kg / c by air pressure in a pressure vessel beforehand)m ² After the mold was clamped, the foamed beads were filled into the mold through the feeder.
[0091]
Next, water vapor (vapor pressure 1.5 kg / cm from the vapor hole formed in the other mold²-G) was supplied into the mold and pre-heated to foam the foamed beads, and then the drain and water vapor were sucked and removed using a vacuum pump.
[0092]
Thereafter, water vapor again (vapor pressure 3.2 to 3.7 kg / cm from the vapor hole)²-G) was supplied into the mold and heated, followed by water cooling, and then mold opening to obtain a synthetic resin in-mold foam molded body with a skin.
[0093]
[Example 2]
After the unevenness for the product design pattern was previously formed on the surface of the one mold by chemical etching, fine unevenness was further formed in the same manner as in Example 1. A synthetic resin in-mold foam-molded article with a skin was obtained in the same manner as in Example 1 except that this mold was used.
[0094]
Example 3
During the main heating, water vapor (vapor pressure: 3.2 to 3.7 kg / cm) from the vapor hole of the other mold.²A synthetic resin in-mold foam-molded body with a skin was obtained in the same manner as in Example 1 except that G) was supplied into the mold and steam heating was performed from the one mold side.
[0095]
Example 4
As in Example 1, except that a # 600 (# 600) sandpaper having fine irregularities formed on the surface is used as the irregularity transfer member, and this is pasted on the surface of the one mold in advance. As a result, a synthetic resin-in-mold foam-molded body with a skin was obtained. The roughness of the fine irregularities of the sandpaper was 10 to 30 μm in amplitude and 100 to 300 μm in amplitude in the surface roughness waveform measured using the same stylus type surface roughness measuring instrument as in Example 1. That is, the difference between the roughness of the fine irregularities and the surface roughness of the thermoplastic resin skin material was an amplitude of 20 μm and a wavelength of 200 μm in the surface roughness waveform. Further, a plurality of fine air holes of about 0.2 mm or less were provided in advance in the sandpaper.
[0096]
Example 5
As an expanded bead, the same Eperan PP as in Example 1 (manufactured by Kaneka Chemical Co., Ltd., trade name, expansion ratio 15 times, air pressure 2 kg / c in advance in the pressure vessel by air pressure)m ² Was used, and this was foamed in-mold to form a synthetic resin in-mold foam molded body having a predetermined shape in advance. Further, the same polyolefin-based thermoplastic resin sheet (TPO sheet) as in Example 1 was used as the thermoplastic resin skin material, and an adhesive was applied in advance to this one surface.
[0097]
Of the two molds, one mold in which fine irregularities having the same roughness as in Example 1 were formed on the surface in advance by chemical etching was an upper mold, and the other mold was a lower mold. The thermoplastic resin skin material is arranged such that the synthetic resin mold foam molded body is disposed on the other mold, and further the surface coated with the adhesive is in contact with the synthetic resin mold foam molded body. Was placed in a softened state by heating.
[0098]
Next, the one mold is clamped while being heated and 2 kg / cm.²A synthetic resin in-mold foam-molded body with a skin was obtained by pressurizing with a pressure of.
[0099]
Example 6
The same polyolefin-based thermoplastic resin sheet (TPO sheet) as in Example 1 was placed on the lower side of the hot press, and 2 kg / cm for 50 seconds while applying 150 ° C. heat.²The surface of the thermoplastic resin skin material was formed to be substantially smooth by pressurizing with the above pressure. In addition, the surface roughness of this thermoplastic resin skin material is an amplitude of 0.1 to 0.5 μm and a wavelength of 10 to 10 in the surface roughness waveform measured using the same stylus type surface roughness measuring instrument as in Example 1. It was 30 μm.
[0100]
A mold having a substantially smooth surface was used as the one mold. The surface roughness of the mold had an amplitude of 0.1 to 0.3 μm and a wavelength of 2 to 10 μm in the surface roughness waveform. That is, the difference between the surface roughness of this one mold and the surface roughness of the thermoplastic resin skin material was an amplitude of 0.4 μm and a wavelength of 28 μm in the surface roughness waveform.
[0101]
A synthetic resin-in-mold foam-molded body with a skin was obtained in the same manner as in Example 1 except that the surface of the thermoplastic resin having a substantially smooth surface and one mold having a substantially smooth surface were used.
[0102]
[Comparative Example 1]
A synthetic resin-in-mold foam-molded body with a skin was obtained in the same manner as in Example 1 except that one mold having the substantially same surface as in Example 6 was used.
[0103]
[Comparative Example 2]
A synthetic resin-in-mold foam-molded body with a skin was obtained in the same manner as in Example 1 except that a thermoplastic resin skin material having the same smooth surface as in Example 6 was used.
[0104]
[Comparative Example 3]
A synthetic resin-in-mold foam-molded body with a skin was obtained in the same manner as in Example 5 except that one mold having the same surface as in Example 6 was used.
[0105]
[Comparative Example 4]
A synthetic resin-in-mold foam-molded body with a skin was obtained in the same manner as in Example 5 except that a thermoplastic resin skin material having the same smooth surface as in Example 6 was used.
[0106]
As described above, the surface properties of the foamed synthetic resin-molded articles with skin obtained in Examples 1 to 6 and Comparative Examples 1 to 4 were observed and evaluated based on the following evaluation criteria. . The results are shown in Table 1.
[0107]
〔Evaluation criteria〕
○: No bead pattern appeared on the surface of the thermoplastic resin skin material.
X: A bead pattern appeared on the surface of the thermoplastic resin skin material.
[0108]
[Table 1]

[0112]
【The invention's effect】
  As aboveClaim1'sAccording to the invention, fine irregularities having the same degree of roughness as the surface roughness of the thermoplastic resin skin material are formed in advance on the surface of the one mold, and the foamed beads are fused and foamed. The surface roughness of this thermoplastic resin skin material is maintained substantially uniform by fusing and integrating the beads and the thermoplastic resin skin material and transferring the fine irregularities onto the surface of the thermoplastic resin skin material. BecauseYesIn so-called simultaneous integral molding, it is possible to produce a synthetic resin-in-mold foam-molded article with a skin having a beautiful appearance without a bead pattern as in the prior art. In addition, even when the original surface roughness of the thermoplastic resin skin material is very rough or very fine, a bead pattern does not appear in the same manner, so that there is an advantage that various thermoplastic resin skin materials can be used.
[0113]
  Claim2According to the invention, on the surface of the mold that comes into contact with the thermoplastic resin skin material, fine irregularities having the same roughness as the surface roughness of the thermoplastic resin skin material are formed in advance, The surface roughness of the thermoplastic resin skin material is substantially equalized by transferring the fine irregularities to the surface of the thermoplastic resin skin material together with the integration of the synthetic resin mold and the thermoplastic resin skin material. So holdYesIn the so-called post-bonding molding, it is possible to produce a synthetic resin-in-mold foam-molded article with a skin having a beautiful appearance without the appearance of a conventional bead pattern. In addition, even when the original surface roughness of the thermoplastic resin skin material is very rough or very fine, a bead pattern does not appear in the same manner, so that there is an advantage that various thermoplastic resin skin materials can be used.
[0115]
  Claim3According to the invention, in addition to the fine unevenness, the product design pattern unevenness is previously formed on the surface of the one mold, and the fine unevenness is transferred to the surface of the thermoplastic resin skin material. At the same time, since the unevenness for the product design pattern is also transferred, in the so-called simultaneous integral molding or post-paste molding, a bead pattern does not appear and the synthetic resin in-mold foam-molded article with a skin having the unevenness for the product design pattern is also obtained. Therefore, a high-class feeling etc. can be imparted to the synthetic resin-in-mold foam-molded body with a skin.
[0116]
  Claim4According to the invention, before placing the thermoplastic resin skin material, because the surface of the thermoplastic resin skin material is formed in advance on the surface of the product design pattern, so-called simultaneous integral molding or post-paste molding, The resulting synthetic resin-in-mold foam-molded body with the skin has the advantage that the bead pattern does not appear and the appearance is beautiful, and the product design pattern irregularities can give a high-class feeling. Moreover, since it is not necessary to form unevenness for the product design pattern on the surface of the one mold, the cost can be reduced.
[Brief description of the drawings]
FIG. 1 is a side sectional view of a synthetic resin-in-mold foam-molded body with a skin according to an embodiment.
FIG. 2 is an explanatory side cross-sectional view showing a state in which a thermoplastic resin skin material is placed on the surface of one mold and clamped in the method of manufacturing a synthetic resin-in-mold foam-molded body with a skin according to the first embodiment. .
FIG. 3 is an enlarged side sectional view of a main part showing an arrangement state of the thermoplastic resin skin material of FIG. 2;
FIG. 4 is an explanatory side sectional view showing a state in which foam beads are filled into a mold.
FIG. 5 is an explanatory side sectional view showing a state in which water vapor is supplied into a mold after filling with expanded beads.
FIG. 6 is an explanatory side sectional view showing how the inside of the mold is evacuated.
FIG. 7 is an explanatory side sectional view showing a state in which water vapor is supplied into the mold and foamed beads are foamed in the mold.
FIG. 8 is a side cross-sectional view of a synthetic resin-in-mold foam-molded body with a skin having an ear portion removed from the mold.
FIG. 9 is an enlarged cross-sectional side view of a main part showing a state where foamed beads are foamed in the mold.
FIG. 10 is an enlarged side cross-sectional view of a main part in the vicinity of the surface of the obtained synthetic resin-in-mold foam-molded body with a skin.
FIG. 11 is an enlarged cross-sectional side view of a main part showing a state in which foamed beads are foamed in the mold in the method for producing an in-mold synthetic resin foam in the mold according to the second embodiment.
FIG. 12 is an enlarged side cross-sectional view of the main part in the vicinity of the surface of the obtained synthetic resin-in-mold foam-molded body with a skin.
FIG. 13 is an enlarged cross-sectional side view of a main part showing a state in which foamed beads are foamed in the mold in the method for producing an in-mold foam molded article with a skin according to the third embodiment.
FIG. 14 is an enlarged cross-sectional side view of a main part showing a state in which foamed beads are foamed in the mold in the method for producing an in-mold foam molded article with a skin according to the fourth embodiment.
FIG. 15 is an enlarged cross-sectional side view of a main part showing a state in which foamed beads are foamed in the mold in the method for producing a synthetic resin foam-molded article with a skin according to the fifth embodiment.
16 is an enlarged cross-sectional side view of a main part showing a state in which the surface of the product design pattern irregularities of FIG. 15 is substantially smooth;
FIG. 17 shows a method for producing a synthetic resin-in-mold foam-molded article with a skin according to the sixth embodiment, in which a synthetic resin-molded foam-molded article and a thermoplastic resin skin material are placed between two molds and clamped. The sectional side view which shows a mode to do.
FIG. 18 is an enlarged cross-sectional side view of a main part showing a state after mold clamping.
FIG. 19 shows that one mold is an upper mold and the other mold is a lower mold, and a thermoplastic resin skin material is placed between the two molds on the synthetic resin-molded foam-molded body. The sectional side view which shows a mode that it arrange | positions to and clamps.
FIG. 20 is an enlarged cross-sectional side view of a main part showing a state after mold clamping.
FIG. 21 is an enlarged cross-sectional side view of a main part showing a state in which a synthetic resin-in-mold foamed body and a thermoplastic resin skin material are fused and integrated by heat when pressure is applied in the state shown in FIG. 18;
FIG. 22 is a side sectional view of the obtained synthetic resin-in-mold foam-molded body with a skin.
23 is an enlarged side sectional view of an essential part in the vicinity of the surface of the synthetic resin-in-mold foam-molded body with a skin shown in FIG.
FIG. 24 shows a synthetic resin mold-in-mold foam-molded article with a skin according to the seventh embodiment, in which a synthetic resin mold-in-mold foam and a thermoplastic resin skin material are fused and integrated using heat and an adhesive together. The principal part expanded side sectional view which shows a mode to make it do.
FIG. 25 is an enlarged side cross-sectional view of a main part in the vicinity of the surface of the obtained synthetic resin-in-mold foam-molded body with a skin.
[Explanation of symbols]
1,21,31,41 Synthetic resin in-mold foam molding with skin
2 Synthetic resin in-mold foam molding
3 Thermoplastic resin skin material
3a Surface
4 Mold
5,15 One mold
5a, 15a Surface
6,16 The other mold
6c Vapor hole
7 Inside mold
8 Foam beads
S water vapor
9 Fine irregularities
12 Product design pattern irregularities

Claims (4)

After placing the thermoplastic resin skin material on one of the two molds that make up the mold and clamping the mold, the mold is filled with foam beads, and these foam beads are expanded by steam heating. In the method for producing a synthetic resin-in-mold foam-molded article with a skin, in which the foamed beads and the thermoplastic resin skin material are fused and integrated together,
On the surface of the one mold, fine irregularities having the same degree of roughness as the surface roughness of the thermoplastic resin skin material are formed in advance, and fusion between the foam beads and the foam beads and the thermoplastic Along with the fusion integration of the resin skin material, the surface roughness of the thermoplastic resin skin material is maintained substantially uniform by transferring the fine irregularities onto the surface of the thermoplastic resin skin material. The manufacturing method of the synthetic resin type in-mold foam-molded body with a skin. When a synthetic resin in-mold foam molded article and a thermoplastic resin skin material are placed between two molds and clamped and pressed, these synthetic resin in-mold foam molded article and thermoplastic resin are heated and / or adhesived. In the method of manufacturing a synthetic resin-in-mold foam-molded body with a skin that integrates the skin material,
On the surface of one mold that comes into contact with the thermoplastic resin skin material, fine irregularities having the same roughness as the surface roughness of the thermoplastic resin skin material are formed in advance, and the synthetic resin in-mold foam molding is performed. Along with the integration of the body and the thermoplastic resin skin material, the surface roughness of the thermoplastic resin skin material is maintained substantially uniform by transferring the fine irregularities onto the surface of the thermoplastic resin skin material. A method for producing a synthetic resin-in-mold foam-molded article with a skin, which is characterized. In addition to the fine unevenness, a product design pattern unevenness is formed in advance on the surface of the one mold, and when transferring the fine unevenness to the surface of the thermoplastic resin skin material, the product design The method for producing a synthetic resin-in-mold foam-molded article with a skin according to claim 1 or 2, wherein the pattern irregularities are also transferred . 3. A synthetic resin mold with a skin according to claim 1 or 2 , wherein irregularities for a product design pattern are formed in advance on the surface of the thermoplastic resin skin material before the thermoplastic resin skin material is arranged . A method for producing a foam molded article.

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