JP3810336B2

JP3810336B2 - Method for producing foamed resin molded product

Info

Publication number: JP3810336B2
Application number: JP2002129338A
Authority: JP
Inventors: 博海谷川; 一雄田島; 貴司岡; 将博太根
Original assignee: Sekisui Kasei Co Ltd
Current assignee: Sekisui Kasei Co Ltd
Priority date: 2002-04-30
Filing date: 2002-04-30
Publication date: 2006-08-16
Anticipated expiration: 2022-04-30
Also published as: JP2003320544A

Description

【０００１】
【発明の属する技術分野】
本発明は、表面に合成樹脂層が積層一体化されてなる発泡樹脂成形品の製造方法に関する。
【０００２】
【従来の技術】
従来から、発泡性スチレン系樹脂粒子を雌雄型間に形成されたキャビティ内に充填し、上記発泡性スチレン系樹脂粒子を加熱、発泡させて所望形状を有する発泡樹脂成形品を製造することが行われている。
【０００３】
そして、上記発泡樹脂成形品の表面に合成樹脂層を積層一体化して表面性を向上させることも行われている。このような表面に合成樹脂層を積層一体化してなる発泡樹脂成形品の製造方法としては、特公平６−１０４３３８号公報に、予め雌型の凹部又は雄型の凸部形状に合致した形状に成形されたブランクを用意し、このブランクを雌雄型に装着し、次に、この雌雄型を型締めして得られたキャビティ内に発泡性合成樹脂粒子を充填し、この発泡性合成樹脂粒子を加熱、発泡させて、表面に合成樹脂層を積層一体化してなる合成樹脂発泡成形品を製造する製造方法が開示されている。
【０００４】
しかしながら、上記発泡樹脂成形品の製造方法では、ブランクを別途用意した成形金型を用いて、雌型の凹部形状又は雄型の凸部形状に合致した形状に予め成形していることから、発泡樹脂成形品の形状が変更された場合には、発泡樹脂成形品の雌雄型を作製しなければならないのは勿論のこと、ブランクを成形する成形金型も別途、作製しなければならず、製造コストがかかるといった問題点があった。
【０００５】
又、上記ブランクは、予め雌型の凹部形状又は雄型の凸部形状に合致した形状に予め成形されていることから、ブランクを雌雄型に装着するにあたって、雌雄型の凹部又は凸部表面に形成された凹凸形状に合致させた状態に調整する必要がある。
【０００６】
ところが、ブランクは合成樹脂シートから形成されていることから、ブランクを雌雄型の凹部又は凸部表面に形成された凹凸形状に合致させた状態に雌雄成形金型に装着するには非常に手間がかかり、発泡樹脂成形品の製造効率が低下するといった問題点があった。
【０００７】
【発明が解決しようとする課題】
本発明は、発泡樹脂成形品の表面を被覆する合成樹脂層を発泡樹脂成形品の形状に沿った形状に成形するための成形金型を別途、必要とせず、しかも、発泡樹脂成形品の形状が変更された場合にあっても、発泡樹脂成形品を成形するための雌雄型の設計を変更するだけで対応することができる製造効率に優れた発泡樹脂成形品の製造方法を提供する。
【０００８】
【課題を解決する手段】
請求項１に記載の発泡樹脂成形品の製造方法は、雄型の凸部に、予め雄型の凸部形状に合致した形状に成形されていない合成樹脂製袋体を被せ、この袋体を上記雄型の凸部表面に向かって真空吸引しつつ成形した後、雌雄型を型締めして形成されたキャビティ内に発泡性合成樹脂粒子を充填し、この発泡性合成樹脂粒子を加熱発泡させて、上記袋体を構成する合成樹脂からなる合成樹脂層が内面に積層一体化されてなる発泡樹脂成形品を製造することを特徴とする。
【０００９】
又、請求項２に記載の発泡樹脂成形品の製造方法は、請求項１に記載の発泡樹脂成形品の製造方法において、袋体の開口部を雄型の凸部基端部表面に係止固定させることを特徴とする。
【００１０】
そして、請求項３に記載の発泡樹脂成形品の製造方法は、雄型の凸部に、予め雄型の凸部形状に合致した形状に成形されていない合成樹脂製第一袋体を被せ、この第一袋体を上記雄型の凸部表面に向かって真空吸引しつつ成形した後、雌雄型を型締めして形成されたキャビティ内に発泡性合成樹脂粒子を充填し、この発泡性合成樹脂粒子を加熱発泡させて得られた発泡樹脂成形品の内面に、上記第一袋体を構成する合成樹脂からなる合成樹脂層を積層一体化させ、続いて、雄型の凸部に発泡樹脂成形品を付着させた状態で雌雄型を型開きし、予め発泡樹脂成形品の外面形状に合致した形状に成形されていない合成樹脂製第二袋体を上記発泡樹脂成形品に被せるか又は上記雌型の凹部内に挿入した上で雌雄型を型締めした後、上記第二袋体を構成する合成樹脂からなる合成樹脂層を上記発泡樹脂成形品の外面に積層一体化して、合成樹脂層が内外面に積層一体化されてなる発泡樹脂成形品を製造することを特徴とする。
【００１１】
更に、請求項４に記載の発泡樹脂成形品の製造方法は、雌型の凹部内に、予め雌型の凹部形状に合致した形状に成形されていない合成樹脂製第一袋体を挿入し、この第一袋体を上記雌型の凹部表面に向かって真空吸引しつつ成形した後、雌雄型を型締めして形成されたキャビティ内に発泡性合成樹脂粒子を充填し、この発泡性合成樹脂粒子を加熱発泡させて得られた発泡樹脂成形品の外面に、上記第一袋体を構成する合成樹脂からなる合成樹脂層を積層一体化させ、続いて、雌型の凹部内に発泡樹脂成形品を付着させた状態で雌雄型を型開きし、予め雄型の凸部形状に合致した形状に成形されていない合成樹脂製第二袋体を上記発泡樹脂成形品内に挿入するか或いは上記雄型の凸部に被せた上で雌雄型を型締めした後、上記第二袋体を構成する合成樹脂からなる合成樹脂層を上記発泡樹脂成形品の内面に積層一体化して、合成樹脂層が内外面に積層一体化されてなる発泡樹脂成形品を製造することを特徴とする。
【００１２】
【発明の実施の形態】
本発明の発泡樹脂成形品の製造方法の一例を図面を参照しつつ説明する。発泡樹脂成形品６の製造に用いられる雌雄型１、２における雌型１は、図１に示したように、発泡樹脂成形品の形状に合致した形状を有する凹部11が凹設されており、この凹部11には、雌型１のチャンバー12と凹部11表面とを連結、連通する貫通孔11a が多数、貫設されている。
【００１３】
そして、上記チャンバー12には、該チャンバー12内に連通させた状態に蒸気供給管13が連結されていると共にこの蒸気供給管13から供給された蒸気から発生する水分をチャンバー12外に排出するための水分排出管14をチャンバー12内に連通させ、更に、上記チャンバー12内を真空吸引して雌雄型１、２間に形成されるキャビティ３内を真空吸引するための真空吸引管15がチャンバー12内に連結、連通されている。
【００１４】
更に、上記チャンバー12内には、チャンバー12内に冷却水を供給するための冷却水供給管16が配設されており、この冷却水供給管16から冷却水をチャンバー12内に散水するように構成されている。
【００１５】
又、雄型２は、図１に示したように、発泡樹脂成形品の形状に合致した形状を有する凸部21が突設されており、この凸部21には、雄型２のチャンバー22と凸部21表面とを連結、連通する貫通孔21a が多数、貫設されている。
【００１６】
そして、上記チャンバー22には、該チャンバー22内に連通させた状態に蒸気供給管23が連結されていると共にこの蒸気供給管23から供給された蒸気から発生する水分をチャンバー22外に排出するための水分排出管24をチャンバー22内に連通させ、更に、上記チャンバー22内を真空吸引して雌雄型１、２間に形成されるキャビティ３内を真空吸引するための真空吸引管25がチャンバー22内に連結、連通されている。
【００１７】
更に、上記チャンバー22内には、チャンバー22内に冷却水を供給するための冷却水供給管26が配設されており、この冷却水供給管26から冷却水をチャンバー22内に散水するように構成されている。
【００１８】
上記雌雄型１、２を用いて発泡樹脂成形品を製造するには、先ず、図１に示したように、雌雄型１、２を型開きして、雄型２の凸部21を露出させた状態とし、この雄型２の凸部21に合成樹脂製第一袋体４を被せる。なお、上記第一袋体４を上記雄型２の凸部21に被せる前に、予め雄型２の蒸気供給管23を通じてチャンバー22内に蒸気を供給して雄型２の凸部21を加熱しておくことが好ましい。
【００１９】
上記第一袋体４は、雄型２の凸部21形状に合致した形状に成形されておらず、後に続く工程によって、雄型２の凸部21形状に沿って完全に合致した形状に成形されて発泡樹脂成形品の内面に積層一体化させることができればよく、具体的には、図２に示したように、雄型２の凸部21における雌雄型１、２の型開き方向に直交する方向の断面を全て包囲し得る大きさの平面矩形状の底面部41と、この底面部41の四方外周縁から突設され且つ上記雄型２の凸部21の高さに合致し或いは僅かに高い一定高さを有する周壁部42とから有底筒状に形成されてなる。なお、上記第一袋体４の底面部41は、雄型２の凸部21形状に合致した形状に成形されておらず、後に続く工程によって、雄型２の凸部21形状に沿って完全に合致した形状に成形されて発泡樹脂成形品の内面に積層一体化させることができればよく、平面円形状等の他の形状であってもよい。
【００２０】
なお、上記第一袋体４を構成する合成樹脂としては、例えば、ポリスチレン、ハイインパクトポリスチレン、スチレン−無水マレイン酸共重合体、スチレン−アクリロニトリル共重合体、スチレン−アクリロニトリル−ブタジエン共重合体等のポリスチレン系樹脂；ポリエチレン、ポリプロピレン、エチレン−酢酸ビニル共重合体等のポリオレフィン系樹脂；ポリエチレンテレフタレート等のポリエステル系樹脂、ナイロン等のポリアミド系樹脂等が挙げられ、必要に応じて、帯電防止剤等の添加剤が添加されていてもよい。
【００２１】
そして、上記第一袋体４を上記雄型２の凸部21に被せた状態では、上記第一袋体４の内面と上記雄型２の凸部21表面との間に部分的に又は全面的に隙間Ａが生じた状態となっている。なお、上記第一袋体４の開口端部を全面的に又は部分的に上記雄型２の凸部21基端表面に形成された係止部に係脱自在に係止、固定させてある。
【００２２】
又、上記第一袋体４としては、雄型２の凸部21における雌雄型１、２の型開き方向に直交する方向の断面を全て包囲し得る大きさのうちの最小の大きさを有する平面矩形状の底面部41と、この底面部41の四方外周縁から突設され且つ上記雄型２の凸部21を全面的に被覆可能な一定高さを有する周壁部42とからなるものが好ましい。
【００２３】
そして、上記雄型２の真空吸引管25を通じて雄型２のチャンバー22内を真空吸引して、上記雄型２の凸部21に被せた第一袋体４を凸部21表面に吸着させて上記雄型２の凸部21上に上記第一袋体４が確実に被せられた状態を確実に保持する。なお、上記雄型２のチャンバー22内に連結、連通された蒸気供給管23、水分排出管24及び冷却水供給管26は閉止されている。
【００２４】
しかる後、上記雌雄型１、２をクラッキングを残した状態に型締めした上で上記雄型１のチャンバー22内の真空吸引を停止して真空吸引管25を閉止した後、蒸気供給管23から蒸気を供給して上記第一袋体４を予備加熱すると共に、蒸気が冷却されて発生した水分を水分排出管24を通じてチャンバー22外に排出する。
【００２５】
次に、上記蒸気供給管23及び上記水分排出管24を閉止した上で、雄型２の真空吸引管25を開放してチャンバー21内を真空吸引し、雄型２の凸部21の貫通孔21aを通じて上記第一袋体４を雄型２の凸部21表面に向かって真空吸引すると共に、上記雌型１の蒸気供給管13を通じてチャンバー11内に蒸気を供給しこの蒸気によって雌型１の凹部11の貫通孔11a を通じて上記第一袋体４を加熱して、上記第一袋体４を上記雄型２の凸部21形状に沿って略合致した状態に真空成形する（図３参照）。この第一袋体４の真空成形では、上記雄型２の凸部21形状に沿って完全に合致した状態に成形する必要はなく、真空成形された第一袋体４とこれに対向する雄型２の凸部21表面との間に隙間が残っていてもよく、所謂、予備成形であってよい。つまり、製造しようとする発泡樹脂成形品の内面が複雑な形状である場合には、上記第一袋体４を上記雄型２の凸部21形状に沿って完全に合致した状態に真空成形することが困難な場合があるからであり、後に続く工程で、上記第一袋体４を上記雄型２の凸部21形状に沿って完全に合致した形状に真空成形できればよい。
【００２６】
続いて、上記雌型１に一体的に設けられた樹脂粒子供給管17を通じて、上記雌雄型１、２間に形成されたキャビティ３内に発泡性合成樹脂粒子５を充填する。なお、上記発泡性合成樹脂粒子５は、合成樹脂に物理型発泡剤を含浸させてなり、加熱によって発泡するものであり、予備発泡させたものも含まれる。なお、本願発明では、予備発泡させた、所謂、予備発泡粒子を主に使用する。
【００２７】
上記発泡性合成樹脂粒子５を構成する合成樹脂としては、例えば、ポリスチレン、ハイインパクトポリスチレン、スチレン−エチレン共重合体、スチレン改質ポリエチレン系樹脂、スチレン−無水マレイン酸共重合体、スチレン−アクリロニトリル共重合体等のポリスチレン系樹脂、ポリエチレン、ポリプロピレン、エチレン−酢酸ビニル共重合体等のポリオレフィン系樹脂、ポリエチレンテレフタレート等のポリエステル系樹脂等が挙げられる。
【００２８】
又、上記物理型発泡剤としては、例えば、プロパン、ブタン、ペンタン、ヘキサン等の脂肪族炭化水素類；シクロペンタン、シクロブタン等の脂肪族環化水素類；トリクロロフルオロメタン、ジクロロジフルオロメタン、ジクロロテトラフルオロメタン、トリクロロトリフルオロエタン、メチルクロライド、メチレンクロライド、エチルクロライド等のハロゲン化炭化水素類等が挙げられる。
【００２９】
そして、図４に示したように、上記雌雄型１、２を完全に型締めして、上記雌雄型１、２間のキャビティ３内に充填した発泡性合成樹脂粒子５の充填圧力によって、上記第一袋体４を雄型２の凸部21表面にさらに正確に沿った状態とした後に、上記雌雄型１、２の蒸気供給管13、23及び水分排出管14、24を開放して、上記雌雄型１、２のチャンバー12、22内に蒸気を供給して雌雄型１、２を加熱し、雌雄型１、２間に形成されたキャビティ３内に充填した発泡性合成樹脂粒子５を加熱、発泡させ、発泡性合成樹脂粒子５、５同士を融着一体化させて発泡樹脂成形品６を成形すると共に、上記雄型２の凸部21表面に沿って成形させた第一袋体４を加熱し、上記発泡性合成樹脂粒子５の発泡圧によって第一袋体４を上記雄型２の凸部21表面に沿って完全に合致した状態に成形し、発泡樹脂成形品６の内面に、上記第一袋体４を構成していた合成樹脂からなる合成樹脂層61を積層一体化する（図５参照）。なお、上記雌雄型１、２の蒸気供給管13、23及び水分排出管14、24以外の管は閉止しておく。
【００３０】
次に、上記雌雄型１、２の蒸気供給管13、23を閉止する一方、上記雌雄型１、２の冷却水供給管16、26を開放し、冷却水を上記雌雄型１、２のチャンバー12、22内に供給し、上記雌雄型１、２を冷却して上記発泡樹脂成形品６を冷却した後、上記雌雄型１、２の冷却水供給管16、26及び水分排出管14、24を閉止すると共に上記雌雄型１、２の真空吸引管15、25を開放して上記雌雄型１、２のチャンバー12、22内を真空吸引して上記キャビティ３内の発泡樹脂成形品６をさらに冷却する。
【００３１】
しかる後、上記雌雄型１、２のキャビティ３内を大気圧に戻した後、上記発泡樹脂成形品６が上記雄型２の凸部21表面に付着した状態に上記雌雄型１、２を型開きする。
【００３２】
続いて、図６に示したように、上記雄型２の凸部21表面に付着した状態の発泡樹脂成形品６に、合成樹脂製第二袋体７を被せる。この第二袋体７は、発泡樹脂成形品６の外面形状に合致した形状に成形されておらず、具体的には、発泡樹脂成形品６における雌雄型１、２の型開き方向に直交する方向の断面外周縁を全て包囲し得る大きさの平面矩形状の底面部71と、この底面部71の四方外周縁から突設され且つ上記雄型２の凸部21の高さに合致し或いは僅かに高い一定高さを有する周壁部72とからなる。なお、第二袋体７の底面部71は、発泡樹脂成形品６における雌雄型１、２の型開き方向に直交する方向の断面外周縁を全て包囲し得る大きさを有しておればよく、平面円形状等の他の形状であってもよい。又、上記第二袋体７を上記雄型２の凸部21に被せることなく、上記第二袋体７を上記雌型１の凹部11内に挿入してもよい。
【００３３】
上記第二袋体７を構成する合成樹脂の厚みは、厚いと、上記雌雄型１、２の型締めの際に上記第二袋体７に皺が生じてしまい、発泡樹脂成形品６の外観性が低下することがあるので、３００μｍ以下が好ましい。
【００３４】
そして、上記第二袋体７を上記発泡樹脂成形品６に被せた状態では、上記第二袋体７の内面と上記発泡樹脂成形品６外面との間に部分的に又は全面的に隙間Ｂが生じた状態となっている。なお、上記第二袋体７の開口端部を全面的に又は部分的に上記雄型２の基端部に係脱自在に係止、固定させてある。
【００３５】
又、上記第二袋体７としては、発泡樹脂成形品６における雌雄型１、２の型開き方向に直交する方向の断面外周縁を全て包囲し得る大きさのうちの最小の大きさを有する平面矩形状の底面部71と、この底面部71の四方外周縁から突設され且つ上記発泡樹脂成形品６の外面を全面的に被覆可能な一定高さを有する周壁部72とからなるものが好ましい。
【００３６】
次に、上記雌雄型１、２をクラッキングを残した状態に型締めした後、上記雌型１の真空吸引管15を開放してチャンバー12内を真空吸引し、上記発泡樹脂成形品６に被せた上記第二袋体７を上記雌型１の凹部11表面側に向かって真空吸引して、上記発泡樹脂成形品６と上記第二袋体７との対向面間に隙間を形成した状態を維持し、上記発泡樹脂成形品６と上記第二袋体７との対向面間に存在する空気を上記第二袋体７の開口部とこれに対向する発泡樹脂成形品６の外面との間から逃がしつつ上記雌雄型１、２を完全に型締めする（図７参照）。
【００３７】
しかる後、上記雌雄型１、２の蒸気供給管13、23及び水分排出管14、24を開放した状態とすると共にその他の管を閉止した状態にして、上記雌雄型１、２のチャンバー12、22内に蒸気を供給し、上記第二袋体７及び上記発泡樹脂成形品６を加熱して、上記第二袋体７を上記発泡樹脂成形品６の外面形状に完全に合致させた状態に成形し、上記第二袋体７を構成していた合成樹脂からなる合成樹脂層62を発泡樹脂成形品６の外面に積層一体化させる。そして、上記雌雄型１、２を型開きすることにより、内外面の双方に合成樹脂層61、62が積層一体化してなる発泡樹脂成形品６を得る（図８参照）。
【００３８】
なお、上記では、内外面の双方に合成樹脂層61、62を積層一体化してなる発泡樹脂成形品６を製造する要領を説明したが、内面にのみ合成樹脂層61を積層一体化してなる発泡樹脂成形品６を製造する場合には、上記雌雄型１、２を型開きした後に第二袋体７を被せることなく、発泡樹脂成形品６の製造を終了すればよい。
【００３９】
又、外面にのみ合成樹脂層62を積層一体化してなる発泡樹脂成形品６を製造する場合には、上記雄型２の凸部21に第一袋体４を被せることなく発泡樹脂成形品６を製造し、この発泡樹脂成形品６に第二袋体７を被せるか或いは第二袋体７を雌型１の凹部11内に挿入して、上記と同様の要領で、外面にのみ合成樹脂層62を積層一体化してなる発泡樹脂成形品６を製造すればよい。
【００４０】
次に、上記では、先ず、雄型２の凸部21に第一袋体４を被せた場合を説明したが、雌型１の凹部11内に第一袋体4'を挿入した場合であってもよく、この場合の要領について以下に説明する。
【００４１】
図９に示したように、上記雌雄型１、２を型開きして、雌型１の凹部11を露出させた状態とし、この雌型１の凹部11内に合成樹脂製第一袋体4'を挿入する。なお、上記雌型１の蒸気供給管13を通じてチャンバー12内に蒸気を供給して雌型１の凹部11を予め加熱しておくことが好ましい。
【００４２】
上記第一袋体4'は、雌型１の凹部11形状に合致した形状に成形されておらず、後に続く工程によって、雌型１の凹部11形状に沿って完全に合致した形状に成形されて発泡樹脂成形品の外面に積層一体化させることができればよく、具体的には、雌型１の凹部11の底面部11b 形状に近い大きさの平面矩形状の底面部41' と、この底面部41' の四方外周縁から突設され且つ上記雌型１の凹部11深さに略合致し或いは僅かに高い一定高さを有する周壁部42' とから有底筒状に形成されてなる。なお、上記第一袋体4'の底面部41' は、雌型１の凹部11形状に合致した形状に成形されておらず、後に続く工程によって、雌型１の凹部11形状に沿って完全に合致した形状に成形されて発泡樹脂成形品の外面に積層一体化させることができればよく、平面円形状等の他の形状であってもよい。
【００４３】
又、上記第一袋体4'の底面部41' の形状が上記雌型１の凹部11の底面部11b 形状よりも小さい場合には、上記雌雄型１、２を型締めする前において、上記第一袋体4'を雌型１の凹部11表面に向かって真空吸引するが、この第一袋体4'の真空吸引が可能な大きさに形成しておく必要がある。
【００４４】
そして、上記第一袋体4'を雌型１の凹部11内に挿入した状態では、雌型１の凹部11表面とこれに対向する上記第一袋体4'の外面との間に部分的に又は全面的に隙間A'が生じた状態となっている。なお、上記第一袋体4'の開口端部を全面的に又は部分的に上記雌型１の凹部11の開口端部表面に係止、固定させておく。
【００４５】
しかる後、上記雌型１の真空吸引管15を通じて雌型１のチャンバー12内を真空吸引して、上記雌型１の凹部11内に挿入した第一袋体4'を凹部 11表面に吸着させて上記雌型１の凹部11内に上記第一袋体4'が確実に挿入された状態を保持する。なお、上記雌型１のチャンバー12内に連結、連通された蒸気供給管13、水分排出管14及び冷却水供給管16は閉止されている。
【００４６】
しかる後、上記雌雄型１、２をクラッキングを残した状態に型締めした上で上記雌型１のチャンバー12内の真空吸引を停止して真空吸引管15を閉止した後、蒸気供給管13から蒸気を供給して上記第一袋体4'を予備加熱すると共に、蒸気が冷却されて発生した水分を水分排出管14を通じてチャンバー12外に排出する。
【００４７】
次に、上記蒸気供給管13及び上記水分排出管14を閉止した上で、雌型１の真空吸引管15を開放してチャンバー11内を真空吸引し、雌型１の凹部11の貫通孔11a
を通じて上記第一袋体4'を雌型１の凹部11表面に向かって真空吸引すると共に、上記雄型２の蒸気供給管23を通じてチャンバー21内に蒸気を供給しこの蒸気によって雄型１の凸部21の貫通孔21a を通じて上記第一袋体4'を加熱して、上記第一袋体4'を上記雌型１の凹部11形状に沿って略合致した状態に真空成形する（図１０参照）。この第一袋体4'の真空成形では、上記雌型１の凹部11形状に沿って完全に合致した状態に成形する必要はなく、真空成形された第一袋体4'とこれに対向する雌型１の凹部11表面との間に隙間が残っていてもよく、所謂、予備成形であってよい。つまり、製造しようとする発泡樹脂成形品の外面が複雑な形状である場合には、上記第一袋体4'を上記雌型１の凹部11形状に沿って完全に合致した状態に真空成形することが困難な場合があるからであり、後に続く工程で、上記第一袋体4'を上記雌型１の凹部11形状に沿って完全に合致した形状に真空成形できればよい。
【００４８】
続いて、上記雄型２に一体的に設けられた樹脂粒子供給管（図示せず）を通じて、上記雌雄型１、２間に形成されたキャビティ３内に発泡性合成樹脂粒子５を充填する。
【００４９】
そして、上記雌雄型１、２を完全に型締めし、上記雌雄型１、２間のキャビティ３内に充填した発泡性合成樹脂粒子５の充填圧力によって、上記第一袋体4'を雌型１の凹部11表面にさらに正確に沿った状態とした後に、上記と同様の要領で、雌雄型１、２間に形成されたキャビティ３内に充填した発泡性合成樹脂粒子５を加熱、発泡させて、発泡性合成樹脂粒子５、５同士を融着一体化させて発泡樹脂成形品６を成形すると共に、上記雌型１の凹部11表面に沿って成形させた第一袋体4'を加熱し、上記発泡性合成樹脂粒子５の発泡圧によって第一袋体4'を上記雌型１の凹部11表面に沿って完全に合致した状態に成形し、発泡樹脂成形品６の外面に、上記第一袋体4'を構成していた合成樹脂からなる合成樹脂層62を積層一体化する（図１１参照）。なお、上記雌雄型１、２の蒸気供給管13、23及び水分排出管14、24以外の管は閉止しておく。
【００５０】
次に、上記と同様の要領で、上記雌雄型１、２を冷却して発泡樹脂成形品６を冷却した後に、上記キャビティ３内の発泡樹脂成形品６を真空吸引によってさらに冷却し、しかる後、上記雌雄型１、２のキャビティ３内を大気圧に戻した後、上記発泡樹脂成形品６が上記雌型１の凹部11表面に付着した状態に上記雌雄型１、２を型開きする。
【００５１】
続いて、図１２に示したように、上記雄型２の凸部21に第二袋体7'を被せる。この第二袋体7'は、雄型２の凸部21形状に合致した形状に成形されておらず、具体的には、雄型２の凸部21における雌雄型１、２の型開き方向に直交する方向の断面を全て包囲し得る大きさの平面矩形状の底面部71' と、この底面部71' の四方外周縁から突設され且つ上記雄型２の凸部21の高さに合致し或いは僅かに高い一定高さを有する周壁部72' とから有底筒状に形成されてなる。なお、上記第二袋体7'の底面部71' は、雄型２の凸部21における雌雄型１、２の型開き方向に直交する方向の断面を全て包囲し得る大きさに形成されておればよく、平面円形状等の他の形状であってもよい。又、上記第二袋体7'は、雌型１の凹部11表面に付着した状態の発泡樹脂成形品６内に挿入されてもよい。
【００５２】
そして、上記第二袋体7'を雄型２の凸部21に被せた状態では、上記第二袋体7'の外面と上記雄型２の凸部21表面との間に部分的に又は全面的に隙間B'が生じた状態となっている。なお、上記第二袋体7'の上端開口部を全面的に又は部分的に上記雄型２の凸部21基端表面に形成された係止部に係脱自在に係止、固定させてある。
【００５３】
次に、上記雌雄型１、２をクラッキングを残した状態に型締めした後、上記雄型２の真空吸引管25を開放してチャンバー22内を真空吸引し、上記第二袋体7'を上記雄型２の凸部21表面側に向かって真空吸引して、上記発泡樹脂成形品６と上記第二袋体7'との対向面間に隙間を形成した状態を維持し、上記発泡樹脂成形品６と上記第二袋体7'との対向面間に存在する空気を上記第二袋体7'の開口部とこれに対向する発泡樹脂成形品６の内面との間から逃がしつつ上記雌雄型１、２を完全に型締めする。
【００５４】
しかる後、上記と同様の要領で、上記第二袋体7'及び上記発泡樹脂成形品６を加熱し、上記第二袋体7'を上記発泡樹脂成形品６の内面形状に完全に合致させた状態に成形し、上記第二袋体7'を構成していた合成樹脂からなる合成樹脂層61を発泡樹脂成形品６の内面に積層一体化させる。そして、上記雌雄型１、２を型開きすることにより、内外面の双方に合成樹脂層61、62が積層一体化してなる発泡樹脂成形品６を得る（図１３参照）。
【００５５】
なお、上記では、内外面の双方に合成樹脂層61、62を積層一体化してなる発泡樹脂成形品６を製造する要領を説明したが、外面にのみ合成樹脂層62を積層一体化してなる発泡樹脂成形品６を製造する場合には、上記雌雄型１、２を型開きした後に第二袋体7'を用いることなく、発泡樹脂成形品６の製造を終了すればよい。
【００５６】
又、内面にのみ合成樹脂層61を積層一体化してなる発泡樹脂成形品６を製造する場合には、上記雌型１の凹部11内に第一袋体4'を挿入することなく発泡樹脂成形品６を製造した後、雄型２の凸部21に第二袋体7'を被せるか或いは第二袋体7'を発泡樹脂成形品６内に挿入して、上記と同様の要領で、内面にのみ合成樹脂層61を積層一体化してなる発泡樹脂成形品６を製造すればよい。
【００５７】
なお、上記実施例では、第一袋体４（4'）及び第二袋体７（7'）を有底筒状に形成したものを用いたが、第一袋体４（4'）及び第二袋体７（7'）として、折曲線を形成して折畳可能に形成したガゼット袋体や、同形、同大の一対の正面矩形状の合成樹脂シート同士を重ね合わせると共にこれら合成樹脂シートの上端を除いた三方外周縁同士を熱融着してなる袋体等であってもよい。
【００５８】
又、発泡性合成樹脂粒子を構成する合成樹脂と、第一袋体４（4'）及び第二袋体７（7'）を構成する合成樹脂とは、発泡性合成樹脂粒子を加熱、発泡させて得られる発泡樹脂成形品６と、第一袋体４（4'）及び第二袋体７（7'）を構成する合成樹脂からなる合成樹脂層61、62との熱融着性を向上させる観点から、互いに相溶性を有する合成樹脂を用いることが好ましい。
【００５９】
具体的には、発泡性合成樹脂粒子を構成する合成樹脂としてポリスチレン系樹脂を用いた場合には、第一袋体４（4'）及び第二袋体７（7'）を構成する合成樹脂としては、ポリスチレン系樹脂が好ましく、伸び性、成形性に優れたハイインパクトポリスチレンがより好ましい。
【００６０】
加えて、発泡性合成樹脂粒子を構成する合成樹脂としてスチレン改質ポリエチレン系樹脂を用いた場合には、第一袋体４（4'）及び第二袋体７（7'）を構成する合成樹脂としては、ポリオレフィン系樹脂が好ましい。
【００６１】
最後に、両面（内外面）に合成樹脂層61、62を積層一体化してなる発泡樹脂成形品６を製造する場合、上記要領の他に、先ず、第一袋体４（4'）及び第二袋体７（7'）を用いることなく発泡樹脂成形品６を製造し、この発泡樹脂成形品６を雌雄型１、２間に形成されたキャビティ３内に配設すると共に、この発泡樹脂成形品６と雄型２の凸部21との間に、予め雄型２の凸部21形状に合致した形状に成形されていない合成樹脂製袋体を介装した上で雌雄型１、２を加熱することによって、上記袋体を構成する合成樹脂からなる合成樹脂層が内面に積層一体化されてなる発泡樹脂成形品を製造し、次に、合成樹脂層が内面に積層一体化されてなる発泡樹脂成形品６を再度、雌雄型１、２間に形成されたキャビティ３内に配設すると共に、この発泡樹脂成形品６と雌型１の凹部11との間に、予め雌型１の凹部11形状に合致した形状に成形されていない合成樹脂製袋体を介装した上で雌雄型１、２を加熱することによって、上記袋体を構成する合成樹脂からなる合成樹脂層を外面に積層一体化して、内外面に合成樹脂層61、62が積層一体化されてなる発泡樹脂成形品６を製造してもよい。
【００６２】
【発明の効果】
本発明の発泡樹脂成形品の製造方法は、上述のように構成されており、予め雄型の凸部形状に合致した形状又は雌型の凹部形状に合致した形状に成形されていない合成樹脂製袋体を用いていることから、袋体を雄型の凸部形状又は雌型の凹部形状に合致した形状に成形するための成形金型を必要としない。
【００６３】
そして、発泡樹脂成形品の形状が変更された場合にあっても、袋体を雄型の凸部に被せ或いは雌型の凹部内に挿入することができ、その後の成形工程において、雄型の凸部形状又は雌型の凹部形状に沿った形状に成形することができる限りは、袋体の形状に変更を加えることなく継続して用いることができ、よって、一種類の袋体を、特定の発泡樹脂成形品の形状に特定されることなく、一定の類似範囲内の発泡樹脂成形品の製造に汎用的に用いることができる。
【００６４】
更に、袋体は、予め雄型の凸部形状又は雌型の凹部形状に合致した形状に成形させていないことから、袋体を雄型の凸部に被せ或いは雌型の凹部内に挿入するにあたって、雌雄型の凹凸形状に合わせた状態に調整しつつ袋体を雌雄型の凹凸部に装着する必要はなく、袋体を単に雄型の凸部に被せ或いは雌型の凹部内に挿入するといった簡単な作業で足り、発泡樹脂成形品の製造効率を向上させることができる。
【００６５】
又、袋体の開口部を雄型の凸部基端部表面に係止固定させ或いは雌型の凹部開口部表面に係止固定させている場合には、袋体を雄型の凸部に被せた状態又は雌型の凹部内に挿入した状態を確実に維持することができ、袋体を雄型の凸部形状又は雌型の凹部形状に沿った状態に確実に成形し、袋体を構成する合成樹脂からなる合成樹脂層を発泡樹脂成形品の表面に確実に且つ美麗に積層一体化させることができる。
【００６６】
しかも、上記のように袋体の開口部を雌雄型の凹凸部の何れかに係止、固定させているので、袋体を係止、固定させている雌雄型とこれに対向する袋体表面との間に発泡性合成樹脂粒子が入ってしまうといった不測の事態は発生せず、美麗な発泡樹脂成形品を製造することができる。
【００６７】
そして、内外面の何れか一方が合成樹脂層で被覆された状態の発泡樹脂成形品における合成樹脂層が被覆されていない表面に、発泡樹脂成形品の外面形状又は雄型の凸部形状に合致した形状に成形されていない袋体を被せ若しくは挿入し、又は、雄型の凸部に被せ若しくは雌型の凹部内に挿入することによって、内外面が合成樹脂層で被覆された美麗な発泡樹脂成形品を簡単に且つ確実に製造することができる。
【図面の簡単な説明】
【図１】第一袋体を雄型の凸部に被せた状態を示した模式縦断面図である。
【図２】第一袋体又は第二袋体を示した模式斜視図である。
【図３】第一袋体を雄型の凸部形状に沿って略合致した状態に真空成形した状態を示した模式縦断面図である。
【図４】雌雄型間に形成されたキャビティ内に発泡性合成樹脂粒子を充填した状態を示した模式縦断面図である。
【図５】雌雄型間に形成されたキャビティ内で発泡性合成樹脂粒子を加熱、発泡させた状態を示した模式縦断面図である。
【図６】発泡樹脂成形品に第二袋体を被せた状態を示した模式縦断面図である。
【図７】内外面に合成樹脂層を積層一体化した発泡樹脂成形品を製造した状態を示した模式縦断面図である。
【図８】内外面に合成樹脂層を積層一体化した発泡樹脂成形品を示した模式縦断面図である。
【図９】雌型の凹部内に第一袋体を挿入した状態を示した模式縦断面図である。
【図１０】第一袋体を雌型の凹部形状に沿って略合致した状態に真空成形した状態を示した模式縦断面図である。
【図１１】雌雄型間に形成されたキャビティ内で発泡性合成樹脂粒子を加熱、発泡させた状態を示した模式縦断面図である。
【図１２】第二袋体を雄型の凸部に被せた状態を示した模式縦断面図である。
【図１３】内外面に合成樹脂層を積層一体化した発泡樹脂成形品を製造した状態を示した模式縦断面図である。
【符号の説明】
１雌型
11 凹部
２雄型
21 凸部
３キャビティ
４、4' 第一袋体
５発泡性合成樹脂粒子
６発泡樹脂成形品
61、62 合成樹脂層
７、7' 第二袋体[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a method for producing a foamed resin molded article in which a synthetic resin layer is laminated and integrated on the surface.
[0002]
[Prior art]
  Conventionally, foamed styrene resin particles are filled into a cavity formed between a male and female mold, and the foamed styrene resin particles are heated and foamed to produce a foamed resin molded product having a desired shape. It has been broken.
[0003]
  And the synthetic resin layer is laminated and integrated on the surface of the foamed resin molded product to improve the surface property. As a method for producing a foamed resin molded product in which a synthetic resin layer is laminated and integrated on such a surface, Japanese Patent Publication No. 6-104338 discloses a shape that matches a shape of a female concave portion or a male convex portion in advance. Prepare a molded blank, attach the blank to a male and female mold, and then fill the cavity obtained by clamping the male and female mold with foamable synthetic resin particles. A manufacturing method for manufacturing a synthetic resin foam molded article obtained by heating and foaming and laminating and integrating a synthetic resin layer on the surface is disclosed.
[0004]
  However, in the method for producing a foamed resin molded product, foaming is performed in advance using a molding die separately prepared for a blank, or a shape that matches the concave shape of the female mold or the convex shape of the male mold. When the shape of the resin molded product is changed, the male and female molds of the foamed resin molded product must be produced, as well as the mold for molding the blank must be produced separately. There was a problem that it was expensive.
[0005]
  In addition, since the blank is preliminarily molded into a shape that matches the female concave shape or the male convex shape, when the blank is mounted on the male and female molds, It is necessary to adjust the state to match the formed uneven shape.
[0006]
  However, since the blank is formed from a synthetic resin sheet, it is very troublesome to attach the blank to the male and female molds in a state where the blank is matched with the concave and convex shape formed on the surface of the male and female molds. Therefore, there is a problem that the production efficiency of the foamed resin molded product is lowered.
[0007]
[Problems to be solved by the invention]
  The present invention does not require a separate molding die for molding the synthetic resin layer covering the surface of the foamed resin molded product into a shape that conforms to the shape of the foamed resin molded product, and the shape of the foamed resin molded product The present invention provides a method for producing a foamed resin molded article excellent in production efficiency, which can be coped with only by changing the design of the male and female molds for molding the foamed resin molded article even when the foamed resin molded article is changed.
[0008]
[Means for solving the problems]
  Claim 1In the method for producing a foamed resin molded article according to the above, a male resin convex portion is covered with a synthetic resin bag body that has not been previously molded into a shape that matches the male convex portion shape, and this bag body is covered with the male mold. After forming while vacuum-sucking toward the convex surface of the mold, the foamable synthetic resin particles are filled into the cavity formed by clamping the male and female molds, and the foamable synthetic resin particles are heated and foamed. A foamed resin molded product is produced in which a synthetic resin layer made of a synthetic resin constituting a bag body is laminated and integrated on an inner surface.
[0009]
  or,Claim 2The manufacturing method of the foamed resin molded article described inClaim 1In the method for producing a foamed resin molded article according to the item 1, the opening of the bag body is locked and fixed to the surface of the male convex base end.
[0010]
  AndClaim 3The method for producing a foamed resin molded article described in the above is a method in which a male resin convex portion is covered with a synthetic resin first bag body that has not been previously molded into a shape that matches the male convex portion shape. Is molded while vacuum-sucking toward the surface of the convex part of the male mold, and then the foamable synthetic resin particles are filled into a cavity formed by clamping the male and female molds, and the foamable synthetic resin particles are heated and foamed. The synthetic resin layer made of the synthetic resin constituting the first bag body is laminated and integrated on the inner surface of the obtained foamed resin molded product, and then the foamed resin molded product is adhered to the male convex portion. The male and female molds are opened in a state of being covered, and the foamed resin molded product is covered with a synthetic resin second bag body that has not been previously molded into a shape that matches the outer surface shape of the foamed resin molded product, or in the recess of the female mold. After the male and female molds are clamped after being inserted into the The made synthetic resin layer integrally laminated on an outer surface of the resin foam product, a synthetic resin layer is characterized by producing a layered integrated formed by the resin foam product in the inner and outer surfaces.
[0011]
  More,Claim 4In the method for producing a foamed resin molded article described in the above, the first bag body made of a synthetic resin that has not been molded into a shape that matches the shape of the recess of the female mold in advance is inserted into the recess of the female mold. Is molded while vacuum-sucking toward the concave surface of the female mold, and then the foamable synthetic resin particles are filled into a cavity formed by clamping the male and female molds, and the foamable synthetic resin particles are heated and foamed. A synthetic resin layer made of the synthetic resin constituting the first bag body was laminated and integrated on the outer surface of the foamed resin molded product obtained in this manner, and then the foamed resin molded product was adhered in the female recess. Open the male and female molds in a state, and insert a synthetic resin second bag body that has not been previously molded into a shape that matches the shape of the male convex section into the foamed resin molded product, or the male convex section. After the male and female molds are clamped on the cover, from the synthetic resin constituting the second bag body That the synthetic resin layer is integrally laminated to the inner surface of the resin foam product, a synthetic resin layer is characterized by producing a layered integrated formed by the resin foam product in the inner and outer surfaces.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
  An example of the method for producing a foamed resin molded product of the present invention will be described with reference to the drawings. As shown in FIG. 1, the female mold 1 in the male and female molds 1 and 2 used for manufacturing the foamed resin molded product 6 is provided with a recess 11 having a shape that matches the shape of the foamed resin molded product. The recess 11 is provided with a large number of through-holes 11a that connect and communicate with the chamber 12 of the female mold 1 and the surface of the recess 11.
[0013]
  In addition, a steam supply pipe 13 is connected to the chamber 12 so as to communicate with the inside of the chamber 12, and moisture generated from the steam supplied from the steam supply pipe 13 is discharged outside the chamber 12. A vacuum suction tube 15 for communicating the inside of the cavity 12 formed between the male and female molds 1 and 2 by vacuum suction in the chamber 12 is connected to the chamber 12. It is connected and communicated inside.
[0014]
  Further, a cooling water supply pipe 16 for supplying cooling water into the chamber 12 is disposed in the chamber 12, and the cooling water is sprayed into the chamber 12 from the cooling water supply pipe 16. It is configured.
[0015]
  Further, as shown in FIG. 1, the male mold 2 is provided with a protruding portion 21 having a shape that matches the shape of the foamed resin molded product, and the protruding portion 21 has a chamber 22 of the male mold 2. A large number of through-holes 21a that connect and communicate with the surface of the convex portion 21 are provided.
[0016]
  A steam supply pipe 23 is connected to the chamber 22 so as to communicate with the chamber 22, and moisture generated from the steam supplied from the steam supply pipe 23 is discharged outside the chamber 22. A vacuum suction tube 25 is provided for communicating the inside of the chamber 22 with a vacuum and sucking the inside of the cavity 3 formed between the male and female molds 1 and 2 by vacuum suction. It is connected and communicated inside.
[0017]
  Further, a cooling water supply pipe 26 for supplying cooling water into the chamber 22 is disposed in the chamber 22, and the cooling water is sprayed into the chamber 22 from the cooling water supply pipe 26. It is configured.
[0018]
  In order to produce a foamed resin molded product using the male and female molds 1 and 2, first, as shown in FIG. 1, the male and female molds 1 and 2 are opened to expose the convex portion 21 of the male mold 2. In this state, the first bag 4 made of synthetic resin is placed on the convex portion 21 of the male mold 2. In addition, before covering the first bag body 4 on the convex portion 21 of the male mold 2, steam is supplied into the chamber 22 through the steam supply pipe 23 of the male mold 2 in advance, and the convex portion of the male mold 2.twenty oneIs preferably heated.
[0019]
  The first bag body 4 is not formed into a shape that matches the shape of the convex portion 21 of the male mold 2, and is formed into a shape that perfectly matches the shape of the convex portion 21 of the male mold 2 by a subsequent process. It is only necessary to be able to be laminated and integrated with the inner surface of the foamed resin molded product. Specifically, as shown in FIG. 2, orthogonal to the mold opening direction of the male and female molds 1 and 2 at the convex portion 21 of the male mold 2. A flat rectangular bottom 41 having a size capable of enclosing the entire cross-section in the direction to be projected, and projecting from the outer periphery of the bottom of the bottom 41 and corresponding to the height of the convex 21 of the male mold 2 or slightly It is formed in a bottomed cylindrical shape from a peripheral wall portion 42 having a high constant height. The bottom surface portion 41 of the first bag body 4 is not formed into a shape that matches the shape of the convex portion 21 of the male mold 2 and is completely formed along the shape of the convex portion 21 of the male mold 2 in the subsequent process. As long as it can be molded and integrated with the inner surface of the foamed resin molded product, and may have other shapes such as a flat circular shape.
[0020]
  Examples of the synthetic resin constituting the first bag body 4 include polystyrene, high impact polystyrene, styrene-maleic anhydride copolymer, styrene-acrylonitrile copolymer, styrene-acrylonitrile-butadiene copolymer, and the like. Polystyrene resins; Polyethylene resins such as polyethylene, polypropylene, and ethylene-vinyl acetate copolymers; Polyester resins such as polyethylene terephthalate; Polyamide resins such as nylon, etc. An additive may be added.
[0021]
  In the state where the first bag 4 is put on the convex portion 21 of the male mold 2, the first bag body 4 is partially or entirely between the inner surface of the first bag body 4 and the surface of the convex portion 21 of the male mold 2. Thus, a gap A is generated. Note that the opening end of the first bag body 4 is detachably locked and fixed to the locking portion formed on the base end surface of the convex portion 21 of the male mold 2 in whole or in part. .
[0022]
  Further, the first bag body 4 has the smallest size among the sizes capable of enclosing all cross sections in the direction perpendicular to the mold opening direction of the male and female molds 1 and 2 in the convex portion 21 of the male mold 2. A flat rectangular bottom 41 and a peripheral wall 42 protruding from the outer periphery of the bottom of the bottom 41 and having a certain height that can cover the convex portion 21 of the male mold 2 entirely. preferable.
[0023]
  Then, the inside of the chamber 22 of the male mold 2 is vacuum-sucked through the vacuum suction tube 25 of the male mold 2, and the first bag body 4 covered with the convex portion 21 of the male mold 2 is adsorbed on the surface of the convex portion 21. The state in which the first bag body 4 is reliably covered on the convex portion 21 of the male mold 2 is securely held. Note that the steam supply pipe 23, the moisture discharge pipe 24 and the cooling water supply pipe 26 connected and communicated with the chamber 22 of the male mold 2 are closed.
[0024]
  Thereafter, the male and female molds 1 and 2 are clamped in a state where cracking is left, the vacuum suction in the chamber 22 of the male mold 1 is stopped and the vacuum suction pipe 25 is closed. Steam is supplied to preheat the first bag body 4, and moisture generated by cooling the steam is discharged out of the chamber 22 through the moisture discharge pipe 24.
[0025]
  Next, after closing the steam supply pipe 23 and the water discharge pipe 24, the vacuum suction pipe 25 of the male mold 2 is opened and the inside of the chamber 21 is vacuum-sucked, and the through hole of the convex part 21 of the male mold 2 is opened. The first bag 4 is vacuum-sucked toward the surface of the convex portion 21 of the male mold 2 through 21a, and steam is supplied into the chamber 11 through the steam supply pipe 13 of the female mold 1, and this steam causes the female mold 1 to The first bag body 4 is heated through the through-hole 11a of the concave portion 11, and the first bag body 4 is vacuum-formed into a state of being substantially aligned with the shape of the convex portion 21 of the male mold 2 (see FIG. 3). . In the vacuum forming of the first bag body 4, it is not necessary to form the first bag body 4 so as to be perfectly matched with the shape of the convex portion 21 of the male mold 2. A gap may remain between the surface of the mold 21 and the so-called preforming. That is, when the inner surface of the foamed resin molded product to be manufactured has a complicated shape, the first bag body 4 is vacuum-molded into a state of being completely matched with the shape of the convex portion 21 of the male mold 2. This is because it may be difficult, and it is only necessary that the first bag body 4 can be vacuum-formed into a shape that perfectly matches the shape of the convex portion 21 of the male mold 2 in the subsequent process.
[0026]
  Subsequently, the foamable synthetic resin particles 5 are filled into the cavity 3 formed between the male and female dies 1 and 2 through the resin particle supply pipe 17 provided integrally with the female die 1. The expandable synthetic resin particles 5 are made by impregnating a synthetic resin with a physical foaming agent and foamed by heating, and include pre-expanded ones. In the present invention, pre-foamed so-called pre-foamed particles are mainly used.
[0027]
  Examples of the synthetic resin constituting the expandable synthetic resin particles 5 include polystyrene, high impact polystyrene, styrene-ethylene copolymer, styrene-modified polyethylene resin, styrene-maleic anhydride copolymer, and styrene-acrylonitrile copolymer. Examples thereof include polystyrene resins such as polymers, polyolefin resins such as polyethylene, polypropylene, and ethylene-vinyl acetate copolymers, and polyester resins such as polyethylene terephthalate.
[0028]
  Examples of the physical blowing agent include aliphatic hydrocarbons such as propane, butane, pentane and hexane; aliphatic cyclized hydrogens such as cyclopentane and cyclobutane; trichlorofluoromethane, dichlorodifluoromethane, dichlorotetra And halogenated hydrocarbons such as fluoromethane, trichlorotrifluoroethane, methyl chloride, methylene chloride, and ethyl chloride.
[0029]
  Then, as shown in FIG. 4, the male and female molds 1 and 2 are completely clamped, and the filling pressure of the expandable synthetic resin particles 5 filled in the cavity 3 between the male and female molds 1 and 2 After making the first bag body 4 more precisely along the surface of the convex portion 21 of the male mold 2, the steam supply pipes 13, 23 and the moisture discharge pipes 14, 24 of the male and female molds 1, 2 are opened, The foamable synthetic resin particles 5 filled in the cavity 3 formed between the male and female molds 1 and 2 are heated by supplying steam into the chambers 12 and 22 of the male and female molds 1 and 2. The first bag formed by heating and foaming to form the foamed resin molded product 6 by fusing the foamable synthetic resin particles 5 and 5 together and forming along the surface of the convex portion 21 of the male mold 2. 4 is heated, and the first bag 4 is completely formed along the surface of the convex portion 21 of the male mold 2 by the foaming pressure of the expandable synthetic resin particles 5. Formed into matched state, the foam on the inner surface of the resin molded article 6, integrally laminated synthetic resin layer 61 made of a synthetic resin that comprised the first bag member 4 (see FIG. 5). In addition, pipes other than the steam supply pipes 13 and 23 and the moisture discharge pipes 14 and 24 of the male and female dies 1 and 2 are closed.
[0030]
  Next, the steam supply pipes 13 and 23 of the male and female molds 1 and 2 are closed, while the cooling water supply pipes 16 and 26 of the male and female molds 1 and 2 are opened, and the cooling water is supplied to the chambers of the male and female molds 1 and 2. 12 and 22, the male and female molds 1 and 2 are cooled to cool the foamed resin molded product 6, and then the cooling water supply pipes 16 and 26 and the water discharge pipes 14 and 24 of the male and female molds 1 and 2 are cooled. And the vacuum suction pipes 15 and 25 of the male and female molds 1 and 2 are opened, and the chambers 12 and 22 of the male and female molds 1 and 2 are vacuum-sucked to further expand the foamed resin molded product 6 in the cavity 3. Cooling.
[0031]
  Thereafter, the inside of the cavity 3 of the male and female molds 1 and 2 is returned to atmospheric pressure, and then the male and female molds 1 and 2 are molded so that the foamed resin molded product 6 is attached to the surface of the convex portion 21 of the male mold 2. Open.
[0032]
  Subsequently, as shown in FIG. 6, the synthetic resin second bag 7 is placed on the foamed resin molded product 6 attached to the surface of the convex portion 21 of the male mold 2. The second bag body 7 is not molded into a shape that matches the outer surface shape of the foamed resin molded product 6, and specifically, is orthogonal to the mold opening direction of the male and female molds 1 and 2 in the foamed resin molded product 6. A flat rectangular bottom surface 71 having a size capable of enclosing the entire outer peripheral edge of the direction and the height of the convex portion 21 of the male mold 2 projecting from the outer peripheral edge of the bottom surface 71 The peripheral wall portion 72 has a constant height that is slightly higher. The bottom surface portion 71 of the second bag body 7 only needs to have a size that can surround the entire outer peripheral edge in the direction orthogonal to the mold opening direction of the male and female molds 1 and 2 in the foamed resin molded product 6. Other shapes such as a planar circular shape may be used. Further, the second bag body 7 may be inserted into the recess 11 of the female mold 1 without covering the second bag body 7 with the convex portion 21 of the male mold 2.
[0033]
  If the synthetic resin constituting the second bag body 7 is thick, wrinkles are generated in the second bag body 7 when the male and female molds 1 and 2 are clamped, and the appearance of the foamed resin molded product 6 Therefore, 300 μm or less is preferable.
[0034]
  And in the state which covered the said 2nd bag body 7 on the said foamed resin molded product 6, the clearance gap B partially or entirely between the inner surface of the said 2nd bag body 7 and the said foamed resin molded product 6 outer surface. Has occurred. Note that the opening end of the second bag body 7 is engaged or fixed to the base end of the male mold 2 so as to be detachable.
[0035]
  The second bag body 7 has the smallest size among the sizes that can surround all the outer peripheral edges in the direction orthogonal to the mold opening direction of the male and female dies 1 and 2 in the foamed resin molded product 6. A flat rectangular bottom surface 71 and a peripheral wall 72 projecting from the outer periphery of the bottom of the bottom surface 71 and having a certain height capable of covering the entire outer surface of the foamed resin molded product 6. preferable.
[0036]
  Next, the male and female molds 1 and 2 are clamped in a state where cracking is left, the vacuum suction tube 15 of the female mold 1 is opened, the inside of the chamber 12 is vacuumed, and the foamed resin molded product 6 is covered. The second bag body 7 is vacuum-sucked toward the surface of the concave portion 11 of the female mold 1 so that a gap is formed between the facing surfaces of the foamed resin molded product 6 and the second bag body 7. The air existing between the facing surfaces of the foamed resin molded product 6 and the second bag body 7 is maintained between the opening of the second bag body 7 and the outer surface of the foamed resin molded product 6 facing the air. Then, the male and female molds 1 and 2 are completely clamped (see FIG. 7).
[0037]
  Thereafter, the steam supply pipes 13 and 23 and the moisture discharge pipes 14 and 24 of the male and female molds 1 and 2 are opened, and the other pipes are closed, and the chambers 12 of the male and female molds 1 and 2 are closed. Steam is supplied into 22 and the second bag 7 and the foamed resin molded product 6 are heated so that the second bag 7 is completely matched with the outer shape of the foamed resin molded product 6. The synthetic resin layer 62 made of synthetic resin that has been molded and formed the second bag 7 is laminated and integrated on the outer surface of the foamed resin molded product 6. Then, by opening the male and female molds 1 and 2, the foamed resin molded product 6 in which the synthetic resin layers 61 and 62 are laminated and integrated on both the inner and outer surfaces is obtained (see FIG. 8).
[0038]
  In the above description, the point of manufacturing the foamed resin molded product 6 in which the synthetic resin layers 61 and 62 are laminated and integrated on both the inner and outer surfaces has been described. However, the foaming in which the synthetic resin layer 61 is laminated and integrated only on the inner surface. When the resin molded product 6 is manufactured, the foamed resin molded product 6 may be manufactured without covering the second bag 7 after the male and female molds 1 and 2 are opened.
[0039]
  Further, when producing the foamed resin molded product 6 in which the synthetic resin layer 62 is laminated and integrated only on the outer surface, the foamed resin molded product 6 is not covered with the first bag 4 on the convex portion 21 of the male mold 2. The foamed resin molded product 6 is covered with the second bag body 7 or the second bag body 7 is inserted into the recess 11 of the female mold 1, and the synthetic resin is applied only to the outer surface in the same manner as described above. What is necessary is just to manufacture the foamed resin molded product 6 formed by laminating and integrating the layers 62.
[0040]
  Next, in the above description, the case where the first bag body 4 is put on the convex portion 21 of the male mold 2 has been described, but the case where the first bag body 4 ′ is inserted into the concave section 11 of the female mold 1 is described. However, the procedure in this case will be described below.
[0041]
  As shown in FIG. 9, the male and female molds 1 and 2 are opened so that the recess 11 of the female mold 1 is exposed, and the first bag 4 made of synthetic resin is placed in the recess 11 of the female mold 1. Insert '. In addition, it is preferable that steam is supplied into the chamber 12 through the steam supply pipe 13 of the female mold 1 to preheat the recess 11 of the female mold 1.
[0042]
  The first bag body 4 ′ is not formed into a shape that matches the shape of the concave portion 11 of the female mold 1 and is formed into a shape that perfectly matches the shape of the concave portion 11 of the female mold 1 in the subsequent process. Specifically, it is only necessary to be able to be laminated and integrated on the outer surface of the foamed resin molded product. Specifically, the bottom surface portion 41 ′ of a rectangular plane having a size close to the shape of the bottom surface portion 11b of the recess 11 of the female mold 1 and the bottom surface It is formed in the shape of a bottomed cylinder from a peripheral wall portion 42 ′ that protrudes from the outer periphery of the four sides of the portion 41 ′ and substantially matches the depth of the recess 11 of the female mold 1 or has a slightly high constant height. The bottom surface portion 41 ′ of the first bag body 4 ′ is not formed into a shape that matches the shape of the recess 11 of the female mold 1 and is completely formed along the shape of the recess 11 of the female mold 1 in the subsequent process. As long as it can be molded and integrated with the outer surface of the foamed resin molded product, and may have other shapes such as a flat circular shape.
[0043]
  Further, when the shape of the bottom surface portion 41 'of the first bag body 4' is smaller than the shape of the bottom surface portion 11b of the recess 11 of the female die 1, before the male and female dies 1 and 2 are clamped, The first bag body 4 ′ is vacuum-sucked toward the surface of the concave portion 11 of the female mold 1, and the first bag body 4 ′ needs to be formed in a size that allows vacuum suction of the first bag body 4 ′.
[0044]
  And in the state which inserted said 1st bag body 4 'in the recessed part 11 of the female type | mold 1, it is partially between the recessed part 11 surface of the female type | mold 1, and the outer surface of said 1st bag body 4' facing this. In other words, the gap A ′ is generated in the whole or the entire surface. The opening end portion of the first bag body 4 ′ is locked or fixed to the opening end portion surface of the recess 11 of the female mold 1 in whole or in part.
[0045]
  Thereafter, the inside of the chamber 12 of the female mold 1 is vacuum-sucked through the vacuum suction tube 15 of the female mold 1, and the first bag 4 'inserted into the recess 11 of the female mold 1 is removed.Recess 11The first bag body 4 ′ is held in a state where the first bag body 4 ′ is securely inserted into the recess 11 of the female mold 1 by being adsorbed on the surface. Note that the steam supply pipe 13, the water discharge pipe 14, and the cooling water supply pipe 16 connected and communicated with the chamber 12 of the female mold 1 are closed.
[0046]
  Thereafter, the male and female dies 1 and 2 are clamped in a state where cracking is left, the vacuum suction in the chamber 12 of the female die 1 is stopped and the vacuum suction pipe 15 is closed, and then the steam supply pipe 13 is connected. Steam is supplied to preheat the first bag body 4 ′, and moisture generated when the steam is cooled is discharged out of the chamber 12 through the moisture discharge pipe 14.
[0047]
  Next, after closing the steam supply pipe 13 and the water discharge pipe 14, the vacuum suction pipe 15 of the female mold 1 is opened and the inside of the chamber 11 is vacuum-sucked, and the through hole 11a of the recess 11 of the female mold 1 is opened.
The first bag 4 ′ is vacuum-sucked toward the surface of the concave portion 11 of the female mold 1 through the steam, and steam is supplied into the chamber 21 through the steam supply pipe 23 of the male mold 2, and the convex of the male mold 1 is generated by this steam. The first bag body 4 ′ is heated through the through hole 21a of the portion 21, and the first bag body 4 ′ is vacuum-formed into a substantially matched state along the shape of the concave portion 11 of the female mold 1 (see FIG. 10). ). In the vacuum forming of the first bag body 4 ′, it is not necessary to form the first bag body 4 ′ so as to be perfectly matched with the shape of the concave portion 11 of the female mold 1, and the first bag body 4 ′ is opposed to the vacuum formed first bag body 4 ′. A gap may remain between the surface of the recess 11 of the female mold 1, and so-called preforming may be performed. That is, when the outer surface of the foamed resin molded product to be manufactured has a complicated shape, the first bag body 4 ′ is vacuum-molded into a state of being completely matched with the shape of the concave portion 11 of the female mold 1. This is because it may be difficult, and it is only necessary that the first bag body 4 ′ can be vacuum-formed into a shape that perfectly matches the shape of the concave portion 11 of the female mold 1 in the subsequent process.
[0048]
  Subsequently, the foamable synthetic resin particles 5 are filled into the cavity 3 formed between the male and female molds 1 and 2 through a resin particle supply pipe (not shown) provided integrally with the male mold 2.
[0049]
  The male and female molds 1 and 2 are completely clamped, and the first bag body 4 ′ is formed into a female mold by the filling pressure of the expandable synthetic resin particles 5 filled in the cavity 3 between the male and female molds 1 and 2. After the surface of the concave portion 11 is more accurately aligned, the foamable synthetic resin particles 5 filled in the cavity 3 formed between the male and female molds 1 and 2 are heated and foamed in the same manner as described above. Then, the foamable synthetic resin particles 5 and 5 are fused and integrated to form the foamed resin molded product 6, and the first bag 4 ′ formed along the surface of the concave portion 11 of the female mold 1 is heated. Then, the first bag body 4 ′ is molded by the foaming pressure of the foamable synthetic resin particles 5 so as to be completely matched along the surface of the concave portion 11 of the female mold 1. A synthetic resin layer 62 made of synthetic resin constituting the first bag body 4 ′ is laminated and integrated (see FIG. 11). In addition, pipes other than the steam supply pipes 13 and 23 and the moisture discharge pipes 14 and 24 of the male and female dies 1 and 2 are closed.
[0050]
  Next, in the same manner as described above, after the male and female molds 1 and 2 are cooled to cool the foamed resin molded product 6, the foamed resin molded product 6 in the cavity 3 is further cooled by vacuum suction, and thereafter After returning the inside of the cavity 3 of the male and female molds 1 and 2 to atmospheric pressure, the male and female molds 1 and 2 are opened in a state where the foamed resin molded product 6 is attached to the surface of the concave portion 11 of the female mold 1.
[0051]
  Subsequently, as shown in FIG. 12, the second bag 7 ′ is put on the convex portion 21 of the male mold 2. This second bag body 7 'is not formed into a shape that matches the shape of the convex portion 21 of the male mold 2, and specifically, the mold opening direction of the male and female molds 1 and 2 at the convex portion 21 of the male mold 2 A flat rectangular bottom surface 71 ′ having a size capable of enclosing the entire cross-section in a direction perpendicular to the bottom surface 71 ′, and projecting from the outer peripheral edge of the bottom surface 71 ′ at the height of the convex portion 21 of the male mold 2 It is formed in the shape of a bottomed cylinder from the peripheral wall portion 72 'that matches or has a slightly high constant height. The bottom surface portion 71 ′ of the second bag body 7 ′ is formed to have a size that can surround the entire cross section in the direction orthogonal to the mold opening direction of the male and female molds 1 and 2 in the convex portion 21 of the male mold 2. Any other shape such as a planar circular shape may be used. Further, the second bag body 7 ′ may be inserted into the foamed resin molded product 6 attached to the surface of the recess 11 of the female mold 1.
[0052]
  In the state where the second bag body 7 ′ is covered with the convex portion 21 of the male mold 2, it is partially or partially between the outer surface of the second bag body 7 ′ and the surface of the convex section 21 of the male mold 2. A gap B ′ is generated on the entire surface. In addition, the upper end opening of the second bag body 7 'is locked or fixed removably on the locking portion formed on the base end surface of the convex portion 21 of the male mold 2 in whole or in part. is there.
[0053]
  Next, the male and female molds 1 and 2 are clamped in a state where cracking is left, the vacuum suction tube 25 of the male mold 2 is opened, and the inside of the chamber 22 is vacuum-sucked, and the second bag body 7 ′ is Vacuum suction is performed toward the surface of the convex portion 21 of the male mold 2 to maintain a state in which a gap is formed between the opposed surfaces of the foamed resin molded product 6 and the second bag body 7 ', and the foamed resin. The air existing between the facing surfaces of the molded product 6 and the second bag body 7 ′ is released from between the opening of the second bag body 7 ′ and the inner surface of the foamed resin molded product 6 facing the opening portion. The male and female molds 1 and 2 are completely clamped.
[0054]
  Thereafter, in the same manner as described above, the second bag body 7 ′ and the foamed resin molded product 6 are heated, and the second bag body 7 ′ is completely matched with the inner surface shape of the foamed resin molded product 6. The synthetic resin layer 61 made of the synthetic resin constituting the second bag body 7 ′ is laminated and integrated on the inner surface of the foamed resin molded product 6. Then, by opening the male and female molds 1 and 2, the foamed resin molded product 6 in which the synthetic resin layers 61 and 62 are laminated and integrated on both the inner and outer surfaces is obtained (see FIG. 13).
[0055]
  In the above description, the point of manufacturing the foamed resin molded product 6 in which the synthetic resin layers 61 and 62 are laminated and integrated on both the inner and outer surfaces has been described. However, the foaming in which the synthetic resin layer 62 is laminated and integrated only on the outer surface. When the resin molded product 6 is manufactured, the foamed resin molded product 6 may be manufactured without using the second bag body 7 'after opening the male and female molds 1 and 2.
[0056]
  Further, when the foamed resin molded product 6 in which the synthetic resin layer 61 is laminated and integrated only on the inner surface, the foamed resin molded product is inserted without inserting the first bag body 4 ′ into the recess 11 of the female mold 1. After the product 6 is manufactured, the second bag body 7 ′ is put on the convex portion 21 of the male mold 2 or the second bag body 7 ′ is inserted into the foamed resin molded product 6, and in the same manner as described above, What is necessary is just to manufacture the foamed resin molded product 6 in which the synthetic resin layer 61 is laminated and integrated only on the inner surface.
[0057]
  In addition, in the said Example, although what formed the 1st bag body 4 (4 ') and the 2nd bag body 7 (7') in the bottomed cylindrical shape was used, the 1st bag body 4 (4 ') and As the second bag 7 (7 '), a gusset bag formed so as to be foldable by forming a fold curve, and a pair of front and side synthetic resin sheets of the same shape and the same size are overlapped with each other and these synthetic resins A bag or the like formed by heat-sealing the three-side outer peripheral edges excluding the upper end of the sheet may be used.
[0058]
  The synthetic resin constituting the foamable synthetic resin particles and the synthetic resin constituting the first bag body 4 (4 ′) and the second bag body 7 (7 ′) are obtained by heating and foaming the foamable synthetic resin particles. Heat-sealability between the foamed resin molded product 6 obtained by the above process and the synthetic resin layers 61 and 62 made of synthetic resin constituting the first bag body 4 (4 ′) and the second bag body 7 (7 ′). From the viewpoint of improvement, it is preferable to use synthetic resins having compatibility with each other.
[0059]
  Specifically, when a polystyrene resin is used as the synthetic resin constituting the expandable synthetic resin particles, the synthetic resin constituting the first bag body 4 (4 ′) and the second bag body 7 (7 ′). Is preferably a polystyrene-based resin, and more preferably high-impact polystyrene having excellent extensibility and moldability.
[0060]
  In addition, when a styrene-modified polyethylene resin is used as the synthetic resin constituting the expandable synthetic resin particles, the synthesis constituting the first bag body 4 (4 ′) and the second bag body 7 (7 ′). The resin is preferably a polyolefin resin.
[0061]
  Finally, when manufacturing the foamed resin molded product 6 in which the synthetic resin layers 61 and 62 are laminated and integrated on both surfaces (inner and outer surfaces), first, in addition to the above procedure, first, the first bag 4 (4 ′) and the second The foamed resin molded product 6 is manufactured without using the two bags 7 (7 '), and the foamed resin molded product 6 is disposed in the cavity 3 formed between the male and female molds 1 and 2, and the foamed resin Between the molded product 6 and the convex part 21 of the male mold 2, a synthetic resin bag body that has not been molded in advance to match the shape of the convex part 21 of the male mold 2 is interposed, and then the male and female molds 1, 2. To produce a foamed resin molded product in which the synthetic resin layer made of the synthetic resin constituting the bag body is laminated and integrated on the inner surface, and then the synthetic resin layer is laminated and integrated on the inner surface. The foamed resin molded product 6 is again disposed in the cavity 3 formed between the male and female molds 1 and 2, and this foamed resin The male and female molds 1 and 2 are heated between a shaped product 6 and a recess 11 of the female mold 1 with a synthetic resin bag not previously formed in a shape matching the shape of the recess 11 of the female mold 1. Thus, the synthetic resin layer made of the synthetic resin constituting the bag body is laminated and integrated on the outer surface, and the foamed resin molded product 6 in which the synthetic resin layers 61 and 62 are laminated and integrated on the inner and outer surfaces is manufactured. Also good.
[0062]
【The invention's effect】
  The method for producing a foamed resin molded product of the present invention is configured as described above, and is made of a synthetic resin that has not been previously molded into a shape that matches a male convex shape or a shape that matches a female concave shape. Since the bag body is used, there is no need for a molding die for molding the bag body into a shape that matches the male convex shape or the female concave shape.
[0063]
  And even when the shape of the foamed resin molded product is changed, the bag can be covered with the male convex part or inserted into the female concave part, and in the subsequent molding process, As long as it can be formed into a convex shape or a shape that conforms to the female concave shape, it can be used continuously without changing the shape of the bag, and therefore one type of bag can be specified. Without being specified by the shape of the foamed resin molded product, it can be generally used for the production of a foamed resin molded product within a certain similar range.
[0064]
  Further, since the bag body is not formed in advance in a shape that matches the male convex shape or the female concave shape, the bag body is put on the male convex portion or inserted into the female concave portion. At the time, it is not necessary to attach the bag body to the male and female mold concavo-convex portion while adjusting the state to match the male and female concavo-convex shape, and the bag body is simply put on the male convex portion or inserted into the female concave portion. Such a simple operation is sufficient, and the production efficiency of the foamed resin molded product can be improved.
[0065]
  In addition, when the opening of the bag body is locked and fixed to the surface of the base end portion of the male convex portion or locked to the surface of the female concave opening portion, the bag body is fixed to the male convex portion. The covered state or the state inserted into the female concave portion can be reliably maintained, and the bag body is reliably molded into a shape along the male convex shape or female concave shape, The synthetic resin layer made of the synthetic resin to be configured can be laminated and integrated reliably and beautifully on the surface of the foamed resin molded product.
[0066]
  In addition, since the opening of the bag body is locked and fixed to any of the male and female uneven portions as described above, the male and female molds that lock and fix the bag body and the bag body surface facing the male and female molds A beautiful foamed resin molded product can be produced without the occurrence of an unexpected situation in which the foamable synthetic resin particles enter between the two.
[0067]
  Then, the surface of the foamed resin molded product in which either one of the inner and outer surfaces is coated with the synthetic resin layer is not covered with the synthetic resin layer, and matches the outer surface shape of the foamed resin molded product or the male convex shape. A beautiful foamed resin whose inner and outer surfaces are covered with a synthetic resin layer by covering or inserting a bag that is not formed into a shape, or by inserting it into a male convex part or inserting it into a female concave part A molded product can be manufactured easily and reliably.
[Brief description of the drawings]
FIG. 1 is a schematic longitudinal sectional view showing a state in which a first bag is placed on a male convex portion.
FIG. 2 is a schematic perspective view showing a first bag body or a second bag body.
FIG. 3 is a schematic longitudinal sectional view showing a state in which the first bag body is vacuum-formed in a state of being substantially matched with the shape of the male convex portion.
FIG. 4 is a schematic longitudinal sectional view showing a state where a foamable synthetic resin particle is filled in a cavity formed between a male and female mold.
FIG. 5 is a schematic longitudinal sectional view showing a state where foamable synthetic resin particles are heated and foamed in a cavity formed between a male and female mold.
FIG. 6 is a schematic longitudinal sectional view showing a state in which a foamed resin molded product is covered with a second bag body.
FIG. 7 is a schematic longitudinal sectional view showing a state in which a foamed resin molded product in which synthetic resin layers are laminated and integrated on the inner and outer surfaces is manufactured.
FIG. 8 is a schematic longitudinal sectional view showing a foamed resin molded product in which synthetic resin layers are laminated and integrated on the inner and outer surfaces.
FIG. 9 is a schematic longitudinal sectional view showing a state in which the first bag is inserted into the female recess.
FIG. 10 is a schematic longitudinal sectional view showing a state in which the first bag body is vacuum-formed in a state of being substantially matched along the female recess shape.
FIG. 11 is a schematic longitudinal sectional view showing a state where foamable synthetic resin particles are heated and foamed in a cavity formed between a male and female mold.
FIG. 12 is a schematic longitudinal sectional view showing a state in which a second bag body is put on a male convex portion.
FIG. 13 is a schematic longitudinal sectional view showing a state in which a foamed resin molded product in which synthetic resin layers are laminated and integrated on the inner and outer surfaces is manufactured.
[Explanation of symbols]
  1 Female
  11 Recess
  2 Male
  21 Convex
  3 cavity
  4, 4 'first bag
  5 Expandable synthetic resin particles
  6 Foamed resin molded products
  61, 62 Synthetic resin layer
  7, 7 'second bag

Claims

Cover the male convex part with a synthetic resin bag that is not molded in advance to match the shape of the male convex part, and mold this bag while vacuuming it toward the surface of the male convex part. After that, the foamable synthetic resin particles are filled into the cavity formed by clamping the male and female molds, and the foamable synthetic resin particles are heated and foamed to form a synthetic resin layer made of the synthetic resin constituting the bag body. A method for producing a foamed resin molded product, characterized in that a foamed resin molded product is produced by laminating and integrating on the inner surface.

2. The method for producing a foamed resin molded article according to claim 1 , wherein the opening of the bag body is locked and fixed to the surface of the male convex base end.

The male convex part is covered with a synthetic resin first bag body that has not been previously formed into a shape that matches the male convex part shape, and the first bag body is vacuumed toward the male convex surface. After molding while sucking, the foamed synthetic resin particles are filled into the cavity formed by clamping the male and female molds, and the foamed synthetic resin particles are heated and foamed on the inner surface of the foamed resin molded product. The synthetic resin layer made of the synthetic resin constituting the first bag body is laminated and integrated, and then the male and female molds are opened with the foamed resin molded product attached to the male convex parts, and foamed in advance. After covering the foamed resin molded product with a synthetic resin second bag that is not molded into a shape that matches the outer surface shape of the resin molded product, or after inserting the female mold into the recess of the female mold, The synthetic resin layer made of the synthetic resin constituting the second bag body is made of the foamed resin molded product. And integrally laminated to the outer surface, the manufacturing method of the foamed resin molded article of synthetic resin layer is characterized by producing a layered integrated formed by the resin foam product in the inner and outer surfaces.

A synthetic resin first bag body that has not been previously formed into a shape that matches the shape of the female recess is inserted into the recess of the female mold, and the first bag is vacuum-sucked toward the surface of the recess of the female mold. Then, after molding, filling the foam formed synthetic resin particles in the cavity formed by clamping the male and female molds, on the outer surface of the foamed resin molded product obtained by heating and foaming the foamable synthetic resin particles, The synthetic resin layer made of the synthetic resin constituting the first bag body is laminated and integrated, and then the male and female molds are opened with the foamed resin molded product attached in the female mold recesses, After inserting a synthetic resin second bag not molded into a shape that matches the shape of the convex part into the foamed resin molded product or covering the male convex part and then clamping the male and female molds The synthetic resin layer made of the synthetic resin constituting the second bag body is made of the foamed resin molded product. And integrally laminated to the surface, the manufacturing method of the foamed resin molded article of synthetic resin layer is characterized by producing a layered integrated formed by the resin foam product in the inner and outer surfaces.