JP4067283B2 - Manufacturing method of molded product and molded product - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a molded article and a molded article. For example, a sheet-like article such as fabric, felt, plastic foam, leather, cotton, synthetic leather, metal foil, and non-woven fabric, and a thermoplastic net are integrated. The present invention can be applied to a sheet-shaped molded article and a manufacturing method thereof, a molded article in which irregularities are provided on a thermoplastic plastic net, and a manufacturing method thereof.
[0002]
[Prior art]
Sheet-like molded products are used for various articles. For example, it is used as a skin material and a core material for bags such as bags and bags, and as a skin material and a core material for shoes, clothing, cushion materials and building materials. The sheet-like molded product is used as a filter relating to water, rain, snow and air (for example, a water-permeable mat placed on a rooftop or a veranda).
[0003]
Conventionally, as such a sheet-like molded product, a flat plastic plate, its foam, felt, cardboard or the like has been used. In addition, a plastic plate or the like and another sheet-like article are bonded with an adhesive to form a sheet-like molded product.
[0004]
[Problems to be solved by the invention]
However, the conventional sheet-shaped molded article has a problem that it is difficult to impart air permeability and the like due to its structure in addition to a heavy plastic plate. For example, in a sheet-like molded product in which a plastic plate and a nonwoven fabric are bonded, the air permeability and the like of the nonwoven fabric may be impaired.
[0005]
On the other hand, if a sheet-shaped molded product is intended to be made lightweight, the sheet-shaped molded product cannot secure sufficient strength and rigidity, and may not fully function as a core material. Arise.
[0006]
In addition, when trying to use plastic injection molding technology, for example, in the case of a large-area filter such as a water-permeable mat, there is a problem that the manufacturing cost increases due to the increase in size of the mold.
[0007]
The present invention has been made in view of the above-described points, and an object of the present invention is to provide a method for producing a molded product and a molded product that can secure sufficient strength at low cost, are light, and have air permeability.
[0008]
[Means for Solving the Problems]
In order to solve the above problems, a method for producing a molded product according to the first invention includes a fabric, felt, plastic foam, leather, on one or both sides of a thermoplastic mesh that serves as a core or a reinforcing material . Arranging and thermoforming a sheet-like article of any area formed of either synthetic leather or non-woven fabric, softening the surface of the thermoplastic mesh, entangled with the eyes of the sheet-like article, The method includes the step of fusing and integrating the thermoplastic mesh and the sheet-like article.
[0009]
The molded product according to the second aspect of the present invention is a thermoplastic mesh that functions as a core or a reinforcing material , and a cloth, felt, and plastic foam integrated on one or both surfaces of the thermoplastic mesh. , A sheet-like article having an arbitrary area formed of leather, synthetic leather, or non-woven fabric , and integration is performed by thermoforming, and at the time of thermoforming, the surface of the thermoplastic plastic mesh is softened. In addition, the sheet-like article is entangled with each other, and the thermoplastic net and the sheet-like article are fused and integrated .
[0010]
According to the configurations of the first and second inventions described above, even when the thermoplastic mesh and the sheet-like article are said to have poor adhesion compatibility, the resin is entangled in the gap and the like, and the fusion is performed. If the sheet-like article is made of another material, it is fused and integrated more strongly. In addition, the product can be lightened by using a thermoplastic mesh having a small stitch and a small wire diameter. The use of a thermoplastic mesh with a large stitch and a large wire diameter can increase the strength of the product. Furthermore, a molded product having desired strength and rigidity can be formed by appropriately selecting the size and wire diameter of a mesh of a thermoplastic plastic mesh. Furthermore, since it is a molded product in which a thermoplastic net and a sheet-like article are integrated, it is possible to prevent the sheet-like article from losing characteristics such as air permeability. Furthermore, a large-area sheet-like molded product by thermoforming can be molded at low cost.
[0011]
Here, thermoforming is performed between molds having an arbitrary shape, or secondary processing for imparting an arbitrary uneven shape to an integrated article of a thermoplastic plastic net and a sheet-like article after thermoforming. By applying, a sheet-like molded product having an arbitrary shape with irregularities can be formed.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
(A) 1st Embodiment Hereinafter, the manufacturing method of the molded article which concerns on this invention, and 1st Embodiment of a molded article are demonstrated based on an accompanying drawing.
[0016]
The method for manufacturing a molded product according to the first embodiment is applicable as a skin material or a core material for bags such as bags or bags, and as a skin material or a core material for shoes, clothing, cushion materials, building materials, or the like. It is a manufacturing method of a sheet-like molded product. Furthermore, it is a production method that can be applied to the production of filters relating to water, rain, snow, air, such as rooftop water-permeable mats.
[0017]
The method for manufacturing a molded product according to the first embodiment is a method in which a sheet-like article is arranged on one or both surfaces of a thermoplastic plastic net, or thermoformed into a sheet.
[0018]
1 to 4 are schematic perspective views illustrating an example of a molded product manufactured by the method for manufacturing a molded product according to the first embodiment.
[0019]
The molded product shown in FIG. 1 is obtained by using a fabric as the sheet-like article 1 and thermoforming the fabric 1, the thermoplastic net 2 and the fabric 1 into a sheet shape.
[0020]
The molded product shown in FIG. 2 is obtained by using synthetic leather as the sheet-like article 1 and thermoforming the synthetic leather 1 and the net 2 made of thermoplastic plastic into a sheet shape. The molded product shown in FIG. 2 is an example of a molded product having irregularities. This molded product is a molded product before applying a skin material for a female hat having a certain degree of rigidity.
[0021]
The molded product shown in FIG. 3 is a sheet-shaped article 1 that is formed by using a nonwoven fabric and thermoforming the thermoplastic mesh 2, the nonwoven fabric 1, and the thermoplastic mesh 2 into a sheet shape. The molded product shown in FIG. 3 is an example in which a thermoplastic mesh 2 is partially applied, and the portion of the thermoplastic mesh 2 functions as a core material. This molded product can be applied to a filter such as an air purifier.
[0022]
The molded product shown in FIG. 4 is obtained by using felt as the sheet-like article 1 and thermoforming the sheet 2 by overlapping the net 2 made of thermoplastic plastic and the felt 1. The molded product shown in FIG. 4 is an example of a molded product having irregularities. This molded product is used, for example, by being pulled to a place with a poor scaffold at a construction site (for surface treatment of soft ground).
[0023]
As in the above example, as the sheet-like article 1, various materials such as fabric, felt, plastic foam, leather, cotton, synthetic leather, metal foil, and nonwoven fabric can be applied.
[0024]
On the other hand, the net 2 made of thermoplastic plastic is a net or net that is molded using polyethylene, polypropylene, EVA, PET, or nylon as a main raw material. For example, a general-purpose net or a net-like material used for surface treatment of soft ground can be used.
[0025]
Here, a net-like thing includes what is called a three-dimensional nonwoven fabric or a fiber network three-dimensional structure. In addition, the term “net” in the claims includes such a net.
[0026]
What is necessary is just to select the magnitude | size and wire diameter of the mesh of the thermoplastic net | network 2 in consideration of an intensity | strength and rigidity according to the use of the manufactured molded article. Moreover, you may make it manufacture the molded article from which the magnitude | size and wire diameter of the mesh | network 2 made from thermoplastics differ so that the molded article from which the intensity | strength and rigidity variation differ may be prepared. In practice, a thermoplastic mesh 2 having a wire diameter of about 1 cm is also commercially available. For example, the wire diameter may be appropriately selected within a range up to about 1 cm.
[0027]
Next, the manufacturing method of the molded article shown in FIGS.
[0028]
In the primary processing, as shown in FIG. 5 (FIG. 5 shows an example of the molded product of FIG. 3), the laminate of the sheet-like article 1 and the thermoplastic mesh 2 is used in a hot press machine. It is sandwiched between the heated upper and lower flat plates 10 and 11, heated and pressurized. The temperature and pressurization time of the flat boards 10 and 11 are set by the controller 13 in response to an operator input. For example, the temperature of the flat plates 10 and 11 is set to 130 ° C. to 200 ° C., and the pressurization time is set to 10 seconds to 2 minutes. The specific numerical value is set according to the combination of the sheet-like article 1 and the thermoplastic mesh 2, the material of the sheet-like article 1, and the like.
[0029]
5 is a spacer (also referred to as a liner), and the thickness of the spacer 12 is an additive that acts on the laminate of the sheet-like article 1 and the thermoplastic net 2. The pressure can be adjusted.
[0030]
Here, the means for heating and pressurizing the sheet-like article 1 and the thermoplastic mesh 2 is not limited to a flat plate of a hot press machine, and a heat roller may be used. A sheet-like molded product can be similarly thermoformed even when heated and pressed between two heat rollers. In this case, the flat plate of the heat press machine heats and presses on a flat surface, whereas the two heat rollers heat and press in a linear fashion, so generally the heating temperature is high and the pressurizing time is Shorter.
[0031]
By this heating and pressurization, the resin on the surface of the thermoplastic mesh 2 is softened, entangled with the eyes of the sheet-like article 1 and adhered to each other. At the same time, since the thermoplastic mesh 2 is softened, it can be molded into an arbitrary shape.
[0032]
The thermoplastic mesh 2 may adhere to the flat plate (hot plate) of the hot press machine. Therefore, in order to improve releasability and improve workability, surface treatment may be performed. A plate or a Teflon sheet (Teflon is a registered trademark) in consideration of releasability may be pasted.
[0033]
Next, secondary processing is performed.
[0034]
The laminated body of the sheet-like article 1 and the thermoplastic net 2 after being heated and pressurized is placed on a flat place and cooled. Thereby, a sheet-like molded product is made.
[0035]
Moreover, the strength and smoothness of the sheet-like molded product can be increased by sandwiching (pressing cold) between press plates having a temperature lower than that of the hot press machine. Furthermore, this method also serves as product curing, and can provide a stable product and facilitates demolding.
[0036]
The shape to be press-molded is not limited to a flat plate, and can be easily provided with irregularities such as a corrugated shape and a dimple shape. Moreover, you may shape | mold the flat plate which has a groove | channel of an unevenness | corrugation with two rollers which gave the surface unevenness | corrugation. The sheet material is sandwiched between press dies or rollers provided with such irregularities, and molded while being pressurized and cooled. The molded product shown in FIGS. 2 and 4 is obtained by such an unevenness forming process.
[0037]
Even a molded product that has been cooled can be reheated by a hot press, a warming box, or the like and formed into an arbitrary shape by the press die or roller.
[0038]
Next, a specific example of the molded product according to the method of manufacturing the molded product will be described.
[0039]
By selecting a skin material having high heat resistance as the sheet-like article 1, it is possible to produce molded products having various functions in various fields where heat resistance is required.
[0040]
In addition, when forming a filter, a sheet-shaped article 1 having a function corresponding to each application, for example, a filter medium such as a nonwoven fabric, a filter medium that becomes a skin material, and the like are appropriately selected to form a filter having various functions. can do. An example of this is a water permeable mat. The water-permeable sheet-like article 1 and the thermoplastic mesh 2 matched to the required strength and the like are bonded by the press die or roller. The water permeable mat to which the thermoplastic net 2 is bonded does not impair the water permeability, which is the original function, and can have sufficient strength.
[0041]
On the other hand, since a polyolefin-based thermoplastic resin typified by polyethylene resin is used as the core material of the molded product, recycling can be facilitated by using this series of resin for sheet-like articles 1 such as skin materials. become.
[0042]
According to the method for manufacturing a molded product and the molded product of the first embodiment, the following effects can be obtained.
[0043]
(1) Since the primary molded product and the secondary molded product manufactured as described above have a thermoplastic mesh 2 as a core, molding having air permeability according to the selected skin material or the like. Product. In other words, by using the mesh 2 made of thermoplastics having a size that does not impair the air permeability of the selected skin material, the air permeability of the skin material, etc. is sufficiently reduced. Can be given strong strength.
[0044]
(2) The product can be lightened by using a thermoplastic mesh 2 having a small stitch and a small wire diameter. It is possible to produce a product that is lightweight and has the required strength and rigidity and is resistant to repeated bending.
[0045]
Moreover, if the net 2 made of thermoplastics having a large stitch and a large wire diameter is used, the strength of the product can be greatly increased.
[0046]
By adjusting the stitches and the wire diameter, the weight, strength and rigidity required for the product can be freely adjusted.
[0047]
(3) Since the filter is reinforced by the thermoplastic plastic net 2 bonded to the sheet-like article 1 made of nonwoven fabric or the like, a frame material for supporting the sheet-like article 1 is not required, and the filter is large at low cost. Can be manufactured. Also, a large area filter such as a water permeable mat can be manufactured at low cost.
[0048]
(4) By appropriately selecting the fabric or skin material that adheres to the net 2 made of thermoplastic plastic, it is excellent in breathability, lightweight, moderately rigid, moderately soft A variety of molded products can be manufactured.
[0049]
Examples of modifications of the first embodiment include the following.
[0050]
(1) In the first embodiment, the area of the sheet-like article 1 and the thermoplastic mesh 2 is not particularly mentioned, but the sheet-like article 1 and the thermoplastic mesh 2 are made the same area. It may also be a different area. For example, a thermoplastic net 2 may be bonded to a part of the sheet-like article 1 to partially reinforce. On the contrary, even if the sheet-like article 1 is bonded to a part of the thermoplastic mesh 2 and the function of the sheet-like article 1 is added to a part of the thermoplastic mesh 2 as a reinforcing material. Good. In these cases, the same operations and effects as those of the first embodiment can be achieved.
[0051]
(2) In the first embodiment, the sheet-like article 1 and the thermoplastic mesh 2 are bonded as they are, but various materials may be packed in the thermoplastic mesh 2. That is, when the skin material is bonded to both side surfaces of the thermoplastic mesh 2, a material having a special function such as activated carbon may be packed in the mesh of the thermoplastic mesh 2. Thereby, the function of the packed material, such as activated carbon, can be added to the original function of the molded product.
[0052]
(B) Second Embodiment Next, a method for manufacturing a molded product and a second embodiment of the molded product according to the present invention will be briefly described with reference to the accompanying drawings.
[0053]
FIG. 6 is a schematic perspective view illustrating an example of a molded product manufactured by the method of manufacturing a molded product according to the second embodiment.
[0054]
The molded product shown in FIG. 6 is obtained by forming irregularities on a thermoplastic mesh 2 by thermoforming. In the case of the second embodiment, the sheet-like article 1 is not applied. The molded product shown in FIG. 6 is, for example, a molded product that is inserted into the shoe in order to prevent the shoe from being deformed.
[0055]
In the case of the second embodiment, the sheet-like article 1 is not applied and adhesion is not required, but the thermoforming process including the process of imparting irregularities is the same as that of the first embodiment.
[0056]
According to the second embodiment, if a net made of a thermoplastic plastic having a small stitch and a small wire diameter is used, a molded article having a light unevenness can be formed. The use of a thermoplastic mesh with a large stitch and a large wire diameter can increase the strength of the product. Furthermore, a molded product having desired strength and rigidity can be formed by appropriately selecting the size and wire diameter of a mesh of a thermoplastic plastic mesh.
[0057]
【The invention's effect】
As described above, according to the present invention, it is possible to achieve a method for manufacturing a molded product and a molded product that can secure sufficient strength at low cost, are light, have air permeability, and the like.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a first example of a molded product according to a first embodiment.
FIG. 2 is a perspective view showing a second example of a molded product according to the first embodiment.
FIG. 3 is a perspective view showing a third example of a molded product according to the first embodiment.
FIG. 4 is a perspective view showing a fourth example of the molded product according to the first embodiment.
FIG. 5 is an explanatory diagram of a thermoforming process (including a pressurizing process) according to the first embodiment;
FIG. 6 is a perspective view showing an example of a molded product according to the second embodiment.
[Explanation of symbols]
1: sheet-like article, 2: net made of thermoplastic plastic.

Claims (4)

Arrange a sheet-like article of any area made of fabric, felt, plastic foam, leather, synthetic leather, or non-woven fabric on one or both sides of a thermoplastic mesh that serves as a core or reinforcement. Thermoforming, softening the surface of the thermoplastic mesh, tangling the eyes of the sheet-like article, and fusing and integrating the thermoplastic mesh and the sheet-like article. The manufacturing method of the molded article characterized by including.   2. The method of manufacturing a molded product according to claim 1, wherein the thermoforming is performed between molds having an arbitrary shape.   2. The method for producing a molded article according to claim 1, further comprising a secondary processing step of imparting an arbitrary uneven shape to the thermoplastic plastic net after thermoforming and an integrated article of the sheet-like article. Any of fabric, felt, plastic foam, leather, synthetic leather, or non-woven fabric that is integrated on one or both sides of a thermoplastic mesh that functions as a core or reinforcing material, and the thermoplastic mesh The sheet-shaped article having an arbitrary area is formed by thermoforming, and at the time of thermoforming, the surface of the thermoplastic mesh is softened and entangled with the eyes of the sheet-like article. A molded article characterized in that the thermoplastic net and the sheet-like article are fused and integrated .

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