JP4230075B2

JP4230075B2 - Method for producing heat-insulating composite plate-shaped molded body that can be folded or rolled up

Info

Publication number: JP4230075B2
Application number: JP36400399A
Authority: JP
Inventors: 清光和田
Original assignee: Eidai Kako KK
Current assignee: Eidai Kako KK
Priority date: 1999-12-22
Filing date: 1999-12-22
Publication date: 2009-02-25
Anticipated expiration: 2019-12-22
Also published as: JP2001170988A

Description

【０００１】
【発明の属する技術分野】
この発明は、例えばシャッター式浴槽蓋、折り畳み式浴槽蓋、折り畳み式ドア、間仕切り等として用いられる折畳み又は巻取り自在な断熱性複合板状成形体の製造方法に関する。
【０００２】
【従来の技術】
例えば、浴槽上面を覆う巻取り自在なシャッター式浴槽蓋としては、硬質合成樹脂製の長尺の中空部材が複数本平行状に配置され、隣り合う中空部材同士が軟質合成樹脂製の長尺の連結片によって連結一体化されると共に、中空部材の中空部に合成樹脂発泡体が一体的に充填されたものが公知であり、軟質合成樹脂で構成された連結片によって連結されているので、不使用時等には巻き取っておくことができるものである。このシャッター式浴槽蓋では、中空部材の中空部内に充填された樹脂発泡体により優れた断熱性能が発揮されるので、浴槽内の湯を効果的に保温することができる。また、中空部材の中空部内に樹脂発泡体が充填一体化されているから、中空部材の剛性を向上させることができる。
【０００３】
上記構成に係る従来のシャッター式浴槽蓋は、次のようにして製作されていた。即ち、硬質合成樹脂製の長尺の中空部材と、軟質合成樹脂製の長尺の連結片とが複数連結一体化された構成単位部材を製造し、これら構成単位部材の複数をその連結片同士を溶着させて中空板状体を予め押出成形によって製作した後、この中空板状体の中空部材の中空空間内に発泡性樹脂を押し出して発泡膨張させて合成樹脂発泡体を該中空空間内に充填状態に一体化させる、いわゆる後充填法により行われていた。
【０００４】
【発明が解決しようとする課題】
しかしながら、上記製造方法では、中空板状体を予め押出成形によって製作した後、更に中空空間内に発泡性樹脂を押し出す工程が必要となるため、生産性が低いという問題があった。
【０００５】
また、既に成形が完了した中空板状体に対して発泡性樹脂を押出発泡するものであるから、得られる浴槽蓋において中空部材と樹脂発泡体との接合力が不十分であり、両者の界面に水が侵入しやすいという問題もあった。即ち、界面に水が侵入してしまうと浴槽蓋としての軽量性を十分に確保できなくなるし、中空部材と樹脂発泡体間で剥離を生じて中空部材の剛性向上効果が得られ難くなる。
【０００６】
この発明は、かかる技術的背景に鑑みてなされたものであって、生産性に優れると共に、中空部材と樹脂発泡体との接合力を十分に確保することのできる、折畳み又は巻取り自在な断熱性複合板状成形体の製造方法を提供することを目的とする。
【０００７】
【課題を解決するための手段】
上記目的を達成するために、本発明者は鋭意研究の結果、中空部材と連結片を同時押出成形可能となされた成形金型において、中空部材を押し出す押出口で取り囲まれた内側空間に発泡性樹脂を押し出す押出口を配置せしめた構成とし、このような構成の成形金型を用いて、中空部材、連結片、樹脂発泡体を同時押出成形することによって、生産性を顕著に向上できると共に、中空部材と樹脂発泡体との接合力を十分に確保できることを見出すに至り、この発明を完成した。
【０００８】
即ち、この発明に係る折畳み又は巻取り自在な断熱性複合板状成形体の製造方法は、硬質合成樹脂からなる長尺の中空部材が複数本平行状に配置され、隣り合う中空部材同士が軟質合成樹脂からなる長尺の連結片によって連結一体化されると共に、前記中空部材の中空空間内に合成樹脂発泡体が充填されてなる、折畳み又は巻取り自在な断熱性複合板状成形体の製造方法であって、前記複合板状成形体の断面形状に対応した配置及び形状で中空部材押出口及び連結片押出口が設けられる一方、前記各中空部材押出口で取り囲まれた内側空間にそれぞれ１ないし複数の発泡体押出口が配置されてなる金型を用い、中空部材押出口より硬質合成樹脂を押し出しつつ、連結片押出口より軟質合成樹脂を押し出すと共に、発泡体押出口より発泡性樹脂を押し出すことによって、前記複合板状成形体を同時押出成形で製造することを特徴とするものである。
【０００９】
また、この発明の別の折畳み又は巻取り自在な断熱性複合板状成形体の製造方法は、硬質合成樹脂からなる長尺の中空部材が複数本平行状に配置され、隣り合う中空部材同士が軟質合成樹脂からなる長尺の連結片によって連結一体化されると共に、前記中空部材の中空空間内に合成樹脂発泡体が充填されてなる、折畳み又は巻取り自在な断熱性複合板状成形体の製造方法であって、前記一体化された中空部材及び連結片の複数連結単位の断面形状に対応した配置及び形状で中空部材押出口及び連結片押出口が設けられる一方、前記各中空部材押出口で取り囲まれた内側空間にそれぞれ１ないし複数の発泡体押出口が配置されてなる金型を用い、中空部材押出口より硬質合成樹脂を押し出しつつ、連結片押出口より軟質合成樹脂を押し出すと共に、発泡体押出口より発泡性樹脂を押し出すことによって、中空空間内に合成樹脂発泡体が充填された中空部材と連結片とが複数連結一体化された構成単位部材を同時押出成形で製造した後、これら構成単位部材の複数をその連結片同士を溶着させることによって前記複合板状成形体を製造することを特徴とするものである。
【００１０】
上記いずれの発明も、金型における中空部材押出口で取り囲まれた内側空間に発泡体押出口が配置されているので、この発泡体押出口より発泡性樹脂を押し出すことによって、中空部材及び連結片を同時押出成形するのにあわせて中空部材の中空空間内に合成樹脂発泡体を充填状態に一体化させることができ、このように中空部材、連結片及び合成樹脂発泡体を同時押出成形することができるので、生産性に優れている。また、中空部材を構成する硬質合成樹脂が押し出されると同時に発泡体押出口より押し出された発泡性樹脂が発泡膨張して該硬質合成樹脂と接触状態となるので、即ち硬質合成樹脂と樹脂発泡体とがそれぞれの成形温度で、又は成形温度に近い温度で接触することとなるので、得られる断熱性複合板状成形体において中空部材と樹脂発泡体との接合力を十分に確保することができる。更に、このように中空部材の中空空間内にこれと十分な接合力を有した樹脂発泡体が充填一体化されているので、中空部材としての剛性を向上させることができる。
【００１１】
また、前記後者の発明においては、中空空間内に合成樹脂発泡体が充填された中空部材と連結片とが複数連結一体化された構成単位部材を同時押出成形で製造した後、これら構成単位部材の複数をその連結片同士を溶着させて断熱性複合板状成形体を製造するものであるので、これら構成単位部材の連結数を任意に設定することによって連結長さの長い板状成形体であっても容易に製造できる利点がある。
【００１２】
上記いずれの発明においても、中空部材押出口より押し出される硬質合成樹脂と、連結片押出口より押し出される軟質合成樹脂とが、金型の内部位置において接触状態となるようになされているのが好ましい。金型の内部位置において接触状態とすることにより、硬質合成樹脂と軟質合成樹脂とを圧接状態に接触させることができるので、両樹脂間の接合強度を向上させることができ、より耐久性に優れた断熱性複合板状成形体を製造できる。
【００１３】
【発明の実施の形態】
まず、この発明に係る製造方法で製造される巻取り自在な断熱性複合板状成形体（１Ａ）の一実施形態を図面を参照しつつ説明する。この断熱性複合板状成形体（１Ａ）は、図６に示すように、硬質合成樹脂からなる長尺の中空部材（２）…が一定間隔をあけて複数本平行状に配置され、隣り合う中空部材（２）同士がその下面縁部において軟質合成樹脂からなる長尺の連結片（３）によって連結一体化されると共に、前記中空部材（２）の中空空間内に合成樹脂発泡体（４）が充填されたものである。隣り合う中空部材（２）同士が軟質の連結片（３）によって連結されているので、容易に巻取ることが可能であり、また中空部材（２）の中空空間内に合成樹脂発泡体（４）が充填されているので、優れた断熱性が得られ、優れた保温効果を発揮させることができるものである。
【００１４】
次に、この発明の製造方法で用いる金型（１０）の一実施形態を図面（図１〜４）を参照しつつ説明する。図４に示すように、金型（１０）は、第１金型（２１）の中心部厚さ方向に貫通して設けられた挿通孔（２３）に、第２金型（２２）の棒状の突出押出部（２４）が挿嵌されることによって両者（２１）（２２）が一体化されたものである。
【００１５】
前記金型（１０）の前面側（押出側）側面には、前記断熱性複合板状成形体（１Ａ）における中空部材（２）（２）（２）（２）及び連結片（３）（３）（３）（３）（３）からなる構成単位部材（６）の断面形状に対応した配置及び形状で中空部材押出口（１１）（１１）（１１）（１１）及び連結片押出口（１２）（１２）（１２）（１２）（１２）が設けられている。即ち、金型（１０）の前面側側面には、その長手方向に沿って断面縁枠状の中空部材押出口（１１）（１１）（１１）（１１）が相互に所定間隔を開けて並列して設けられる一方、相隣り合う中空部材押出口（１１）（１１）間を掛け渡す態様で連結片押出口（１２）が３個設けられ、更に長手方向の両端の中空部材押出口（１１）（１１）に接して長手方向外方に連なる連結片押出口（１２）（１２）がそれぞれ設けられている。
【００１６】
前記中空部材押出口（１１）で取り囲まれた内側空間には、それぞれ発泡体押出口（１３）が設けられている。なお、この実施形態では１つの中空部材押出口（１１）に対して発泡体押出口（１３）が１つ内挿配置された構成を採用しているが、特にこのような構成に限定されるものではなく、１つの中空部材押出口（１１）に対して複数個の発泡体押出口（１３）が内挿配置された構成を採用しても良い。
【００１７】
前記中空部材押出口（１１）は、第１金型（２１）内に設けられた第１押出流路（３４）を介して第１金型（２１）の側面に設けられた第１押出機接続孔（３１）に連通されている。なお、この第１押出機（図示しない）は硬質合成樹脂を所定の押出圧力で押し出すようになされており、この第１押出機から押し出されてくる硬質合成樹脂が、第１押出機接続孔（３１）、第１押出流路（３４）を順に通過して中空部材押出口（１１）より押し出されて中空部材（２）の押出成形が行われる。
【００１８】
また、前記連結片押出口（１２）は、第１金型（２１）内に設けられた第２押出流路（３５）を介して第１金型（２１）の上面に設けられた第２押出機接続孔（３２）に連通されている。なお、この第２押出機（図示しない）は軟質合成樹脂を所定の押出圧力で押し出すようになされており、この第２押出機から押し出されてくる軟質合成樹脂が、第２押出機接続孔（３２）、第２押出流路（３５）を順に通過して連結片押出口（１２）より押し出されて連結片（３）の押出成形が行われる。
【００１９】
また、前記発泡体押出口（１３）は、第２金型（２２）内に設けられた第３押出流路（３６）を介して第２金型（２２）の背面側に設けられた第３押出機接続孔（３３）に連通されている。なお、この第３押出機（図示しない）は、発泡性樹脂を所定の押出圧力で押し出すようになされており、この第３押出機から押し出されてくる発泡性樹脂が、第３押出機接続孔（３３）、第３押出流路（３６）を順に通過して発泡体押出口（１３）より押し出されて合成樹脂発泡体（４）の押出発泡成形が行われる。
【００２０】
なお、本実施形態では、図４に示すように、金型（１０）の内部位置において、第１押出流路（３４）と第２押出流路（３５）とが合流するようになされている。従って、第１押出流路（３４）を流過する硬質合成樹脂と、第２押出流路（３５）を流過する軟質合成樹脂とが金型（１）の内部位置において接触し、即ち両樹脂が流路内において圧接状態に接触するので、両樹脂間の接合力を向上させることができ、ひいては中空部材（２）と連結片（３）の接合強度に優れた断熱性複合板状成形体（１Ａ）を製造することができる。従って、一層耐久性に優れた断熱性複合板状成形体（１Ａ）を提供することができる。
【００２１】
次に、上記金型（１０）を用いたこの発明の断熱性複合板状成形体（１Ａ）の製造方法について説明する。
【００２２】
前記金型（１０）の第１押出機接続孔（３１）に接続された第１押出機に硬質合成樹脂を供給する一方、第２押出機接続孔（３２）に接続された第２押出機に軟質合成樹脂を供給すると共に、第３押出機接続孔（３３）に接続された第３押出機に発泡性樹脂を供給し、それぞれの押出機より各樹脂を押し出す。
【００２３】
しかして、加熱溶融状態の硬質合成樹脂が、第１押出機接続孔（３１）、第１押出流路（３４）を経て中空部材押出口（１１）より押し出される一方、加熱溶融状態の軟質合成樹脂が、第２押出機接続孔（３２）、第２押出流路（３５）を経て連結片押出口（１２）より押し出され、同時に加熱状態の発泡性樹脂が、第３押出機接続孔（３３）、第３押出流路（３６）を経て発泡体押出口（１３）より押し出されて前記硬質合成樹脂の内部（中空部材の内部）で直ちに発泡を開始して発泡体（４）が形成され、このようにして各中空空間内に合成樹脂発泡体（４）（４）（４）（４）が充填された中空部材（２）（２）（２）（２）と、連結片（３）（３）（３）（３）（３）とが交互に連結一体化された構成単位部材（６Ａ）（図５参照）を同時押出成形で製造することができる。
【００２４】
次いで、上記構成単位部材（６Ａ）の複数をその連結片（３）同士を溶着させることによって図６に示す断熱性複合板状成形体（１Ａ）を製造する。連結片（３）同士の溶着方法としては、特に限定されず、例えば高周波誘電加熱法、超音波ウエルダー法、接着剤により接着する方法等が挙げられる。
【００２５】
次に、この発明に係る製造方法で製造される折畳み自在な断熱性複合板状成形体（１Ｂ）の一実施形態を図面を参照しつつ説明する。この断熱性複合板状成形体（１Ｂ）は、図８に示すように、硬質合成樹脂からなる長尺の中空部材（２）…が一定間隔をあけて複数本平行状に配置され、隣り合う中空部材（２）同士が軟質合成樹脂からなる長尺の連結片（３）によって連結一体化されると共に、前記中空部材（２）の中空空間内に合成樹脂発泡体（４）が充填されたものである。連結片（３）による連結態様としては、中空部材（２）の上面縁部同士を連結する第１連結態様、中空部材（２）の下面縁部同士を連結する第２連結態様の２種類採用されて、これら第１連結態様と第２連結態様が交互配置となるようになされているので、容易に折畳むことが可能であり、また中空部材（２）の中空空間内に合成樹脂発泡体（４）が充填されているので、優れた断熱性が得られ、優れた保温効果を発揮させることができるものである。
【００２６】
上記構成に係る断熱性複合板状成形体（１Ｂ）を製造するのに用いる金型（１５）の一実施形態を図７に示す。金型（１５）は、第１金型（２１）の中心部厚さ方向に貫通して設けられた挿通孔（２３）に、第２金型（２２）の棒状の突出押出部（２４）が挿嵌されることによって両者（２１）（２２）が一体化されたものである。前記金型（１０）の前面側（押出側）側面には、前記折畳み自在な断熱性複合板状成形体（１Ｂ）における中空部材（２）（２）（２）（２）及び連結片（３）（３）（３）（３）（３）からなる構成単位部材（６Ｂ）の断面形状に対応した配置及び形状で中空部材押出口（１１）（１１）（１１）（１１）及び連結片押出口（１２）（１２）（１２）（１２）（１２）が設けられている。前記中空部材押出口（１１）で取り囲まれた内側空間には、それぞれ発泡体押出口（１３）が設けられている。もちろん、前記同様に、１つの中空部材押出口（１１）に対して複数個の発泡体押出口（１３）を配置した構成を採用することもできる。
【００２７】
なお、この金型（１５）における各押出流路、各押出機接続孔等の構成等については前記実施形態と同様の態様であるので、これらの説明は省略し、これら同様部分については前記実施形態と同一の符号を付した。
【００２８】
上記金型（１５）を用いた折畳み自在な断熱性複合板状成形体（１Ｂ）の製造は前記実施形態と同様に行う。即ち、前記金型（１５）の第１押出機接続孔（３１）に接続された第１押出機に硬質合成樹脂を供給する一方、第２押出機接続孔（３２）に接続された第２押出機に軟質合成樹脂を供給すると共に、第３押出機接続孔（３３）に接続された第３押出機に発泡性樹脂を供給し、それぞれの押出機より各樹脂を押し出す。
【００２９】
しかして、加熱溶融状態の硬質合成樹脂が、第１押出機接続孔（３１）、第１押出流路（３４）を経て中空部材押出口（１１）より押し出される一方、加熱溶融状態の軟質合成樹脂が、第２押出機接続孔（３２）、第２押出流路（３５）を経て連結片押出口（１２）より押し出され、同時に加熱状態の発泡性樹脂が、第３押出機接続孔（３３）、第３押出流路（３６）を経て発泡体押出口（１３）より押し出されて前記硬質合成樹脂の内部（中空部材の内部）で直ちに発泡を開始して発泡体（４）が形成され、このようにして各中空空間内に合成樹脂発泡体（４）（４）（４）（４）が充填された中空部材（２）（２）（２）（２）と、連結片（３）（３）（３）（３）（３）とが交互に連結一体化された構成単位部材（６Ｂ）を同時押出成形で製造することができる。
【００３０】
次いで、上記構成単位部材（６Ｂ）の複数をその連結片（３）同士を溶着させることによって図８に示す断熱性複合板状成形体（１Ｂ）を製造する。連結片（３）同士の溶着方法としては、特に限定されず、例えば高周波誘電加熱法、超音波ウエルダー法、接着剤により接着する方法等が挙げられる。
【００３１】
以上のように、この発明の製造方法によれば、金型における中空部材押出口（１１）で取り囲まれた内側空間に発泡体押出口（１３）が配置されて、この押出口（１３）より発泡性樹脂を押し出すものであるから、中空部材（２）及び連結片（３）を同時押出成形するのにあわせて中空部材（２）の中空空間内に合成樹脂発泡体（４）を充填状態に一体化させることができ、このように相異なる３種類の部材（２）（３）（４）を同時押出成形することができるので、生産性に優れている。また、押出直後の硬質合成樹脂（中空部材）の内部空間内において、発泡性樹脂が発泡膨張して該硬質合成樹脂と接触するので、即ち硬質合成樹脂と樹脂発泡体（４）とがそれぞれの成形温度であるいは成形温度に近い温度で接触するので、得られる断熱性複合板状成形体（１Ａ）（１Ｂ）において中空部材（２）と樹脂発泡体（４）との接合力を十分に確保することができる。従って、中空部材（２）と樹脂発泡体（４）の界面への水の侵入を防止することができ、断熱性複合板状成形体（１Ａ）（１Ｂ）として軽量性を十分に確保することができる。
【００３２】
なお、上記製造方法は、連結長さの長い（即ち中空部材の連結数の多い）断熱性複合板状成形体を製造するのに好適な方法であり、連結長さの短い（中空部材の連結数の少ない）断熱性複合板状成形体を製造する場合には、前記連結片（３）同士を溶着させる工程は特に設けなくても良い。即ち前記の３種同時押出成形された単位構成部材（６Ａ）（６Ｂ）自体を製品の断熱性複合板状成形体（１Ａ）（１Ｂ）とすることも可能であり、要するにいずれの製造方法を適用するかは連結長さに応じて適宜選択すれば良い。
【００３３】
この発明の製造方法において用いる硬質合成樹脂としては、特に限定されるものではないが、例えばポリプロピレン樹脂、ＡＢＳ樹脂（アクリロニトリル−ブタジエン−スチレン共重合体樹脂）、硬質塩化ビニル樹脂等が挙げられる。中でも、耐熱性、耐薬品性に優れると共に焼却処理の際等に塩化水素等の有毒ガスを発生することがなく環境保全の要請に十分に応えることができることから、ポリプロピレン樹脂を用いるのが好ましい。
【００３４】
また、この発明の製造方法で用いる軟質合成樹脂としては、特に限定されず、例えば熱可塑性エラストマー、あるいはポリプロピレン等の硬質合成樹脂に改質剤を添加して軟質化した軟質合成樹脂等が挙げられる。
【００３５】
前記前者の熱可塑性エラストマーとしては、例えば水素添加スチレン・ブタジエンラバー（ＨＳＢＲ）等に代表される水素添加スチレン・共役ジエン系ラバー、あるいはスチレン・エチレン／ブチレン・スチレンブロック共重合体等に代表される水素添加スチレン・共役ジエン・スチレンブロック共重合体、あるいはまたエチレン、プロピレン、ブテン−１よりなる群から選択される２種以上の成分の共重合体（例えばエチレン・ブテン共重合体ゴム、プロピレン・ブテン共重合体ゴム、エチレン・プロピレン・ブテン共重合体ゴムなど）等が挙げられる。
【００３６】
前記後者における軟質化のための改質剤としては、例えば前者の熱可塑性エラストマーが挙げられ、特に好適なものとしてはエチレン・プロピレン・ジエン・メチレン共重合体、スチレン・エチレン・ブチレン・スチレン共重合体、スチレン・エチレン・プロピレン・スチレン共重合体等が挙げられる。
【００３７】
前記軟質合成樹脂としては、その他エチレン・酢酸ビニル共重合体樹脂、エチレン・アクリル酸エチル共重合体樹脂等が挙げられる。
【００３８】
また、この発明の製造方法で用いる発泡性樹脂としては、特に限定されず、その樹脂成分としては例えばスチロール樹脂、ウレタン樹脂、ＡＢＳ樹脂、ポリプロピレン樹脂、ポリエチレン樹脂等が挙げられる。なお、押出発泡の際の発泡倍率は、５〜２０倍の範囲となるように設定するのが好ましい。もちろん、例えば発泡性ポリスチレンビーズ等の発泡性合成樹脂ビーズを含有してなる発泡性樹脂を用いて高発泡（２０〜４０倍）させても良い。この発泡性樹脂の発泡によって独立気泡の合成樹脂発泡体（４）が発泡押出成形されるようにするのが好ましい。このように合成樹脂発泡体（４）を独立気泡タイプのものとすれば、この発泡体（４）自体への水の侵入も阻止することができ、板状体（１Ａ）（１Ｂ）としての軽量性を一層確実に確保することができる利点がある。
【００３９】
なお、前記硬質合成樹脂、軟質合成樹脂、発泡性樹脂いずれにおいても、必要に応じて酸化防止剤、安定剤、充填剤、紫外線吸収剤、帯電防止剤、顔料等の各種添加剤を添加しても良い。
【００４０】
この発明の製造方法で製造される断熱性複合板状成形体（１Ａ）（１Ｂ）は、その用途は特に限定されないが、例えばシャッター式浴槽蓋、折り畳み式浴槽蓋、折り畳み式ドア、間仕切り等として用いられる。この発明の製造方法を用いれば、前述したように、中空部材（２）と樹脂発泡体（４）間の接合力に優れて、中空部材（２）と樹脂発泡体（４）の界面への水の侵入を効果的に防止できるので、水の侵入による軽量性の低下の回避を特に求められるシャッター式浴槽蓋、折り畳み式浴槽蓋の製造方法として特に好適である。
【００４１】
【実施例】
次に、この発明の具体的実施例について説明する。
【００４２】
＜実施例１＞
図１に示す構成の金型（１０）を用いて上述した製造方法により巻取り自在な断熱性複合板状成形体（１Ａ）を製造した。硬質合成樹脂としてはポリプロピレン樹脂を用い、軟質合成樹脂としてポリプロピレン系熱可塑性エラストマーを用い、発泡性樹脂としては「エスレンビーズ（商品名）」（発泡剤を含有する発泡性ポリスチレンビーズ、含有ガス成分はブタンガス、積水化成品工業株式会社製）を用いた。前記発泡性樹脂の発泡倍率が１５倍となるようにして、中空部材、連結片及び合成樹脂発泡体（独立気泡）を同時押出成形することによって構成単位部材（中空部材４個、合成樹脂発泡体４個及び連結片５個からなる）を得、これら構成単位部材を５個その連結片同士で溶着させて、巻取り自在な断熱性複合板状成形体（１Ａ）を得た。
【００４３】
＜実施例２＞
発泡性樹脂として「エスレンビーズ」に代えて発泡性ポリプロピレンビーズを用いた以外は、実施例１と同様にして、巻取り自在な断熱性複合板状成形体（１Ａ）を得た。
【００４４】
＜実施例３＞
図７に示す構成の金型（１５）を用いて上述した製造方法により折畳み自在な断熱性複合板状成形体（１Ｂ）を製造した。硬質合成樹脂としてはポリプロピレン樹脂を用い、軟質合成樹脂としてポリプロピレン系熱可塑性エラストマーを用い、発泡性樹脂としては前記「エスレンビーズ（商品名）」を用いた。前記発泡性樹脂の発泡倍率が１５倍となるようにして、中空部材、連結片及び合成樹脂発泡体（独立気泡）を同時押出成形することによって構成単位部材（中空部材４個、合成樹脂発泡体４個及び連結片５個からなる）を得、これら構成単位部材を５個その連結片同士で溶着させて、折畳み自在な断熱性複合板状成形体（１Ｂ）を得た。
【００４５】
＜実施例４＞
発泡性樹脂として「エスレンビーズ」に代えて発泡性ポリプロピレンビーズを用いた以外は、実施例３と同様にして、折畳み自在な断熱性複合板状成形体（１Ｂ）を得た。
【００４６】
実施例１〜４で製造した断熱性複合板状成形体は、いずれも浴槽蓋として長期間使用しても、中空部材と樹脂発泡体との間に水が侵入することがなく、浴槽蓋としての軽量性を十分に維持できると共に、中空部材の優れた剛性も長期使用によって低下するようなことは認められなかった。また、実施例２、４の断熱性複合板状成形体は、中空部材、連結片及び合成樹脂発泡体（中空部材の中空空間内の）のいずれもが同種の樹脂（ポリプロピレン樹脂）で構成されているので、該複合板状成形体のリサイクル利用が容易なものとなる利点がある。
【００４７】
【発明の効果】
請求項１及び請求項２の製造方法によれば、中空部材、連結片及び合成樹脂発泡体を同時押出成形することができるので、生産性に優れている。また、硬質合成樹脂と樹脂発泡体とをそれぞれの成形温度で又は成形温度に近い温度で接触させて接合させることができるので、中空部材と樹脂発泡体の接合強度に優れたものを製造することができ、得られる板状成形体において中空部材と樹脂発泡体の界面に水が侵入することを効果的に防止でき、ひいては断熱性複合板状成形体として軽量性を十分に維持することができる。更に、中空部材の中空空間内にこれと十分な接合強度で接合された樹脂発泡体を充填することができるので、中空部材としての剛性を顕著に向上させることができる。
【００４８】
また、請求項２の製造方法は、構成単位部材の連結数を任意に設定することで、連結長さの長い板状成形体であっても容易に製造できる利点がある。
【００４９】
請求項３の製造方法によれば、上記効果に加えて、硬質合成樹脂からなる中空部材と、軟質合成樹脂からなる連結片の間の接合強度を一層向上させることができ、より耐久性に優れた断熱性複合板状成形体を製造できる。
【図面の簡単な説明】
【図１】この発明の製造方法で用いる金型を示す前面側斜視図である。
【図２】同じく背面側斜視図である。
【図３】図１におけるＡ−Ａ線の断面図である。
【図４】図３におけるＢ−Ｂ線の断面図である。
【図５】金型より同時押出成形された構成単位部材を示す断面図である。
【図６】断熱性複合板状成形体を示す斜視図である。
【図７】この発明の製造方法で用いる金型の他の例を示す前面側斜視図である。
【図８】断熱性複合板状成形体の他の例を示す断面図である。
【符号の説明】
１Ａ、１Ｂ…断熱性複合板状成形体
２…中空部材
３…連結片
４…樹脂発泡体
６Ａ、６Ｂ…構成単位部材
１０、１５…金型
１１…中空部材押出口
１２…連結片押出口
１３…発泡体押出口[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a foldable or windable heat-insulating composite plate-like molded body used as, for example, a shutter-type bathtub lid, a folding bathtub lid, a folding door, a partition, or the like.
[0002]
[Prior art]
For example, as a retractable shutter-type bathtub lid that covers the upper surface of the bathtub, a plurality of long hollow members made of hard synthetic resin are arranged in parallel, and adjacent hollow members are made of soft synthetic resin. In addition to being connected and integrated by a connecting piece, a hollow member of a hollow member that is integrally filled with a synthetic resin foam is known and connected by a connecting piece made of a soft synthetic resin. It can be wound up during use. In this shutter-type bathtub lid, excellent heat insulation performance is exhibited by the resin foam filled in the hollow portion of the hollow member, so that hot water in the bathtub can be effectively kept warm. Moreover, since the resin foam is filled and integrated in the hollow part of the hollow member, the rigidity of the hollow member can be improved.
[0003]
The conventional shutter-type bathtub lid according to the above configuration has been manufactured as follows. That is, a structural unit member in which a plurality of long hollow members made of hard synthetic resin and a long connecting piece made of soft synthetic resin are connected and integrated is manufactured, and a plurality of these structural unit members are connected to each other. After the hollow plate-like body is manufactured by extrusion molding in advance, the foamable resin is extruded into the hollow space of the hollow member of the hollow plate-like body, and the foamed resin is expanded to expand the synthetic resin foam into the hollow space. It has been carried out by a so-called post-filling method, in which it is integrated into a filled state.
[0004]
[Problems to be solved by the invention]
However, the above manufacturing method has a problem in that the productivity is low because a step of extruding a foamable resin into the hollow space after the hollow plate-like body is manufactured in advance by extrusion molding is required.
[0005]
In addition, since the foamable resin is extruded and foamed to a hollow plate-shaped body that has already been molded, the bonding strength between the hollow member and the resin foam is insufficient in the obtained bathtub lid, and the interface between the two There was also a problem that water could easily enter. That is, if water enters the interface, the lightness as a bathtub lid cannot be secured sufficiently, and separation between the hollow member and the resin foam occurs, making it difficult to obtain the effect of improving the rigidity of the hollow member.
[0006]
The present invention has been made in view of such a technical background, and has excellent productivity, and can sufficiently secure a bonding force between the hollow member and the resin foam, and can be folded or wound up. It aims at providing the manufacturing method of an adhesive composite plate-shaped molded object.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, as a result of intensive research, the present inventor has made a foaming property in the inner space surrounded by the extrusion port for extruding the hollow member in a molding die capable of simultaneously extruding the hollow member and the connecting piece. With a configuration in which an extrusion port for extruding the resin is arranged, and using a molding die with such a configuration, by simultaneously extruding a hollow member, a connecting piece, and a resin foam, productivity can be significantly improved, The inventors have found that the bonding force between the hollow member and the resin foam can be sufficiently ensured, thereby completing the present invention.
[0008]
That is, in the method for producing a heat-insulating composite plate-like molded body that can be folded or rolled up according to the present invention, a plurality of long hollow members made of hard synthetic resin are arranged in parallel, and adjacent hollow members are soft. Manufacture of a heat-insulating composite plate-like molded body that can be folded or rolled up, which is connected and integrated by a long connecting piece made of synthetic resin, and is filled with a synthetic resin foam in the hollow space of the hollow member. In the method, the hollow member extrusion port and the connection piece extrusion port are provided in an arrangement and shape corresponding to the cross-sectional shape of the composite plate-shaped molded body, and each of the inner spaces surrounded by the hollow member extrusion ports is 1 each. Or, using a mold in which a plurality of foam extrusion ports are disposed, while extruding a hard synthetic resin from a hollow member extrusion port and extruding a soft synthetic resin from a connection piece extrusion port, and a foamable resin from a foam extrusion port By extruding, it is characterized in that in preparing the composite plate-shaped molded body coextrusion.
[0009]
In addition, according to another method of manufacturing a heat-insulating composite plate-like molded body that can be folded or rolled up according to the present invention, a plurality of long hollow members made of a hard synthetic resin are arranged in parallel, and adjacent hollow members are arranged together. A heat-insulating composite plate-shaped molded body that can be folded or rolled up, and is integrally connected by a long connecting piece made of a soft synthetic resin and filled with a synthetic resin foam in the hollow space of the hollow member. In the manufacturing method, the hollow member extrusion port and the connection piece extrusion port are provided in an arrangement and a shape corresponding to a cross-sectional shape of a plurality of connection units of the integrated hollow member and the connection piece. When one or a plurality of foam extrusion ports are arranged in the inner space surrounded by, each of the synthetic resin is extruded from the connecting piece extrusion port while extruding the hard synthetic resin from the hollow member extrusion port. After extruding a foamable resin from the foam extrusion port, a structural unit member in which a plurality of hollow members filled with a synthetic resin foam in a hollow space and a plurality of connecting pieces are integrated and manufactured by co-extrusion molding The composite plate-like molded body is produced by welding a plurality of these structural unit members to each other.
[0010]
In any of the above inventions, since the foam extrusion port is disposed in the inner space surrounded by the hollow member extrusion port in the mold, the hollow member and the connecting piece can be obtained by extruding the foamable resin from the foam extrusion port. The synthetic resin foam can be integrated into the hollow space of the hollow member in accordance with the simultaneous extrusion molding of the hollow member, and thus the hollow member, the connecting piece and the synthetic resin foam can be coextruded. Can be used, so it is highly productive. Further, since the hard synthetic resin constituting the hollow member is extruded and at the same time, the foamable resin extruded from the foam extrusion port expands and comes into contact with the hard synthetic resin, that is, the hard synthetic resin and the resin foam. Are brought into contact at the respective molding temperatures or at a temperature close to the molding temperature, it is possible to sufficiently secure the bonding force between the hollow member and the resin foam in the obtained heat insulating composite plate-like molded body. . Further, since the resin foam having sufficient bonding force with the hollow member is filled and integrated in the hollow space of the hollow member, the rigidity as the hollow member can be improved.
[0011]
In the latter invention, after a structural unit member in which a hollow member filled with a synthetic resin foam in a hollow space and a plurality of connection pieces are integrally connected is manufactured by coextrusion, these structural unit members are manufactured. In order to manufacture a heat-insulating composite plate-shaped molded body by welding a plurality of the connecting pieces, a plate-shaped molded body having a long connection length can be obtained by arbitrarily setting the number of connections of these structural unit members. Even if it exists, there exists an advantage which can be manufactured easily.
[0012]
In any of the above inventions, it is preferable that the hard synthetic resin extruded from the hollow member extrusion port and the soft synthetic resin extruded from the connecting piece extrusion port are in contact with each other at the internal position of the mold. . By making the contact state at the inner position of the mold, the hard synthetic resin and the soft synthetic resin can be brought into contact with each other in a pressure contact state, so that the bonding strength between the two resins can be improved and the durability is more excellent. A heat insulating composite plate-like molded body can be produced.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
First, an embodiment of a rollable heat-insulating composite plate-like molded body (1A) manufactured by the manufacturing method according to the present invention will be described with reference to the drawings. As shown in FIG. 6, the heat insulating composite plate-like molded body (1A) has a plurality of long hollow members (2) made of a hard synthetic resin arranged in parallel at regular intervals and adjacent to each other. The hollow members (2) are connected and integrated with each other by a long connecting piece (3) made of a soft synthetic resin at the lower surface edge, and a synthetic resin foam (4) is formed in the hollow space of the hollow member (2). ) Is filled. Since the adjacent hollow members (2) are connected to each other by the soft connecting piece (3), they can be easily wound, and the synthetic resin foam (4) is placed in the hollow space of the hollow member (2). ) Is filled, an excellent heat insulating property can be obtained, and an excellent heat retaining effect can be exhibited.
[0014]
Next, an embodiment of a mold (10) used in the manufacturing method of the present invention will be described with reference to the drawings (FIGS. 1 to 4). As shown in FIG. 4, the mold (10) has a rod-like shape of the second mold (22) in an insertion hole (23) provided penetrating in the thickness direction of the center of the first mold (21). By inserting and fitting the protruding extruded portion (24), both (21) and (22) are integrated.
[0015]
On the front side (extrusion side) side surface of the mold (10), the hollow members (2) (2) (2) (2) and the connecting piece (3) ( 3) Hollow member extrusion ports (11) (11) (11) (11) and connecting piece extrusion ports in an arrangement and shape corresponding to the cross-sectional shape of the structural unit member (6) comprising (3), (3) and (3) (12) (12) (12) (12) (12) are provided. That is, on the front side surface of the mold (10), the hollow member extrusion ports (11), (11), (11), and (11) having a cross-sectional edge frame shape along the longitudinal direction thereof are arranged in parallel at a predetermined interval. On the other hand, three connection piece extrusion ports (12) are provided in such a manner as to span between adjacent hollow member extrusion ports (11) and (11), and further, hollow member extrusion ports (11 at both ends in the longitudinal direction). ) (11) are provided with connecting piece extrusion ports (12) and (12) that are continuous outward in the longitudinal direction.
[0016]
A foam extrusion port (13) is provided in each of the inner spaces surrounded by the hollow member extrusion port (11). In this embodiment, a configuration in which one foam extrusion port (13) is inserted and arranged with respect to one hollow member extrusion port (11) is adopted, but the configuration is particularly limited to such a configuration. Instead of this, a configuration may be adopted in which a plurality of foam extrusion ports (13) are inserted into one hollow member extrusion port (11).
[0017]
The hollow member extrusion port (11) is a first extruder provided on a side surface of the first mold (21) via a first extrusion channel (34) provided in the first mold (21). It communicates with the connection hole (31). The first extruder (not shown) is configured to extrude a hard synthetic resin at a predetermined extrusion pressure, and the hard synthetic resin extruded from the first extruder has a first extruder connection hole ( 31) and passes through the first extrusion flow path (34) in order, and is extruded from the hollow member extrusion port (11) to perform extrusion molding of the hollow member (2).
[0018]
The connecting piece extrusion port (12) is provided on the upper surface of the first mold (21) via the second extrusion channel (35) provided in the first mold (21). It communicates with the extruder connection hole (32). The second extruder (not shown) is configured to extrude a soft synthetic resin at a predetermined extrusion pressure. The soft synthetic resin extruded from the second extruder has a second extruder connection hole ( 32) and sequentially passing through the second extrusion flow path (35) and extruded from the connection piece extrusion port (12), and the connection piece (3) is extruded.
[0019]
The foam extrusion port (13) is provided on the back side of the second mold (22) through a third extrusion channel (36) provided in the second mold (22). 3 It communicates with the extruder connection hole (33). In addition, this 3rd extruder (not shown) is made to extrude foamable resin by predetermined | prescribed extrusion pressure, and the foamable resin extruded from this 3rd extruder is the 3rd extruder connection hole. (33), passing through the third extrusion flow path (36) in order, extruded from the foam extrusion port (13), and extrusion foaming of the synthetic resin foam (4) is performed.
[0020]
In the present embodiment, as shown in FIG. 4, the first extrusion flow path (34) and the second extrusion flow path (35) are joined at the internal position of the mold (10). . Accordingly, the hard synthetic resin flowing through the first extrusion flow path (34) and the soft synthetic resin flowing through the second extrusion flow path (35) are in contact at the internal position of the mold (1), that is, both Since the resin contacts the pressure contact state in the flow path, the bonding force between the two resins can be improved, and as a result, the heat insulating composite plate-shaped molding with excellent bonding strength between the hollow member (2) and the connecting piece (3). The body (1A) can be manufactured. Therefore, it is possible to provide the heat insulating composite plate-like molded body (1A) having further excellent durability.
[0021]
Next, the manufacturing method of the heat insulation composite plate-shaped molded object (1A) of this invention using the said metal mold | die (10) is demonstrated.
[0022]
A second extruder connected to the second extruder connection hole (32) while supplying hard synthetic resin to the first extruder connected to the first extruder connection hole (31) of the mold (10). The soft synthetic resin is supplied to the third extruder, and the foamable resin is supplied to the third extruder connected to the third extruder connection hole (33), and each resin is extruded from each extruder.
[0023]
Thus, the hard synthetic resin in the heated and melted state is extruded from the hollow member extrusion port (11) through the first extruder connection hole (31) and the first extrusion flow path (34), while the soft synthetic in the heated and melted state. The resin is extruded from the connection piece extrusion port (12) through the second extruder connection hole (32) and the second extrusion flow path (35), and at the same time, the foamable resin in a heated state becomes the third extruder connection hole ( 33), extruded from the foam extrusion port (13) through the third extrusion channel (36), and immediately starts foaming inside the hard synthetic resin (inside the hollow member) to form the foam (4). In this way, the hollow members (2) (2) (2) (2) filled with the synthetic resin foams (4) (4) (4) (4) in the respective hollow spaces, and the connecting pieces ( 3) Structural unit member (6A) in which (3), (3), (3), and (3) are alternately connected and integrated (see FIG. 5) It can be produced by coextrusion.
[0024]
Next, a plurality of the structural unit members (6A) are welded together with the connecting pieces (3) to produce the heat insulating composite plate-like molded body (1A) shown in FIG. The method for welding the connecting pieces (3) is not particularly limited, and examples thereof include a high frequency dielectric heating method, an ultrasonic welder method, and a method of bonding with an adhesive.
[0025]
Next, an embodiment of a foldable heat-insulating composite plate-like molded body (1B) manufactured by the manufacturing method according to the present invention will be described with reference to the drawings. As shown in FIG. 8, the heat insulating composite plate-like molded body (1B) has a plurality of long hollow members (2) made of a hard synthetic resin arranged in parallel at regular intervals and adjacent to each other. The hollow members (2) are connected and integrated with each other by a long connecting piece (3) made of a soft synthetic resin, and the hollow space of the hollow member (2) is filled with the synthetic resin foam (4). Is. As a connection mode by the connection piece (3), two types of the first connection mode for connecting the upper surface edges of the hollow member (2) and the second connection mode for connecting the lower surface edges of the hollow member (2) are adopted. Since the first connection mode and the second connection mode are arranged alternately, they can be easily folded, and the synthetic resin foam is formed in the hollow space of the hollow member (2). Since (4) is filled, an excellent heat insulating property can be obtained and an excellent heat retaining effect can be exhibited.
[0026]
FIG. 7 shows an embodiment of a mold (15) used for manufacturing the heat insulating composite plate-shaped body (1B) according to the above configuration. The mold (15) is inserted into the insertion hole (23) provided through the central mold in the thickness direction of the first mold (21), and the rod-shaped protruding extruded portion (24) of the second mold (22). The two (21) and (22) are integrated by inserting. On the front side (extrusion side) side surface of the mold (10), hollow members (2) (2) (2) (2) and connecting pieces (2) in the foldable heat insulating composite plate-like molded body (1B) ( 3) Hollow member extrusion ports (11) (11) (11) (11) and connection in an arrangement and shape corresponding to the cross-sectional shape of the structural unit member (6B) comprising (3) (3) (3) (3) Single extrusion ports (12) (12) (12) (12) (12) are provided. A foam extrusion port (13) is provided in each of the inner spaces surrounded by the hollow member extrusion port (11). Of course, the structure which has arrange | positioned several foam extrusion port (13) with respect to one hollow member extrusion port (11) similarly to the above is also employable.
[0027]
In addition, about the structure of each extrusion flow path, each extruder connection hole, etc. in this metal mold | die (15), since it is the aspect similar to the said embodiment, these description is abbreviate | omitted, About these same parts, it carries out the said implementation. The same reference numerals as those of the forms are attached.
[0028]
The foldable heat-insulating composite plate-like molded body (1B) using the mold (15) is manufactured in the same manner as in the above embodiment. That is, while supplying hard synthetic resin to the first extruder connected to the first extruder connection hole (31) of the mold (15), the second extruder connected to the second extruder connection hole (32). While supplying a soft synthetic resin to an extruder, a foamable resin is supplied to the 3rd extruder connected to the 3rd extruder connection hole (33), and each resin is extruded from each extruder.
[0029]
Thus, the hard synthetic resin in the heated and melted state is extruded from the hollow member extrusion port (11) through the first extruder connection hole (31) and the first extrusion flow path (34), while the soft synthetic in the heated and melted state. The resin is extruded from the connection piece extrusion port (12) through the second extruder connection hole (32) and the second extrusion flow path (35), and at the same time, the foamable resin in a heated state becomes the third extruder connection hole ( 33), extruded from the foam extrusion port (13) through the third extrusion channel (36), and immediately starts foaming inside the hard synthetic resin (inside the hollow member) to form the foam (4). In this way, the hollow members (2) (2) (2) (2) filled with the synthetic resin foams (4) (4) (4) (4) in the respective hollow spaces, and the connecting pieces ( 3) (3) (3) (3) (3) and the structural unit member (6B) in which the integrated unit is alternately connected and integrated simultaneously In can be produced.
[0030]
Next, a plurality of the structural unit members (6B) are welded together with the connecting pieces (3) to produce a heat insulating composite plate-like molded body (1B) shown in FIG. The method for welding the connecting pieces (3) is not particularly limited, and examples thereof include a high frequency dielectric heating method, an ultrasonic welder method, and a method of bonding with an adhesive.
[0031]
As described above, according to the manufacturing method of the present invention, the foam extrusion port (13) is disposed in the inner space surrounded by the hollow member extrusion port (11) in the mold, and from the extrusion port (13). Since the foamable resin is extruded, the synthetic resin foam (4) is filled in the hollow space of the hollow member (2) in accordance with the simultaneous extrusion molding of the hollow member (2) and the connecting piece (3). Since the three different types of members (2), (3), and (4) can be simultaneously extruded, the productivity is excellent. Further, in the internal space of the hard synthetic resin (hollow member) immediately after extrusion, the foamable resin expands and comes into contact with the hard synthetic resin, that is, the hard synthetic resin and the resin foam (4) are in contact with each other. Since the contact is made at the molding temperature or at a temperature close to the molding temperature, sufficient bonding strength between the hollow member (2) and the resin foam (4) is secured in the obtained heat insulating composite plate-like molded body (1A) (1B). can do. Therefore, it is possible to prevent water from entering the interface between the hollow member (2) and the resin foam (4), and to ensure sufficient lightness as the heat insulating composite plate-like molded bodies (1A) (1B). Can do.
[0032]
In addition, the said manufacturing method is a method suitable for manufacturing a heat insulating composite plate-shaped molded object with a long connection length (that is, a large number of connections of hollow members), and a short connection length (connection of hollow members). In the case of producing a heat-insulating composite plate-like molded body having a small number, the step of welding the connecting pieces (3) may not be particularly provided. That is, it is possible to use the above-described three-component co-extruded unit component members (6A) and (6B) themselves as the heat insulating composite plate-like molded products (1A) and (1B). It may be selected as appropriate depending on the connection length.
[0033]
The hard synthetic resin used in the production method of the present invention is not particularly limited, and examples thereof include polypropylene resin, ABS resin (acrylonitrile-butadiene-styrene copolymer resin), and hard vinyl chloride resin. Among them, it is preferable to use a polypropylene resin because it is excellent in heat resistance and chemical resistance and does not generate a toxic gas such as hydrogen chloride at the time of incineration or the like and can sufficiently meet the demand for environmental conservation.
[0034]
In addition, the soft synthetic resin used in the production method of the present invention is not particularly limited, and examples thereof include a thermoplastic synthetic resin or a soft synthetic resin softened by adding a modifier to a hard synthetic resin such as polypropylene. .
[0035]
Examples of the former thermoplastic elastomer include hydrogenated styrene / conjugated diene rubber represented by hydrogenated styrene / butadiene rubber (HSBR), or styrene / ethylene / butylene / styrene block copolymer. Hydrogenated styrene / conjugated diene / styrene block copolymer or a copolymer of two or more components selected from the group consisting of ethylene, propylene and butene-1 (for example, ethylene / butene copolymer rubber, propylene / Butene copolymer rubber, ethylene / propylene / butene copolymer rubber, etc.).
[0036]
Examples of the modifier for softening in the latter include, for example, the former thermoplastic elastomer, and particularly preferred are ethylene / propylene / diene / methylene copolymers, styrene / ethylene / butylene / styrene copolymers. And a styrene / ethylene / propylene / styrene copolymer.
[0037]
Examples of the soft synthetic resin include other ethylene / vinyl acetate copolymer resins and ethylene / ethyl acrylate copolymer resins.
[0038]
Moreover, it does not specifically limit as expandable resin used with the manufacturing method of this invention, As a resin component, a styrene resin, a urethane resin, an ABS resin, a polypropylene resin, a polyethylene resin etc. are mentioned, for example. In addition, it is preferable to set the expansion ratio in the case of extrusion foaming so that it may become the range of 5-20 times. Of course, for example, a foamable resin containing foamable synthetic resin beads such as foamable polystyrene beads may be used for high foaming (20 to 40 times). It is preferable that the closed cell synthetic resin foam (4) is foam-extruded by foaming of the foamable resin. Thus, if the synthetic resin foam (4) is of the closed cell type, water can be prevented from entering the foam (4) itself, and the plate-like bodies (1A) (1B) can be prevented. There is an advantage that light weight can be more reliably ensured.
[0039]
In any of the hard synthetic resin, soft synthetic resin, and foamable resin, various additives such as an antioxidant, a stabilizer, a filler, an ultraviolet absorber, an antistatic agent, and a pigment may be added as necessary. Also good.
[0040]
The use of the heat insulating composite plate-like molded body (1A) (1B) manufactured by the manufacturing method of the present invention is not particularly limited. For example, as a shutter-type bathtub lid, a folding bathtub lid, a folding door, a partition, etc. Used. If the manufacturing method of this invention is used, as above-mentioned, it is excellent in the joining force between a hollow member (2) and a resin foam (4), and it is to the interface of a hollow member (2) and a resin foam (4). Since water can be effectively prevented from entering, it is particularly suitable as a method for manufacturing a shutter-type bathtub lid and a folding bathtub lid that are particularly required to avoid a reduction in lightness due to water penetration.
[0041]
【Example】
Next, specific examples of the present invention will be described.
[0042]
<Example 1>
A heat-insulating composite plate-like molded body (1A) that can be wound up was manufactured by the above-described manufacturing method using the mold (10) having the configuration shown in FIG. Polypropylene resin is used as the hard synthetic resin, polypropylene thermoplastic elastomer is used as the soft synthetic resin, and “Eslen beads (trade name)” (expandable polystyrene beads containing a foaming agent, butane gas component is butane gas as the foamable resin. Sekisui Plastics Co., Ltd.) was used. A structural unit member (four hollow members, synthetic resin foam) is formed by coextrusion molding of the hollow member, the connecting piece and the synthetic resin foam (closed cells) so that the foaming resin has a foaming ratio of 15 times. 4 pieces and 5 connecting pieces), 5 of these structural unit members were welded together with each other to obtain a heat-insulating composite plate-like molded body (1A) that can be wound up.
[0043]
<Example 2>
A heat-insulating composite plate-like molded body (1A) that can be rolled up was obtained in the same manner as in Example 1 except that expandable polypropylene beads were used instead of “eslen beads” as the expandable resin.
[0044]
<Example 3>
A foldable heat-insulating composite plate-like molded body (1B) was manufactured by the above-described manufacturing method using the mold (15) having the configuration shown in FIG. A polypropylene resin was used as the hard synthetic resin, a polypropylene thermoplastic elastomer was used as the soft synthetic resin, and the “Eslen beads (trade name)” was used as the foamable resin. A structural unit member (four hollow members, synthetic resin foam) is formed by coextrusion molding of the hollow member, the connecting piece and the synthetic resin foam (closed cells) so that the foaming resin has an expansion ratio of 15 times. 4 pieces and 5 connecting pieces), and 5 of these structural unit members were welded together with each other to obtain a foldable heat-insulating composite plate-like molded body (1B).
[0045]
<Example 4>
A foldable heat-insulating composite plate-like molded body (1B) was obtained in the same manner as in Example 3, except that expandable polypropylene beads were used instead of “eslen beads” as the expandable resin.
[0046]
Even if all the heat insulating composite plate-shaped molded bodies produced in Examples 1 to 4 are used as a bathtub lid for a long period of time, water does not enter between the hollow member and the resin foam, and as a bathtub lid. It was not recognized that the light weight of the hollow member could be sufficiently maintained, and that the excellent rigidity of the hollow member was not lowered by long-term use. In addition, in the heat insulating composite plate-like molded bodies of Examples 2 and 4, all of the hollow member, the connecting piece, and the synthetic resin foam (in the hollow space of the hollow member) are made of the same kind of resin (polypropylene resin). Therefore, there is an advantage that the composite plate-like molded body can be easily recycled.
[0047]
【The invention's effect】
According to the manufacturing method of Claim 1 and Claim 2, since a hollow member, a connection piece, and a synthetic resin foam can be coextruded, it is excellent in productivity. In addition, since the hard synthetic resin and the resin foam can be brought into contact with each other at a molding temperature or at a temperature close to the molding temperature and bonded, a product having excellent bonding strength between the hollow member and the resin foam is manufactured. In the obtained plate-like molded product, water can be effectively prevented from entering the interface between the hollow member and the resin foam, and as a result, the heat-insulating composite plate-shaped molded product can sufficiently maintain lightness. . Furthermore, since the resin foam joined to the hollow space of the hollow member with sufficient joining strength can be filled, the rigidity as the hollow member can be remarkably improved.
[0048]
Moreover, the manufacturing method of Claim 2 has the advantage that it can manufacture easily even if it is a plate-shaped molded object with a long connection length by setting the number of connection of a structural unit member arbitrarily.
[0049]
According to the manufacturing method of claim 3, in addition to the above effects, the bonding strength between the hollow member made of hard synthetic resin and the connecting piece made of soft synthetic resin can be further improved, and the durability is more excellent. A heat insulating composite plate-like molded body can be produced.
[Brief description of the drawings]
FIG. 1 is a front perspective view showing a mold used in the manufacturing method of the present invention.
FIG. 2 is a rear perspective view of the same.
FIG. 3 is a cross-sectional view taken along line AA in FIG.
4 is a cross-sectional view taken along line BB in FIG. 3. FIG.
FIG. 5 is a cross-sectional view showing a structural unit member co-extruded from a mold.
FIG. 6 is a perspective view showing a heat insulating composite plate-like molded body.
FIG. 7 is a front side perspective view showing another example of a mold used in the manufacturing method of the present invention.
FIG. 8 is a cross-sectional view showing another example of a heat insulating composite plate-like molded body.
[Explanation of symbols]
1A, 1B ... heat insulating composite plate-shaped molded body
2 ... Hollow member
3. Connection piece
4 ... Resin foam
6A, 6B ... structural unit members
10, 15 ... Mold
11 ... Hollow member extrusion port
12 ... Connecting piece extrusion port
13 ... Foam extrusion port

Claims

A plurality of long hollow members made of a predetermined synthetic resin are arranged in parallel, and adjacent hollow members are connected and integrated by a long connecting piece made of a soft synthetic resin softer than the predetermined synthetic resin. In addition, a method for producing a foldable or rollable heat-insulating composite plate-like molded body, in which a hollow space of the hollow member is filled with a synthetic resin foam,
While the hollow member extrusion port and the connecting piece extrusion port are provided in an arrangement and shape corresponding to the cross-sectional shape of the composite plate-shaped molded body, one or a plurality of foams are provided in the inner space surrounded by each hollow member extrusion port. Using a mold in which an extrusion port is arranged, while extruding a predetermined synthetic resin from a hollow member extrusion port, extruding a soft synthetic resin softer than the predetermined synthetic resin from a connection piece extrusion port, and a foam extrusion port was pushed out more foamable resin, the predetermined composite resin extruded from the time the hollow member extrusion port, and the soft synthetic resin extruded from the connecting piece extrusion port becomes the contact inside position of the mold By doing so, the composite plate-shaped molded body is manufactured by coextrusion molding, and a method for manufacturing a heat-insulating composite plate-shaped molded body that can be folded or rolled up.

A plurality of long hollow members made of a predetermined synthetic resin are arranged in parallel, and adjacent hollow members are connected and integrated by a long connecting piece made of a soft synthetic resin softer than the predetermined synthetic resin. In addition, a method for producing a foldable or rollable heat-insulating composite plate-like molded body, in which a hollow space of the hollow member is filled with a synthetic resin foam,
While the hollow member extrusion port and the connection piece extrusion port are provided in an arrangement and shape corresponding to the cross-sectional shape of the plurality of connection units of the integrated hollow member and the connection piece, the inner space surrounded by the respective hollow member extrusion ports A soft synthetic resin that is softer than the predetermined synthetic resin from the connecting piece extrusion port while extruding the predetermined synthetic resin from the hollow member extrusion port using a mold in which one or a plurality of foam extrusion ports are respectively disposed with extrude, and pushed out the foamable resin from foam extrusion port, and a predetermined synthetic resin extruded from the time the hollow member extrusion port, and the soft synthetic resin extruded from the connecting piece extrusion port, the mold by such a contact at the inner position, the structural unit members and hollow members of synthetic resin foam filled in the hollow space and the connecting pieces are more integrally connected simultaneous The composite plate-like molded body is manufactured by extrusion molding, and then the plurality of structural unit members are welded together to produce the composite plate-shaped molded body, which can be folded or rolled up. Manufacturing method.

The method for producing a heat-insulating composite plate-like molded body that can be folded or rolled up according to claim 2, wherein the welding is performed by an ultrasonic welder method.

The folding according to any one of claims 1 to 3, wherein the foamable resin expands and contacts with the predetermined synthetic resin in the internal space of the predetermined synthetic resin hollow member immediately after extrusion. Or the manufacturing method of the heat insulation composite plate-shaped molded object which can be wound up freely.

Polypropylene resin is used as the predetermined synthetic resin, and the soft synthetic resin is a soft synthetic resin, thermoplastic elastomer, ethylene / vinyl acetate copolymer resin or ethylene / acrylic acid, which is softened by adding a thermoplastic elastomer to polypropylene. The manufacturing method of the heat insulating composite plate-shaped molded object of any one of Claims 1-4 which uses an ethyl copolymer resin.

Polypropylene resin is used as the predetermined synthetic resin, and as the soft synthetic resin, a soft synthetic resin obtained by adding a thermoplastic elastomer to polypropylene and softened, a polypropylene thermoplastic elastomer, an ethylene / vinyl acetate copolymer resin or an ethylene The manufacturing method of the heat insulating composite plate-shaped molded object of any one of Claims 1-4 which uses an ethyl acrylate copolymer resin.