JP4429041B2 - Manufacturing method and manufacturing apparatus for composite molded product and composite molded product - Google Patents

Description

  The present invention relates to a composite molded article in which a skin made of a thermoplastic resin sheet (hereinafter abbreviated as a sheet) and a foamed synthetic resin molded article are laminated, a method for producing the same, and a production apparatus. The composite molded product of the present invention includes, for example, housing equipment members such as unit bath ceiling materials, automobile interior materials (instrumental panels, door panels, seat back panels, steering wheels, handles, etc.), furniture (chair seats). Etc.), containers, interior materials, wall materials and the like.

The purpose of improving the surface of a foamed synthetic resin molded article is to improve durability. Conventionally, as a method of improving the surface of a foamed synthetic resin molded product, a sheet made of polypropylene (PP), polyethylene (PE), high impact polystyrene (HIPS), etc. is laminated on the surface of the foamed synthetic resin molded product, and this is applied to the skin. A composite molded product has been proposed.
Conventionally, as a method of manufacturing this type of composite molded product, after attaching a skin film or sheet pre-formed in a shape along the cavity surface to one or both of the male mold and the female mold, the mold is clamped. In a method for producing a foamed resin molded article with a skin by filling and expanding the foamed resin particles and heating and foaming the particles, the surface of the cavity film is increased by increasing the pressure in the cavity of the skin film or sheet attached to the cavity surface. A method for producing a foamed resin molded article with a skin, characterized in that it comprises a step of further closely adhering to (see, for example, Patent Document 1).

Further, even when the skin material does not have air permeability and the foam layer has a large thickness, the foam material in the mold and the foam material in the mold are strengthened at the same time as the foam material is produced from the pre-foamed particles. There has been proposed a method for producing a polypropylene resin-in-mold foam-molded body having a skin that can be integrated and does not cause poor fusion (for example, see Patent Document 2).
JP 2002-292669 A JP-A-6-891

Patent Document 1 describes that a foamed resin molded article with a skin is manufactured by mounting a sheet on the uneven surface, but details thereof are not described.
Patent Document 2 describes a fixture such as an insert, but does not describe details of its structure and the like.
In general, it takes time and effort to accurately position and fix the sheet in the mold, and there is a problem that it is difficult to manufacture a non-defective product because the sheet is easily displaced during foaming in the mold.
In addition, in the conventional technology in which a sheet is formed in advance and then placed in a mold and filled with thermoplastic resin foam particles, an extra manufacturing process is required to form the sheet separately, and the manufacture There is a problem that takes time and labor.

  The present invention has been made in view of the above circumstances, and in order to easily and efficiently produce a composite molded product in which a skin made of a thermoplastic resin sheet (hereinafter referred to as a sheet) is laminated on the surface of a thermoplastic resin foam molded product. An object of the present invention is to provide a manufacturing method of the above, a manufacturing apparatus used therefor, and a composite molded product obtained by the method.

In order to achieve the above object, the present invention provides a male that constitutes a molding die by engaging a sheet edge of a frame member having a sheet engaging portion with a sheet edge engaged with the sheet material. By attaching the frame material to the female mold of the mold and the female mold, heating and softening the sheet, clamping the male mold and the female mold, and pressing the sheet with the convex portion provided in the male mold The sheet is molded in-mold, the sheet is brought into contact with the male mold side, and then the foamed thermoplastic resin particles are filled between the female mold and the sheet, and then the mold is heated to a temperature equal to or higher than the fusion temperature of the foamed thermoplastic resin particles. A composite characterized in that it is molded in-mold by heating to a temperature, and a composite molded product is produced in which a sheet skin is laminated on the surface of a thermoplastic resin foam molded product and a frame material is joined to the edge thereof A method for producing a molded article is provided.
In the manufacturing method of the present invention, the frame material that protrudes from the peripheral edge of the male mold and presses the frame material attached to the female mold at its tip, and the frame material is pressed by a plurality of pressing pins that advance and retreat according to the interval between the male mold and the female mold. Then, it is preferable to fix the sheet to the frame member.
In the production method of the present invention, the frame material is preferably a fixing frame material used when attaching the composite molded product to another part.

The present invention also includes a male mold and a female mold each having a large number of vapor holes, and a mold in which a cavity is formed that matches the outer shape of the composite molded product manufactured when the mold is clamped. In an apparatus for manufacturing a composite molded product in which a sheet and thermoplastic foam particles are placed inside and the composite molded product is manufactured by in-mold molding by heating above the fusion temperature of the thermoplastic resin foam particles, Provided is an apparatus for manufacturing a composite molded product, characterized in that an attachment portion is provided for removably attaching a frame member having the sheet stretched by locking the edge of the sheet to the stop portion.
In the manufacturing apparatus of the present invention, a configuration is provided in which a plurality of pressing pins are provided that protrude from the peripheral edge of the male mold and press the frame member attached to the female mold at the tip, and advance and retreat according to the interval between the male mold and the female mold. It is preferable that
In the manufacturing apparatus of the present invention, the frame material is preferably a fixing frame material used when the composite molded product is attached to another part.

  Further, the present invention is obtained by the above-described production method according to the present invention, and is characterized in that a sheet skin is laminated on the surface of a thermoplastic resin foam molded article and a frame material is bonded to the edge thereof. Provide composite molded products.

The method for producing a composite molded product according to the present invention includes a male member that forms a mold by engaging a sheet edge of a frame member having a sheet engaging portion with a sheet edge engaged with the frame member. The frame material is attached to the female mold of the mold and the female mold, the sheet is heated and softened, the mold is clamped and the sheet is pressed and molded by the male convex portion, the male mold side sheet and the female mold Thermoplastic resin foam particles are filled in between and heated, and molded in-mold, and a composite molded product is produced in which the surface of the thermoplastic resin foam molded product is laminated, so the sheet is attached. Since the edge of the sheet can be firmly fixed, no deviation occurs during sheet forming, and a high-quality composite molded product can be stably manufactured.
In addition, the softened sheet is pressed by the male convex part and molded, and the sheet is molded by the pressure generated during the molding of the foamed particles. It is possible to manufacture a composite molded product having a simple shape.

Further, the composite molded product manufacturing apparatus of the present invention has a structure in which a female die is provided with an attachment portion for removably attaching a frame member in which the edge of the sheet is engaged with the sheet engagement portion and the sheet is stretched. Therefore, the frame member with the sheet stretched is attached to the female mold attachment part, and after heating and softening the sheet, the mold is clamped and the sheet is pressed and molded by the male convex part. Fill the thermoplastic resin foam particles between the sheet and the female mold, heat and mold in-mold, laminate the sheet skin on the surface of the thermoplastic resin foam molding, and join the frame material to the edge The formed composite molded product can be efficiently manufactured using a single molding apparatus.
In addition, by pressing the frame member attached to the female mold at the tip thereof protruding from the peripheral edge of the male mold, by having a configuration provided with a plurality of pressing pins that advance and retreat according to the interval between the male mold and the female mold, The fixing force of the sheet can be increased, and the sheet can be reliably prevented from shifting during sheet forming.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIGS. 1-7 is a figure for demonstrating an example of the manufacturing method of the composite molded product which concerns on this invention, FIG. 1 attaches the frame material 5 which stretched | stretched the sheet | seat 2 to the attaching part 7 of the female die 4. FIG. FIG. 2 is a cross-sectional view of the main part of the frame member 5 used in the method of the present invention, and FIG. 3 shows a state in which the frame member 5 is fixed by the pressing pin 13 of the male mold 3. 4 is a cross-sectional view of the main part of the mold 1 shown in FIG. 4, FIG. 4 is a cross-sectional view of the main part of the mold 1 showing a state in which a sheet heated by the male mold 3 is formed simultaneously with clamping, and FIG. FIG. 6 is a perspective view showing an example of a composite molded product obtained by the manufacturing method of the present invention, and FIG. 7 is a diagram showing the composite molded product attached as a ceiling material. It is principal part sectional drawing which shows a state.
In these drawings, reference numeral 1 denotes a molding die, 2 denotes a sheet, 3 denotes a male die, 3A denotes a convex portion, 4 denotes a female die, 5 denotes a frame material, 6 denotes a sheet locking portion, 7 denotes a mounting portion, and 8 denotes a mounting portion. Piece, 9 is a locking claw, 10 is a support convex part, 11 is a cover attaching part, 11A is a protrusion, 12 is a storage part, 13 is a pressing pin, 14 is a cavity, 15 is a thermoplastic resin foam molded product, 16 is a composite A molded article, 17 is a skin, 18 is a wall, and 19 is a decorative cover.

  In the manufacturing method of the present invention, as a manufacturing apparatus to be used, a mounting portion 7 for attaching the frame material 5 to the peripheral portion of the female die 4 is provided, and protrudes from the peripheral portion of the male die 3 to the female die 4 at its tip. A plurality of pressing pins 13 that press the attached frame material 5 and advance and retreat according to the distance between the male mold 3 and the female mold 4 are provided, and a part of the frame material 5 (supporting convex portion) is clamped to the male mold 3. 10 and the cover mounting portion 11) are used, which are provided with the mold 1 provided with a storage portion 12 for storing the same. The configuration of each part of the manufacturing apparatus other than the mold 1 is not particularly limited, and the configuration of a conventionally known foam molding apparatus that is usually used for in-mold foam molding of thermoplastic resin foam molded products can be employed.

  In the molding die 1, the attachment portion 7 for attaching the frame member 5 can be a pin-like attachment portion 7 that is formed to protrude along the periphery of the female die 4 at predetermined intervals. With such an attachment portion 7, the frame material 5 can be easily attached, and the foamed particles are moved by the attachment portion 7 when the mold 14 is clamped to fill the cavity 14 with the thermoplastic resin foam particles. The thermoplastic resin foam particles can be filled in the peripheral portion without any gap.

  In the mold 1, the plurality of pressing pins 13 protruding from the peripheral edge of the male mold 3 can be attached to the peripheral edge of the male mold 3 by a spring or an air cylinder, and particularly preferably attached by an air cylinder so as to be able to advance and retreat. These air cylinders are attached to the back side of the peripheral edge (housing portion 12) of the male mold 3, and are set by inserting a pressing pin 13 into a through hole (not shown). The pressing pin 13 presses the frame member 5 attached to the female die 4 at its tip, fixes the sheet 2 locked by the frame member 5 so as not to come out of the frame member, and reliably prevents the sheet 2 from shifting. Used to do. The pressing pin 13 presses the frame material 5 attached to the female die 4 at its tip, and is pushed in along with the movement of the male die 3 at the time of clamping.

  In this mold 1, the male mold 3 is provided in accordance with the shape and size of the portion of the frame material 5 exposed in the composite molded product 16 that is partly manufactured of the frame material 5 when the mold is clamped. The supporting convex portion 10 and the cover attaching portion 11 and the concave portion for accommodating the peripheral portion thereof are provided.

An apparatus for manufacturing a composite molded article having such a mold 1 attaches a frame material 5 with a sheet 2 stretched to an attachment portion 7 of a female mold 4, heats and softens the sheet 2, and then clamps the mold. Then, the sheet 2 is pressed and molded by the convex portion 3A of the male mold 3, and the thermoplastic resin foam particles are filled between the sheet 3 on the male mold 3 side and the female mold 4, and are heated and molded in the mold. The composite molded product 16 in which the skin 17 made of the sheet 2 is laminated on the surface of the thermoplastic resin foam molded product 15 and the frame material 5 is joined to the edge thereof is efficiently manufactured using a single molding apparatus. be able to.
Further, a plurality of pressing pins 13 that protrude from the peripheral edge of the male mold 3 and press the frame member 5 attached to the female mold 3 at the tip thereof and advance and retreat according to the distance between the male mold 3 and the female mold 4 are provided. By setting it as a structure, the fixing force of the sheet | seat 2 can be raised and the shift | offset | difference of the sheet | seat 2 at the time of sheet forming can be prevented reliably.

  FIG. 2 is a sectional view of an essential part of the frame member 5 used in the method of the present invention. The frame member 5 is made of a synthetic resin such as a polyethylene resin or a polypropylene resin. In this example, the frame member 5 has a long U-shape, a main body portion on which a sheet locking portion 6 that is locked with the sheet 2 interposed therebetween is formed, and a pair of mounting pieces protruding above the main body portion. 8, and a support convex portion 10 and a cover attaching portion 11 that are formed to protrude from below the main body portion. The mounting piece 8 is attached to the mounting portion 7 of the female mold 4 so that the frame member 5 is detachably mounted on the female mold 4 side, and is embedded in the thermoplastic resin foam molded product 15 after in-mold foam molding. Thus, it has a function of strengthening the bonding between the thermoplastic resin foam molded product 15 and the frame material 5. In addition, when the support convex part 10 and the cover attaching part 11 are attached to the wall 18 of the composite molded product 16, they can be easily attached with the upper end part of the wall 18 being inserted between them, A decorative cover 19 can be easily attached to the cover attaching portion 11.

  As shown in FIG. 2, it is desirable to provide a plurality of locking claws 9 on the sheet locking portion 6 of the frame member 5. When the sheet is sandwiched between the sheet locking portions 6, the locking claws 9 bite into the sheet 2, and it becomes difficult for the sheet 2 to come out of the sheet locking portions 6. The locking structure of the sheet 2 by the sheet locking portion 6 is not limited to this example.

The sheet 2 used in the method of the present invention is preferably a thermoplastic resin single-layer sheet, a laminated sheet obtained by laminating a plurality of sheets or films, or a sheet obtained by laminating a plurality of sheets or films. Examples of the thermoplastic resin include polyethylene, polypropylene, polystyrene, and polyethylene terephthalate (PET). The sheet 2 may be formed only from a non-foamed sheet or film, or a low-magnification foamed resin sheet may be used. As the low-magnification foamed resin sheet, a laminated sheet in which a high impact polystyrene film is laminated as a surface layer on a foamed polystyrene resin sheet having a density of 140 to 500 kg / m ³ is preferable.

As the thermoplastic resin expanded particles, for example, expanded beads obtained by pre-expanding a resin such as polyethylene, polypropylene, polystyrene, polyethylene terephthalate (PET) to an appropriate density are used. Preferred thermoplastic resin foam particles in the present invention include polystyrene resin foam beads having a density in the range of 50 to 200 kg / m ³ .

  In order to produce a composite molded article using these materials by the method of the present invention, first, in the male and female molds in the mold open state (see FIGS. 1 and 3), the attachment part 7 on the female mold 4 side A frame member 5 on which a sheet 2 is stretched in advance is attached. As shown in FIG. 1, the frame member 5 is attached in a state where the edge of the sheet 2 is engaged and the attachment portion 7 of the female mold 4 is sandwiched between a pair of engaging claws 8.

  Next, as shown in FIG. 3, the pressing pin 13 is raised from the storage portion 12 of the male mold 3, the tip thereof is brought into contact with the frame material 5 attached to the female mold 4, and the frame material 5 is pressed. Due to the pressing of the pressing pin 13, the frame member 5 attached with the sheet 2 interposed therebetween is pressed between the distal end of the mounting portion 7 and the pressing pin 13, and is thus sandwiched between the sheet locking portions 6. It is possible to reliably prevent the sheet 2 from coming off or slipping.

  Next, the mold 1 is heated by steam through the male mold 3 and the female mold 4 to heat and soften the sheet 2. This sheet softening condition is appropriately set according to the material of the sheet 2 to be used, the sheet thickness, and the like.

  Next, one or both of the male mold 3 and the female mold 4 are moved in the direction in which the respective molds approach and the molds are clamped. At the time of clamping, the convex portion 3A of the male mold 3 comes into contact with the softened sheet 2, and the sheet 2 is formed along the shape of the convex portion 3A.

  FIG. 4 is a view showing a state in which the male mold 3 and the female mold 4 are clamped. In this clamped state, the sheet 2 formed by the convex portion 3A adheres to the inner surface side of the male mold 3. A cavity 14 is formed between the sheet 2 and the inner surface side of the female mold 4. The frame 5 has an upper portion in contact with the attachment portion 7 of the female mold 4 and a lower portion in contact with the upper end of the male storage portion 12. The support convex portion 10 and the cover mounting portion 11 of the frame member 5 are inserted into a concave portion (storage space) provided in the storage portion 12 of the male mold 3.

Next, the foamed thermoplastic resin particles are filled into the cavity 14 through a supply pipe (not shown) connected to one of the female dies 4.
Next, the molding die 1 is steam-heated to a temperature equal to or higher than the fusing temperature of the thermoplastic resin foamed particles and subjected to in-mold foam molding, and as shown in FIG. A composite molded product is manufactured in which the frame material 5 is bonded to the edge of the laminated material.

  In this in-mold foam molding, as shown in FIG. 5, the attachment piece 8 of the frame material 5 is embedded in the thermoplastic resin foam molded product 15, and the thermoplastic resin foam molded product 15 and the frame material 5. The sheet 2 is laminated on the one surface side of the thermoplastic resin foam molded product 15 with the edge being locked to the frame member 5. During this in-mold foam molding, the sheet 2 is pressed against the inner surface of the male mold 3 by the foamed and expanded thermoplastic resin foam molded product 15 and undergoes molding in which the shape of the male mold 3 is transferred. can get.

  Next, after the mold 1 is cooled with cooling water and drained, operations such as evacuation and introduction of air after evacuation are performed, the male mold 3 is separated from the female mold 4 and the mold is opened, and the composite molded product is molded. Take out from. When the composite molded product is removed from the mold 1, the mounting piece 8 of the frame material 5 is extracted from the mounting portion 7 of the female mold 4.

In the manufacturing method of this composite molded product, the edge of the sheet 2 is locked to the sheet locking portion 6 of the frame material 5 having the sheet locking portion 6, and the sheet 2 is stretched on the frame material 5. The frame 5 is attached to the female mold 4 out of the male mold 3 and the female mold 4 constituting the sheet, and after heating and softening the sheet 2, the mold 2 is clamped and the sheet 2 is pressed by the convex portion 3A of the male mold 3, Molded, filled with thermoplastic resin foam particles between the sheet 3 on the male mold 3 side and the female mold 4, heated and molded in-mold, and the outer surface of the thermoplastic resin foam molded article 15 made of the sheet 2. Since the composite molded product is manufactured by laminating the sheet 2, the attachment of the sheet 2 is easy, and the edge of the sheet 2 can be firmly fixed. It can be manufactured stably.
Further, since the softened sheet 2 is pressed and molded by the convex portion 3A of the male mold 3, and the sheet is molded by the pressure generated when the foamed particles are molded in the mold, a clean outer skin can be obtained. At the same time, it is possible to manufacture a complex molded article having a complicated shape.

FIG. 6 is a perspective view showing an example of a composite molded product manufactured using the above-described method for manufacturing a composite molded product according to the present invention.
This composite molded product 16 has a structure in which a skin 17 made of a sheet 2 is laminated on one surface side of a thermoplastic resin foam molded product 15 and a frame material 5 is joined to the edge thereof. As a design surface, for example, it is used as a ceiling material of a bathtub. In the present invention, the shape and dimensions of the composite molded product 16 are not particularly limited. Applications of the composite molded article 21 include, for example, housing equipment members such as unit bath ceiling materials, automobile interior materials (instrumental panels, door panels, seat back panels, steering wheels, handles, etc.), furniture (chair seats). Part, etc.), containers, interior materials, wall materials, etc., but are not limited thereto.

FIG. 7 shows a state in which the composite molded product 16 is attached to the upper end portion of the wall 18 with the frame material 5 as a fixing frame material when the composite molded product 16 shown in FIG. 6 is used as a ceiling material.
In the example shown in FIG. 7, the upper end portion of the wall 18 is designed to be fitted into a concave portion between the support convex portion 10 and the cover mounting portion 11 provided so as to project downward from the frame member 5. Therefore, in order to attach the composite molded product 16 (ceiling material) to the upper end portion of the wall 18, the composite molded product 16 is placed on the upper end of the wall 18, and a wall is formed between the support convex portion 10 of the frame material 5 and the cover mounting portion 11. After the upper end of 18 is fitted and the composite molded product 16 is pushed down, the composite molded product 16 can be attached by a simple operation of fastening an appropriate place with a bolt. Further, the exposed cover attaching portion 11 on the inner surface side of the wall 18 can be covered with the decorative cover 19 by using the protrusion 11A.

  This composite molded product 16 is molded by pressing the softened sheet 2 with the convex portion 3A of the male mold 3 by the manufacturing method described above, and further molding the sheet 2 with the pressure generated during the in-mold molding of the expanded particles. Therefore, the skin 17 having a beautiful appearance can be obtained. Moreover, even if it is the complex molded product 16 of a complicated shape, since the sheet | seat 2 can transfer the shape of the male mold | type 3 neatly, the high quality composite molded product 16 which has the skin 17 excellent in the designability can be provided.

It is a figure explaining the manufacturing method of the composite molded product which concerns on this invention, and is principal part sectional drawing of the shaping | molding die which shows the state which attached the frame material which stretched the sheet | seat to the attachment part of the female die. It is principal part sectional drawing which illustrates the frame material used for the method of this invention. It is principal part sectional drawing of the shaping | molding die which shows the state which fixed the frame material with the male press pin. It is principal part sectional drawing of the shaping | molding die which shows the state which shape | molded the sheet | seat heated with the male mold simultaneously with mold clamping. It is principal part sectional drawing of the shaping | molding die which shows the state which manufactures a composite molded product by in-mold foam molding. It is a perspective view which shows an example of the composite molded product obtained with the manufacturing method of this invention. It is principal part sectional drawing which shows the state which attached the composite molded product as a ceiling material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Molding type | mold, 2 ... Sheet | seat, 3 ... Male type | mold, 3A ... Convex part, 4 ... Female type | mold, 5 ... Frame material, 6 ... Sheet | seat latching | locking part, 7 ... Mounting part, 8 ... Mounting piece, 9 ... Locking Claw, 10 ... support convex part, 11 ... cover attaching part, 11A ... projection, 12 ... storage part, 13 ... pressing pin, 14 ... cavity, 15 ... thermoplastic resin foam molded product, 16 ... composite molded product, 17 ... skin , 18 ... wall, 19 ... decorative cover.

Claims (7)

  A male mold and a female mold constituting a mold are formed by latching the edge of the thermoplastic resin sheet to the sheet latching portion of the frame member having the sheet latching portion and stretching the thermoplastic resin sheet on the frame member. Among them, the frame material is attached to the female mold, and the thermoplastic resin sheet is heated and softened, and then the male mold and the female mold are clamped, and the thermoplastic resin sheet is pressed by the convex portion provided in the male mold. In this way, the thermoplastic resin sheet is molded in the mold, the sheet is brought into contact with the male mold side, and then the foamed thermoplastic resin particles are filled between the female mold and the thermoplastic resin sheet, and then the mold is molded into the thermoplastic resin. A composite that is heated in the mold at a temperature equal to or higher than the fusing temperature of the foamed particles, and a surface layer of a thermoplastic resin sheet is laminated on the surface of the thermoplastic resin foam molded product, and a frame material is bonded to the edge thereof. Composite molded product characterized by manufacturing molded product Manufacturing method.   The frame material attached to the female mold is pressed at the tip of the male mold by projecting from the peripheral edge of the male mold, and the frame material is pressed by a plurality of pressing pins that advance and retreat according to the distance between the male mold and the female mold to The method for producing a composite molded product according to claim 1, wherein the method is fixed to a frame material.   The method for producing a composite molded product according to claim 1 or 2, wherein the frame material is a fixing frame material used when the composite molded product is attached to another part. A male mold and a female mold having a large number of vapor holes are provided, and a mold is formed in which a cavity is formed that matches the outer shape of the composite molded product manufactured when the mold is clamped, and a thermoplastic resin is formed in the cavity. In an apparatus for manufacturing a composite molded product in which a sheet and thermoplastic resin expanded particles are put and heated to a temperature higher than the fusion temperature of the thermoplastic resin expanded particles to manufacture a composite molded product by in-mold molding,
An apparatus for manufacturing a composite molded product, characterized in that a female die is provided with an attachment portion for removably attaching a frame member on which the edge of the thermoplastic resin sheet is engaged with the sheet engagement portion and the sheet is stretched. .   5. The composite molding according to claim 4, wherein a plurality of pressing pins are provided that project from the peripheral edge of the male mold and press the frame member attached to the female mold at the tip thereof, and advance and retract according to the distance between the male mold and the female mold. Product manufacturing equipment.   6. The apparatus for producing a composite molded product according to claim 4, wherein the frame material is a fixing frame material used when the composite molded product is attached to another part. It is obtained by the manufacturing method according to any one of claims 1 to 3, wherein a surface layer made of a thermoplastic resin sheet is laminated on a surface of a thermoplastic resin foam molded article and a frame material is bonded to an edge thereof. Characteristic composite molded product.

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