JP4432010B2 - Molded product having sponge-like member - Google Patents

Molded product having sponge-like member Download PDF

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Publication number
JP4432010B2
JP4432010B2 JP2000055252A JP2000055252A JP4432010B2 JP 4432010 B2 JP4432010 B2 JP 4432010B2 JP 2000055252 A JP2000055252 A JP 2000055252A JP 2000055252 A JP2000055252 A JP 2000055252A JP 4432010 B2 JP4432010 B2 JP 4432010B2
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Japan
Prior art keywords
sponge
thermoplastic resin
flexible foam
welding
foam member
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JP2000055252A
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JP2001239588A (en
Inventor
恭 内山
正 菅野
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Shinohara Co Ltd
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Shinohara Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/126—Tenon and mortise joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
    • B29C66/3022—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined
    • B29C66/30223—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined said melt initiators being rib-like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、スポンジ状の部材を用いた成形品に関するものであり、スポンジ状の発泡体部材を硬質の合成樹脂部材に接着して成る成形品及び該成形品に関するする。
【０００２】
【従来の技術】
従来、スポンジ状の部材を有する成形品として、例えば、スポンジ状の塗布用部品を合成樹脂製の柄部に固定して成る化粧料塗布具や塗料用塗布具、スポンジ状材料から成るブラシ部材を合成樹脂製の把持部に固定して成る清掃用具等、多様な成形品が知られている。また、スポンジ状部材は様々な家庭用品や工業用品に接着されて用いられている。
【０００３】
これらの成形品は、これを構成するスポンジ状部材や合成樹脂部材を用途や目的に適合した素材を用いて形成するために、スポンジ状部材の素材と、このスポンジ部品を取り付ける合成樹脂部材の素材は、異種の素材が使用されている場合が多い。従って、二つの部材間の固定には、接着剤を使用して接着したり、別に固定用の部材を使って組み付けたり、針金で固定するなどの手段が採用されている。
【０００４】
【発明が解決しようとする課題】
しかしながら、接着剤による固定手段は、スポンジ状部材に接着剤が必要以上に染み込んでスポンジ状部材の性能が低下したり、ポリエチレンのような素材には接着性がないことから使用できる汎用合成樹脂素材が制限されてしまう等の問題がある。また、接着剤を使用して成る成形品は、耐薬品性や耐溶剤性が悪く、スポンジ部に含浸させる溶液によって接着面が剥離しやすくなる等、接着剤を使用したことに伴う問題を多く有しており、用途の点で大きな制約を受けている。
【０００５】
また、固定用の部材や針金等の別部品を使って機械的にスポンジ状部材を固定する手段は、固定の為の部品数が増えるうえに、成形品の構造が複雑化して製造工程数も多くる。従って、効率の良い製造が出来ず経済的にも不利であった。
【０００６】
本発明は、上記の問題に鑑みてなされたもので、接着剤やスポンジ状部材を固定するための別部品を使用していないスポンジ状部材を有する成形品及び該成形品の製造方法を提供することにある。
【０００７】
【課題を解決するための手段】
本発明の請求項１に係るスポンジ状部材を有する成形品は、所定形状の熱可塑性樹脂部材と前記熱可塑性樹脂部材とは異種の素材から成る可撓性発泡体部材とを当接させ、前記可撓性発泡体部材の表面から超音波振動溶着機の溶着ホーンを圧接させて超音波振動により前記熱可塑性樹脂部材の一部分を溶融し、前記溶融した樹脂を前記可撓性発泡体部材に浸潤させて硬化して成り、接着剤やスポンジ状部品を固定するための別部品を全く使用することなく構成した。
【０００８】
本発明の請求項２に係るスポンジ状部材を有する成形品は、可撓性発泡体部材に取付穴を設け、前記取付穴に熱可塑性樹脂部材の少なくとも一部分が挿入されていることを特徴としており、熱可塑性樹脂部材の溶着部が可撓性発泡体部材に被覆されて露見せず、見映えの良い成形品とすることができる。
【０００９】
本発明の請求項３に係るスポンジ状部材を有する成形品は、該成形品が洗滌用具であり、耐薬品性や耐溶剤性に優れた洗滌用具を提供することができる。
【００１０】
本発明の請求項４に係る成形品の製造方法は、所定形状の熱可塑性樹脂部材と前記熱可塑性樹脂とは異種の素材から成る可撓性発泡体部材とを当接させ、前記可撓性発泡体部材の表面から超音波振溶着機の溶着ホーンを圧接させて超音波振動により前記熱可塑性樹脂部材の一部分を溶融し、前記溶融した樹脂を前記可撓性発泡体部材に浸潤させて硬化させるものである。
【００１１】
熱可塑性樹脂部材の一部分を溶融して液状化させた樹脂を可撓性発泡部材の網目状構造をした間隙に浸潤させて硬化させることにより、熱可塑性樹脂部材と可撓性発泡部材は溶着部で立体的に結合し、本来素材同士の分子レベルでは融合しない素材から成る部材同士が強固に固定される。
【００１２】
本発明の請求項５に係る成形品の製造方法は、超音波振動の終了後、溶着ホーンによる圧接状態を１〜５秒間持続させることを特徴としており、これにより熱可塑性樹脂部材の溶融部分と可撓性発泡体部材との強制された圧接時間が長くなり、この間に液化した溶融樹脂が可撓性発泡体部材の網目構造に十分に浸潤し、溶融樹脂が硬化することにより立体的な結合を確実にすることができる。
【００１３】
本発明の請求項６に係る成形品の製造方法は、熱可塑性樹脂部材にエネルギー・ダイレクターを突設し、前記エネルギー・ダイレクターを溶融することにより接着部の面積を大きくすることができる。
【００１４】
【発明の実施の形態】
以下、本発明の好適な実施の形態を添付図面を参照しながら詳細に説明する。
【００１５】
図１乃至図３は、本発明のスポンジ状部材を有する成形品Ｓの第１の実施の形態を示しており、成形品Ｓは、本実施の形態では化粧料塗布用具や清掃用具として使用するのに好適なスポンジ状の用具として示してあり、熱可塑性樹脂部材１と可撓性発泡体部材５とから構成されている。
【００１６】
熱可塑性樹脂部材１は、成形品Ｓの柄部や把持部を構成するものであり、ＰＰ、ＡＢＳ、ＰＥＴ等の汎用熱可塑性合成樹脂材料を用いて射出成形方法で長方形に形成されている。図２に示す例では、熱可撓性樹脂部材１の可撓性発泡体部材５を溶着させる面は平坦面とされている。
【００１７】
可撓性発泡体部材５は、成形品Ｓの塗布部やブラシ部を構成するものであり、本実施の形態では、塗布具や清掃用具として好適なように、間隙率が高く十分な可撓性を有し長方形に形成されたウレタン発泡体を使用している。
【００１８】
図２は、上記の成形品Ｓの製造工程を示している。超音波溶着装置の固定治具（図示省略）に固定された熱可塑性樹脂部材１の上面に可撓性発泡体部材５を戴置し、可撓性発泡体部材５の表面から周知の超音波溶着機（図示省略）の溶着ホーン１０を圧接させて２０ｋＨｚの超音波振動を発振する。
【００１９】
これにより、溶着ホーン１０で圧縮された可撓性発泡体部材５を介して、溶着ホーン１０の先端で間接的に押圧されている熱可塑性樹脂部材１の部分が溶融する。図２（ｂ）に示すように、溶融部分６が液状化することにより、可撓性発泡体部材５の溶着ホーン１０による押圧力を受けている部分が撓んで液状化した溶融部分６に溶融することなく圧入する。
【００２０】
上述した操作により、可撓性発泡体部材５の圧入部分に溶融樹脂が浸潤するが、超音波振動の終了後、溶着ホーン１０による圧接状態を１〜５秒間持続させることが好ましい。これにより熱可塑性樹脂部材１の溶融部分６と可撓性発泡体部材５との溶着ホーン１０による強制された圧接時間が長くなり、この間に液状化した溶融樹脂が可撓性発泡体部材５の網目構造に十分に浸潤する。そして、浸潤した溶融樹脂が硬化することにより熱可塑性樹脂部材１の溶融部分６に両部材１、５が立体的に結合した溶着部７が形成され、強固な固定ができる。硬化手段は自然硬化でも冷風による強制硬化でもよい。
【００２１】
本実施の形態では、可撓性発泡体部材５の複数箇所に先端部が棒状の溶着ホーン１０を用いてスポット溶着したので、成形品Ｓの表面に溶着による変形で生じた複数の窪み８が形成されている。この窪み８は、溶融樹脂量を調節することや、圧縮復元性の大きな可撓性発泡体部材５を選択することにより、その深さを浅くしたり目立たなくすることが可能である。窪み８の形状は使用する溶着ホーン１０の形状により変わるものであることは言うまでもない。
【００２２】
また、この製造方法における溶着手段は、熱可塑性樹脂部材１の側だけを溶融して可撓性発泡体部材５を立体的に溶着するものであるので、熱可塑性樹脂部材１の素材としては、異材質との接着性が悪く、且つ柔質のため超音波による伝達溶着には不適とされている軟質のＰＥ、ＰＰも使用することができる。
【００２３】
図３は、成形品Ｓの別の設計による溶着工程を示しており、基本的に上記の工程と同一であるので、図において、上記と共通する部分については同一部号を付しその説明を省略する。
【００２４】
図３（ａ）に示すように、この設計による熱可塑性樹脂部材１の溶着予定箇所には一対のエネルギー・ダイレクター２、２が突設してあり、エネルギー・ダイレクター２、２の突端２ａ、２ａの位置は、溶着ホーン１０の先端面積の大きさの範囲内にあるように設定されている。また、熱可塑性発泡体部材５の溶着面となる側は熱可塑性樹脂部材１に形成されたエネルギー・ダイレクター２と対応する形状に形成されている。
【００２５】
溶着ホーン１０を押圧して振動させると、エネルギー・ダイレクター２、２の部分が溶融する。図３（ｂ）に示すように、溶融部分６が熱可塑性樹脂部材１の表面よりも内側に深くなることが避けられ、液状化した樹脂は溶着ホーン１０による押圧位置を中心にして径方向へ広く浸潤する。従って溶融部分６の面積が広がり、熱可塑性樹脂部材１の表面に広く溶着部７が形成される。
【００２６】
図４乃至図５は、本発明のスポンジ状部材を有する成形品Ｓの第２の実施の形態を拡大して示している。この成形品Ｓは、目元や口元など顔のデリケートな凹凸の部分を洗滌する美容用洗滌用具であり、球形に形成された圧縮復元性の大きな可撓性発泡体部材１と、使用する時に把持軸（図示省略）へ連結する為の連結杆部４を形成する熱可塑性樹脂部材１とから構成されている。
【００２７】
図４に示すように、成形品Ｓが組立られる前の可撓性発泡体部材５には取付孔９が設けられている。また、熱可塑性樹脂部材１は、舌片状の軸部３と連結杆部４とからなり、軸部３の基端における正面と背面には、それぞれ一対のエネルギー・ダイレクター２が突設されている。
【００２８】
成形品Ｓ（洗滌用具）は、可撓性発泡体部材５の取付穴９に熱可塑性樹脂部材１の軸部３を挿入し、超音波溶着機により軸部３両面のエネルギー・ダイレクター２を片面ずつ順次溶融して溶着する。軸部３の両面における溶融したエネルギー・ダイレクター２の位置には、二部材１、５が立体的に結合した溶着部７、７が形成される。尚、二つの溶着コーンで挟んで軸部３両面のエネルギー・ダイレクター２を同時に溶融して溶着してもよい。
【００２９】
本実施の形態における成形品Ｓは、可撓性発泡体部材５が熱可塑性樹脂部材１の軸部３を被覆して溶着部７、７が露出しておらず、且つ、溶着後の可撓性発泡体部材５は完全に球形に自己復元して溶着時の変形が解消されており、見映えの良い美容用洗滌用具となっている。
【００３０】
尚、既述した可撓性発泡体部材５と熱可塑性樹脂部材１との固定手段は、パフやアイシャドウチップのような化粧用塗布具や、洗滌用スポンジのような清掃用具の成形手段として好適であるばかりでなく、その他、様々な家庭用品や工業用品におけるスポンジ状部材の接着手段としても適用されることは言うまでもない。
【００３１】
【発明の効果】
本発明は、以上説明したような形態で実施され、以下に記載されるような効果を奏する。
【００３２】
本発明のスポンジ状部材を有する成形品は、熱可塑性樹脂部材と前記熱可塑性樹脂部材とは異種の素材から成る可撓性発泡体部材とを超音波振動で溶着し、接着剤や可撓性発泡体部材を固定する為の別部品を全く使用していないので、構造がシンプルで部品数も製造工程数も少なく、安価に生産することができる。
【００３３】
また、接着剤を使用しないので、接着剤の染み込みによる可撓性発泡体部材の性能の低下を招くことが無く、耐薬品性や耐溶剤性、衛生性に優れている。また、金属部材を使用してないので廃棄時に分別を必要とせず、環境問題に対応した製品とすることができる。
【００３４】
本発明の成形品の製造方法では、熱可塑性樹脂部材と前記熱可塑性樹脂とは異種の素材から成る可撓性発泡体部材とを超音波振動により前記熱可塑性樹脂部材の一部分を溶融し、溶融した樹脂を可撓性発泡体部材に浸潤させて硬化させるものであるので、二部材は溶着部において立体的に結合し、本来素材同士の分子レベルでは融合しない素材から成る部材同士を強固に固定することができる。
【００３５】
また、接着剤を使用しないので、従来、製造工程中の接着剤の量に左右され易すかった接着部の強度が安定するとともに、硬化時間を必要としないので製造時間を短縮することができる。
【図面の簡単な説明】
【図１】本発明のスポンジ状部材を有する成形品の第１の実施の形態を示す斜視図。
【図２】図１の成形品の製造工程を示す、（ａ）は溶着前の状態の断面図、（ｂ）は溶着中の断面図、（ｃ）は溶着後の断面図。
【図３】図１の成形品の別の設計による製造工程を示す、（ａ）は溶着前の状態の断面図、（ｂ）は溶着中の断面図、（ｃ）は溶着後の断面図。
【図４】本発明のスポンジ状部材を有する成形品の第２の実施の形態を、組立てる前の状態で示す正面図。
【図５】図４の成形品の組立溶着後の状態を示す側面図。
【符号の説明】
１ 熱可塑性樹脂部材，２ エネルギー・ダイレクター，５ 可撓性発泡体部材，９ 取付穴，１０ 溶着ホーン，[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a molded article using the sponge-like member, a sponge-like foam member to a molded article and a molded article formed by bonding a synthetic resin member rigid.
[0002]
[Prior art]
Conventionally, as a molded product having a sponge-like member, for example, a cosmetic applicator, a paint applicator, or a brush member made of a sponge-like material, in which a sponge-like application part is fixed to a synthetic resin handle. Various molded products such as a cleaning tool fixed to a synthetic resin gripping part are known. Sponge-like members are used by being bonded to various household and industrial products.
[0003]
These molded products are made of a sponge-like member and a synthetic resin member that use the material suitable for the purpose and purpose. In many cases, different materials are used. Therefore, for fixing between the two members, means such as bonding using an adhesive, assembly using another fixing member, and fixing with a wire are employed.
[0004]
[Problems to be solved by the invention]
However, the adhesive fixing means is a general-purpose synthetic resin material that can be used because the sponge-like member soaks more than necessary and the performance of the sponge-like member is reduced, or a material such as polyethylene is not adhesive. There are problems such as being restricted. In addition, molded products using adhesives have many problems associated with the use of adhesives, such as poor chemical resistance and solvent resistance, and the adhesive surface is easily peeled off by the solution impregnated in the sponge part. And has significant limitations in terms of application.
[0005]
In addition, the means for mechanically fixing the sponge-like member using another part such as a fixing member or a wire increases the number of parts for fixing, and also makes the structure of the molded product complicated and increases the number of manufacturing processes. Many. Therefore, efficient production is not possible and it is economically disadvantageous.
[0006]
The present invention has been made in view of the above problems, and provides a molded article having a sponge-like member that does not use an adhesive or a separate part for fixing the sponge-like member, and a method for manufacturing the molded article. There is.
[0007]
[Means for Solving the Problems]
According to a first aspect of the present invention, there is provided a molded article having a sponge-like member, wherein a thermoplastic resin member having a predetermined shape is brought into contact with a flexible foam member made of a different material from the thermoplastic resin member, A welding horn of an ultrasonic vibration welding machine is pressed from the surface of the flexible foam member to melt a part of the thermoplastic resin member by ultrasonic vibration, and the molten resin is infiltrated into the flexible foam member. It was made to harden, and it was constituted without using any other parts for fixing the adhesive or sponge-like parts.
[0008]
A molded article having a sponge-like member according to claim 2 of the present invention is characterized in that an attachment hole is provided in the flexible foam member, and at least a part of the thermoplastic resin member is inserted into the attachment hole. In addition, the welded portion of the thermoplastic resin member is covered with the flexible foam member so that it is not exposed, and a molded article having a good appearance can be obtained.
[0009]
The molded product having a sponge-like member according to claim 3 of the present invention is a cleaning tool, and can provide a cleaning tool excellent in chemical resistance and solvent resistance.
[0010]
According to a fourth aspect of the present invention, there is provided a method for producing a molded article, comprising: bringing a thermoplastic resin member having a predetermined shape into contact with a flexible foam member made of a different material from the thermoplastic resin; A welding horn of an ultrasonic vibration welding machine is pressed from the surface of the foam member to melt a part of the thermoplastic resin member by ultrasonic vibration, and the molten resin is infiltrated into the flexible foam member and cured. It is something to be made.
[0011]
The thermoplastic resin member and the flexible foam member are welded by infiltrating and curing the resin liquefied by melting a part of the thermoplastic resin member into the gap formed in the network structure of the flexible foam member. The members made of materials that are three-dimensionally bonded and originally do not fuse at the molecular level of the materials are firmly fixed.
[0012]
The method for producing a molded product according to claim 5 of the present invention is characterized in that after the ultrasonic vibration is finished, the pressure contact state by the welding horn is maintained for 1 to 5 seconds, whereby the molten portion of the thermoplastic resin member and The forced pressure contact time with the flexible foam member becomes longer, and the molten resin liquefied during this time sufficiently infiltrates into the network structure of the flexible foam member, and the molten resin hardens to form a three-dimensional bond. Can be ensured.
[0013]
In the method for producing a molded product according to claim 6 of the present invention, the area of the bonded portion can be increased by projecting an energy director on the thermoplastic resin member and melting the energy director.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of the invention will be described in detail with reference to the accompanying drawings.
[0015]
1 to 3 show a first embodiment of a molded product S having a sponge-like member of the present invention, and the molded product S is used as a cosmetic application tool or a cleaning tool in this embodiment. It is shown as a suitable sponge-like tool, and is composed of a thermoplastic resin member 1 and a flexible foam member 5.
[0016]
The thermoplastic resin member 1 constitutes a handle portion or a grip portion of the molded product S, and is formed into a rectangle by an injection molding method using a general-purpose thermoplastic synthetic resin material such as PP, ABS, or PET. In the example shown in FIG. 2, the surface to which the flexible foam member 5 of the heat flexible resin member 1 is welded is a flat surface.
[0017]
The flexible foam member 5 constitutes an application part and a brush part of the molded product S. In this embodiment, the flexible foam member 5 has a high porosity and sufficient flexibility so as to be suitable as an application tool or a cleaning tool. The urethane foam which has the property and was formed in the rectangle is used.
[0018]
FIG. 2 shows a manufacturing process of the molded product S described above. A flexible foam member 5 is placed on the upper surface of the thermoplastic resin member 1 fixed to a fixing jig (not shown) of the ultrasonic welding apparatus, and a known ultrasonic wave is applied from the surface of the flexible foam member 5. A welding horn 10 of a welding machine (not shown) is brought into pressure contact to oscillate a 20 kHz ultrasonic vibration.
[0019]
Thereby, the portion of the thermoplastic resin member 1 that is indirectly pressed at the tip of the welding horn 10 is melted through the flexible foam member 5 compressed by the welding horn 10. As shown in FIG. 2B, when the melted portion 6 is liquefied, the portion subjected to the pressing force by the welding horn 10 of the flexible foam member 5 is bent and melted into the liquefied melted portion 6. Press fit without doing.
[0020]
Although the molten resin infiltrates into the press-fitted portion of the flexible foam member 5 by the above-described operation, it is preferable to maintain the pressure contact state by the welding horn 10 for 1 to 5 seconds after the end of the ultrasonic vibration. As a result, the forced pressing time of the melted portion 6 of the thermoplastic resin member 1 and the flexible foam member 5 by the welding horn 10 becomes long, and the molten resin liquefied in the meantime becomes longer in the flexible foam member 5. Fully infiltrate the network structure. The infiltrated molten resin is cured to form a welded portion 7 in which the members 1 and 5 are three-dimensionally joined to the melted portion 6 of the thermoplastic resin member 1 and can be firmly fixed. The curing means may be natural curing or forced curing with cold air.
[0021]
In the present embodiment, spot welding is performed using a stick-shaped welding horn 10 having a tip at a plurality of locations on the flexible foam member 5, so that a plurality of depressions 8 caused by deformation due to welding are formed on the surface of the molded product S. Is formed. The depth of the recess 8 can be reduced or made inconspicuous by adjusting the amount of the molten resin or by selecting the flexible foam member 5 having a high compression recovery property. Needless to say, the shape of the recess 8 varies depending on the shape of the welding horn 10 to be used.
[0022]
Moreover, since the welding means in this manufacturing method melt | dissolves only the thermoplastic resin member 1 side and welds the flexible foam member 5 in three dimensions, as a raw material of the thermoplastic resin member 1, Soft PE and PP, which have poor adhesion to different materials and are unsuitable for transmission welding by ultrasonic waves due to softness, can also be used.
[0023]
FIG. 3 shows a welding process according to another design of the molded product S, which is basically the same as the above-described process. Omitted.
[0024]
As shown in FIG. 3 (a), a pair of energy directors 2 and 2 project from the planned welding position of the thermoplastic resin member 1 by this design, and the projecting ends 2a of the energy directors 2 and 2 are provided. The position 2a is set to be within the range of the size of the tip area of the welding horn 10. Further, the side to be the welding surface of the thermoplastic foam member 5 is formed in a shape corresponding to the energy director 2 formed on the thermoplastic resin member 1.
[0025]
When the welding horn 10 is pressed and vibrated, the portions of the energy directors 2 and 2 are melted. As shown in FIG. 3 (b), it is avoided that the melted portion 6 becomes deeper inward than the surface of the thermoplastic resin member 1, and the liquefied resin moves in the radial direction around the pressing position by the welding horn 10. Widely infiltrate. Accordingly, the area of the melted portion 6 is expanded, and the welded portion 7 is formed widely on the surface of the thermoplastic resin member 1.
[0026]
4 to 5 show an enlarged view of the second embodiment of the molded product S having the sponge-like member of the present invention. The molded product S is a cosmetic cleaning tool for cleaning delicate uneven portions of the face such as the eyes and mouth, and is formed into a spherical and flexible foam member 1 having a high compression restoring property and gripped when used. It is comprised from the thermoplastic resin member 1 which forms the connection collar part 4 for connecting with a axis | shaft (illustration omitted).
[0027]
As shown in FIG. 4, a mounting hole 9 is provided in the flexible foam member 5 before the molded product S is assembled. The thermoplastic resin member 1 is composed of a tongue-shaped shaft portion 3 and a connecting collar portion 4, and a pair of energy directors 2 project from the front and back surfaces of the proximal end of the shaft portion 3. ing.
[0028]
In the molded product S (washing tool), the shaft portion 3 of the thermoplastic resin member 1 is inserted into the mounting hole 9 of the flexible foam member 5, and the energy directors 2 on both surfaces of the shaft portion 3 are attached by an ultrasonic welding machine. One side is melted and welded sequentially. At the positions of the melted energy director 2 on both surfaces of the shaft portion 3, weld portions 7 and 7 in which the two members 1 and 5 are three-dimensionally coupled are formed. The energy directors 2 on both sides of the shaft 3 may be melted and welded at the same time, sandwiched between two welding cones.
[0029]
In the molded product S according to the present embodiment, the flexible foam member 5 covers the shaft portion 3 of the thermoplastic resin member 1 so that the weld portions 7 and 7 are not exposed, and the flexible member after the weld is flexible. The expandable foam member 5 is completely restored to a spherical shape and the deformation at the time of welding is eliminated, so that the cosmetic cleaning tool has a good appearance.
[0030]
In addition, the fixing means of the flexible foam member 5 and the thermoplastic resin member 1 described above is used as a molding means for a cosmetic applicator such as a puff or eye shadow chip, or a cleaning tool such as a cleaning sponge. Needless to say, it is not only suitable, but also applied as a means for adhering sponge-like members in various household and industrial products.
[0031]
【The invention's effect】
The present invention is implemented in the form as described above, and has the effects described below.
[0032]
The molded product having a sponge-like member of the present invention is obtained by welding a thermoplastic resin member and a flexible foam member made of a different material from the thermoplastic resin member by ultrasonic vibration, and thereby adhesive or flexible Since no separate parts for fixing the foam member are used, the structure is simple, the number of parts and the number of manufacturing processes are small, and the production can be inexpensively performed.
[0033]
Further, since no adhesive is used, the performance of the flexible foam member is not deteriorated due to the penetration of the adhesive, and the chemical resistance, solvent resistance, and hygiene are excellent. In addition, since no metal member is used, separation is not required at the time of disposal, and the product can cope with environmental problems.
[0034]
In the method for producing a molded article of the present invention, a part of the thermoplastic resin member is melted by ultrasonic vibration of a thermoplastic resin member and a flexible foam member made of a different material from the thermoplastic resin. Since the molded resin is infiltrated into the flexible foam member and cured, the two members are three-dimensionally bonded at the welded part, and members made of materials that are not originally fused at the molecular level between the materials are firmly fixed to each other. can do.
[0035]
Further, since no adhesive is used, the strength of the bonded portion, which has been easily affected by the amount of the adhesive during the manufacturing process, is stabilized, and the manufacturing time can be shortened because no curing time is required.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a first embodiment of a molded product having a sponge-like member of the present invention.
2A and 2B show a manufacturing process of the molded article of FIG. 1, wherein FIG. 2A is a cross-sectional view before welding, FIG. 2B is a cross-sectional view during welding, and FIG. 2C is a cross-sectional view after welding.
FIGS. 3A and 3B show a manufacturing process according to another design of the molded product of FIG. 1, wherein FIG. 3A is a sectional view before welding, FIG. 3B is a sectional view during welding, and FIG. 3C is a sectional view after welding; .
FIG. 4 is a front view showing a second embodiment of a molded product having a sponge-like member of the present invention in a state before assembling.
5 is a side view showing a state after assembly and welding of the molded product of FIG. 4; FIG.
[Explanation of symbols]
1 thermoplastic resin member, 2 energy director, 5 flexible foam member, 9 mounting hole, 10 welding horn,

Claims (2)

所定形状の熱可塑性樹脂部材と前記熱可塑性樹脂部材とは異種の素材から成る可撓性発泡体部材とを当接させ、前記可撓性発泡体部材の表面から超音波溶着機の溶着ホーンを圧接させて超音波振動により前記熱可塑性樹脂部材の一部分を溶融し、前記溶融した樹脂を前記可撓性発泡体部材に浸潤させて硬化して成るスポンジ状部材を有する成形品において、前記可撓性発泡体部材に取付穴を設け、前記取付穴に熱可塑性樹脂部材の少なくとも一部分が挿入されて成ることを特徴とするスポンジ状部材を有する成形品。A thermoplastic resin member having a predetermined shape and a flexible foam member made of different materials are brought into contact with each other, and a welding horn of an ultrasonic welder is attached to the surface of the flexible foam member. In a molded article having a sponge-like member formed by melting a part of the thermoplastic resin member by ultrasonic vibration and infiltrating the molten resin into the flexible foam member and curing , the flexible member A molded article having a sponge-like member , wherein an attachment hole is provided in a porous foam member, and at least a part of a thermoplastic resin member is inserted into the attachment hole . 前記成形品が洗滌用具であることを特徴とする請求項１記載のスポンジ状部材を有する成形品。Molded article having a sponge-like member according to claim 1, wherein said molded article is characterized by cleaning equipment der Rukoto.
JP2000055252A 2000-03-01 2000-03-01 Molded product having sponge-like member Expired - Fee Related JP4432010B2 (en)

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