JP7089276B2 - Manufacturing method of patterned foam molded products - Google Patents

Description

The present invention relates to a method for producing a patterned foam molded product.

Conventionally, in order to obtain a foam molded product having a pattern on the outer surface, the foam before molding has been pressurized and heated by using a mold having irregularities corresponding to the pattern. (See, for example, Patent Document 1).

However, in the conventional one, the outer surface pattern of the foam molded product is limited to the uneven shape of the mold. Therefore, with the conventional one, it is not possible to obtain a foam molded product having a different pattern on the outer surface unless the mold itself, which is a relatively expensive facility, is changed. In other words, it has become extremely difficult to flexibly manufacture foam molded products having different patterns by the conventional method for manufacturing foam molded products.

Japanese Unexamined Patent Publication No. 57-77538

The present invention has been made by paying attention to the above circumstances, and provides a method for manufacturing a foam molded product with a pattern, which can flexibly manufacture a foam molded product having a different pattern without changing the mold. To do.

That is, the present invention has the following configuration.

The invention according to claim 1 is to obtain an intermediate molded product by forming a foundation pattern composed of recesses on the outer surface of the foundation foam, and then arrange the intermediate molded product between a pair of molds. It is a method for manufacturing a patterned foam molded product, which is obtained by pressurizing and heating with a pair of dies to obtain a patterned foam molded product in which a final pattern consisting of recesses after processing is exposed on the outer surface . A foam molded product with a pattern in which a breathable cloth material is placed between the molding surface of the mold and the intermediate molded product, and then the intermediate molded product is heated and pressed by the mold. It is a manufacturing method .

The invention according to claim 2 is the patterned foam according to claim 1, wherein the basic foam is in the shape of a flat plate, and the main molding surface constituting the molding surface of the mold is in the shape of a flat surface. It is a manufacturing method of a body molded product.

The invention according to claim 3 is the invention according to claim 1 or 2, wherein the outer surface of the basic foam is cut using a router processing machine to obtain an intermediate molded product having a basic pattern composed of the recessed portion on the outer surface. It is a manufacturing method of a foam molded product with a pattern.

The invention according to claim 4 is the manufacture of the patterned foam molded article according to claim 1, 2 or 3, wherein the depth dimension of the recess formed in the intermediate molded article is set to 3 to 5 mm. The method.

The invention according to claim 5 is the method for manufacturing a patterned foam molded product according to claim 1, 2, 3 or 4, wherein the patterned foam molded product is a floor panel or a wall surface panel.

As described above, according to the present invention, it is possible to provide a method for manufacturing a foam molded product with a pattern, which can flexibly manufacture a foam molded product having a different pattern without changing the mold.

The perspective view which shows the intermediate molded article in one Embodiment of this invention. The schematic end view which shows the manufacturing process using the mold in the same embodiment. The perspective view which shows the final patterned foam molded article in the same embodiment. The explanatory view of the manufacturing process of the foam molded article with a pattern in the same embodiment. FIG. 1 is a cross-sectional view taken along the line AA in FIG. FIG. 3 is a sectional view taken along line BB in FIG. X partial enlarged view in FIG. FIG. 6 is an enlarged view of the Y portion in FIG.

Hereinafter, an embodiment of the present invention will be described with reference to FIGS. 1 to 8.

This embodiment applies the present invention to a method for manufacturing a patterned foam molded product 3 in which a brick pattern M2, which is a pattern that can be visually recognized by a user, is exposed.

As shown in FIG. 3 and the like, the patterned foam molded product 3 has a substantially rectangular plate shape. The patterned foam molded product 3 is suitably used as a floor panel or a wall panel.

As shown in FIG. 2, the patterned foam molded product 3 is processed by pressurization and heating by a pair of molds K1 and K2, that is, upper and lower molds K1 and K2 (so-called “thermal pressure molding”, and in the following, It is made through "thermal pressure molding").

The patterned foam molded product 3 expresses the brick pattern M2, which is the final pattern that can be visually grasped, by the presence of the post-processed recessed portion h2 provided on the outer surface by undergoing thermal pressure molding.

Hereinafter, the method for producing the patterned foam molded product 3 will be described in detail with reference to FIGS. 1 to 8 in particular. Note that FIG. 4 schematically shows the manufacturing process.

First, as shown in FIG. 4A, the basic foam 1 as a base material is prepared. In this embodiment, the basic foam 1 has a substantially rectangular flat plate shape. The basic foam 1 is composed of a closed-cell polyethylene foam crosslinked with a chemical cross-linking agent.

Next, as shown in FIG. 4 (b), the foundation pattern M1 composed of the recessed portion h1, that is, the foundation pattern M1 which is the basis of the final brick pattern M2 is formed on the outer surface of the foundation foam 1, thereby intermediate. Obtain the molded product 2. It is desirable that the thickness dimension w1 of the intermediate molded product 2 shown in FIG. 5 (same as the thickness dimension of the basic foam 1) is set within the range of 10 to 20 mm. In this embodiment, the thickness dimension w1 of the intermediate molded product 2 is set to 15 mm.

The foundation pattern M1 formed on the intermediate molded product 2 partially scrapes the outer surface of the foundation foam 1 using a router processing machine (not shown) to form a recessed portion h1 having a predetermined depth dimension d1. It is provided by doing. The recessed portion h1 provided in the intermediate molded product 2 has a bottom surface portion h11 and a side surface portion h12 extending from both ends of the bottom surface portion h11 in a direction substantially orthogonal to the bottom surface portion h11. It has a channel shape as a whole.

The depth dimension d1 of the recessed portion h1 formed on the outer surface of the intermediate molded product 2 is set within the range of 3 to 5 mm. When the depth dimension d1 of the recessed portion h1 is shorter than 3 mm, the brick pattern M2 composed of the recessed portion h2 after processing that appears after being pressurized and heated by the upper and lower molds K1 and K2 becomes significantly unclear. It turned out that it would be. On the other hand, when the depth dimension d1 of the recessed portion h1 formed on the outer surface of the intermediate molded product 2 is longer than 5 mm, the recessed portion is pressed and heated by the upper and lower molds K1 and K2. The portion h1 is not uniformly deformed, and as a result, burrs and distortions that are elements that impair the appearance are formed in the post-processed recessed portion h2 after being pressurized and heated by the upper and lower molds K1 and K2. There was found. In other words, if the depth dimension d1 of the recessed portion h1 in the intermediate molded product 2 is set to 3 to 5 mm, the bottom surface portion h21 and the side surface portion constituting the post-processed recessed portion h2 in the patterned foam molded product 3 The portion h22 is held in an appropriate form.

As shown in FIG. 4 (c), after obtaining the above-mentioned intermediate molded product 2, the intermediate molded product 2 is placed between the upper and lower molds K1 and K2, which are a pair of molds, and then both molds. The intermediate molded product 2 is pressurized and heated under predetermined conditions by the molds K1 and K2. The upper and lower molds K1 and K2 are provided with molding surfaces K11 and K21 on the side facing the intermediate molded product 2, respectively. Each of the molded surfaces K11 and K21 includes main molded surfaces K111 and K211 facing the main outer surface of the intermediate molded product 2, and edge molded surfaces K112 and K212 arranged on the peripheral edges of the main molded surfaces K111 and K211. ing.

In this embodiment, the main molding surfaces K111 and K211 are planar. Further, when the upper and lower dies K1 and K2 are in close contact with each other, that is, when hot pressure forming is performed by the upper and lower dies K1 and K2, the separation dimension between the main forming surfaces K111 and K211 is set to 8 mm. ing. As a result, the thickness dimension w2 of the final patterned foam molded product 3 is formed to be about 8 mm.

The upper and lower jerseys J1 and J2, which are breathable cloth materials, are arranged between the molding surfaces K11 and K12 of the upper and lower molds K1 and K2 and the intermediate molded product 2. In other words, the intermediate molded product 2 and the upper and lower jerseys J1 and J2 covering the outer surface of the intermediate molded product 2 are pressurized and heated using both molds K1 and K2 to obtain a final brick pattern. The foam molded product 3 having M2 is obtained.

Here, the upper and lower jerseys J1 and J2 cover substantially the entire outer surface of the intermediate molded product 2 including the basic pattern M2 in the process of thermal pressure forming by the upper and lower molds K1 and K2. .. Therefore, the upper and lower jerseys J1 and J2 impart the same fine outer surface characteristics (fine uneven shape) to substantially the entire outer surface of the intermediate molded product 2 based on the fine mesh peculiar to the material. It is something to gain. Further, the upper and lower jerseys J1 and J2 make it easy to take out the final patterned foam molded product 3 from the upper and lower dies K1 and K2 after being processed by the upper and lower dies K1 and K2.

The heating temperature for the intermediate molded product 2 by the upper and lower molds K1 and K2 is set within the range of 120 ° C to 160 ° C. In this embodiment, the heating temperature by the molds K1 and K2 is set to 146 ° C.

The pressing force applied to the intermediate molded product 2 by the upper and lower molds K1 and K2 is set within the range of 50 kg / cm ² to 150 kg / cm ² . In this embodiment, the pressing force by the mold is set to 100 kg / cm ² .

The time for hot-press molding the intermediate molded product 2 by the upper and lower dies K1 and K2 (that is, the time for pressurization and heating by the upper and lower dies K1 and K2) is set to 8 minutes.

After pressurizing and heating the intermediate molded product 2 having the basic pattern M1 with the upper and lower molds K1 and K2, the intermediate molded product 2 is heated to room temperature, that is, 10 ° C., which is a temperature corresponding to room temperature over about 20 minutes. When the temperature is cooled to ~ 35 ° C, both molds K1 and K2 are opened. In this embodiment, the intermediate molded product 2 is cooled to 24 ° C. over 20 minutes, and then the final molded product is separated from both molds K1 and K2. Then, the jerseys J1 and J2 are removed by peeling off from the surface of the foam molded product 3 after pressurization and heating, and the final brick pattern M2 as shown in FIG. 4D is exposed. The body molded product 3 is obtained.

As described above, in the method for producing the patterned foam molded product 3 according to the present embodiment, the intermediate molded product 2 is obtained by forming the basic pattern M1 composed of the recessed portion h1 on the outer surface of the basic foam 1. Later, the intermediate molded product 2 is placed between the upper and lower dies K1 and K2, which are a pair of dies, and then pressurized and heated by the dies K1 and K2. The foam molded product 3 with a pattern in which the patterned brick pattern M2 is exposed is obtained. Therefore, it is possible to provide a method for manufacturing a patterned foam molded product 3 that can flexibly manufacture a foam molded product 3 having a different pattern without changing the molds K1 and K2.

That is, the intermediate molded product 2 is generated by providing an arbitrary foundation pattern M1 composed of the recessed portion h1 on the outer surface of the foundation foam 1, and then the intermediate molded product 2 is heated and pressed by the molds K1 and K2. , The final patterned foam molded product 3 is obtained. Therefore, in the method for manufacturing the patterned foam molded product 3 shown in the present embodiment, various basic patterns M1 are provided on the intermediate molded product 2 without depending on the uneven shape provided on the molds K1 and K2. This makes it possible to flexibly manufacture the foam molded product 3 having a different pattern.

The basic foam 1 has a flat plate shape. The main molding surfaces K111 and K211 constituting the molding surfaces K11 and K21 of the upper and lower molds K1 and K2 are flat. Therefore, as the upper and lower molds K1 and K2, those having an extremely simple form can be adopted, and the plate-shaped foam molded product 3 having a different outer surface pattern without changing the molds K1 and K2. Can be flexibly manufactured.

After arranging the upper and lower jerseys J1 and J2, which are breathable cloth materials, between the molding surfaces K11 and K21 of the upper and lower molds K1 and K2 and the intermediate molded product 2, the intermediate molded product 3 is placed on the upper and lower molds. It is heated and pressurized by the molds K1 and K2. Therefore, as a result of completing the process of thermal pressure forming by the molds K1 and K2, all the exposed surfaces including the basic pattern M2 in the intermediate molded product 3 are provided with a fine uneven shape based on the fine stitches of the jersey material. As a result, uniform visual and tactile properties can be imparted to the region used as the outer surface of the final foam molded product 3. That is, there is a problem due to the difference in the outer surface characteristics between the post-machining concave recess h2 and the flat surface portion adjacent to the post-machining concave recess h2, for example, a difference in the degree of dust accumulation, or non-uniformity in touch feeling. It is possible to suitably solve the problem that the problem occurs.

An outer surface of the foundation foam 1 is cut using a router processing machine (not shown) to obtain an intermediate molded product 2 having a foundation pattern M1 having a recessed portion h1 on the outer surface. Therefore, by forming the foundation pattern M1 composed of various recesses h1 on the outer surface of the foundation foam 1 by the router processing machine, it is possible to manufacture various intermediate molded products 2 having different foundation patterns M1. It has become.

The depth dimension d1 of the recessed portion h1 formed in the intermediate molded product 2 is set to 3 to 5 mm. Therefore, even after thermal pressure molding (heating and pressurization) by the upper and lower dies K1 and K2, the visible final pattern M2 can be appropriately expressed, and the post-processing recessed portion h2 constituting the final pattern M2 is formed. The finish will be appropriate without spoiling the appearance.

Since the patterned foam molded product 3 is a floor panel or a wall surface panel, a foam molded product having various variations of patterns can be suitably obtained by the manufacturing method of the patterned foam molded product 3. It becomes a thing.

The present invention is not limited to the embodiment described in detail above.

Various shapes of the basic foam can be adopted, and the shape is not limited to that shown in the above-described embodiment.

Various materials can be applied to the material of the basic foam, and the material is not limited to that shown in the above-described embodiment.

The composition of the basic foam is also not limited to that shown in the above-described embodiment. For example, the basic foam may be formed by combining a plurality of foam sheets.

The basic pattern displayed on the intermediate molded product may be formed on a part of the outer surface, and does not have to be formed on the entire outer surface. For example, when the intermediate molded product has a flat plate shape, it may be at least one having a basic pattern formed on the outer surface on one side.

The portion of the mold corresponding to the outer surface of the intermediate molded product is not necessarily limited to a flat surface.

The cloth material is not limited to the jersey, and various cloths can be applied.

The basic pattern of the intermediate molded product is not limited to the one made by using the router processing machine, and it goes without saying that the basic pattern may be formed by a processing means other than the router processing machine.

In addition, the specific configuration of each part is not limited to the above embodiment, and various modifications can be made without departing from the spirit of the present invention.

1 ... Basic foam 2 ... Intermediate molded product 3 ... Foam molded product with pattern M1 ... Basic pattern M2 ... Final pattern (brick pattern)
K1, K2 ... Mold (upper mold, lower mold)

Claims (5)

After obtaining an intermediate molded product by forming a foundation pattern consisting of recesses on the outer surface of the foundation foam, the intermediate molded product is placed between a pair of dies and then pressurized and heated by the pair of dies. Then, it is a manufacturing method of a patterned foam molded product in which a patterned foam molded product in which a final pattern consisting of a concave portion after processing is expressed on the outer surface is obtained.
A patterned foam molded product in which a breathable cloth material is placed between the molding surface of the mold and the intermediate molded product, and then the intermediate molded product is heated and pressed by the mold. Manufacturing method . The method for producing a molded foam product with a pattern according to claim 1, wherein the basic foam is in the shape of a flat plate, and the main molding surface constituting the molding surface of the mold is in the shape of a flat surface. The method for manufacturing a patterned foam molded product according to claim 1 or 2, wherein the outer surface of the basic foam is cut using a router processing machine to obtain an intermediate molded product having a basic pattern consisting of the recessed portion on the outer surface. .. The method for producing a patterned foam molded product according to claim 1, 2 or 3, wherein the depth dimension of the recess formed in the intermediate molded product is set to 3 to 5 mm. The method for manufacturing a patterned foam molded product according to claim 1, 2, 3 or 4, wherein the patterned foam molded product is a floor panel or a wall surface panel.

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