JP7248646B2 - Foam molded article, laminate, and method for producing laminate - Google Patents

Description

TECHNICAL FIELD The present invention relates to a foam molded product, a laminate, and a method for producing a laminate.

Conventionally, there has been known a laminate formed by adhering another member such as a sheet or a film to the surface of a foam molded product. As such a laminate, there is known a laminate formed by melting a foamed molded article or another member with heat and bonding the foamed molded article and another member by thermal fusion.

An example of this laminate is the foam composite article disclosed in US Pat. This foam composite product is formed by heat-sealing a resin film to a foam substrate having an uneven surface. Further, as an example of a laminate formed by heat-sealing, there is a sanitary equipment room member disclosed in Patent Document 2. Furthermore, as an example of a foamed molded product, a foamed container having a convex portion, which is a trace of a core vent, appears on the surface, which is disclosed in Patent Document 3, is known.

Japanese Utility Model Laid-Open No. 59-131824 (published on September 4, 1984) Japanese Patent Application Laid-Open No. 2008-221520 (published on September 25, 2008) Japanese Patent Application Laid-Open No. 2013-180772 (published on September 12, 2013)

However, the foam composite disclosed in Patent Document 1 has a problem that the adhesiveness between the foam molded article and other members is weak, or the degree of adhesion between the foam molded article and other members is uneven. .

In addition, in the foam composite disclosed in Patent Document 1, air pockets are likely to occur between the foam molded article and other members, and as a result, the adhesiveness between the foam molded article and other members is weakened. Alternatively, there is also a problem that adhesion unevenness occurs.

One aspect of the present invention is to realize a foam-molded article that reduces heat deterioration of the base surface of the foam-molded article when it is heat-sealed to another member, and that can be strongly heat-sealed to another member. for the purpose.

In order to solve the above problems, a foam molded article according to an aspect of the present invention is a foam molded article that is heat-sealed to another member, wherein at least one foam-molded article that is heat-sealed to the other member is provided. The one surface is formed of a base surface and at least one protrusion formed on the base surface, and the base surface is exposed to the outside around the protrusion.

A foam-molded article according to an aspect of the present invention is a foam-molded article to be heat-sealed to another member, wherein at least one surface of the foam-molded article to be heat-sealed to the other member comprises a base surface, and at least one protrusion formed on the base surface, wherein the protrusion melts first when heat-sealed to the other member.

A foam-molded article according to an aspect of the present invention is a foam-molded article to be heat-sealed to another member, wherein at least one surface of the foam-molded article to be heat-sealed to the other member comprises a base surface, and at least one protrusion formed on the base surface, wherein the protrusion first receives a stress when heat-sealed to the other member.

A foam-molded article according to an aspect of the present invention is a foam-molded article to be heat-sealed to another member, wherein at least one surface of the foam-molded article to be heat-sealed to the other member comprises a base surface, and at least one protrusion formed on the base surface, wherein the protrusion has at least two surfaces when viewed from above (plan view), and a boundary between the two surfaces. As a line, there is at least one boundary line that intersects the direction from the outside of the protrusion toward the center of the tip.

According to one aspect of the present invention, there is provided a foam-molded article that reduces thermal deterioration of the base surface of the foam-molded article when heat-sealed to another member, and that can be strongly heat-sealed to another member. can be realized.

(a) and (c) to (i) are diagrams showing an example of the shape of the protrusions of the foam molded body according to the embodiment of the present invention, and (b) is a cross-sectional view showing the cross section of the laminate. is. (a) to (g) are diagrams showing an example of the shape of protrusions of a foam molded article according to an embodiment of the present invention. (a) to (h) are diagrams showing an example of the shape of the protrusions of the foam molded article according to the embodiment of the present invention. (a) to (g) are diagrams showing an example of the shape of protrusions of a foam molded article according to an embodiment of the present invention. (a) and (b) are cross-sectional views showing cross-sections of a foam-molded article when the base surface of the foam-molded article is not flat. (a) is a diagram showing a conventional foam molded article, (b) is a diagram showing a foam molded article having a plurality of hemispherical projections, and (c) is a diagram showing a hemispherical projection. FIG. 3 is a diagram showing a foamed molded article having a plurality of projections and the projections shown in FIGS. 2(d) and 2(e). (a) to (c) are diagrams showing the state of another member peeled off from the foamed molded article after heat-sealing the other member to the foamed molded article, and (d) to (f) are foamed FIG. 3 is a diagram showing a state of a foam molded article when the other member is peeled off after heat-sealing the other member to the molded article. (g) to (i) are diagrams showing a state when another member is heat-sealed to the foam molded article.

(Regarding the shape of the projecting part of the foam molded body)
In FIGS. 1 to 3, the boundary line between the two surfaces of the projection is expressed by a line, but this boundary line is not limited to what can be expressed by a line. For example, as shown in FIG. 4, when the contour line of the cross section of the protrusion is a line that can be approximated by a higher-order curve, the boundary line between the two surfaces corresponds to the inflection point of the contour line. If there is no inflection point, the boundary line between the two surfaces corresponds to the central point of the flat portion between the two surfaces. Also, the boundary line between these two surfaces may not appear clearly when viewed from above (in a plan view). In this case, the boundary line between the two surfaces of the protrusion includes the boundary line corresponding to the inflection point and the center point. Boundary lines corresponding to the inflection point and the center point are indicated by dashed lines as shown in FIG.

(a) and (c) to (i) of FIG. 1 are diagrams showing an example of the shape of the protrusions of the foam molded body, and (b) of FIG. 1 is a sectional view showing the cross section of the laminate 1 is.

FIG. 1(c) is a top view of the protrusion 120, and FIG. 1(a) is a cross-sectional view of the foam molded article 10 taken along the dotted line x1-x2 shown in FIG. 1(c). . As shown in (a) of FIG. 1, the other member 20 is heat-sealed to the side of the foam molded article 10 on which the protrusions 120 are formed. That is, the foam molded article 10 is heat-sealed to the other member 20 .

As the foam molded article 10, a known foam molded article such as a foam sheet, a foam board, an expanded particle in-mold foam molded article, or an injection foam molded article can be used. The foam molded article 10 is made of a thermoplastic resin. As a result, the thermoplastic resin can be melted and the foam molded article 10 and the other member 20 can be heat-sealed. The thermoplastic resin is not particularly limited, and examples thereof include polyolefin resins, polystyrene resins, styrene-modified polyolefin resins, polyester resins, polyphenylene ether resins, and polycarbonate resins. The expansion ratio of the foam molded article 10 is not particularly limited, but when a polyolefin resin is used as the thermoplastic resin, it is, for example, 5 times, 10 times, 15 times, 20 times, 30 times, 40 times, 45 times, or 60 times. etc.

In addition, since the foam molded article 10 is composed of expanded particles, the foam molded article 10 can be melted and the foam molded article 10 and the other member 20 can be heat-sealed. Further, when the foam molded article 10 is composed of foamed particles, the protrusions 120 can be easily formed by in-mold foam molding.

It should be noted that the foam molded article 10 has a remarkable effect according to one aspect of the present invention, is excellent in cushioning properties, chemical resistance, heat resistance, and strain recovery rate after compression, and is easy to recycle. From this point, it is preferable to use an olefin-based resin. Furthermore, from these points, it is more preferable that the foam molded article 10 is formed by in-mold foam molding of polyolefin-based resin foam particles.

The other member 20 is not particularly limited as long as it can be heat-sealed with the foam molded article 10 . For example, the other member 20 may be a sheet made of a thermoplastic resin or a thermosetting resin, a film, or a non-woven fabric. Homopolymers, random copolymers, block copolymers, or mixtures thereof can be used as thermoplastic or thermosetting resins. Thermoplastic or thermoset resins may also include thermoplastic or thermoset resins reinforced with fibers, fillers, rubber components, or the like. Among the materials described here, from the viewpoint of adhesiveness, the other member 20 is preferably a sheet or film made of a thermoplastic resin.

As shown in (a) of FIG. 1, at least one surface of the foam molded article 10 to be heat-sealed with the other member 20 includes a base surface 110 and at least one protrusion 120 formed on the base surface 110. and formed from For example, when the foam molded body 10 is a plate-like rectangular parallelepiped, only one surface to be heat-sealed to the other member 20 may be formed from the base surface 110 and the protrusions 120 . Alternatively, only one surface that is heat-sealed to the other member 20 and a surface that is heat-sealed to the other member 20 and faces the one surface may be formed from the base surface 110 and the protrusions 120 . Further, the entire surface of the rectangular parallelepiped to be heat-sealed with the other member 20 may be formed from the base surface 110 and the protrusions 120 . Around the protrusion 120, the base surface 110 is exposed to the outside.

Further, when the foam molded body 10 and the other member 20 are heat-sealed, the protrusions 120, which have a small heat capacity and are easily melted, begin to melt at the tips. Therefore, the tips of the protrusions 120 are reliably melted, so that the foam molded body 10 and the other member 20 can be uniformly heat-sealed over the surface direction. Therefore, the foam molded article 10 and the other member 20 can be strongly heat-sealed.

Further, as shown in FIG. 1(b), when the foam molded body 10 and the other member 20 are heat-sealed, the protrusion 120 melts and spreads. This reduces excess heat reaching the base surface 110 . Since the protrusions 120 are preferentially melted, deterioration of the base surface 110 due to heat can be reduced. Therefore, it is possible to reduce the decrease in adhesiveness due to thermal deterioration of the base surface 110 and the change in the shape of the foam molded article 10 (particularly, the shape of the base surface 110). When the molded foam 10 and the other member 20 are heat-sealed, if the distance between the projections 120 is small, the projections 120 melt and the molded foam 10 and the other member 20 are heat-sealed. By stacking, the laminate 1 is formed. Further, when the distance between the protrusions 120 is large, the protrusions 120 are preferentially melted, and then the base surface 110 is melted, so that the foam molded article 10 and the other member 20 are heat-sealed to form a laminate. 1 is formed.

As a result, the laminate 1 in which the foam molded article 10 and the other member 20 are firmly heat-sealed can be formed. In addition, it is possible to manufacture the laminate 1 in which the possibility that the shape of the foam molded product 10 is different from the required shape is reduced. Applications of the laminate 1 include interior panels for vehicles, deck boards for vehicles, automobile and railway vehicle applications such as tibia pads, dressing tables, floor materials, heat insulating core materials for walls, heat insulating floor materials for bathrooms, and residences such as bath lids. Applications include transport applications such as returnable boxes and pallets, building materials such as forms and base materials, floating tools such as buoys, and storage tools such as tool boxes.

When the foam molded article 10 and the other member 20 are heat-sealed, the projecting portion 120 is the first to melt when heat-sealed with the other member 20 . As a result, the protrusion 120 melts first, so that the foam molded article 10 and the other member 20 can be strongly heat-sealed. Moreover, since the protrusion 120 melts preferentially, deterioration of the base surface 110 due to heat can be reduced.

Further, when the foam molded article 10 and the other member 20 are heat-sealed, the protrusion 120 is the first to receive stress when being heat-sealed with the other member 20 . This causes protrusions 120 to melt first because stress is applied to protrusions 120 first. Furthermore, as described above, since the protrusions 120 are preferentially melted, deterioration of the base surface 110 due to heat can be reduced.

As shown in FIG. 1(a), a depression 121 is formed at the tip of the projection 120. As shown in FIG. As shown in (c) of FIG. 1 , the recessed portion 121 has a recessed bottom surface 123 having a rectangular shape, and has a structure in which an inclined surface 122 is formed around the recessed bottom surface 123 when viewed from above. . The inclined surface 122 is inclined so as to become lower in the direction from the outside of the protrusion 120 toward the depressed bottom surface 123 when viewed from above. The inclined surface 122 has a trapezoidal shape. Also, the bottom surface of the protrusion 120 (boundary surface between the base surface 110 and the protrusion 120) is rectangular.

The projection 120 has five surfaces when viewed from above, and at least one boundary that intersects the direction from the outside of the projection 120 toward the center of the tip as a boundary between two of the five surfaces. line exists. Considering, for example, the direction d1 as the direction from the outside of the protrusion 120 toward the center of the tip, the boundary line b1 between the inclined surface 122 and the depressed bottom surface 123 intersects the direction d1.

In the configuration of the protrusion 120 , the portion around the depressed portion 121 has a shape having a ridgeline on the side of the other member 20 . This ridgeline is formed by a boundary line between the inclined surface 122 and the outer surface of the protrusion 120 . The portion around the depressed portion 121 has a tapered shape with this ridgeline as the top and is easily melted. Therefore, when the foam molded body 10 and the other member 20 are heat-sealed, the projecting portion 120 can be melted more reliably. Therefore, the foam molded article 10 and the other member 20 can be heat-sealed more firmly.

(e) and (f) of FIG. 1 are top views of the protrusions 120a and 120a_1, respectively, and (d) of FIG. It is sectional drawing of the foaming molding 10a in x2. As shown in (d) and (e) of FIG. 1, instead of the foam molded article 10, a foam molded article 10a having projections 120a formed on the base surface 110 may be used. The projecting portion 120a has a structure in which a depressed portion 121a is formed at the tip of a hemispherical shape. The depression 121a has a curved surface and a circular shape when viewed from above. Further, as shown in FIG. 1(e), the depressed portion 121a is formed in the center of the projecting portion 120a when viewed from above. Furthermore, the bottom surface of the protrusion 120a (boundary surface between the base surface 110 and the protrusion 120a) is circular. Considering, for example, the direction d2 as the direction from the outside of the protrusion 120a toward the center of the tip, the boundary line b2 between the two surfaces intersects the direction d2.

In addition, as shown in (f) of FIG. 1, a protrusion 120a_1 may be formed on the base surface 110, and a depressed portion 121a_1 formed at the tip of the protrusion 120a_1 is curved, and It has an elliptical shape when viewed from above. Both ends of the depressed portion 121a_1 overlap with the boundary line between the base surface 110 and the projecting portion 120a_1 when viewed from above. Furthermore, the bottom surface of the protrusion 120a_1 (boundary surface between the base surface 110 and the protrusion 120a_1) is circular. In addition, considering the direction d3, for example, as the direction from the outside of the protrusion 120a_1 toward the center of the tip, the boundary line b3 between the two surfaces intersects the direction d3.

According to the configuration of the protrusion 120a and the protrusion 120a_1, the bottom of the protrusion 120a is circular, and the bottom of the protrusion 120a_1 is circular. Accordingly, when the foam molded body 10a and the other member 20 are heat-sealed, the protrusion 120a spreads circularly and melts, and the protrusion 120a_1 spreads circularly and melts. Therefore, the foam molded article 10a and the other member 20 can be heat-sealed more firmly.

FIG. 1(i) is a top view of the protrusion 120b, and FIG. 1(g) is a cross-sectional view of the foam molded body 10b taken along the dotted line y1-y2 shown in FIG. 1(i). . (h) of FIG. 1 is a cross-sectional view of the foam molded article 10b taken along the dotted line x1-x2 shown in (i) of FIG. As shown in (g) of FIG. 1, instead of the foam molded article 10, a foam molded article 10b having projections 120b formed on the base surface 110 may be used.

The projecting portion 120b has a structure in which a depressed portion 121b is formed at the tip of a hemispherical shape. The depressed portion 121b has a curved surface and an elliptical shape when viewed from above. Further, as shown in FIG. 1(i), the depressed portion 121a is formed in the center of the projecting portion 120b when viewed from above. Considering, for example, the direction d4 as the direction from the outside of the protrusion 120b toward the center of the tip, the boundary line b4 between the two surfaces intersects the direction d4. Furthermore, the bottom surface of the protrusion 120b (the boundary surface between the base surface 110 and the protrusion 120b) is elliptical.

FIG. 2(b) is a top view of the protrusion 120c, FIG. 2(c) is a top view of the protrusion 120c_1, and FIG. 10B is a cross-sectional view of the foam molded body 10c along the dotted line x1-x2 shown in (b) and (c) of FIG. As shown in FIGS. 2A and 2B, instead of the foam molded article 10, a foam molded article 10c having projections 120c formed on the base surface 110 may be used.

The projecting portion 120 c includes a first projecting portion 124 and a second projecting portion 125 , and the second projecting portion 125 is formed on the upper surface of the first projecting portion 124 . The first protrusion 124 and the second protrusion 125 have rectangular parallelepiped shapes. Further, as shown in FIG. 2B, the second protrusion 125 is formed in the center of the first protrusion 124. As shown in FIG. Furthermore, the bottom surface of the protrusion 120c (the boundary surface between the base surface 110 and the protrusion 120c) is rectangular. Considering, for example, the direction d5 as the direction from the outside of the protrusion 120c toward the center of the tip, the boundary line b5 between the two surfaces intersects the direction d5.

Incidentally, as shown in FIG. 2C, a protrusion 120c_1 may be formed on the base surface 110, and second protrusions 125 and 126 may be formed on the upper surface of the first protrusion 124. there is The second protrusion 126 may have the same shape as the second protrusion 125, or may have a different shape. Also, three or more second protrusions may be formed on the upper surface of the first protrusion 124 . Furthermore, the bottom surface of the protrusion 120c_1 (boundary surface between the base surface 110 and the protrusion 120c_1) is rectangular. Considering, for example, the direction d6 as the direction from the outside of the protrusion 120c_1 toward the center of the tip of the second protrusion 125, the boundary line b6 between the two surfaces intersects the direction d6. In addition, considering the direction d7, for example, as the direction from the outside of the protrusion 120c_1 toward the center of the tip of the second protrusion 126, the boundary line b7 between the two surfaces intersects the direction d7.

In the configuration of the protrusion 120c, the second protrusion 125, which has a smaller heat capacity and is easily melted, tends to spread over the surface of the first protrusion 124 when melted by heat. Also, the first protrusion 124 to be melted has a small heat capacity. Therefore, when the foam molded body 10c and the other member 20 are heat-sealed, the projecting portion 120c can be melted more reliably. Therefore, the foam molded body 10c and the other member 20 can be heat-sealed more firmly. It should be noted that the second protrusion 125 is preferably formed near the tip of the first protrusion 124 . As a result, the vicinity of the tip portion of the second protrusion 125 can be reliably melted.

(e) of FIG. 2 is a top view of the protrusion 120d, and (d) of FIG. 2 is a cross-sectional view of the molded foam 10d taken along the dotted line x1-x2 shown in (e) of FIG. . As shown in (d) and (e) of FIG. 2, instead of the foam molded article 10, a foam molded article 10d having projections 120d formed on the base surface 110 may be used.

The projecting portion 120d includes a first projecting portion 124a and a second projecting portion 125a, and the second projecting portion 125a is formed at the tip of the first projecting portion 124a. The first protrusion 124a and the second protrusion 125a are curved. Further, as shown in FIG. 2(e), the second protrusion 125a is formed in the center of the first protrusion 124a. Furthermore, the bottom surface of the protrusion 120d (boundary surface between the base surface 110 and the protrusion 120d) is circular. Considering, for example, direction d8 as the direction from the outside of projection 120d toward the center of the tip, boundary line b8 between the two surfaces intersects direction d8.

Incidentally, as shown in FIGS. 2(f) and 2(g), a protrusion 120d_1 may be formed on the base surface 110, and the protrusion 120d_1 includes the first protrusion 124a and the second protrusion 125a. 126a; Second protrusions 125a and 126a are formed on the first protrusion 124a. The second protrusion 126a may have the same shape as the second protrusion 125a, or may have a different shape. Further, three or more second protrusions may be formed on the upper surface of the first protrusion 124a. Furthermore, the bottom surface of the protrusion 120d_1 (boundary surface between the base surface 110 and the protrusion 120d_1) is circular.

Considering, for example, the direction d9 as the direction from the outside of the protrusion 120d_1 toward the center of the tip of the second protrusion 125a, the boundary line b9 between the two surfaces intersects the direction d9. Considering, for example, the direction d10 as the direction from the outside of the protrusion 120d_1 toward the center of the tip of the second protrusion 126a, the boundary line b10 between the two surfaces intersects the direction d10. 2(g) is a top view of the protrusion 120d_1, and FIG. 2(f) is a cross-sectional view of the foam molded body 10d_1 along the dotted line x1-x2 shown in FIG. 2(g). is.

(c) of FIG. 3 is a top view of the projection 120e, and (a) of FIG. 3 is a cross-sectional view of the molded foam 10e taken along the dotted line y1-y2 shown in (c) of FIG. . (b) of FIG. 3 is a cross-sectional view of the molded foam 10e taken along the dotted line x1-x2 shown in (c) of FIG. As shown in FIG. 3(a), instead of the foam molded article 10, a foam molded article 10e having projections 120e formed on the base surface 110 may be used.

As shown in (c) of FIG. 3 , the projection 120 e is formed of two trapezoidal inclined surfaces 131 and two triangular inclined surfaces 132 . The two inclined surfaces 131 are inclined such that the upper sides of the two inclined surfaces 131 overlap each other and the lower sides of the two inclined surfaces 131 are separated from each other.

Two inclined surfaces 132 are formed on both sides of the two inclined surfaces 131, and the two inclined surfaces 132 are also inclined. The inclined surfaces 131 and 132 are inclined so as to increase in the direction from the outer side of the protrusion 120e toward the center of the protrusion 120e when viewed from above. Further, the bottom surface of the protrusion 120e (boundary surface between the base surface 110 and the protrusion 120e) is rectangular. Considering, for example, the direction d11 as the direction from the outside of the protrusion 120e toward the center of the tip, the boundary line b11 between the two inclined surfaces 131 intersects the direction d11.

(e) of FIG. 3 is a top view of the protrusion 120f, and (d) of FIG. It is a sectional view. As shown in (d) of FIG. 3, instead of the foam molded body 10, a foam molded body 10f having projections 120f formed on the base surface 110 may be used. As shown in (e) of FIG. 3, the protrusion 120f is formed of four trapezoidal inclined surfaces 133 and a rectangular upper surface 134 . The four sides of the upper surface 134 respectively overlap the upper sides of the four inclined surfaces 133, and the four inclined surfaces 133 are inclined. The inclined surface 133 is inclined so as to become higher in a direction from the outside of the protrusion 120f toward the center of the protrusion 120f when viewed from above. Further, the bottom surface of the protrusion 120f (boundary surface between the base surface 110 and the protrusion 120f) is rectangular. Considering, for example, the direction d12 as the direction from the outside of the protrusion 120f toward the center of the tip, the boundary line b12 between the inclined surface 133 and the upper surface 134 intersects the direction d12.

In addition, as shown in (f) of FIG. 3, a protrusion 120f_1 may be formed on the base surface 110 . The projection 120f_1 is formed of three trapezoidal inclined surfaces 135 and a triangular upper surface 136. As shown in FIG. Three sides of the upper surface 136 respectively overlap the upper sides of the three inclined surfaces 135, and the three inclined surfaces 135 are inclined. The inclined surface 135 is inclined so as to increase in the direction from the outer side of the protrusion 120f_1 toward the center of the protrusion 120f_1 when viewed from above. Also, the bottom surface of the protrusion 120f_1 (boundary surface between the base surface 110 and the protrusion 120f_1) is triangular. Considering, for example, the direction d13 as the direction from the outside of the protrusion 120f_1 toward the center of the tip, the boundary line b13 between the inclined surface 135 and the upper surface 136 intersects the direction d13.

(h) of FIG. 3 is a top view of the protrusion 120g, and (g) of FIG. 3 is a cross-sectional view of the foam molded body 10g taken along the dotted line x1-x2 shown in (h) of FIG. . As shown in (g) of FIG. 3, instead of the foam molded article 10, a foam molded article 10g having projections 120g formed on the base surface 110 may be used. As shown in (h) of FIG. 3, the protrusion 120g is formed of eight sloped surfaces 137 having a trapezoidal shape, and a top surface 138 and a bottom surface 139 having a rectangular shape. The eight inclined surfaces 137 may have the same shape or different shapes. The shape of the top surface 138 may be the same as or different from the shape of the bottom surface 139 . The protrusion 120g has a shape obtained by cutting off two corners of an octahedron. The two corner-cut portions correspond to the top surface 138 and the bottom surface 139 . Considering, for example, the direction d14 as the direction from the outside of the protrusion 120g toward the center of the tip, the boundary line b14 between the inclined surface 137 and the upper surface 138 intersects the direction d14.

The four sides of the top surface 138 overlap with the top sides of the four inclined surfaces 137 on the upper side of the projection 120g, and the four sides of the bottom surface 139 respectively overlap the four inclined surfaces 137 on the lower side of the projection 120g. overlaps the bottom edge of The lower sides of the four inclined surfaces 137 on the upper side of the protrusion 120g overlap the upper sides of the four inclined surfaces 137 on the lower side of the protrusion 120g. The eight inclined surfaces 137 are inclined. The bottom surface 139 of the protrusion 120g (boundary surface between the base surface 110 and the protrusion 120g) is rectangular.

(b) of FIG. 4 is a top view of the protrusion 120h, and (a) of FIG. 4 is a cross-sectional view of the molded foam 10h taken along the dotted line x1-x2 shown in (b) of FIG. . As shown in FIG. 4A, instead of the foam molded body 10, a foam molded body 10h having projections 120h formed on the base surface 110 may be used.

As shown in FIG. 4B, the protrusion 120h is formed of curved surfaces 140, 141, and 146. As shown in FIG. As shown in FIG. 4A, the contour line of the cross section of the projection 120h is a line that can be approximated by a higher-order curve, and the boundary line b15 between the two curved surfaces 140 and 146 is the inflection point v1 of the contour line. correspond to A boundary line b18 between the two curved surfaces 141 and 146 corresponds to an inflection point v2 of the outline. The bottom surface of the protrusion 120h (boundary surface between the base surface 110 and the protrusion 120h) is circular. Considering, for example, the direction d15 as the direction from the outside of the protrusion 120h toward the center of the tip, the boundary line b15 between the two curved surfaces 140 and 146 intersects the direction d15. A boundary line b18 between the two curved surfaces 141 and 146 intersects the direction d15.

(e) of FIG. 4 is a top view of the protrusion 120i, and (c) of FIG. 4 is a cross-sectional view of the foam molded article 10i taken along the dotted line x1-x2 shown in (e) of FIG. . (d) of FIG. 4 is a cross-sectional view of the molded foam 10i taken along the dotted line x3-x4 shown in (e) of FIG. As shown in (c) of FIG. 4, instead of the foam molded article 10, a foam molded article 10i having projections 120i formed on the base surface 110 may be used. As shown in (e) of FIG. 4, the protrusion 120i is formed of a curved surface 142 and a curved surface 143. As shown in FIG. The curved surface 143 has a substantially triangular shape and a concave shape when viewed from above. In addition, the curved surface 143 may have a substantially rectangular shape when viewed from above.

As shown in (c) of FIG. 4, the contour line of the cross section of the projection 120i is a line that can be approximated by a higher-order curve, and the boundary line b16 between the two curved surfaces 142 and 143 is at the center point c1 of the contour line. Applicable. The center point c1 is the center point of the flat portion between the two curved surfaces 142 and 143 in the cross section of the protrusion 120i. Further, the bottom surface of the protrusion 120i (boundary surface between the base surface 110 and the protrusion 120i) is circular. Considering, for example, the direction d16 as the direction from the outside of the protrusion 120i toward the center of the tip, the boundary line b16 between the two curved surfaces 142 and 143 intersects the direction d16.

(g) of FIG. 4 is a top view of the protrusion 120j, and (f) of FIG. 4 is a cross-sectional view of the molded foam 10j along the dotted line x1-x2 shown in (g) of FIG. . As shown in (f) of FIG. 4, instead of the foam molded body 10, a foam molded body 10j having projections 120j formed on the base surface 110 may be used. As shown in (g) of FIG. 4 , the projection 120 j is formed of curved surfaces 144 and 145 .

As shown in (f) of FIG. 4, the contour line of the cross section of the projection 120j is a line that can be approximated by a higher-order curve, and the boundary line b17 between the two curved surfaces 144 and 145 is at the center point c2 of the contour line. Applicable. The center point c2 is the center point of the flat portion between the two curved surfaces 144 and 145 in the cross section of the protrusion 120j. Further, the bottom surface of the protrusion 120j (boundary surface between the base surface 110 and the protrusion 120j) is circular. Considering, for example, the direction d17 as the direction from the outside of the protrusion 120j toward the center of the tip, the boundary line b17 between the two curved surfaces 144 and 145 intersects the direction d17.

The shape of the protrusion is not limited to the shapes shown in FIGS. 1 to 4, and may be a hemisphere, a quadrangular pyramid, a cone, a rectangular parallelepiped, or the like, and is not particularly limited. In addition, the protrusions as described above are formed on the base surface 110 (on the surface) at a density of 1/cm ² or more and 25/cm ² or less, and at least 20% or more of the base surface 110 has a density of 25/cm 2 or less. It may be formed over The protrusions as described above are formed on the base surface 110 at a density of 1/cm ² or more and are formed over at least 20% or more of the base surface 110, thereby forming a foamed molded article. The other member 20 can be strongly heat-sealed. In addition, the possibility that the foam molded body will be peeled off from the other member 20 can be reduced. Also, by providing various kinds of protrusions as described above on the base surface 110, a foam molded body may be formed.

Furthermore, by forming the above-described projections on the base surface 110 at a density of 25 pieces/cm ² or less, the above-described projections are not formed on the base surface 110 more than necessary, Manufacturing costs can be reduced.

Also, due to the configuration of the projections shown in FIGS. 1 to 4, these projections have at least two surfaces when viewed from above, and the boundary between the two surfaces is the outside of these projections. There is at least one boundary line that intersects the direction from to the center of the tip. As a result, when viewed from above, the shape of these projections does not have the same regularity in the direction from the outside to the tip of these projections, but in the direction from the outside to the tip of these projections It has a shape with a tapered portion due to a change in regularity along the way. The shape of these protrusions is, for example, a shape in which the angle formed by the bottom surface of the protrusion and the contour line changes in the cross section of the protrusion, or a shape in which the curvature changes (has an inflection point). Alternatively, the shape of these protrusions may be a multi-stage shape or a shape having a ridgeline at the tip.

In addition, when the foam molded body and the other member 20 are heat-sealed, these projections have a tapered portion due to the presence of the boundary line in these projections, so that these projections are easily melted. . Therefore, the foam molded body and the other member 20 can be strongly heat-sealed. Furthermore, since these protrusions are preferentially melted, deterioration of the base surface 110 due to heat can be reduced. Therefore, it is possible to reduce the change in the shape of the foam molded body (in particular, the shape of the base surface 110).

1 (a) to (c), the protrusions 120a shown in (d) and (e) of FIG. 1, the protrusion 120a_1 shown in (f) of FIG. g) to (i), projections 120c shown in FIGS. 2(a) and (b), and projections 120d shown in FIGS. 2(d) and (e), projections may be a multi-stage shape. As a result, since the highest portion in the height direction of the multi-stage shape is easily melted, the protrusions can be melted more reliably when the foam molded body and the other member 20 are heat-sealed.

Like the protrusions 120e shown in FIGS. 3(a) to 3(c), the protrusions 120f shown in FIGS. 3(d) to 3(f), and the protrusions 120g shown in FIGS. Further, the shape of the protrusion may be a shape that tapers in a direction toward the tip of the protrusion from the outside when viewed from above and has a ridge line at the tip of the protrusion. As a result, the ridgeline portion at the tip of the protrusion is easily melted. Therefore, when the foam molded body and the other member 20 are heat-sealed, the protrusions can be melted more reliably.

Like the projection 120c_1 shown in (c) of FIG. 2 and the projection 120d_1 shown in (f) and (g) of FIG. It may be a shape having a projection). As a result, since the portions of the plurality of projections (second projections) of the projections are easily melted, the projections can be melted more reliably when the foam molded body and the other member 20 are heat-sealed.

That is, the shape of the protrusion is (1) a multi-stage shape, (2) a shape tapering from the outside toward the tip of the protrusion when viewed from above, and having a ridgeline at the tip of the protrusion, and ( 3) At least one shape selected from the group consisting of shapes having a plurality of protrusions at the tips of the protrusions.

Although the size of the projection described above is not particularly limited, for example, the area of the bottom surface of the projection (boundary surface between the base surface 110 and the projection) is 0.25 mm ² or more, 0.50 mm ² or more, 1.00 mm ² or more, 1.20 mm ² or more, 1.40 mm ² or more, 1.60 mm ² or more, 1.80 mm ² or more, 2.00 mm ² or more, 2.20 mm ² or more, 2.40 mm ² or more ^{4 _ _ _ _ _ _ _} .50 mm ² or more, 5.00 mm ² or more, 5.50 mm 2 or more, 6.00 mm ² or more, 7.00 mm ² or more, 8.00 ^{mm 2 or} more, 9.00 mm ² or more, 10.00 mm ^{2 or} more, 11.00 mm ² or more, 12.00 mm ² or more, 13.00 mm ² or more, 14.00 mm 2 or more, or 15.00 mm ² or more, and 100.00 mm ² or less, 90.00 ^{mm 2 or} less, 80.00 mm ² or less, 70.00 mm ² or less, 60.00 mm ² or less, 50.00 mm ² or less, 40.00 mm 2 or less, 30.00 mm ^{2 or} less, 20.00 mm ² or less, 19.00 mm ² or less, 18.00 mm ² or less, 17. 00 mm ² or less, 16.00 mm ² or less, 15.00 mm ² or less, 14.00 mm 2 or less, 13.00 mm ^{2 or} less, 12.00 mm ² or less, 11.00 mm ^{2 or} less, or 10.00 mm ^{2 or} less, etc. can be done.

Further, for example, the height of the protrusion is 0.3 mm or more, 0.4 mm or more, 0.5 mm or more, 0.6 mm or more, 0.7 mm or more, 0.8 mm or more, 0.9 mm or more, 1.0 mm or more. , 1.5 mm or more, 2.0 mm or more, 2.5 mm or more, 3.0 mm or more, 3.5 mm or more, 4.0 mm or more, 4.5 mm or more, 5.0 mm or more, 6.0 mm or more, 7.0 mm or more , 8.0 mm or more, 9.0 mm or more, or 10.0 mm or more, etc., and 10.0 mm or less, 9.0 mm or less, 8.0 mm or less, 7.0 mm or less, 6.0 mm or less, 5.0 mm or less , 4.5 mm or less, 4.0 mm or less, 3.5 mm or less, 3.0 mm or less, 2.5 mm or less, 2.0 mm or less, 1.5 mm or less, 1.0 mm or less, 0.9 mm or less, 0.8 mm or less , or 0.7 mm or less. In such a case, the adhesiveness between the foam molded article and the other member 20 tends to be good.

When forming the first protrusion and the second protrusion, the size of the first protrusion is the size of the protrusion described in the previous paragraph, and the size of the second protrusion is the size of the first protrusion. It is preferably smaller in size than the protrusion. The height of the entire protrusion when forming the first protrusion and the second protrusion is preferably within the range of the height of the protrusion described in the previous paragraph.

(About base surface)
The base surface 110 is exposed to the outside around the protrusions described above. When the projections are arranged on the base surface 110 at approximately equal intervals, the base surface 110 looks like grid-like grooves, and when the foam molded body and the other member 20 are laminated, the base surface 110 allows air to escape. It has a function as a groove for discharging. Thereby, it is possible to suppress the occurrence of air pockets between the foam molded body and the other member 20 . As a result, the foam molded article and the other member 20 can be strongly heat-sealed, and the occurrence of uneven adhesion can be suppressed.

(Method for producing foam molded article)
Next, a method for producing a foam molded article will be described. A foam molded article is manufactured using a stationary mold and a movable mold that form a molding chamber for forming a foam molded article. First, a fixed mold and a movable mold are closed to form a molding chamber, and the molding chamber is filled with expanded particles. Then, the foamed particles are heated by passing steam through the molding chamber to fuse the foamed particles to each other. In order to allow water vapor to pass through the molding chamber, a known vent hole (core vent) or drilled hole may be provided in the mold. After that, the molding chamber is cooled by showering the mold with cooling water or the like, and the fixed mold and the movable mold are opened to take out the foam molded product. A foam molded article can be produced by the method described above. Such a method is called in-mold foam molding. The method described here is an example.

When forming the protrusion according to one aspect of the present invention, instead of providing a known vent hole or drilled hole as it is in the mold, a vent hole is formed in order to achieve the purpose and effect of one aspect of the present invention. Alternatively, it is preferable to appropriately adjust the size, position, and shape of the drilled hole. In other words, it can be said that conventionally known vent holes or drill holes are insufficient from the viewpoint of the object and effect of one aspect of the present invention.

At least a part of the molding surface of at least one of the stationary mold and the movable mold has a plurality of depressions so that the protrusions as described above are formed on the base surface 110. is formed. In other words, the recess forms a protrusion as described above on the base surface 110 . The molding surface is the surface of the mold that constitutes the molding chamber. The shapes of the plurality of recesses are shapes that fit into the respective protrusions as described above. In this way, when the protrusion is formed by the recess, by adjusting the shape and size (size) of the recess, the shape and size (size) of the protrusion including the recessed portion and the second protrusion described above can be adjusted. ) can be formed with a high degree of freedom and accuracy.

However, the shape of the recess does not necessarily have to fit the projection exactly. For example, consider the case where the shape of the depression is hemispherical, and approximately spherical expanded particles having a slightly larger diameter than the diameter of the hemispherical depression are foam-molded in a mold. In this case, a plurality of foamed particles may imperfectly enter one depression, that is, a situation may occur in which a portion of the plurality of foamed particles enters one depression without completely filling the depression with foamed particles. obtain. As a result, the protrusions in the obtained in-mold foam-molded product tend to be semispherical with recessed tips. This is because it is difficult for the foamed particles filled in the molding chamber to fit completely in the depressions, and the foamed particles are less likely to receive heat from the mold during in-mold foam molding, which weakens the fusion between the foamed particles. is. Therefore, the interface portion between the foamed particles tends to collapse. In such a case, a protrusion having a depressed portion at the tip is likely to be formed.

Further, for example, consider the case where the shape of the recess is hemispherical, and approximately spherical expanded particles having a diameter sufficiently smaller than the diameter of the hemispherical shape of the recess are foam-molded in a mold. In this case, since the foamed particles filled in the molding chamber tend to fit completely in the recesses, the shape of the recesses tends to be precisely fitted to the protrusions. In other words, the protrusion tends to conform to the shape of the depression, that is, tends to be hemispherical with no depression at the tip.

Conversely, consider the case where substantially spherical foamed particles having a diameter sufficiently larger than the hemispherical diameter of the dent are subjected to in-mold foam molding. In this case, it is difficult for the foamed particles filled in the molding chamber to fit in the depressions, and the possibility that a plurality of foamed particles fit in the depressions is low, so that the projections tend to be hemispherical projections without depressions formed at the tips. Tend. At this time, the foamed particles filled in the molding chamber are difficult to fit into the depressions, but are softened and expanded by the steam during molding, so that the foamed particles can easily fit into the depressions. As a result, the protruding portion tends to conform to the shape of the recess.

However, as described above, when the shape of the protrusions is adjusted by adjusting the diameter of the hemispherical shape of the recesses and the diameter of the expanded particles, it is not possible to adjust all the protrusions to the intended shape. , various shapes of protrusions tend to be mixed in the foamed molded product. A method of adjusting the shape and dimensions (size) of the recess is preferable for adjusting the shape of the protrusion as intended.

As a method of forming the projection, instead of the recess, a hole penetrating the mold may be formed in the mold. This hole communicates between the molding chamber and the outside of the mold, and the diameter of the hole is smaller than the diameter of the expanded particles. As a result, when the foamed particles are filled into the molding chamber, the foamed particles do not enter the pores and the foamed particles do not leak from the molding chamber through the pores. Further, when the foamed beads are heated with steam, the foamed beads expand while being softened, and part of the foamed beads enters the pores, thereby forming protrusions on the base surface 110 .

When a hole penetrating the mold is formed in the mold instead of the recess, the mold can be manufactured more easily than when a recess is formed in the mold. Moreover, even after manufacturing a mold without holes, holes can be easily formed in the mold, and the degree of freedom in forming the protrusions can be improved. For example, in the case of heat-sealing the foam molded body and the other member 20, when the foam molded body has a portion with weak adhesion, a hole is formed in the molding surface of the mold corresponding to the weak adhesive portion of the foam molded body. By forming , the adhesiveness between the foam molded body and the other member 20 can be improved. The recesses and the holes may be used in combination to form the recesses and the holes in the molding surface of the mold.

A hole penetrating the mold may be formed in at least one of the plurality of recesses. This hole communicates between the molding chamber and the outside of the mold, and discharges the air in the molding chamber to the outside of the mold when the foamed particles are filled into the mold. This makes it easier for the foamed particles to fill the recesses, making it easier to form projections. Also, when the foamed particles are heated by steam during molding, the foamed particles filled in the depressions soften and expand, making it easier to fit in the depressions. Cheap. Furthermore, a portion of the foamed particles can be formed as the second projection by entering the pores. That is, the second protrusions 125a of the protrusions 120d shown in (d) and (e) of FIG. 2 may be formed by slightly entering the pores of the foamed particles.

In addition, the depressed portion 121a of the protrusion 120a shown in (d) and (e) of FIG. may Specifically, for example, by adjusting the steam pressure and/or the heating time, gaps are generated between the expanded particles. By creating gaps between the foamed particles, the foamed particles are not completely transferred to the shape of the depression of the mold, and the recessed portion 121a of the protrusion 120a can be formed.

More specifically, by gradually changing the steam pressure when heating the expanded particles, the gaps between the expanded particles that have entered the depressions of the mold are filled, and the expanded particles are completely transferred to the shape of the depressions of the mold. Adjust the water vapor pressure to be lower than the water vapor pressure This reduces the expansion of the foamed particles due to steam.

As described above, by adjusting the water vapor pressure and/or the heating time when heating the foamed particles filled in the molding chamber, it is possible to find the conditions for forming the depressed portion 121a of the protrusion 120a. However, the method of forming the depressed portion 121a of the projection 120a is not limited to the method of adjusting the steam pressure and/or the heating time, and by adjusting various molding conditions, the depressed portion 121a of the projection 120a can be formed. may be formed.

Further, the protrusions as described above may be formed on the base surface 110 by directly shaving the foam molded body with a tool or the like without using the fixed mold and the movable mold. Alternatively, the above-described protrusions may be formed on the base surface 110 by heating a mold having a shape that fits the above-described protrusions and pressing this mold against the foam molded body. Moreover, the following examples are mentioned as another example of the method of forming a protrusion part in a foam molding. When manufacturing a known thermoplastic foam board, thermoplastic foam sheet, or injection foam molding, a method of thermally pressing with an uneven mold for transfer, a method of transferring using an uneven roller, or cutting A method of forming projections by processing may be mentioned. By these methods, it is possible to form a foam molded body that is heat-sealed to the other member 20 .

(Laminate manufacturing method)
When the other member 20 is heat-sealed to the foam-molded article, the foam-molded article having at least one protrusion as described above formed on the base surface 110 is softened without being preheated, or by being preheated. The softened other member 20 may be laminated. A laminate is formed by laminating the other member 20 on the foam molded article. By preliminarily softening the other member 20, the adhesiveness between the foam molded article and the other member 20 can be improved. Further, when the melting point of the other member 20 is lower than the melting point of the foam molded body, the other member 20 softens earlier than the foam molded body. Therefore, since no excessive pressure is required during lamination, the shape of the foam molded article is not changed. Further, it is possible to laminate the other member 20 on the foam-molded body while suppressing deterioration of the resin of the foam-molded body.

On the other hand, if the melting point of the other member 20 is higher than the melting point of the foam molded body, the projections of the foam molded body are more likely to melt when the foam molded body is laminated with the other member 20, so excessive pressure is applied during lamination. Since it is not necessary, the shape of the foam molded product is not changed. Further, it is possible to laminate the other member 20 on the foam-molded body while suppressing deterioration of the resin of the foam-molded body.

As a method for manufacturing a laminate as described above, specifically, a method for manufacturing a laminate by laminating and heat-sealing the foam molded article and the other member 20, the laminate surface where the protrusion is formed (2) includes a lamination step of laminating the other member 20 and a pressing step of pressing the laminated foam molded body and the other member 20 . It is preferable that the laminate manufacturing method further includes a decompression step. Hereinafter, the method for manufacturing the laminate will be described in each step.

Lamination step The lamination step is a step of laminating the other member 20 on the lamination surface of the foam molded body (the surface on which the other member 20 is laminated) on which the protrusions are formed. Specifically, the base surface 110 is a step of laminating another member 20 softened without preheating or softened by preheating on the foamed molded body in which at least one protrusion as described above is formed. The foam molded body used in the lamination step is a foam molded body manufactured by the manufacturing method described above.

- Pressing step The pressing step is a step of pressing the foam molded body laminated in the laminating step and the other member 20 . The press pressure is not particularly limited as long as the pressure does not change the shape of the foam molded article. Also, the pressing time is not particularly limited.

In the foam molded body, the base surface 110 is exposed to the outside around the protrusions. When the projections are arranged on the base surface 110 at approximately equal intervals, the base surface 110 looks like grid-like grooves, and when the foam molded body and the other member 20 are laminated, the base surface 110 allows air to escape. It has a function as a groove for discharging. Thereby, it is possible to suppress the occurrence of air pockets between the foam molded body and the other member 20 . As a result, the foam molded article and the other member 20 can be strongly heat-sealed, and the occurrence of uneven adhesion can be suppressed.

- Heat-sealing step The heat-sealing step is a step of heat-sealing the foam molded body and the other member 20 . The heat-sealing step may be performed simultaneously with the pressing step, or may be performed after the pressing step. The heat-sealing temperature and time may be set according to the melting points of the foam molded article and the other member 20, and are not particularly limited.

Specifically, the following three molding methods are mentioned as the method of performing the pressing step and the heat-sealing step.

(1) Heat compression (press) molding (molding in which a pressing step and a heat-sealing step are performed simultaneously) in which the foam molded body and the other member 20 are sandwiched between hot press plates;
(2) Compression roll molding (of the press process) without heating the other member 20 in advance or heating it in advance, and passing the foam molded body and the other member 20 together through at least one unheated or heated roll Forming in which the heat-sealing process is performed later, or molding in which the pressing process and the heat-sealing process are performed at the same time, or pressing (pressing process) with unheated rolls and then heat-sealing with heated rolls. (Molding to perform heat fusion process)),
(3) Integral blow molding in which the foam molded body and the other member 20 in a softened or molten state are placed between split molds and surface-bonded by clamping the molds (pressing process and heat-sealing process are performed at the same time) molding),
etc.

After laminating the foam molded body and the other member 20, for example, by going through a press process such as the above-mentioned heat compression (press) molding, compression roll molding, or integral blow molding, the foam molded body and the other member 20 are separated. This facilitates the discharge of air trapped in the foamed molded body, and suppresses the occurrence of air pockets between the foam molded body and the other member 20 .

- Decompression step The decompression step, which is performed as necessary, may be performed simultaneously with at least one of the lamination step, the pressing step, and the heat-sealing step, and may be performed before the lamination step or between the above steps. may be performed before the lamination step and throughout the entire process including between the above steps. It is preferable that the depressurization step is performed simultaneously with the pressing step. The degree of pressure reduction may be a degree of pressure reduction that does not change the shape of the foam molded body. Specifically, the amount of air accumulated between the foam molded body and the other member 20 is It may be appropriately adjusted in consideration of the surface properties and the like.

By performing the depressurization process, the air trapped between the foam molded article and the other member 20 is more efficiently discharged through the base surface 110 functioning as a groove, so that the foam molded article and the other member 20 are more efficiently discharged. It is possible to further suppress the occurrence of air pockets between

As a decompression method, a method of decompressing the entire space surrounding the foam molded body and the other member 20, a method of decompressing all or part of the space surrounding the boundary portion between the foam molded body and the other member 20, a method of decompressing the foam molded body and others. A method of decompressing a part of the boundary portion with the member 20 (directly extracting the air accumulated between the foam molded article and the other member 20), and the like. When the projections are arranged on the base surface 110 at approximately equal intervals, the base surface 110 looks like a grid-like groove, so that a part of the space surrounding the boundary between the foam molded body and the other member 20, Alternatively, the method of depressurizing a part of the boundary between the foam molded body and the other member 20 can also discharge the air trapped between the foam molded body and the other member 20 .

In addition to the pressing process and the heat-sealing process, examples of the method of further performing the above-described decompression process include vacuum forming and air pressure forming. And when performing a decompression process, a press process can also be performed using an atmospheric|air pressure difference. Specific examples of such vacuum forming and pressure forming include forming using a TOM forming machine (three-dimensional surface decoration forming machine) manufactured by Fuse Vacuum Co., Ltd.

However, the method for manufacturing the laminate is not limited to the manufacturing method including the steps described above.

(When the base surface of the foam molded product is not flat)
5(a) and 5(b) are cross-sectional views showing sections of a foam-molded article when the base surface of the foam-molded article is not flat. As shown in (a) of FIG. 5, the base surface 111 of the foam molded body 11 is formed of a horizontal surface 111a, a vertical surface 111b, and an inclined surface 111c.

The vertical surface 111b is a surface perpendicular to the horizontal surface 111a. The inclined plane 111c is a plane between two horizontal planes 111a, and is inclined from the higher horizontal plane 111a of the two horizontal planes 111a toward the lower horizontal plane 111a of the two horizontal planes 111a. It is the surface. The horizontal surface 111a, the vertical surface 111b, and the inclined plane 111c are each formed with the projections 120d, but projections of other shapes as described above may be formed. Moreover, the horizontal surface 111a, the vertical surface 111b, and the inclined plane 111c may be appropriately combined to form a base surface having another shape.

Moreover, as shown in FIG. 5(b), the base surface 112 of the foam molded body 12 is a curved surface. Although the projection 120d is formed on the base surface 112, projections of other shapes as described above may be formed. The base surface of the foam molded article may have a non-horizontal shape other than the shape of the base surface shown in FIGS. 5(a) and 5(b). Thus, the base surface of the foam molded article does not have to be a horizontal surface. The other member 20 can be heat-sealed even to a foam molded article having a non-horizontal base surface.

FIG. 6(a) is a diagram showing a conventional foam molded article 105, and FIG. 6(b) is a diagram showing a foam molded article 106 having a plurality of hemispherical protrusions. FIG. 6(c) is a diagram showing a foam molded body 107 in which a plurality of hemispherical protrusions and a plurality of protrusions 120d are formed.

As shown in FIG. 6(a), no projections are formed on the base surface of the conventional foam molded article 105. As shown in FIG. However, the surface of the foam molded body 105 is not completely flat, and the foam molded body 105 has fine irregularities. As shown in FIG. 6B, a plurality of hemispherical protrusions are formed on the base surface of the foam molded body 106 . As shown in FIG. 6C, on the base surface of the foam molded body 107, a plurality of hemispherical protrusions and the above-described plurality of protrusions 120d are formed in a mixed manner.

FIGS. 7A to 7C are diagrams showing the state of the other member 20 peeled off from the foam-molded article after the other member 20 has been heat-sealed to the foam-molded article. (d) to (f) of FIG. 7 are diagrams showing the state of the foam-molded article when the other member 20 is peeled off after the other member 20 is heat-sealed to the foam-molded article. (g) to (i) of FIG. 7 are diagrams showing the state when the other member 20 is heat-sealed to the foam molded body. In FIG. 7, this other member 20 is a film.

7(a), (d), and (g) are diagrams relating to a conventional foam molded article 105, and FIGS. 7(b), (e), and (h) are foam molded articles. 106, and (c), (f), and (i) of FIG.

As shown in FIGS. 7A to 7C, after the other member 20 is heat-sealed to the foam molded body, the other member 20 peeled off from the foam molded body has a part of the foam molded body. Adhering. Here, the larger the amount of the foam-molded product adhering to the other member 20, the stronger the fusion between the foam-molded product and the other member 20 is.

The laminate shown in (g) to (i) of FIG. 7 can be produced as follows. The foam molded bodies 105, 106, and 107 are obtained by in-mold foam molding of polypropylene-based resin foam particles. As the expanded polypropylene resin particles, for example, Eperan manufactured by Kaneka Corporation can be used. The foam molded article 105 is a conventional foam molded article formed using expanded polypropylene resin particles having a diameter of about 5 mm, and is subjected to in-mold foam molding without forming depressions and holes on the molding surface of the mold. In other words, the protrusion according to one aspect of the present invention is not formed on the surface of the foam molded body 105 that is heat-sealed to the other member 20 .

The foam-molded article 106 is a foam-molded article according to one aspect of the present invention, which is formed using expanded polypropylene resin particles having a diameter of about 5 mm and is subjected to in-mold foam molding using a mold having depressions formed on the molding surface. . In this case, approximately hemispherical depressions having a diameter of 3.5 mm and a depth of 1 mm are formed at regular intervals on the molding surface of the mold at a density of 4/cm ² . As a result, a substantially hemispherical protrusion having a diameter of 3.5 mm (bottom surface area of 9.6 mm ² ) and a height of 1 mm is formed on the surface of the foam molded body 106 that is heat-sealed to the other member 20 .

The foam-molded article 107 is a foam-molded article according to one aspect of the present invention, which is formed using expanded polypropylene resin particles having a diameter of about 5 mm and is subjected to in-mold foam molding using a mold having depressions formed on the molding surface. . The bottom of said recess has a diameter of 1.5mm which penetrates the mold . A 5 mm hole is provided. In this case, on the molding surface of the mold, for example, substantially hemispherical depressions having a diameter of 3.5 mm and a depth of 1 mm are formed at regular intervals at a density of 4/cm ² . A hole with a diameter of 1.5 mm is formed in the bottom of the depression. In other words, the projections 120d are formed on the base surface 110 of the foam molded body by every two depressions. The protrusion 120d has a substantially hemispherical first protrusion with a diameter of 3.5 mm (bottom surface area of 9.6 mm ² ) and a height of 1 mm, and a diameter of 1.5 mm formed at the tip of the first protrusion. , and a second protrusion having a height of about 1 mm.

Next, for example, a commercially available polypropylene resin film with a thickness of 0.2 mm is placed on each surface of the foam molded bodies 105, 106, and 107, and a hot plate adjusted to a temperature of 150 ° C. is applied from above the polypropylene resin film. Press at a pressure of 6 gf/cm ² for 1 minute and 30 seconds. As described above, the laminates of (g) to (i) in FIG. 7 can be produced. The method for manufacturing the laminate described here is an example.

Among the amounts of the foamed molded body attached to the other member 20 shown in (a) to (c) of FIG. 7, the amount of the foamed molded body 105 attached to the other member 20 shown in (a) of FIG. 7 is the smallest. , the amount of the foam molded body 107 adhering to the other member 20 shown in (c) of FIG. 7 is the largest. That is, among (a) to (c) of FIG. 7, the adhesiveness between the foam molded body 105 and the other member 20 is the weakest, and the adhesiveness between the foam molded body 107 and the other member 20 is the strongest. Moreover, since a part of the other member 20 shown in FIG. 7C is torn, the adhesiveness between the foam molded body 107 and the other member 20 is particularly strong.

Therefore, by forming the hemispherical protrusions on the base surface of the foam molded body 106, when the foam molded body 106 and the other member 20 are heat-sealed, the adhesiveness between the foam molded body 106 and the other member 20 increases. can be improved. Further, by forming the projections 120d on the base surface of the foam molded body 107, when the foam molded body 107 and the other member 20 are heat-sealed, the adhesiveness between the foam molded body 107 and the other member 20 is enhanced. can be improved.

In particular, on the base surface of the foam molded body 107, a plurality of hemispherical protrusions and a plurality of protrusions 120d described above are formed in a mixed manner. Adhesiveness can be improved over the entire adhesive surface despite the provision of a certain protrusion.

FIG. 2 of Patent Document 2 discloses a configuration in which unevenness is formed on the lower side of the foam layer. ) irregularities due to air bubbles that sometimes occur, that is, irregularities formed between foamed particles or at the interface between foamed particles. Therefore, the unevenness is different from the protrusion of one embodiment of the present invention. In addition, the fact that this foam layer has weak adhesiveness to other members has been described using the above-described foam molded body 105 .

Further, in the invention described in Patent Document 2, it is disclosed that a foam layer is welded to the surface of a base material by residual heat of the base material. Therefore, the invention described in Patent Document 2 suggests that heat is transmitted to the entire base material. On the other hand, in one aspect of the present invention, by bringing a heated mold or other member 20 into contact with the protrusions formed on the foam molded article, the heat is preferentially transferred to the protrusions, thereby melt the

The present invention is not limited to the above-described embodiments, but can be modified in various ways within the scope of the claims, and can be obtained by appropriately combining technical means disclosed in different embodiments. is also included in the technical scope of the present invention.

〔summary〕
A foam-molded article according to an aspect of the present invention is a foam-molded article to be heat-sealed to another member, wherein at least one surface of the foam-molded article to be heat-sealed to the other member comprises a base surface, and at least one protrusion formed on the base surface, and the base surface is exposed to the outside around the protrusion.

According to the above configuration, when the foamed molded article and the other member are heat-sealed, melting starts from the tip of the protrusion that has a small heat capacity and is easily melted. Therefore, the tips of the protrusions are reliably melted, so that the foam molded article and the other member can be heat-sealed uniformly over the surface direction. Therefore, the foam molded article and the other member can be strongly heat-sealed.

In addition, since the protrusions are preferentially melted, deterioration of the base surface due to heat can be reduced. Therefore, it is possible to reduce the deterioration of the adhesiveness due to deterioration of the base surface due to heat and the change in the shape of the foam molded product (particularly, the shape of the base surface).

Furthermore, since the base surface is exposed to the outside around the protrusion, it is possible to suppress the occurrence of air pockets between the foam molded article and other members. As a result, the foam molded article and the other member can be strongly heat-sealed, and the occurrence of adhesion unevenness can be suppressed.

In the foam molded article according to another aspect of the present invention, the protrusion may include a first protrusion and a second protrusion, and the first protrusion may be formed with the second protrusion. preferable.

According to the above configuration, the protrusion may include the first protrusion and the second protrusion, and the second protrusion may be formed on the first protrusion. The second protrusion, which has a smaller heat capacity and is easily melted, tends to spread over the surface of the first protrusion when melted by heat. Also, the first protrusion to be melted has a small heat capacity. Therefore, when the foam molded article and the other member are heat-sealed, the protrusions can be melted more reliably. Therefore, it is possible to more firmly heat-seal the foam molded article and the other member. It should be noted that the second protrusion is preferably formed near the tip of the first protrusion. Also, there may be a plurality of second protrusions.

In the foam-molded article according to another aspect of the present invention, it is preferable that the projection has a depressed portion formed at a tip of the projection.

According to the above configuration, the depression is formed at the tip of the protrusion. Since the portion around the depressed portion has a ridge-like shape and is easily melted, the protrusion can be melted more reliably when the foamed molded article and another member are heat-sealed. Therefore, it is possible to more firmly heat-seal the foam molded article and the other member.

In the foam molded article according to another aspect of the present invention, it is preferable that the boundary surface between the base surface and the protrusion is circular or elliptical.

According to the above configuration, since the boundary surface between the base surface and the protrusion is circular or elliptical, the protrusion expands in a circular or elliptical shape when the foam molded article and another member are heat-sealed. melt. As a result, the foam molded article and the other member can be heat-sealed more firmly.

In the foam-molded article according to another aspect of the present invention, the foam-molded article is preferably composed of expanded particles.

According to the above configuration, since the foamed molded article is composed of expanded particles, the foamed molded article can be melted to heat-seal the foamed molded article and another member. Further, when the foamed molded article is composed of foamed particles, the protrusions can be easily formed by in-mold foam molding.

In the foam molded article according to another aspect of the present invention, the protrusions are formed on the base surface at a density of 1/cm ² or more and 25/cm ² or less, and at least 20% of the base surface It is preferably formed over the above region.

According to the above configuration, the protrusions are formed on the base surface at a density of 1/cm ² or more, and are formed over at least 20% or more of the base surface, thereby forming a foamed molded article. It can be strongly heat-sealed with other members. In addition, it is possible to reduce the possibility that the foam molded body will be peeled off from other members.

Furthermore, since the projections are formed on the base surface at a density of 25 pieces/cm ² or less, the production cost can be reduced without forming excessive projections on the base surface.

A foam-molded article according to an aspect of the present invention is a foam-molded article to be heat-sealed to another member, wherein at least one surface of the foam-molded article to be heat-sealed to the other member comprises a base surface, and at least one protrusion formed on the base surface, wherein the protrusion melts first when heat-sealed to the other member.

According to the above configuration, the protrusions are melted first, so that the foam molded article and the other member can be strongly heat-sealed as described above. In addition, since the protrusions are preferentially melted, deterioration of the base surface due to heat can be reduced.

Furthermore, since the base surface is exposed to the outside around the protrusion, it is possible to suppress the occurrence of air pockets between the foam molded article and other members. As a result, the foam molded article and the other member can be strongly heat-sealed, and the occurrence of adhesion unevenness can be suppressed.

A foam-molded article according to an aspect of the present invention is a foam-molded article to be heat-sealed to another member, wherein at least one surface of the foam-molded article to be heat-sealed to the other member comprises a base surface, and at least one protrusion formed on the base surface, wherein the protrusion first receives a stress when heat-sealed to the other member.

According to the arrangement, the protrusions are the first to melt because the stress is applied to the protrusions first. As a result, the protruding portion melts preferentially, so that deterioration of the base surface due to heat can be reduced.

Furthermore, since the base surface is exposed to the outside around the protrusion, it is possible to suppress the occurrence of air pockets between the foam molded article and other members. As a result, the foam molded article and the other member can be strongly heat-sealed, and the occurrence of adhesion unevenness can be suppressed.

A foam-molded article according to an aspect of the present invention is a foam-molded article to be heat-sealed to another member, wherein at least one surface of the foam-molded article to be heat-sealed to the other member comprises a base surface, and at least one protrusion formed on the base surface, wherein the protrusion has at least two surfaces when viewed from above (plan view), and a boundary between the two surfaces. As a line, there is at least one boundary line that intersects the direction from the outside of the protrusion toward the center of the tip.

According to the above configuration, the projection has at least one boundary line that intersects the direction from the outside of the projection toward the center of the tip as the boundary between the two surfaces when viewed from above. Therefore, when viewed from above, the shape of the protrusion does not have the same regularity in the direction from the outside to the tip of the protrusion, but has different regularity in the direction from the outside to the tip of the protrusion. It is a shape that has a tapered portion by changing. The shape of the protrusion may be, for example, a shape in which the angle formed by the bottom surface of the protrusion and the contour line changes in the cross section of the protrusion, or a shape in which the curvature changes (has an inflection point). Alternatively, the shape of the protrusion may be a multi-stage shape or a shape having a ridgeline at the tip.

In addition, when the foam molded article and another member are heat-sealed, the protrusions have a tapered portion due to the presence of the boundary line in the protrusions, so that the protrusions are easily melted. Therefore, it is possible to strongly heat-seal the foam molded article and the other member. Furthermore, since the protrusions melt preferentially, deterioration of the base surface due to heat can be reduced. Therefore, it is possible to reduce the change in the shape of the foam molded product (particularly, the shape of the base surface).

Furthermore, since the base surface is exposed to the outside around the protrusion, it is possible to suppress the occurrence of air pockets between the foam molded article and other members. As a result, the foam molded article and the other member can be strongly heat-sealed, and the occurrence of adhesion unevenness can be suppressed.

A laminate according to an aspect of the present invention is formed by laminating the foam molded article and the other member.

According to the above configuration, it is possible to form a laminated body in which the foam molded article and the other member are firmly heat-sealed. In addition, it is possible to manufacture a laminate that reduces the possibility that the shape of the foam molded product will differ from the desired shape.

A method for manufacturing a laminate according to one aspect of the present invention is a method for manufacturing a laminate by laminating and heat-sealing the foam molded article and the other member, wherein the protrusion is formed on the laminate surface where the protrusion is formed , a lamination step of laminating another member, and a pressing step of pressing the laminated foam molded body and the other member.

According to the above configuration, it is possible to manufacture a laminate in which the foam molded article and the other member are firmly heat-sealed. In addition, it is possible to manufacture a laminate that reduces the possibility that the shape of the foam molded product will differ from the desired shape.

Furthermore, since the base surface is exposed to the outside around the protrusion, it is possible to suppress the occurrence of air pockets between the foam molded article and other members. As a result, it is possible to produce a laminated body capable of strongly heat-sealing the foam molded article and other members and suppressing the occurrence of adhesion unevenness.

It is preferable that the method for manufacturing a laminate according to another aspect of the present invention further includes a decompression step.

According to the above configuration, it is possible to further suppress the occurrence of air pockets between the foam molded article and the other member.

1 laminate 10, 10a, 10b, 10c, 10d, 10d_1, 10e, 10f,
10g, 10h, 10i, 10j, 11, 12, 105, 106, 107 foam molding 20 other member 110, 111, 112 base surface 111a horizontal surface 111b vertical surface 111c inclined plane 120, 120a, 120a_1, 120b, 120c, 120c_1,
120d, 120d_1, 120e, 120f, 120f_1, 120g,
120h, 120i, 120j Projections 121, 121a, 121a_1, 121b Depressions 122, 131, 132, 133, 135, 137 Inclined surfaces 123 Bottom surfaces of depressions 124, 124a First projections 125, 125a, 126, 126a Second projections 134, 136, 138 Top surface 139 Bottom surface 140-145 Curved surface b1-b17 Boundary line c1, c2 Center point d1-d17 Direction v1 Inflection point

Claims (16)

A foam molded article that is heat-sealed with another member,
At least one surface of the foam molded article that is heat-sealed to the other member is formed of a base surface and at least one protrusion formed on the base surface,
The base surface is exposed to the outside around the protrusion,
the projecting portion melts and spreads when the foam molded body and the other member are heat-sealed;
an area of a boundary surface between the base surface and the protrusion is 0.25 mm ² or more and 100.00 mm ² or less;
The height of the protrusion is 0.3 mm or more and 10.0 mm or less,
The protrusions are formed on the base surface at a density of 1/cm ² or more and 25/cm ² or less, and are formed over an area of at least 20% or more of the base surface. A foamed molded product. The protrusion includes a first protrusion and a second protrusion,
The foam molded article according to claim 1, wherein the second protrusion is formed on the first protrusion. A foam molded article that is heat-sealed with another member,
At least one surface of the foam molded article that is heat-sealed to the other member is formed of a base surface and at least one protrusion formed on the base surface,
The base surface is exposed to the outside around the protrusion,
The protrusion includes a first protrusion and a second protrusion,
The second protrusion is formed on the first protrusion,
an area of a boundary surface between the base surface and the protrusion is 0.25 mm ² or more and 100.00 mm ² or less;
The height of the protrusion is 0.3 mm or more and 10.0 mm or less,
The protrusions are formed on the base surface at a density of 1/cm ² or more and 25/cm ² or less, and are formed over an area of at least 20% or more of the base surface. A foamed molded product. 2. The foam molded article according to claim 1, wherein the projection has a depression formed at the tip of the projection. A foam molded article that is heat-sealed with another member,
At least one surface of the foam molded article that is heat-sealed to the other member is formed of a base surface and at least one protrusion formed on the base surface,
The base surface is exposed to the outside around the protrusion,
The protrusion has a depression formed at the tip of the protrusion ,
an area of a boundary surface between the base surface and the protrusion is 0.25 mm ² or more and 100.00 mm ² or less;
The height of the protrusion is 0.3 mm or more and 10.0 mm or less,
The protrusions are formed on the base surface at a density of 1/cm ² or more and 25/cm ² or less, and are formed over an area of at least 20% or more of the base surface. A foamed molded product. 6. The foam molded article according to any one of claims 1 to 5, wherein a boundary surface between the base surface and the protrusion is circular or elliptical. 7. The foam molded article according to any one of claims 1 to 6, wherein the foam molded article is composed of expanded particles. A foam molded article that is heat-sealed with another member,
At least one surface of the foam molded article that is heat-sealed to the other member is formed of a base surface and at least one protrusion formed on the base surface,
The projection is the one that melts first when heat-sealed with the other member,
the projecting portion melts and spreads when the foam molded body and the other member are heat-sealed;
an area of a boundary surface between the base surface and the protrusion is 0.25 mm ² or more and 100.00 mm ² or less;
The height of the protrusion is 0.3 mm or more and 10.0 mm or less,
The protrusions are formed on the base surface at a density of 1/cm ² or more and 25/cm ² or less, and are formed over an area of at least 20% or more of the base surface. A foamed molded product. A foam molded article that is heat-sealed with another member,
At least one surface of the foam molded article that is heat-sealed to the other member is formed of a base surface and at least one protrusion formed on the base surface,
The projection is the one that melts first when heat-sealed with the other member,
The protrusion includes a first protrusion and a second protrusion,
The second protrusion is formed on the first protrusion ,
an area of a boundary surface between the base surface and the protrusion is 0.25 mm ² or more and 100.00 mm ² or less;
The height of the protrusion is 0.3 mm or more and 10.0 mm or less,
The protrusions are formed on the base surface at a density of 1/cm ² or more and 25/cm ² or less, and are formed over an area of at least 20% or more of the base surface. A foamed molded product. A foam molded article that is heat-sealed with another member,
At least one surface of the foam molded article that is heat-sealed to the other member is formed of a base surface and at least one protrusion formed on the base surface,
The projection is the one that melts first when heat-sealed with the other member,
The protrusion has a depression formed at the tip of the protrusion ,
an area of a boundary surface between the base surface and the protrusion is 0.25 mm ² or more and 100.00 mm ² or less;
The height of the protrusion is 0.3 mm or more and 10.0 mm or less,
The protrusions are formed on the base surface at a density of 1/cm ² or more and 25/cm ² or less, and are formed over an area of at least 20% or more of the base surface. A foamed molded product. A foam molded article that is heat-sealed with another member,
At least one surface of the foam molded article that is heat-sealed to the other member is formed of a base surface and at least one protrusion formed on the base surface,
The protrusion first receives a stress when heat-sealed with the other member,
the projecting portion melts and spreads when the foam molded body and the other member are heat-sealed;
an area of a boundary surface between the base surface and the protrusion is 0.25 mm ² or more and 100.00 mm ² or less;
The height of the protrusion is 0.3 mm or more and 10.0 mm or less,
The protrusions are formed on the base surface at a density of 1/cm ² or more and 25/cm ² or less, and are formed over an area of at least 20% or more of the base surface. A foamed molded product. A foam molded article that is heat-sealed with another member,
At least one surface of the foam molded article that is heat-sealed to the other member is formed of a base surface and at least one protrusion formed on the base surface,
The protrusion first receives a stress when heat-sealed with the other member,
The protrusion includes a first protrusion and a second protrusion,
The second protrusion is formed on the first protrusion ,
an area of a boundary surface between the base surface and the protrusion is 0.25 mm ² or more and 100.00 mm ² or less;
The height of the protrusion is 0.3 mm or more and 10.0 mm or less,
The protrusions are formed on the base surface at a density of 1/cm ² or more and 25/cm ² or less, and are formed over an area of at least 20% or more of the base surface. A foamed molded product. A foam molded article that is heat-sealed with another member,
At least one surface of the foam molded article that is heat-sealed to the other member is formed of a base surface and at least one protrusion formed on the base surface,
The protrusion first receives a stress when heat-sealed with the other member,
The protrusion has a depression formed at the tip of the protrusion ,
an area of a boundary surface between the base surface and the protrusion is 0.25 mm ² or more and 100.00 mm ² or less;
The height of the protrusion is 0.3 mm or more and 10.0 mm or less,
The protrusions are formed on the base surface at a density of 1/cm ² or more and 25/cm ² or less, and are formed over an area of at least 20% or more of the base surface. A foamed molded product. A laminated body formed by laminating the foamed molded article according to any one of claims 1 to 13 and the other member. A method for manufacturing a laminate by laminating and heat-sealing the foamed molded article according to any one of claims 1 to 13 and the other member,
A lamination step of laminating another member on the lamination surface on which the protrusion is formed, and
A pressing step of pressing the laminated foam molded body and the other member,
A method for manufacturing a laminate, comprising: 16. The method for manufacturing a laminate according to claim 15 , further comprising a decompression step.

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