JPH0328302B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method and apparatus for cutting and cutting a foam molded article having a skin layer, and more specifically to a novel skin layer that is free from the problems of filling defects with foamed resin beads and wrinkles of the skin layer. The present invention relates to a method and apparatus for producing a foamed molded article.

Conventionally, various techniques have been proposed for manufacturing foam molded articles having a skin layer. For example, Tokukai Akira
In No. 56-72936, a surface material such as a metal foil is placed inside the lower female mold, foamed resin beads are placed on top of the surface material, and the surface material and the inner surface of the female mold are bonded. A method of heating and foaming after evacuating the cavity is disclosed, and Japanese Patent Application Laid-Open No. 109732/1983 discloses a method of blowing steam or hot air for heating and foaming into the mold cavity to pressure-form the skin material onto the molding surface. Discloses a method of injecting and filling expandable resin beads and foaming them by heating.

However, in all of these methods, a sheet-like material is first placed in the mold and then filled with foamed resin beads, so the sheet-like material blocks the slit on one side, making it difficult for air to escape. The inside of the mold is partitioned with a sheet-like material, creating areas where beads cannot be filled. As a result, incomplete filling of beads occurs, resulting in a high product defect rate. Furthermore, since the sheet-like material has difficulty conforming to the mold, it is difficult to form a desired shape, and wrinkles are likely to occur. Furthermore, since vacuum equipment is required, the device becomes complicated and expensive. In addition to this, there is a regret that it is not possible to bond thin materials together.

In view of the above-mentioned circumstances, the present inventor conducted extensive research to overcome these problems, and as a result, arrived at the present invention, which can solve the above-mentioned problems at once.

That is, when manufacturing a composite foamed molded product consisting of a skin layer and a foamed molded product, the present invention involves filling a mold cavity formed by a core mold and a cavity mold with foamed resin beads, heating and cooling the molded product. Then, the molds are opened at appropriate intervals, and while the temporarily fused product is held in one mold, the skin layer is inserted and fixed with a support needle protruding from the periphery of the other mold. , a method for manufacturing a composite foam molded article having a skin layer, which comprises heating the skin layer while closing both molds and performing heat molding, and further a manufacturing apparatus suitably used in the manufacturing method. In a molding device consisting of a core mold and a cavity mold, support needles for fixing the skin layer are provided protruding from the periphery of one mold, and support needles for fixing the skin layer are provided protruding from the periphery of the other mold. The present invention relates to an apparatus for manufacturing a composite foam molded article having a skin layer characterized by having accommodation holes formed therein.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below based on drawings showing embodiments of the present invention.

1 to 3 are schematic diagrams showing an example of the manufacturing apparatus of the present invention. In the figure, 1 is a core mold, 2 is a cavity mold, 3 is a filling device, 4 is a steam or hot air pore, 5 is a support needle accommodation hole, 6 is a support needle for fixing the epidermal layer, and 7 is a resin bead. , 8 is the epidermal layer.

In FIG. 1, a support needle 6 for fixing the skin layer is provided protruding from the peripheral edge of the core mold 1, and an accommodation hole 5 for accommodating the support needle 6 is provided at an opposing position of the cavity mold 2. It is perforated. Further, a resin bead filler 3 is attached to the cavity mold 2. A mold cavity 9 is formed between the core mold 1 and the cavity mold 2. Although not shown, it is of course equipped with piping for steam or hot air, cooling water, and the like.

In this state, the mold cavity 9 is filled with resin beads from the filler 3 and heated to temporarily fuse them. Temporary welding in this case means that the temporary welding material is heated to such an extent that it does not collapse when the mold is opened, and that steam or other heat is used during the subsequent main heating (heating when integrally molding the skin layer and the temporary welding material). Refers to the state in which there are gaps between foamed resin beads so that hot air can sufficiently penetrate inside. Therefore, it is preferable to select heating conditions for the temporary fusion bonding such that the molded product does not shrink due to main heating. These conditions cannot be defined unconditionally depending on the type of resin, the thickness of the molded body, etc., but low pressure (0.2
One-sided heating under normal pressure (up to about Kg/cm ² ) or normal pressure is preferred. Of course, in the case of heat-resistant resin, normal molding conditions may be used.

Next, after cooling, the mold is opened at appropriate intervals. The situation in this case is shown in Fig. 2, where the obtained temporarily fused material is held in one mold (cavity mold 2 in the figure) and the skin layer 8 is inserted between both molds. The other mold (core mold 1 in the figure) is inserted into the supporting needle 6 protruding from the periphery of the other mold, and fixed, and heated by blowing steam or hot air from the core mold 1 side. Close the mold. The skin layer 8 is fixed at its periphery with support needles 6, and is held between the temporarily fused material and the core mold 1 while being spread by heating.

FIG. 3 shows a state in which the skin layer 8 is held between the temporarily fused material and the core mold 1. In this state, main heating is performed. The main heating may be either normal heating or unilateral heating, but normal heating is generally more effective in fusing the skin layer and the molded article.

When obtaining a composite foam molded article according to the present invention, it is convenient to attach a cutter to the meeting end of both molds. The cutter is not particularly limited, and may be either a flat blade, a zigzag blade, or the like. Both the cavity mold and the core mold may be installed so that the skin layer is cut when the skin layer is sandwiched and closed. Furthermore, if a cross guider or the like is used to automatically supply a predetermined length of the skin layer and then grip and stretch it, the work efficiency can be greatly increased. FIG. 4 shows an apparatus that is equipped with a delivery roll 9 and a gripping roll 10, and a cutter 11 is attached to the end of the core mold 1 that meets the cavity mold 2. The skin layer delivery device is attached to either the top or side of the mold depending on the vertical or horizontal length of the mold.

As the expandable resin beads used in the present invention, thermoplastic resins such as polyolefins such as polystyrene, polyethylene and polypropylene, and polyvinyl chloride are suitable.

Further, as the skin layer, thermoplastic foamed or non-foamed sheets, films, woven fabrics, nonwoven fabrics, and other materials that are malleable by heating can be suitably used. If the adhesiveness between the foam molded article and the skin layer is insufficient, it is desirable to use an adhesive. For example, it is preferable to apply a thermoplastic adhesive to the back surface of the skin layer (the surface to be bonded to the foamed molded product) in advance and dry it so that it functions as an adhesive during the main heating.

As mentioned above, in the present invention, first, a temporarily fused product of a foamed molded product is made, then the skin layer is fixed with a support needle, spread by heating and adhered to the temporarily fused product, and the skin layer is formed by main heating. This method is characterized in that a foamed molded article is obtained in which layers are integrally fused together. Therefore, the present invention has the following advantages: (1) Unlike the conventional method in which a skin layer is first placed on the mold surface and then filled with resin beads, the present invention uses normal filling, so even thin objects can be sufficiently filled. , (2) Since the skin layer is fixed with a support needle and fused to the surface of the molded product while being spread with heat, wrinkles do not occur, and a predetermined shape can be found sharply and accurately. 3) Since vacuum equipment is not required, the equipment can be small-scale and therefore inexpensive; (4) Interlocking with the delivery roll and gripping roll;
Moreover, by equipping the mold with a cutter,
It has many advantages such as being able to save a lot of labor, and its usefulness is extremely large.

[Brief explanation of the drawing]

1 to 3 are schematic diagrams showing one example of an embodiment of the present invention, and FIG. 4 is a schematic diagram showing another embodiment of the present invention. 1...Core mold, 2...Cavity mold, 3...
... Filler, 4 ... Steam or hot air pore, 5 ... Support needle accommodation hole, 6 ... Support needle, 7 ... Foamed resin beads, 8 ... Skin layer, 9 ... Delivery roll, 10
...Gripping roll, 11...Cutter.

Claims (1)

[Scope of Claims] 1. When manufacturing a composite foamed molded product consisting of a skin layer and a foamed molded product, foamed resin beads are filled into mold cavities formed by a core mold, a cavity mold, and a tee mold. After cooling, the molds are opened at appropriate intervals, and while the temporarily fused material is held in one mold, the skin layer is inserted and a support protruding from the periphery of the other mold is inserted. 1. A method for producing a composite foam molded article having a skin layer, which comprises fixing with a needle, heating the skin layer while closing both molds, and performing heat molding. 2. The manufacturing method according to claim 1, wherein the temporarily fused product is formed by heating under low pressure to normal pressure. 3. The manufacturing method according to claim 1, wherein an adhesive is interposed between the temporarily fused material and the skin layer. 4. In a molding device consisting of a core mold and a cavity mold, support needles for fixing the skin layer are provided protruding from the peripheral edge of one mold, and the support needles are housed in the opposing peripheral edge of the other mold. An apparatus for producing a composite foam molded article having a skin layer formed by perforating holes. 5. The manufacturing apparatus according to claim 4, wherein a cutter is attached to the meeting end of both molds. 6. The manufacturing apparatus according to claim 4 or 5, comprising means for automatically supplying the skin layer to a predetermined length and means for gripping the end of the skin layer.