JPH0452207B2 - - Google Patents
Info
- Publication number
- JPH0452207B2 JPH0452207B2 JP59079862A JP7986284A JPH0452207B2 JP H0452207 B2 JPH0452207 B2 JP H0452207B2 JP 59079862 A JP59079862 A JP 59079862A JP 7986284 A JP7986284 A JP 7986284A JP H0452207 B2 JPH0452207 B2 JP H0452207B2
- Authority
- JP
- Japan
- Prior art keywords
- skin material
- material sheet
- mold
- resin particles
- mold cavity
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000000463 material Substances 0.000 claims description 71
- 239000002245 particle Substances 0.000 claims description 52
- 229920005989 resin Polymers 0.000 claims description 43
- 239000011347 resin Substances 0.000 claims description 43
- 238000000034 method Methods 0.000 claims description 32
- 238000010438 heat treatment Methods 0.000 claims description 14
- 239000006260 foam Substances 0.000 claims description 13
- 238000010097 foam moulding Methods 0.000 claims description 13
- 229920005992 thermoplastic resin Polymers 0.000 claims description 5
- 238000000465 moulding Methods 0.000 description 19
- 239000000945 filler Substances 0.000 description 9
- 238000001816 cooling Methods 0.000 description 6
- 238000005336 cracking Methods 0.000 description 6
- 230000000694 effects Effects 0.000 description 4
- 238000003825 pressing Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- -1 polyethylene Polymers 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 2
- 239000000498 cooling water Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 238000005429 filling process Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 239000004794 expanded polystyrene Substances 0.000 description 1
- 239000006261 foam material Substances 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 229920005669 high impact polystyrene Polymers 0.000 description 1
- 239000004797 high-impact polystyrene Substances 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920006327 polystyrene foam Polymers 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Description
【発明の詳細な説明】
＜産業上の利用分野＞
この発明は発泡成形方法に関し、詳しくは発泡
体の型内成形と同時に、発泡体に表皮材シートを
一体接合する、いわゆる同時成形方法に関してい
る。[Detailed Description of the Invention] <Industrial Application Field> The present invention relates to a foam molding method, and more specifically to a so-called simultaneous molding method in which a skin material sheet is integrally bonded to the foam at the same time as in-mold molding of the foam. .
＜従来の技術＞
従来、同時成形方法の一種として、第３図に示
すように合成樹脂シートあるいはフイルム、編
布、織布および不織布等の表皮材シート１を、発
泡成形用の成形型２，３の型窩４内に挟み込んで
配置した後、成形型３に取付けた充填器５によつ
て発泡ポリスチレンビーズ等の発泡性熱可塑性樹
脂粒子を型窩４に充填し、型窩４背面の蒸気室へ
導入した蒸気等の加熱媒体によつて上記樹脂粒子
を加熱膨脹させて、発泡成形を行うと同時に表皮
材シートを、成形される発泡体に一体接合する方
法がある。<Prior art> Conventionally, as a type of simultaneous molding method, as shown in FIG. 3 and placed in the mold cavity 4, the mold cavity 4 is filled with foamed thermoplastic resin particles such as expanded polystyrene beads by the filling device 5 attached to the mold 3, and the steam on the back side of the mold cavity 4 is filled. There is a method in which the resin particles are heated and expanded by a heating medium such as steam introduced into a chamber to perform foam molding, and at the same time, the skin material sheet is integrally joined to the foam to be molded.
上記方法で使用する成形装置のうち、充填器５
および樹脂粒子の供給機構としては、通常の発泡
成形装置と同じものが使用されている。即ち、充
填器５には、樹脂粒子の供給口５ａと圧力エアー
導入口５ｂが設けてあり、供給口５ａは導管７を
経てホツパー８に接続されている。 Among the molding devices used in the above method, the filling machine 5
As the resin particle supply mechanism, the same one as in a normal foam molding apparatus is used. That is, the filling device 5 is provided with a resin particle supply port 5a and a pressure air introduction port 5b, and the supply port 5a is connected to a hopper 8 via a conduit 7.
そして、圧力エアー導入口５ｂに３〜７Kg／cm2
の圧力エアーを導入することによつて、充填器５
内でエゼクター効果による吸引力を作用させ、ホ
ツパー８内の樹脂粒子を導管７を通つて充填器５
内へ吸引し、圧力エアーとともに樹脂粒子を型窩
４内へ充填するものである。 Then, apply 3 to 7 kg/cm 2 to the pressure air inlet 5b.
By introducing pressurized air of
A suction force due to the ejector effect is applied inside the hopper 8, and the resin particles in the hopper 8 are passed through the conduit 7 to the filler 5.
The mold cavity 4 is filled with resin particles together with pressurized air.
しかし、上記エゼクター効果による吸引力は
0.03〜0.1Kg／cm2と弱いので、表皮材シート１を
型窩４の型内面に押し付ける力は無く、型内面と
表皮材シート１との間に〓間が生じたり、表皮材
シート１に歪みやシワが発生したり、また発泡成
形品の肉厚が薄い場合には、上記〓間等によつて
樹脂粒子が型窩４全体に充分行き渡らず、充填不
良を起す可能性もあつた。 However, the suction force due to the above ejector effect is
Since it is weak at 0.03 to 0.1 Kg/ cm2 , there is no force to press the skin material sheet 1 against the mold inner surface of the mold cavity 4, and a gap may occur between the mold inner surface and the skin material sheet 1, or the skin material sheet 1 may If distortions or wrinkles occur or if the foam molded product has a thin wall, the resin particles may not be sufficiently distributed throughout the mold cavity 4 due to the above-mentioned gaps, which may cause filling defects.
その為、表皮材シート１を予め型内面に密着す
る形状に成形しておけば、上記問題は解決できる
が、表皮材シート１を成形する手間がかかり、そ
の為の成形装置も必要で、コスト的に高くつく欠
点がある。また、表皮材シート１が布のように柔
軟で成形困難なものの場合には、上記方法も採用
できない。 Therefore, if the skin material sheet 1 is molded in advance into a shape that fits tightly onto the inner surface of the mold, the above problem can be solved, but it takes time and effort to mold the skin material sheet 1, and a molding device for that purpose is also required, which increases the cost. It has the disadvantage of being expensive. Further, if the skin material sheet 1 is soft and difficult to mold, such as cloth, the above method cannot be adopted.
＜目的および構成＞
そこで、この発明においては、上記従来技術の
欠点を解消し、表皮材シートと発泡体との同時成
形を能率良く低コストで行えると同時に、仕上り
も良好な同時成形品が得られる方法を開発したも
のであり、その方法としては、成形型の型窩内へ
表皮材シートを配置した後、発泡性熱可塑性樹脂
粒子を充填し、該粒子を蒸気等の加熱媒体により
加熱膨脹させて、発泡成形を行うと同時に表皮材
シートと一体接合する方法において、別途製造さ
れてある一葉の表皮材シートを雌雄両型で周辺部
を挾み保持して型窩内に配置した後、加圧された
発泡粒タンク内に蓄えた樹脂粒子を表皮材シート
の背面位置から加圧状態のまま型窩内に圧送充填
して発泡成形するとともに表皮材シートを雌雄型
一方の型内面に沿わせて成形させることを特徴と
している。<Purpose and Structure> Therefore, the present invention solves the drawbacks of the above-mentioned conventional techniques, allows simultaneous molding of a skin material sheet and a foam material efficiently and at low cost, and at the same time provides a simultaneously molded product with a good finish. This method involves placing a skin material sheet into the cavity of a mold, filling it with expandable thermoplastic resin particles, and heating and expanding the particles with a heating medium such as steam. In the method of performing foam molding and integrally joining the skin material sheet at the same time, after placing a separately manufactured skin material sheet in the mold cavity by holding the peripheral part between male and female molds, Resin particles stored in a pressurized foam grain tank are fed and filled into the mold cavity under pressure from the back side of the skin material sheet to perform foam molding, and the skin material sheet is placed along the inner surface of one of the male and female molds. It is characterized by being molded together.
＜実施態様＞
次いで、この発明の実施態様について、図を参
照しながら以下に例示する。<Embodiments> Next, embodiments of the present invention will be illustrated below with reference to the drawings.
第１図に示す成形装置において、１０は成形型
のうちの雌型、２０は雄型であり、両型１０，２
０間に型窩３０が形成されている。また、両型１
０，２０の型窩３０背面には夫々蒸気室１１，２
１が形成してあり、各蒸気室１１，２１には蒸気
弁１２，２２を経て加熱蒸気を導入可能になつて
いる。１３，２３はドレン弁であり、蒸気室１
１，２１内の蒸気や冷却水を排出可能にしてい
る。成形型１０，２０には、そのほか冷却水配管
や成形品の取出機構も取付けられが、従来の成形
装置と同様の構造でよく、図示を省略している。 In the molding apparatus shown in FIG. 1, 10 is a female mold, 20 is a male mold, and both molds 10, 2
A mold cavity 30 is formed between the holes. Also, both types 1
Steam chambers 11 and 2 are provided on the back side of the mold cavity 30 of 0 and 20, respectively.
1 is formed, and heated steam can be introduced into each steam chamber 11, 21 via steam valves 12, 22. 13 and 23 are drain valves, and the steam chamber 1
Steam and cooling water inside 1 and 21 can be discharged. The molds 10 and 20 are also equipped with cooling water piping and a molded product take-out mechanism, which may have the same structure as a conventional molding device and are not shown in the drawings.
次に４０は充填器であり、雌型１０の側面に取
付けてあつて、先端を型窩３０内に開孔させてい
る。４１は充填器４０に樹脂粒子を供給するため
の供給口である。その他の構造については従来の
充填器４０と同様のものであるが、圧力エアーの
導入口４２については従来のような樹脂粒子の充
填には用いず、余分の樹脂粒子を後述する発泡粒
タンク６０に戻す、いわゆるブローバツクの為に
使用する。従つて、通常の圧力エアー導入口４２
を備えた充填器を流用する場合には、圧力エアー
導入口４２を電磁弁等で閉塞しておき、樹脂粒子
のブローバツクの際には、従来と同様に圧力エア
ーを導入して使用する。 Next, reference numeral 40 denotes a filling device, which is attached to the side surface of the female mold 10 and has its tip opened into the mold cavity 30. 41 is a supply port for supplying resin particles to the filler 40. The rest of the structure is similar to the conventional filling device 40, but the pressure air inlet 42 is not used for filling resin particles as in the conventional case, and excess resin particles are stored in a foamed particle tank 60 (described later). It is used for so-called blowback. Therefore, the normal pressure air inlet 42
When reusing a filling device equipped with a filler, the pressurized air inlet 42 is closed with a solenoid valve or the like, and when blowing back the resin particles, pressurized air is introduced and used as in the conventional method.
充填器４０の供給口４１には導管５０が連結さ
れてあり、この導管５０の他端は、樹脂粒子を一
時貯えておく発泡粒タンク６０に連結されてい
る。 A conduit 50 is connected to the supply port 41 of the filling device 40, and the other end of this conduit 50 is connected to a foamed grain tank 60 in which resin particles are temporarily stored.
発泡粒タンク６０は内圧が加わつても良い耐圧
タンクにて形成されてあり、導管５０との連結部
分には、供給弁６１が取付けてある。また、６２
は圧力エアー導入弁であり、発泡粒タンク６０内
に圧力エアーを導入可能にしている。６３はタン
ク６０内の圧力を抜くための圧抜き弁であり、大
気中へ開放されている。６４は樹脂粒子の導入用
開閉弁であり、樹脂粒子の貯溜部へ連結されてい
る。 The foamed grain tank 60 is formed of a pressure-resistant tank to which internal pressure can be applied, and a supply valve 61 is attached to the connection portion with the conduit 50. Also, 62
is a pressure air introduction valve, which allows pressure air to be introduced into the foamed grain tank 60. 63 is a pressure relief valve for releasing the pressure inside the tank 60, and is opened to the atmosphere. Reference numeral 64 denotes a resin particle introduction on-off valve, which is connected to a resin particle reservoir.
なお、導管５０は発泡粒タンク６０から充填器
４０へ余分に送られた樹脂粒子を、この導管５０
を経て発泡粒タンク６０へ送り返すようになつて
いる。 Note that the conduit 50 carries excess resin particles sent from the foamed grain tank 60 to the filling device 40.
The foamed grains are sent back to the foamed grain tank 60 through the.
以上のような成形装置を使用する成形方法につ
いて説明する。 A molding method using the molding apparatus as described above will be explained.
まず、この発明で使用する予め別途製造してお
く表皮材シートＳとしては、ポリスチレン、ポリ
エチレン、ポリプロピレン等の熱可塑性樹脂から
なるシートまたはフイルムのように、加熱軟化さ
せて成形できる素材と、不織布、織布、編布ある
いは柔軟性のある合成樹脂シートまたはフイルム
のように、柔軟で伸縮性のある素材とが使用され
るが、両種の素材によつて成形方法が少し異なる
ので、最初に加熱成形できる素材の場合について
述べる。 First, the skin material sheet S, which is separately produced in advance and used in this invention, is made of a material that can be molded by heating and softening, such as a sheet or film made of thermoplastic resin such as polystyrene, polyethylene, or polypropylene; Flexible and stretchable materials such as woven fabrics, knitted fabrics, or flexible synthetic resin sheets or films are used, but the molding method is slightly different depending on the two types of materials, so they must be heated first. We will discuss the case of materials that can be molded.
一葉の表皮材シートＳは雌雄両型１０，２０で
周辺部を挟み保持して、型窩３０内に配置する。
なお、表皮材シートＳは連続した長尺のものを両
型１０，２０の中間に垂下した状態で、型閉めを
行うことによつて両型１０，２０間に所定長さ分
を挟み込み、同時成形終了後には、上記長尺の表
皮材シートＳを順次垂下させることによつて、連
続的に表皮材シートＳを供給できるようにすれ
ば、能率的に作業が行える。型窩３０内で両型１
０，２０間に挟み込まれた表皮材シートＳは、図
の場合、雄型２０の内面側に当接して配置されて
おり、表皮材シートＳの背面側即ち型窩３０の雌
型１０側に樹脂粒子を充填して発泡成形を行う。
そして、この状態では、表皮材シートＳは、型内
面の凹凸形状に対して完全には密着せず、部分的
に〓間が形成された状態のままになつている。 One leaf of the skin material sheet S is held in the mold cavity 30 with its peripheral portion held between male and female molds 10 and 20.
Note that the skin material sheet S is a continuous long sheet that is suspended between the molds 10 and 20, and by closing the molds, a predetermined length of the skin material sheet S is sandwiched between the molds 10 and 20. After the molding is completed, the long skin material sheets S are allowed to hang down one after another so that the skin material sheets S can be continuously supplied, thereby making the work more efficient. Both types 1 in the mold cavity 30
In the case of the figure, the skin material sheet S sandwiched between 0 and 20 is placed in contact with the inner surface of the male mold 20, and is placed on the back side of the skin material sheet S, that is, on the female mold 10 side of the mold cavity 30. Fill with resin particles and perform foam molding.
In this state, the skin material sheet S does not completely adhere to the uneven shape of the inner surface of the mold, and gaps remain partially formed.
次に、雌雄両型１０，２０の蒸気弁１２，２２
およびドレン弁１３，２３を開き、加熱蒸気を蒸
気室１１，２１内へ導入して表皮材シートＳを加
熱した後、排出する。一定時間蒸気で加熱する
と、表皮材シートＳは変形可能な程度に軟化する
ので、蒸気弁１２，２２を閉じて加熱を止める。
上記加熱時間としては、約２〜３秒でよい。 Next, the steam valves 12, 22 of the hermaphroditic type 10, 20
Then, the drain valves 13 and 23 are opened, and heated steam is introduced into the steam chambers 11 and 21 to heat the skin material sheet S and then discharged. When heated with steam for a certain period of time, the skin material sheet S softens to the extent that it can be deformed, so the steam valves 12 and 22 are closed to stop the heating.
The heating time may be about 2 to 3 seconds.
次に成形型１０，２０をわずかに開き、いわゆ
るクラツキング状態にする。このクラツキング幅
ｔは約２〜15mmである。 Next, the molds 10 and 20 are opened slightly to bring them into a so-called cracking state. This cracking width t is about 2 to 15 mm.
この状態で圧力エアー導入弁６２を開き発泡粒
タンク６０を加圧する。加圧圧力は約３〜７Kg／
cm2である。なお、このとき圧抜き弁６３および開
閉弁６４は閉じて、圧力が逃げないようにしてお
く。また、この段階までに、開閉弁６４を開いて
樹脂粒子を発泡粒タンク６０内に貯めておく。樹
脂粒子の量は、１シヨツトの発泡成形に使用する
分量とする。 In this state, the pressurized air introduction valve 62 is opened to pressurize the foamed grain tank 60. Pressure is approximately 3-7Kg/
cm2 . At this time, the pressure release valve 63 and the on-off valve 64 are closed to prevent pressure from escaping. Furthermore, by this stage, the on-off valve 64 is opened to store the resin particles in the foamed particle tank 60. The amount of resin particles is the amount used for one shot of foam molding.
発泡粒タンク６０に加圧状態の樹脂粒子を貯め
た状態で、供給弁６１を開くと、樹脂粒子は圧力
エアーとともに導管５０から充填器４０を経て、
型窩３０内へ圧送される。 When the supply valve 61 is opened with pressurized resin particles stored in the foamed particle tank 60, the resin particles pass through the filler 40 from the conduit 50 with pressurized air.
It is pumped into the mold cavity 30.
そして、樹脂粒子が加圧状態のまま型窩３０内
に充満するにつれ、軟化された表皮材シートＳは
樹脂粒子および圧力エアーに押圧され、型内面の
凹凸形状に沿つて変形させれながら密着するよう
押し付けられる。従つて、型窩３０内に樹脂粒子
が完全に充填された段階では、表皮材シートＳは
型内面に〓間無く密着して成形され、表皮材シー
トＳと樹脂粒子も〓間無く密着する。なお型窩３
０内に導入された圧力エアーはクラツキング〓間
から外部に排出される。 Then, as the resin particles fill the mold cavity 30 in a pressurized state, the softened skin material sheet S is pressed by the resin particles and the pressurized air, and is brought into close contact with the mold while being deformed along the uneven shape of the inner surface of the mold. I'm being pushed like that. Therefore, at the stage when the mold cavity 30 is completely filled with resin particles, the skin material sheet S is molded in close contact with the inner surface of the mold, and the skin material sheet S and the resin particles are also closely contacted with each other without any time. Furthermore, mold cavity 3
The pressurized air introduced into the cracking space is discharged to the outside from the cracking space.
その後の蒸気による加熱工程や冷却工程あるい
は成形品の取出工程等については、従来の発泡成
形と全く同じように行うので、詳細な説明は省
く。 The subsequent heating process using steam, cooling process, and removal process of the molded product are performed in exactly the same manner as in conventional foam molding, so detailed explanations will be omitted.
なお、樹脂粒子の充填工程において、余分の樹
脂粒子が充填器４０や導管５０内に残つた場合に
は、充填器４０の圧力エアー導入口４２を開き、
圧力エアーにて樹脂粒子を、導管５０を経て発泡
粒タンク６０内に戻すようにする。 In addition, in the resin particle filling process, if excess resin particles remain in the filler 40 or conduit 50, open the pressure air inlet 42 of the filler 40,
The resin particles are returned to the foamed grain tank 60 through the conduit 50 using pressurized air.
以上に説明した方法では、表皮材シートＳを型
窩３０の雄型２０側に当接配置して、発泡成形品
の雄型２０側の形状に沿つて一体接合している
が、表皮材シートＳを雌型１０側の形状に沿つて
一体接合することもできる。この場合には、充填
器４０を雄型２０側に設け、型窩３０内に樹脂粒
子を充填する際に、表皮材シートＳと雄型２０の
間に樹脂粒子を充填して、表皮材シートＳを雌型
１０側の型内面に押し付けて成形するようにすれ
ばよい。 In the method described above, the skin material sheet S is placed in contact with the male mold 20 side of the mold cavity 30 and integrally joined along the shape of the male mold 20 side of the foam molded product. S can also be integrally joined along the shape of the female mold 10 side. In this case, the filler 40 is provided on the side of the male mold 20, and when filling the mold cavity 30 with resin particles, the resin particles are filled between the skin material sheet S and the male mold 20, and the skin material sheet The molding may be carried out by pressing S onto the inner surface of the mold on the female mold 10 side.
次に上記方法と一部異なる。変更例について説
明する。この方法は、表皮材シートＳとして柔軟
で伸縮性のある素材を使用する場合に適用する方
法である。 Next, there are some differences from the above method. An example of the change will be explained. This method is applied when a flexible and stretchable material is used as the skin material sheet S.
使用する成形装置は前記方法と同じであり、表
皮材シートＳを成形型１０，２０に挟み込んで配
置するまでは、前記方法と全く同様である。 The molding apparatus used is the same as the method described above, and the process until the skin material sheet S is placed between the molds 10 and 20 is completely the same as the method described above.
次の工程で、前記方法の場合には、表皮材シー
トＳを蒸気で加熱軟化させたが、この方法では加
熱軟化工程は行わず、直ちに次の樹脂粒子充填工
程に進む。 In the next step, in the case of the method described above, the skin material sheet S was heated and softened with steam, but in this method, the heating and softening step is not performed and the process immediately proceeds to the next resin particle filling step.
充填工程も前記方法と同じように行うが、この
とき表皮材シートＳは加熱軟化されていなくと
も、表皮材自体の伸縮性によつて、樹脂粒子およ
び圧力エアーで押圧されて、型窩３０の型内面の
凹凸形状に沿つて伸縮変形し、型内面と表皮材シ
ートＳとが〓間なく密着する。 The filling process is also carried out in the same manner as the above method, but at this time, even if the skin material sheet S is not heated and softened, it is pressed by the resin particles and pressurized air due to the elasticity of the skin material itself, and the mold cavity 30 is filled. It expands and contracts along the uneven shape of the inner surface of the mold, and the inner surface of the mold and the skin material sheet S immediately come into close contact with each other.
その後工程は前記方法と全く同じでよい。 The subsequent steps may be exactly the same as the above method.
上記方法の場合、表皮材シートＳの加熱軟化工
程が省略でき、作業が一層能率的に行え、コスト
も安価になる。なお表皮材シートＳ自体に伸縮性
を有するものが、型に良好に沿わせ得て好適であ
る。以上のような、この発明方法は、ポリスチレ
ン、ポリエチレン等の各種熱可塑性樹脂の発泡体
と表皮材シートＳとの同時成形により製造する、
各種物品の製造に自由に適用でき、例えば冷蔵庫
用露受皿、自動車用天井材、その他の物品の製造
に好適である。 In the case of the above method, the step of heating and softening the skin material sheet S can be omitted, the work can be performed more efficiently, and the cost can be reduced. Note that it is preferable that the skin material sheet S itself has elasticity, since it can be made to fit the mold well. As described above, the method of the present invention is produced by simultaneous molding of a foam of various thermoplastic resins such as polystyrene and polyethylene and a skin material sheet S.
It can be freely applied to the manufacture of various articles, and is suitable for, for example, the manufacture of refrigerator trays, ceiling materials for automobiles, and other articles.
＜効果＞
以上のごとく構成された、この発明方法によれ
ば、一葉の表皮材シートＳを成形型１０，２０に
挟み込んで型窩３０内に配置した後、表皮材シー
トＳの背面側から樹脂粒子を型窩３０内に充填す
る際に、樹脂粒子を加圧された発泡粒タンク６０
内に一旦貯え、この加圧エネルギーを利用して、
圧力エアーとともに樹脂粒子を、充填器４０を経
て型窩３０内へ圧送するので、表皮材Ｓを型内面
に押し付ける押圧力が非常に強く、表皮材シート
Ｓと型内面との間の〓間を無くするのに大きな効
果を発揮する。<Effects> According to the method of the present invention configured as described above, after one leaf of the skin material sheet S is sandwiched between the molds 10 and 20 and placed in the mold cavity 30, resin is applied from the back side of the skin material sheet S. When filling the mold cavity 30 with particles, the foamed grain tank 60 is pressurized with resin particles.
Once stored inside, and using this pressurized energy,
Since the resin particles are fed together with pressurized air into the mold cavity 30 through the filler 40, the pressing force that presses the skin material S against the inner surface of the mold is very strong, and the gap between the skin material sheet S and the mold inner surface is very strong. It is very effective in eliminating it.
即ち、従来のエゼクター効果を利用した供給方
法では表皮材シートＳに対する押圧力は弱いが、
この発明では加圧された発泡粒タンク６０から、
直接圧力エアーで樹脂粒子を圧送して、加圧状態
のまま供給するので、圧力エネルギーの無駄も無
く、強力な押圧力が生じるのである。 That is, in the conventional feeding method using the ejector effect, the pressing force against the skin material sheet S is weak;
In this invention, from the pressurized foamed grain tank 60,
Since the resin particles are directly pumped with pressurized air and supplied in a pressurized state, there is no waste of pressure energy and a strong pressing force is generated.
従つて、従来の同時成形方法では、表皮材シー
トＳを予め型内面形状に沿うよう成形しておく必
要があつたのを、この発明方法では全く必要なく
なり、作業工程の削滅および能率化を図り、表皮
材シートＳ用の成形装置を無くすことができる。
また、表皮材シートＳが柔軟で予め成形しておく
ことが困難な素材であつても、この発明方法であ
れば充分に同時成形を行うことができ、同時成形
の適用範囲および用途の拡大にも貢献できること
になる。 Therefore, in the conventional simultaneous molding method, it was necessary to mold the skin material sheet S in advance to conform to the inner surface shape of the mold, but this method of the present invention does not require it at all, which reduces the number of work steps and improves efficiency. In addition, a molding device for the skin material sheet S can be eliminated.
In addition, even if the skin material sheet S is a flexible material that is difficult to form in advance, the method of this invention can sufficiently perform simultaneous forming, thereby expanding the scope and use of simultaneous forming. will also be able to contribute.
そして、製造される発泡成形品は、表皮材シー
トＳの平滑度や成形形状の精度等の仕上りが良好
で、不良品の発生率も少なく、また発泡体側の成
形にとつても、充填不良が起り難く、充填時間も
短かくて済み、表皮材シートＳと発泡体との一体
性も優れたものになる。 The foam molded products produced have good finishes such as the smoothness of the skin material sheet S and the precision of the molded shape, and the incidence of defective products is low, and there is no problem with filling defects when molding the foam side. This is less likely to occur, the filling time is short, and the integrity of the skin material sheet S and the foam is excellent.
実施例 １
発泡成形品（厚さ５mm×1200mm×1000mmでやや
湾曲）
ポリスチレン発泡樹脂粒子（発泡倍率25倍）を
使用した。Example 1 Foamed molded product (thickness: 5 mm x 1200 mm x 1000 mm, slightly curved) Polystyrene foam resin particles (expansion ratio: 25 times) were used.
表皮材シートＳ
ハイインパクトポリスチレンシート（厚さ0.3
mm）
上記樹脂粒子を内圧３Kg／cm2の発泡粒タンク６
０に貯えておく。そして、上記表皮材シートＳを
成形型１０，２０に挟み込み、蒸気弁１２，２２
およびドレン弁１３，２３を２秒間開き、次にド
レン弁１３，２３のみを閉じ、型窩３０の蒸気圧
力を0.8Kg／cm2にして３秒間経過させて、表皮材
シートＳの加熱軟化を行つた。Skin material sheet S High impact polystyrene sheet (thickness 0.3
mm) The above resin particles are stored in a foamed granule tank 6 with an internal pressure of 3Kg/ cm2 .
Store it at 0. Then, the skin material sheet S is sandwiched between the molds 10 and 20, and the steam valves 12 and 22 are
Then, the drain valves 13 and 23 are opened for 2 seconds, then only the drain valves 13 and 23 are closed, and the steam pressure in the mold cavity 30 is set to 0.8 Kg/cm 2 for 3 seconds to soften the skin material sheet S by heating. I went.
その後、成形型１０，２０を少し開いてクラツ
キングを取り（ｔ＝３mm）、この状態で樹脂粒子
の供給弁６１を開き、発泡粒タンク６０内の樹脂
粒子を型窩３０へ２秒で充填出来た。 After that, the molds 10 and 20 are slightly opened to remove cracking (t=3 mm), and in this state, the resin particle supply valve 61 is opened, and the resin particles in the foamed particle tank 60 can be filled into the mold cavity 30 in 2 seconds. Ta.
充填完了後、蒸気弁１２，２２およびドレン弁
１３，２３を３秒間開き、その後ドレン弁１３，
２３のみを閉じ、蒸気室１１，２１内の圧力0.8
Kg／cm2で12秒間加熱し、発泡成形を行つた。その
後、水冷30秒、放冷25秒の後、成形品を取出した
ところ、表皮材シートＳと発泡体との一体性に優
れ、仕上りの良好な製品が得られた。 After filling is completed, steam valves 12, 22 and drain valves 13, 23 are opened for 3 seconds, and then drain valves 13, 23 are opened.
23 is closed, the pressure inside the steam chambers 11 and 21 is 0.8
Foam molding was performed by heating at Kg/cm 2 for 12 seconds. Thereafter, after cooling with water for 30 seconds and cooling for 25 seconds, the molded product was taken out, and a product with excellent integrity between the skin material sheet S and the foam and a good finish was obtained.
実施例 ２
(1) 発泡成形品
POD発泡樹脂粒子（発泡倍率15倍）
(2) 表皮材シートＳ
不織布の片面にPVAフイルムを積層して発
泡体との接着性を良好にしている。Example 2 (1) Foamed molded product POD foamed resin particles (expansion ratio 15 times) (2) Skin material sheet S A PVA film is laminated on one side of a nonwoven fabric to improve adhesion to the foam.
(3) 作業工程
成形型１０，２０のクラツキング幅ｔ＝４mm
取り、上記表皮材シートＳを配置した後、発泡
粒タンク６０内の圧力３Kg／cm2にして樹脂粒子
を充填したところ充填時間は２秒であつた。次
に、発泡成形工程においては、金型加熱２秒、
一方加熱（蒸気圧0.5Kg／cm2）および両面加熱
（蒸気圧力0.7Kg／cm2設定で実測値1.0Kg／cm2）
10秒、水冷60秒、放冷40秒にて成形品を取り出
したところ、良好な製品が得られた。(3) Working process Cracking width t of molds 10 and 20 = 4 mm
After the above-mentioned skin material sheet S was placed, the pressure inside the foamed grain tank 60 was set to 3 kg/cm 2 and resin particles were filled, and the filling time was 2 seconds. Next, in the foam molding process, the mold was heated for 2 seconds,
One-sided heating (steam pressure 0.5Kg/cm 2 ) and double-sided heating (actual value 1.0Kg/cm 2 at steam pressure 0.7Kg/cm 2 setting)
When the molded product was taken out after cooling for 10 seconds, cooling with water for 60 seconds, and cooling for 40 seconds, a good product was obtained.
図はこの発明方法に使用する装置の実施態様を
例示するものであり、第１図は表皮材シートをセ
ツトした状態における装置の構造図、第２図は樹
脂粒子充填時における装置の構造図、第３図は従
来装置の構造図である。
１０，２０……成形型、１２，２２……蒸気
弁、３０……型窩、４０……充填器、４１……供
給口、５０……導管、６０……発泡粒タンク、６
２……圧力エアー導入弁６３……圧抜き弁、６４
……開閉弁、Ｓ……表皮材シート。
The figures illustrate an embodiment of the apparatus used in the method of the present invention, in which Figure 1 is a structural diagram of the apparatus in a state where a skin material sheet is set, Figure 2 is a structural diagram of the apparatus when resin particles are filled, FIG. 3 is a structural diagram of a conventional device. 10, 20... Molding mold, 12, 22... Steam valve, 30... Mold cavity, 40... Filler, 41... Supply port, 50... Conduit, 60... Foamed grain tank, 6
2...Pressure air introduction valve 63...Pressure relief valve, 64
...Opening/closing valve, S...Skin material sheet.
Claims (1)
後、発泡性熱可塑性樹脂粒子を充填し、該粒子を
蒸気等の加熱媒体により加熱膨脹させて、発泡成
形を行うと同時に表皮材シートと一体接合する方
法において、別途製造されてある一葉の表皮材シ
ートを雌雄両型で周辺部を挾み保持して型窩内に
配置した後、加圧された発泡粒タンク内に蓄えた
樹脂粒子を、表皮材シートの背面位置から加圧状
態のまま型窩内に圧送充填して発泡成形するとと
もに表皮材シートを雌雄型一方の型内面に沿わせ
て成形させることを特徴とする発泡成形方法。1. After placing the skin material sheet in the mold cavity of the mold, it is filled with expandable thermoplastic resin particles, and the particles are heated and expanded with a heating medium such as steam to perform foam molding and simultaneously form the skin material sheet. In the integral bonding method, a separately manufactured sheet of skin material is sandwiched between male and female molds and placed in the mold cavity, and then the resin particles are stored in a pressurized foam grain tank. A foam molding method characterized in that the skin material sheet is pressurized and filled into the mold cavity from the rear position of the skin material sheet to perform foam molding, and the skin material sheet is molded along the inner surface of one of the male and female molds. .
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP59079862A JPS60222212A (en) | 1984-04-19 | 1984-04-19 | Method and apparatus for foam molding |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP59079862A JPS60222212A (en) | 1984-04-19 | 1984-04-19 | Method and apparatus for foam molding |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS60222212A JPS60222212A (en) | 1985-11-06 |
| JPH0452207B2 true JPH0452207B2 (en) | 1992-08-21 |
Family
ID=13702009
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP59079862A Granted JPS60222212A (en) | 1984-04-19 | 1984-04-19 | Method and apparatus for foam molding |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS60222212A (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108943561B (en) * | 2018-09-02 | 2024-09-06 | 台山市舒力床具机械有限公司 | Automatic double-mode sponge continuous foaming machine and sponge foaming method using same |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS59145125A (en) * | 1983-02-09 | 1984-08-20 | Minoru Sangyo Kk | Preparation of thermoplastic resin expanded material with skin layer |
-
1984
- 1984-04-19 JP JP59079862A patent/JPS60222212A/en active Granted
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS59145125A (en) * | 1983-02-09 | 1984-08-20 | Minoru Sangyo Kk | Preparation of thermoplastic resin expanded material with skin layer |
Also Published As
| Publication number | Publication date |
|---|---|
| JPS60222212A (en) | 1985-11-06 |
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