JPH0871258A - Sponge block toy and manufacture thereof - Google Patents

Abstract

PURPOSE: To provide a lightweight block toy hardly broken and capable of being safely used by a child. CONSTITUTION: A block piece P is formed with a synthetic resin foam body of soft independent bubbles. Punched pieces 2 punched from a piece main body 1 are inserted into punched holes 3 to be protruded at one end and retreated at the other end, and they are integrally fused to the piece main body 1 to form projections and recesses for coupling.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention has one or a plurality of fitting projections and corresponding fitting recesses on a part of the outer peripheral surface thereof, and by fitting these fitting projections to each other, The present invention relates to a block toy composed of an assembly of a large number of block pieces that can be detachably connected, and a manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, a block toy of this type is generally made of an injection-molded product made of a hard synthetic resin.

[0003]

Therefore, the block piece of the conventional product is hard in itself, hurts when stepped on by a foot, and sometimes injured, which is not always safe as an infant toy. It wasn't very good. In addition, there is a drawback that noise is generated when a large number of block pieces are disturbed by hand.

The present invention has the main purpose of eliminating the above-mentioned drawbacks, and is more resistant to dirt and can be washed,
An object of the present invention is to provide a block toy that is suitable for use in a bathroom and that does not waste material in manufacturing and can be manufactured and provided at a relatively low cost.

[0005]

SUMMARY OF THE INVENTION The present invention is based on the fact that the block piece is made of a flexible synthetic resin foam having closed cells, which is flexible and elastic. It is a unique addition to the state.

That is, the first aspect of the present invention comprises an assembly of a large number of block pieces (P) having a predetermined shape and made of a thermoplastic synthetic resin foam having the elasticity of closed cells. ) Has one or a plurality of columnar punched pieces (2) formed by punching in an annular shape by penetrating the piece body (1) straight at a predetermined position in the thickness direction. 2) is such that one end of the piece body (1) is axially displaced in the punching hole (3) in such a manner that one end projects from one surface of the piece body (1).
The body of the piece (1) is integrated by fusion bonding with
On both surfaces of the columnar punching piece (2), a fitting convex portion (4) made of a projecting portion at one end portion and a fitting concave portion (5) made of the other end portion of the punching hole (3) are formed respectively. In addition, a sponge block toy is characterized in that a skin layer (6) is formed on the entire outer surface of the block piece (P) including the piece body (1) and the fitting protrusion (4). It is a summary.

A second aspect of the present invention relates to a method for manufacturing the block toy made of sponge, wherein a plate-like body (P1) having a predetermined shape and made of a thermoplastic synthetic resin foam having closed cell elasticity is used as a starting material. By punching the plate-like body portion (P1) at a predetermined position in the thickness direction to form an annular shape,
Or a plurality of cylindrical punched pieces (2) for punching holes (3)
A first molding die (11) having a molding convex portion (13) of a predetermined height at a position corresponding to the punched piece (2), and at the same corresponding position as described above. By using a second molding die (12) having a molding concave portion (14) having a depth corresponding to the molding convex portion (13), both molding dies (1
1) The piece body (1) made of the plate-like body (P1) is loaded into the cavities (11a) and (12a) of (12),
A punching piece (2) by the pressing action of the molding convex portion (13)
After the mold is clamped by shifting the position in the punching hole (3) in the axial direction, it is heated from the surroundings by the first and second molding dies (11) (12), and the piece body (1) and the punching piece ( 2) is integrated by heat fusion bonding, and then cooled and taken out from the molding dies (11) and (12).

The type of resin of the block piece (P) is not particularly limited, and for example, a foamed material such as ethylene vinyl acetate copolymer resin (EVA), polypropylene resin, urethane resin may be used. It is advantageous to use a polyethylene resin foam from the viewpoint of cost, easiness of manufacturing, etc., and in that case, the expansion ratio is 15 to 2
It is preferable to use a foam having about 5 times foaming.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A block toy according to the present invention is composed of an assembly of a large number of block pieces (P) having various shapes such as a rectangle, a square and a circle and having a predetermined thickness.
As an example thereof, a rectangular block piece (P) is shown in FIGS. 1 and 2.

The block piece (P) is composed of a polyethylene resin foam having 10 to 30 times expansion, preferably about 15 to 25 times expansion, which is a closed cell, and has a rectangular disk-shaped piece body (1). , A plurality of punched pieces (2) for forming a joint part for combination therewith.

As shown in the manufacturing method described later, the punching piece (2) is formed into a piece body (1) by punching the piece body (1) straight at a predetermined position in the thickness direction so as to form an annular shape. It has a cylindrical shape and is made of the same material. The punched piece (2) has a punched hole (3).
Inside, the plurality of fitting projections (4) are formed on one surface of the piece body (1) with the projecting portion at one end thereof being displaced in the axial direction, and the punching hole (3) at the other end side. By retreating from the punching hole (3), a fitting concave portion (5) corresponding to the fitting convex portion (4) is formed on the other end side of the punching hole (3).

In principle, a plurality of fitting protrusions (4) and recesses (5) are formed in each block piece (P) and have the same shape and size and the same pitch. Some block pieces (P) included in the set are
One having only one fitting convex portion (4) and the same concave portion (5), or a punched hole (3) obtained by removing the punching piece (2).
May be left as it is. Therefore, the present invention also includes a block toy including such a block piece in its scope.

The piece body (1) and the punched piece (2) are integrated by heat fusion bonding in a state where they are displaced from each other as described above. That is, the outer peripheral surface of the punched piece (2) is fusion-bonded and integrated with the inner peripheral surface of the punched hole (3).

On the outer surface of the block piece (P) including the piece body (1) and the fitting protrusion (4), a skin layer (6) having a smooth surface and no pores is formed over the entire surface. ing. The skin layer (6) is formed by heating and melting the surface portion and then cooling the surface portion. When forming the skin layer (6), the skin layer (6) is fitted with respect to the diameter of the fitting convex portion (4). By forming the recesses (5) to have the same or slightly smaller diameters, the two can be fitted tightly and closely.

The block toy described above is used to assemble and play various shaped objects as shown in FIGS. 3 and 4 by using a large number of block pieces (P). Assembling is carried out by fitting the protrusions (4) and the recesses (5) of the mutual block pieces (P).
What is done by closely fitting is similar to the conventional product.

Next, a method for manufacturing the block piece (P) will be described.

In this production, a plate-like body (P1) of a predetermined size made of a closed-cell elastic thermoplastic synthetic resin foam is used as a starting material. Then, first, as shown in FIG. 5, this plate-like body (P1) is provided with a plurality of cylindrical cutting blades (1
6), the plate-like body (P1) is punched into an annular shape in the thickness direction by performing a press punching process using the press lower plate (15) provided with 0) and the flat press upper plate (16).
As shown in (1), one or a plurality of cylindrical punched pieces (2) are formed in the punched holes (3). This press punching may be performed using the plate-like body (P1) divided into the size of each unit block piece (P), or may be performed using the large plate-like body (P1). After that, this may be divided into the size of each block piece (P).

Next, a piece main body (1) having a punched piece (2) of a predetermined size made of the plate-like body (P1).
Is heat-molded using the heat-molding dies (11) and (12). Here, the first molding die (11) has a cavity (11) corresponding to the piece body (1) as shown in FIG.
It is assumed that the bottom surface in a) has a molding convex portion (13) of a predetermined height at a corresponding position of the punched piece (2), and the second molding die (12) is a bottom surface in the cavity (12a). It is assumed that a molding concave portion (14) having a depth corresponding to the molding convex portion (13) is provided at a corresponding position.

Then, the piece body (1) having the punched piece (2) is first forcibly pushed into the cavity (11a) of the first molding die (11) and pressed by the molding convex portion (13). The punching piece (2) is displaced in the punching hole (3) by a predetermined distance in the axial direction, and then the second molding die (12) is fitted and clamped, and the two dies (11) (1)
2) The cavities (11a) and (12a) are tightly loaded. Here, the molding convex portion (13) is the molding concave portion (1
Although the diameter may be the same as that of 4), the fitting convex portion (4) of the block piece (P) is closely fitted to the fitting concave portion (5) by making the diameter relatively small. It is preferable in that it can be combined. That is, it is preferable in that the fitting strength at the time of assembling the block piece (P) can be made strong.

Next, the molds (11) and (12) are heated to a temperature higher than the melting temperature of the block piece material by a heating means (illustrated in the drawing) such as a heater equipped with them. When the foam material is made of polyethylene foam, the heating temperature is preferably set to about 135 to 145 ° C. By this heating, the entire surface portion of the piece body (1) and the punched piece (2) are thermally melted, and both are fused at the contact portion. Therefore, after heating for a predetermined time,
By cooling the molds (11) and (12), the piece body (1) and the punching piece (2) are joined and integrated, and
A skin layer (6) is formed on the entire surface, and after cooling, the mold (1
1) By opening (12) and taking out the molded product,
It is possible to obtain the block piece (P) as shown in FIG.

[0021]

In the block toy according to the present invention, since the block piece (P) constituting the block toy is made of an elastic synthetic resin foam, the block toy is light and easy to handle, and is also soft and tramplable. It doesn't hurt, it doesn't hurt, and it's very safe. Moreover, even if the block pieces (P) touch each other during handling, they can play quietly without making a rattling noise.

Further, since it is made of foam having closed cells, it does not absorb water and floats on water, so it can be used while floating in hot water in the bathroom, and there is no restriction on the place of play. Moreover, since the surface has the skin layer (6), it is less likely to get dirty and is easy to wash, and the fitting strength between the fitting convex portion (4) and the fitting concave portion (5) can be firmly maintained.

Also, the piece body (1) and the fitting protrusion (4)
Since the punching piece (2) for forming the block is made of the same material, the hardness of the entire block piece (P) can be made to be almost uniform, and there is no discomfort during use. Moreover, since the fitting convex portion (4) is formed by one end of the punching piece (2) integrated in the punching hole (3) in a buried state, the fitting convex portion (4) may drop off. Since the piece body (1) is not likely to be damaged, the durability can be improved.

Further, according to the manufacturing method of the present invention, the block toy having the above-mentioned various characteristics can be easily manufactured, and the fitting convex portion (4) is formed by the punching piece (2) from the piece body (1). Since it is used for forming, the material is not wasted and it can be economically advantageous.

[Brief description of drawings]

FIG. 1 is a partially fragmented perspective view showing one block piece of a block toy according to the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a perspective view showing an example of assembling a modeled object using the block toy according to the present invention.

FIG. 4 is a perspective view showing an example of assembling another shaped article.

FIG. 5 is a front view showing a press punching step in the block piece manufacturing method.

FIG. 6 is a perspective view of the block piece material after the punching process.

FIG. 7 is a cross-sectional view showing a state where a piece main body having a punched piece is loaded in a first molding die in a molding step.

FIG. 8 is a cross-sectional view showing a state during a heat molding step using a mold.

[Explanation of symbols]

 (P) ... Block piece (1) ... Piece body (2) ... Punching piece (3) ... Punching hole (4) ... Fitting convex part (5) ... Fitting concave part (6) ... Skin layer (10) Cutting blade (11) First mold (11a) Cavity (12) Second mold (12a) Cavity (13) Mold convex Part (14) ··· Molding recess

Claims (3)

[Claims] 1. An aggregate of a large number of block pieces (P) of a predetermined shape made of a thermoplastic synthetic resin foam having the elasticity of closed cells, wherein each block piece (P) has its body ( 1)
Has one or a plurality of cylindrical punching pieces (2) formed by punching in an annular shape by penetrating straight in the thickness direction at a predetermined position, and the punching pieces (2) have one end at the piece body. By shifting the position in the punching hole (3) in the axial direction so as to project from one side of (1) and being fused and integrated with the piece body (1), both sides of the piece body (1) are A fitting protrusion (4) formed of a protrusion at one end of the columnar punching piece (2) and a fitting recess (5) formed of the other end of the punching hole (3) are formed, and A sponge block toy, characterized in that a skin layer (6) is formed on the entire outer surface of a block piece (P) including a piece body (1) and a fitting projection (4). 2. The sponge block toy according to claim 1, wherein the block piece (P) is made of a polyethylene resin foam having a foaming capacity of 15 to 25 times. 3. A plate-shaped body (P1) having a predetermined shape and made of a closed-cell elastic thermoplastic synthetic resin foam is used as a starting material, and the plate-shaped body portion (P1) is provided at a predetermined position in the thickness direction. By punching in an annular shape through the hole, one or a plurality of cylindrical punched pieces (2) are left in the punched holes (3), and then the punched pieces (2) are placed at positions corresponding to the punched pieces (2). A first molding die (11) having a molding protrusion (13) of a predetermined height,
Using a second molding die (12) having a molding concave portion (14) having a depth corresponding to the molding convex portion (13) at the same position, the cavity () of both molding dies (11) and (12) is used. 11
a) (12a) is loaded with the piece body (1) made of the plate-like body (P1), and the punching piece (2) is pressed by the molding convex portion (13) into the punching hole (3) in the axial line. After the mold is clamped by shifting the position in the direction, it is heated from the periphery by the first and second molding dies (11) and (12), and the piece body (1) and the punched piece (2) are integrated by heat fusion bonding. A method of manufacturing a block toy made of sponge, characterized in that it is cooled and then cooled and taken out from the molding die (11) (12).