JPH09183195A - Houshold electric appliance provided with polyolefin-based resin structural body and its preparation - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a component prepd. by using a polyolefin recycled resin with excellent recycling properties, appearance, etc., and being hardly flawed and being favorable in its manufacturing cost. SOLUTION: A houshold electric appliance comprises a base made of a polyolefin resin and a surface sheet made of a polyolefin resin provided with unevenness by means of embossing and is provided with a structural body prepd. by integrally laminating the sheet and the base so as to bring the face with no unevenness of the sheet into contact with the base. In addition, the method for its preparation comprises a method wherein a molten polyolefin resin is calendered into a sheet and after unevenness is provided on one face of the sheet by means of embossing, the sheet is cut and molded as preliminaries and it is mounted into an injection mold in such a way that the opposite face to the uneven face of the sheet is brought into contact with the resin filled by injection and a molten polylefin resin for the base is filled into the mold by injection to integrally mold the sheet and the base.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a household electric appliance such as an electric vacuum cleaner, an electric washing machine, an air purifier and the like, which is provided with a polyolefin resin structure excellent in recyclability, appearance, functionality and the like, and its production. Regarding the method.

[0002]

2. Description of the Related Art In recent years, resource problems and environmental problems have been discussed on a global scale, and environmental problems have become the first issue to be considered in production. for that reason,
Since "environmentally friendly products" are required, it is also an important issue to recycle, that is, to use materials that can be easily recycled.

By the way, a plastic product that is processed into an industrial product by processing resources such as petroleum and ore is easy to process.
Since it is inexpensive and has excellent durability, plastic parts are used in many parts in home electric appliances. Since it is a social demand to use a material that can be easily recycled for household appliances, it is desired to use a polyolefin resin such as polypropylene that is easily recyclable among plastics.

[0004] Further, the polyolefin resin has a high specific gravity (polypropylene: 0.91, polyethylene: 0.93) because the molar ratio of hydrogen atoms to carbon atoms is 2: 1 and the ratio of hydrogen atoms is high, and polypropylene resin is a plastic. The lightest of all. Furthermore, polyolefin resins are excellent in abrasion resistance, water resistance, chemical resistance, electrical resistance, etc.,
Moreover, because of its light specific gravity, the price per unit volume is low. Therefore, the polyolefin-based resin is low in price and is useful for household appliances for mass production.

However, since the polyolefin resin has a high molding shrinkage ratio, the dimensional accuracy is not stable, warpage and sink marks are likely to occur, and the adhesiveness of secondary processing (painting, printing, bonding, etc.) is poor. , The molding surface has gloss, but it is weak in scratching and easily scratched, so
The reality is that it is not used in home appliances.

[0006] In particular, a molded product using a recycled resin material obtained by recycling a waste material of a polyolefin-based resin has stones, sink marks, weld lines, etc., and the appearance is deteriorated. It cannot be used in products. A method of painting the surface to improve the appearance is also conceivable, but since painting is generally done by a spray method using an organic solvent, it leads to environmental pollution.
Since it takes a lot of space and time for drying, the economy is poor. Also, it is difficult to cover sink marks and weld lines even when trying to restore the surface by painting,
There are inconveniences such as easy cracking and brittleness.

By the way, Japanese Patent Laid-Open No. 59-39535 discloses a laminated sheet comprising a base sheet made of a resin such as polyethylene, polypropylene, an ethylene copolymer or a propylene copolymer, a metallic layer and a clear sheet. Disclosed is a structure obtained by integrally molding a substrate and a laminated sheet by mounting the laminated sheet on an injection molding die and injecting a resin for the substrate into the mold by injection molding. Has been done. This laminated sheet is for giving a metallic feeling, and the surface of the laminated sheet is embossed at the time of injection molding by using an injection molding die in which the mounting surface of the laminated sheet is made uneven. However, when embossing is performed using a mold like this,
The manufacturing cost of the mold is high, which is a cost disadvantage.

Further, Japanese Patent Laid-Open No. 62-212114 discloses a PV.
A sheet made of a resin such as C, polyethylene, polypropylene, ABS, etc., the surface of which has been embossed and / or printed, is previously molded, and this sheet is mounted on an injection molding die for a substrate. A structure obtained by integrally molding a substrate and a sheet by injecting and filling a resin into the mold is disclosed. This sheet is for surface decoration, and is embossed to make the surface uneven before molding the sheet. However,
If this uneven sheet is used as it is for injection molding, the unevenness will be thermally deformed. Therefore, in this method, a mold release agent is applied to the uneven surface before injection molding to fill the recesses and prevent deformation. The mold release agent is removed after molding. Therefore, the efficiency is poor because an extra step is included, and the economical efficiency is poor because a release agent is used.

[0009]

SUMMARY OF THE INVENTION Therefore, an object of the present invention is a member using a recycled resin obtained by recycling a polyolefin resin, particularly a waste material of the polyolefin resin, which has recyclability, appearance, etc. Another object of the present invention is to provide a home electric appliance including a member which is excellent in scratch resistance, is hard to be damaged, and is advantageous in terms of manufacturing cost, and a manufacturing method thereof.

[0010]

Means for Solving the Problems As a result of intensive studies to solve the above problems, the present inventors have found that a recycled resin obtained by reprocessing waste material of a polyolefin resin is molded into a substrate. By laminating with a polyolefin resin sheet with embossing and other irregularities such as a grain pattern, it is possible to successfully cover the sink marks and weld lines of the substrate and prevent whitening and surface scratches due to stress during molding. The present invention has been completed by discovering that the substrate and the sheet are made of the same material, so that the substrate and the sheet can be integrated without using an adhesive and the recycling is facilitated.

The present invention comprises a base material made of a polyolefin resin and a surface sheet made of a polyolefin resin having an unevenness by embossing on one side, and the surface of the surface sheet having no unevenness is the base material. There is provided a home appliance including a structure in which the sheet and the base are laminated and integrated so as to be in contact with each other. Further, the present invention is a method for manufacturing the above-mentioned home electric appliances, wherein the step of forming a molten polyolefin resin for a surface sheet into a sheet by calendering (A-1), and embossing on one side of the sheet. Including the step (A-2) of providing unevenness, the manufacturing step (A) of the topsheet, and the step (B-1) of cutting the topsheet obtained in the step (A), the cut topsheet Preforming step (B-2), and the preformed surface sheet,
The sheet is mounted in an injection molding die in such a direction that the surface opposite to the uneven surface is in contact with the resin to be injected and filled, and then the molten polyolefin resin for the substrate is injected and filled into the cavity of the mold. Provided is a method for producing a household electric appliance, which includes a step (B) of manufacturing a structure including a step (B-3) of integrally molding a topsheet and a substrate. Furthermore, the present invention is a method for producing the above-mentioned home electric appliance, wherein a step of forming a molten polyolefin resin for a surface sheet into a sheet by calendering (A-1), and embossing on one side of the sheet. Including the step (A-2) of providing unevenness, the manufacturing step (A) of the topsheet, and the step (B-1) of cutting the topsheet obtained in the step (A), the cut topsheet , The injection molding die provided with an exhaust hole is installed in such a direction that the surface opposite to the uneven surface of the sheet is in contact with the resin to be injected and filled, and then the surface sheet is preformed by vacuum evacuation, Next, including a step (B-4) of injection-filling a molten polyolefin-based resin for a substrate into the cavity of the mold to integrally form a surface sheet and the substrate, including a step of manufacturing a structure (B) A method for manufacturing home appliances that is characterized by Subjected to. Hereinafter, the present invention will be described more specifically.

[0012] The polyolefin resin which is the material of the top sheet of the top sheet present invention, ethylene, propylene, 4-methyl-1-pentene, 1
-A polymer obtained by polymerizing an olefin such as an α-olefin having 4 to 10 carbon atoms such as butene.
Specific examples include polyethylene, polypropylene, ethylene-propylene random copolymers, ethylene-propylene block copolymers, ethylene-α-olefin copolymers and the like. As these polyolefin-based resins, both virgin materials and recycled materials can be used.

To these polyolefin resins, known additives generally added to thermoplastic resins, for example,
Stabilizers, antioxidants, ultraviolet absorbers, plasticizers, antistatic agents, surfactants, fillers, colorants and the like may be optionally blended according to the purpose, but in blending the additives, It is necessary to consider the type of additive, the amount of the additive, etc. so as not to impair the object and effect of the invention. Also, by blending a resin with a heat-resistant filler, the heat resistance of the obtained sheet can be improved, so that the accuracy of embossing can be improved and even a sheet with a small thickness can be injected as described below. It is possible to prevent breakage of the sheet and deformation of unevenness during molding. As such a filler having a heat resistance effect, for example, a fine particle material such as calcium carbonate, kaolin, mica, talc and the like can be mentioned, and the blending amount of the filler is a base material (polyolefin resin and other optional additives). It is preferably 5 to 10% by weight relative to Further, if the influence on the environment is excluded, aluminum flakes, mineral substances such as glass fibers, asbestos, glass fiber substances, materials such as carbon black may be used.

The surface sheet has one surface provided with unevenness such as a grain pattern by embossing. The thickness of the topsheet is usually 100-1000 μm, preferably 1
It is from 00 to 300 μm. If the sheet is too thick, the tensile strength of the film becomes too high, so that it is difficult to soften and molding becomes difficult, and the adhesiveness to the base resin also decreases. If the sheet is too thin, the tensile strength of the film will be too low and it may not be able to withstand the shear stress of the base resin injected and filled in the injection molding described later, and it may break. Becomes difficult to form.

The topsheet may be a transparent sheet. In the case of forming a transparent sheet, it is preferable to use a virgin material as a raw material resin in order to improve transparency and appearance quality. Further, in the case of a transparent sheet, it is preferable that printing is performed on the surface which is not embossed by embossing. By laminating such a printed transparent sheet on the substrate, it becomes easier to hide the substrate on the printed surface, and the appearance becomes more excellent.
Moreover, since the sheet is laminated on the substrate so that the printed surface of the sheet contacts the substrate, the printed surface is protected.

Further, when a transparent sheet having embossed unevenness on one side and printing on the surface not having the unevenness is used as the surface sheet, the transparent sheet is a polyolefin having a color. It is preferably used as a laminated sheet laminated on a base sheet made of a resin. By forming a transparent sheet on a base sheet, the printing surface of the transparent sheet is protected by the base sheet during injection molding for integral molding with the base body described later, and is hindered by the resin injected and filled. Never. Further, by using such a laminated sheet, the concealing property of the substrate can be further enhanced, and a desired color can be obtained by changing only the color of the base sheet without changing the color of the substrate. It is possible and the cost can be reduced. When using a laminated sheet, the thickness of the transparent sheet is usually 30 to 100 μm.
m, preferably 50 to 150 μm, and the thickness of the base sheet is usually 30 to 970 μm, preferably 50 to 150 μm. The transparent sheet preferably uses a virgin material as the raw material resin as described above, but the base sheet may be either a recycled material or a virgin material. Also,
The base sheet is colored by mixing a raw material resin with a colorant such as a pigment. When a recycled material is used as the raw material resin, a colorant darker than the color of the recycled material is used.

Manufacturing step (A) of surface sheet : Step (A-1) First, various additives are blended with the raw material resin as needed, and after mixing, they are melted and rolled into a sheet. Such molding is performed by calender molding in terms of forming a uniform surface. Calender molding is a method of rolling between two or more heated rolls to continuously form a sheet, and the number of calender rolls and the roll arrangement are not particularly limited. Further, the calender molding conditions can also be carried out under the conventional calender molding conditions of a general polyolefin resin, for example, the roll temperature varies depending on the type of resin used, but in the case of polypropylene, usually,
180-195 ° C. The width of the obtained sheet is usually 1000 to 1200 mm.

Step (A-2) Next, the sheet obtained by the above-mentioned roll forming is embossed to make unevenness on one surface. Embossing is a process of applying pressure to a sheet heated to an appropriate temperature with an embossing roll to form an uneven relief pattern such as a texture pattern on the surface, and the heating temperature of the sheet is equal to or higher than the softening temperature of the sheet. Well, usually 180-195 ° C. In addition, the unevenness depth can be set as appropriate, and when it is desired to make it fine (for example, graininess), the unevenness depth becomes small, and when it is desired to make it rough, the unevenness depth becomes large. Especially,
When printing on the surface of a sheet that does not have unevenness, taking into account the depth (three-dimensional effect) produced by the synergistic effect of unevenness and printing, the unevenness depth is good, and the surface is easily scratched. From the viewpoint of preventing the thickness, 40 to 50 μm is preferable.

When the sheet is subjected to printing such as a stone pattern, it is applied to the surface to which no unevenness is given before embossing the sheet. As a printing method, gravure printing is preferable in that a wide sheet can be printed, a long sheet can be printed, multicolor printing can be performed, and productivity is high. Gravure printing is a type of intaglio printing that fills the depressions on the printing cylinder (plate) with ink, scrapes off excess ink in the ridges with a doctor knife, and leaves the sheet in the depressions between the printing cylinder and the impression copper. It is a method of adhering the ink to the sheet. For multicolor printing, a drum type gravure printing machine can be used. Further, if necessary, characters may be printed by offset printing, silk screen printing, or the like.

When the laminated sheet obtained by laminating the transparent sheet as described above on the base sheet is used as the surface sheet, the transparent sheet and the base sheet can be laminated and integrated by thermocompression bonding such as roll processing. it can. In this case, the transparent sheet is laminated and integrated so that the printed surface is in contact with the base sheet. The temperature of the bonding surface of the transparent sheet and the base sheet during thermocompression bonding varies depending on the raw material resin, but when using polypropylene resin, it is usually 150
The temperature should be ~ 160 ° C. The temperature of the uneven surface of the transparent sheet may be a temperature at which the unevenness is not deformed, and is usually 160 ° C or lower.

Process (B) for manufacturing the structure : The surface sheet having one surface having irregularities and printed as necessary as described above is contacted with the polyolefin resin substrate with the surface having no irregularities. A structure is obtained by laminating and integrating as described above. Hereinafter, a method for manufacturing this structure will be described.

Step (B-1) First, the surface sheet should have an appropriate shape and size in consideration of the physical properties such as the thermal expansion coefficient of the sheet according to the shape and size of the surface of the member of the household electric appliance to be manufactured. Cut into pieces.
If the sheet is not cut into a proper size, wrinkles, curling, etc. will occur when integrally molded with the substrate, and the finished state of the surface will deteriorate.

Step (B-2) The cut sheet obtained in the step (B-2) is preformed. Preforming is performed by vacuum forming or heat processing at 160 ° C or lower.
For example, in the case of preforming by vacuum forming, the unevenness of the surface sheet is formed on the flat surface of the vacuum forming mold that is maintained at a temperature at which the polyolefin resin softens, for example, in the case of polypropylene resin, at about 100 to 120 ° C. By arranging so that the surfaces not marked with are in contact, and then evacuating,
The topsheet is molded by drawing it onto a die that has a molded product facing the flat portion so that the uneven surface of the sheet is in contact. At this time, the temperature of the mold taken from the molded product is usually 1
The temperature is kept at 60 ° C. or lower, preferably about 50 to 80 ° C. so that the unevenness does not deform. The degree of vacuum is usually 0.7 to 0.
It is about 97 mmHg, and the exhaust time is usually about 5 to 10 seconds for a thin sheet.

When preforming by thermal processing, the temperature
Place it on a concave mold of about 50 to 80 ° C so that the uneven surface of the surface sheet is in contact with the mold surface, and then press the convex mold at a temperature of about 100 to 120 ° C from the surface side of the surface sheet with no unevenness. It is performed by pressing in.

Step (B-3) Injection for producing a member of a household electric appliance to be produced in such a direction that a preformed sheet is oriented such that the surface of the sheet having no unevenness is in contact with the resin for injection filling. Attach to the molding die. Further, the temperature of the mold on which the sheet is mounted varies depending on the type of resin used, but is a temperature at which unevenness is not deformed, specifically 160 ° C. or lower, preferably 50 to 80 ° C. The temperature of the mold on which the base resin is in contact is usually 1 when polypropylene is used as the raw material resin.
The temperature is 00 to 120 ° C.

Subsequently, a molten polyolefin resin for a substrate is injection-filled in a cavity of a die in which the sheet is mounted, and the sheet and the molten resin are joined and integrated by the thermal energy and pressure to manufacture a structure. To be done. Here, the resin to be filled is a polyolefin resin, and any of the same resins as the above-mentioned resin for the surface sheet can be used. Further, known additives to be added to general thermoplastic resins may be blended with these resins, and examples of the additives include those exemplified as the additives in the surface sheet. As the conditions for injecting and filling the molten base resin, the conditions generally used as injection molding conditions for polyolefin resins can be used as they are. Specifically, in the case of polypropylene, the resin temperature is usually 180 to 200 ° C. The injection pressure varies depending on the size of the molding machine, and is usually about 2100 kg / cm ² in a 170-ton class molding machine. The injection speed is usually 120 to 190 cm ³ / sec. Further, the temperature in the cylinder of the injection molding machine is usually 150 to 180 ° C. when polypropylene is used as the raw material resin.

Step (B-4 ) Further, instead of the above steps (B-2) and (B-3), the above step (B-4)
-1) Attach the cut sheet obtained in 1) to an injection-molding die provided with an exhaust hole in such an orientation that the surface of the sheet with no irregularities is in contact with the resin to be injected and filled, and then vacuum exhaust. To preform the sheet in the mold by injection molding, and then injection-fill the molten polyolefin resin for the substrate into the mold to integrally form the sheet and the substrate to produce a structure. can do. In this method, an injection mold is used in which an exhaust hole is provided in the mold on which the sheet is mounted, and a vacuum mechanism for exhausting air from the mold cavity is further provided. The vacuum molding conditions and the injection molding conditions are the same as those in the above step (B-3).

In addition, in the step (B-3) or the step (B-4), in order to improve the appearance of the surface of the resulting structure and prevent the surface sheet from being turned over or wrinkles, a gate is provided. A direct gate provided on the substrate side opposite to the surface sheet, that is, on the substrate surface of the structure is preferable. As the gate, any one such as a pin gate can be used. However, when the pin gate is adopted, the resin injected from the cylinder concentrates on one point of the surface sheet and hits the pressure of the resin flowing into the cavity at that point. May have an adverse effect on the surface sheet, such as unevenness or damage on the printed surface or the uneven surface. As a countermeasure, there is a method of increasing the cross-sectional area of the gate or increasing the number of gates. However, in the case of a gate with a circular cross-sectional shape, increasing the cross-sectional area makes it difficult to cut the gate after molding, and increasing the number of gates increases the number of gates to be cut after molding. There is also an inconvenience that the number of man-hours for the gate processing increases. Therefore, as the gate, its tip portion continuously expands from the sprue side toward the cavity side, and the cross-sectional shape of the tip portion is a horizontally long rectangular shape as shown in FIG.
It is preferable to use an elongated shape such as an elliptical shape. By making the cross-sectional shape elongated,
Since the cross-sectional area can be increased while keeping the width of the gate small, the gate can be easily cut after molding, the number of gate processing steps can be reduced, and the production efficiency is excellent.
In order to facilitate the cutting of the gate, the maximum width w of the gate in the lateral direction is usually preferably about 2 to 3 mm.
The gate can also be obtained by using a gate whose tip portion continuously extends from the sprue side toward the cavity side and whose cross-sectional shape is a cross shape as shown in FIG. Although the cross-sectional area can be increased, the gate is slightly more difficult to cut as compared with an elongated cross-sectional shape.

In this way, a structure suitable for the shape and size of the member of the household electric appliance to be applied can be obtained. Since this structure is formed by laminating the surface sheet having the unevenness formed by embossing, it is possible to cover the sink mark, weld line, etc. of the recycled resin substrate,
The appearance is also excellent. Moreover, since the substrate is laminated with a sheet, the resin used for the substrate may have any color. Further, since the surface decoration of the structure itself can be easily changed by changing the color, pattern, etc. of the sheet, it is possible to manufacture various designs with one injection mold. In addition, since the material of the sheet and the base material is the same polyolefin resin, it is possible to reduce the weight and cost, and an adhesive is not required when laminating and integrating, and the recycling is easy. It also has the effect. Further, since the sheet is embossed, it has a high surface hardness, is less likely to be scratched, and is effective in preventing whitening. Furthermore, the sheet can cover sink marks and welds, and even if you want to color it, you can print the sheet, so there is no need to spray-paint with an organic solvent, it does not pollute the environment, and it is cost effective. Is also advantageous.

Specific examples of home appliances equipped with such a structure include those for which plastic members are currently used, such as vacuum cleaners, electric washing machines, and air cleaners. Can be mentioned.

In addition, commercially available laundry detergents include
Many contain fluorescent agents. Normally, ABS resins used in electric washing machines are easily corroded and damaged by fluorescent agents, but polyolefin-based resins such as polypropylene are resistant to fluorescent agents. Is more convenient to use in an electric washing machine.

[0032]

Embodiments of the present invention will be described below in more detail with reference to FIGS. However, the present invention is not limited to this. In the following examples, materials, parts, arrows and the like of the same kind are designated by the same reference numerals, and duplicate explanations are omitted. Example 1 This example illustrates the present invention based on the manufacture of an electric vacuum cleaner having a polyolefin resin structure. FIG. 1 is a side view showing the structure of the structure 1 used in this example. The structure 1 is a substrate 10 made of polypropylene resin (hereinafter referred to as PP resin).
And a surface sheet 20 made of PP resin having an embossed surface 24 having an embossed pattern on one surface by embossing. The uneven surface 2 of the surface sheet 20.
The surface sheet 20 and the substrate 10 are laminated and integrated so that the back surface of the substrate 4 contacts the substrate 10. The topsheet 20 includes a translucent transparent sheet 26 having an embossed surface 24 and a base sheet 28 laminated and integrated with the base body 10. The transparent sheet 26 has an uneven surface 2
4 is provided with a printing surface 32 on which printing is performed, and the printing surface 3
The transparent sheet 26 and the base sheet 28 are laminated and integrated with each other. Further, in this embodiment, the thickness of the transparent sheet 26 is 125 μm, the thickness of the base sheet 28 is 145 μm, and the total thickness of the topsheet 20 is 270.
It is set to μm. Further, in the present embodiment, the thickness of the base body is set to about 3 mm, but in consideration of the strength, it is appropriately set depending on each part of the electric vacuum cleaner.

FIG. 2 is an external view of the electric vacuum cleaner, and a schematic structure of the electric vacuum cleaner having the structure 1 as described above will be described with reference to FIG. In the drawings, reference numeral 100 generally indicates an electric vacuum cleaner. The electric vacuum cleaner includes a cleaner main body 110 having a dust collecting chamber, an electric blower unit, a cord reel unit, and the like, and a dust collecting chamber. The suction hose assembly 152 includes a suction hose portion 152, an extension pipe portion 154, and a suction portion 156 which are connected to each other.

The outer appearance of the cleaner body 110 has a rounded front recess including a lower cover 112 for covering a lower portion, an upper cover 114 for covering an upper portion, a lid cover 116 and a grill cover 118. , A pair of large-diameter rear wheels 120 on the left and right sides of the lower rear part, and 1 on the bottom center of the lower front part.
A small number of free wheels 122 are arranged. The upper cover 114 arranged at the rear of the cleaner body 110 and the lid cover 116 arranged at the front of the cleaner body 110 are divided into front and rear in the vicinity of the center of gravity of the cleaner body 110, and the handle portion 124 is provided on the dividing line.
Is provided. The handle portion 124 has an inverted U-shape supported at two positions on both sides, and is pivotably supported so as to be housed in a concave handle housing portion 126 formed in the upper cover 114.

The lid cover 116 can be opened through a hinge part (not shown) provided on the dividing line side by removing the clamp provided at the front part, and the disposable paper filter mounted in the dust collecting chamber is replaced. be able to. Further, the lid cover 116 is provided with a mounting port 128 for a suction hose portion having a shutter-type opening / closing lid. At the center of the front part of the upper cover 114, there is provided a main body switch section 130 which is provided so as to project toward the lid cover 116 side. The main body switch section 130 is composed of an infrared receiving section at the center, power switches on both sides and a cord reel button. To be done. The operation display unit 13 is provided between the handle unit 124 and the main body switch unit 130.
2 are arranged. The grill cover 118 has an exhaust filter inside and is detachably arranged at a position covering the upper rear surface of the cleaner body 110 so as to cover an exhaust ventilation part provided on the rear surface of the cleaner body 110. Further, a bumper portion 134 that is formed so as to project to the periphery is provided at a joint portion between the lid cover 116 and the lower cover 112, which is located in front of the cleaner body 110.

On the upper portion of the extension pipe portion 154, the handle portion 1 for operating the suction port portion 156 via the extension pipe portion 154.
58 and a hand operation unit 160 that gives an instruction to drive the cleaner body 110 via an infrared signal.

According to the electric vacuum cleaner 100, the suction hose portion 152 of the suction hose assembly 150 is grasped at the mounting port 128 of the cleaner body 110 to move the suction port portion 156, and the suction hose portion 152 is pulled for cleaning. Machine body 1
It is possible to use 10 by following (running straight and turning). In addition, the cleaner body 110 is provided with a hand operation unit 160.
The dust that has been sucked in through the suction port 156 is operated via the suction hose assembly 150 and the cleaner body 1
The remaining air collected in the dust collection chamber 10 is exhausted from the exhaust ventilation part of the filter cover.

In the vacuum cleaner 100 according to this embodiment, the PP resin structure 1 can be used in each of the components, but here, the large rear wheel 12 having a large diameter is used.
0 as an example, the structure and manufacturing method will be described in detail with reference to FIGS.

First, FIG. 3 is an external view of the large rear wheel 120. FIG. 3 (a) is a central sectional view of the large rear wheel, FIG. 3 (b) is a front view of a top sheet, and FIG. [Fig. 4] is a side view of the top sheet. In the figure, a large rear wheel 120
Is a thin-walled molded product having a diameter of 179 mm and a wheel width of 20 mm and a thickness of 3 mm. The base body 10 serves as the base structure of the large rear wheel 120 and the wheel cap at the outer center of the large rear wheel 120. Sheet 20 provided at the position
And a tire body 136 around the rear large wheel 120. The base body 10 is composed of a spherical body portion 138 having a diameter of 139 mm in which the surface sheet 20 is provided and a tire body supporting portion 140 formed around the spherical body portion 138. The outer side of the base body 10 is concave near the periphery of the spherical body portion 138. And the inner side of the base body 10 is formed on the outer side and the inner side of the tire body supporting portion 140.
By forming the ring-shaped ribs 142 and 144 of the book, the strength of the entire large rear wheel 120 is increased.

A cylindrical rotary shaft 146 is rotatably attached to the cleaner body 110 at the center of the inner wall of the base 10.
The rotary shaft 146 has a notch 148a at its tip and a protrusion 148b for preventing the rear wheel from coming off.
Are formed. The rear large wheel 120 is assembled by pressing into the cylindrical bearing (not shown) formed on the side wall surface of the cleaner body 110 from the outside of the body. Further, a gate portion 50a for resin insertion at the time of injection molding is provided at the center of the cylindrical rotary shaft 146.
0a is removed by folding after molding.

The topsheet 20 has a structure similar to that of FIG. 1, has a rib 217 having a diameter of 179 mm and a height of 2 mm around a spherical surface having a radius of 500 mm, and has a spherical body portion 138 at the center of the base body 10. As a cover, it has a thin cap shape with an overall height of 6 mm. Further, the tire body 136 is provided so as to enclose the tire body support portion 140. The tire body 136 is made of polyolefin-based EB.
Ethylene belonging to A (ethylene-vinyl acetate copolymer)
By molding a vinyl acetate copolymer as a material, wear resistance is improved and running performance is improved without impairing environmental properties and recyclability.

The method of manufacturing the large rear wheel 120 of this embodiment will be described in detail with reference to FIGS. 5 to 9 based on FIG. First, referring to FIG. 4, the manufacturing method of this PP resin structure is as follows.
A sheet manufacturing process 1000 for creating the topsheet 20,
The manufacturing process 2000 includes a structure manufacturing process in which the surface sheet 20 and the base body 10 are integrally molded to form a structure, and a product assembly process 3000 in which each structure and other devices and parts are assembled. When a product using the PP resin structure 1 is distributed to the market and discarded, a product having reproducible physical properties is collected and crushed after the crushing process 4000, and then the sheet manufacturing process 1000 or the structure. It is supplied to the body manufacturing process 2000 and recycled. On the other hand, for example, those that do not have the physical properties as the PP resin structure due to being recycled a plurality of times are incinerated or landfilled in the incineration step 4500.

In this embodiment, when manufacturing the large rear wheel 120, in the seat manufacturing process 1000, first, PP
The PP resin melted in the resin melting step 1100 is calendered in the next sheet forming step 1200 to form a sheet. Since the topsheet 20 is a laminated sheet in this embodiment, in the sheet creating step 1200, a transparent sheet creating step 1210 for creating the transparent sheet 26 and a base sheet creating step 1220 for creating the base sheet are performed. In the sheet forming process 1200, the melted PP is
Calender molding machine for resin, eg roll diameter 610mm
(12 inches), the number of rolls is 4, the roll arrangement is inverted L-shape, and the roll temperature is 190 ° C. A sheet is rolled and formed into a sheet by a calendar forming machine. Here, the transparent sheet 26 is formed into a sheet having a thickness of 125 μm by using a transparent virgin material of PP resin in order to improve transparency and appearance quality. Further, the base sheet 28 is formed in a sheet shape having a thickness of 145 μm by filling a pigment into a virgin material or a recycled material of PP resin. When the recycled material is used for the base sheet 28, a pigment darker than the recycled material is filled. Next, the obtained transparent sheet 26 is processed by the sheet printing process 1300.
Print a stone pattern on one side of the by gravure printing, then,
In the sheet embossing step 1400, an uneven pattern is formed on the surface of the transparent sheet 26 which is not printed by an embossing roll having a roll temperature of 160 ° C. In this embodiment, the uneven pattern is a uniform grain pattern.

Next, in the lamination integration process 1500,
The transparent sheet 26 on which the uneven pattern and the printing are applied and the base sheet 28 are thermocompression bonded by a roll process or the like so that the base sheet 28 and the printed surface 32 are in contact with each other. Here, PP resin is 1
Deformation occurs at around 60 ° C. Therefore, during thermocompression bonding, the embossed surface 24 is deformed by setting the adhesive surface from 150 ° C to 160 ° C and the embossed surface 24 side lower than 160 ° C. Glue both sheets together.

Next, the manufacturing process 2000 of a structure using the surface sheet 20 will be described in detail. First, in the sheet cutting step 2100, the topsheet 20 is formed as shown in FIG.
In consideration of the size of the rib 21 and the coefficient of thermal expansion, etc. shown in FIG.
No. 0, it is processed into the appearance shown in FIGS. 3 (b) and 3 (c), and pre-molding prior to injection molding is performed. This preforming is performed by a vacuum forming method or thermal processing at 160 ° C. or lower. In the case of performing the vacuum forming method, the surface sheet 2 is such that the base sheet 28 side is in contact with the flat surface portion of the vacuum forming mold kept at a temperature at which the PP resin is softened, for example, 100 to 120 ° C.
0 is arranged, and then the surface sheet 20 is vacuum-evacuated, and the surface sheet 20 is attracted and molded so that the transparent sheet 26 side of the sheet is in contact with a mold having the large rear wheels 120 facing it. At this time, the temperature of the mold with the large rear wheel is set to about 50 to 80 ° C. to prevent the unevenness from being deformed. In the case of preforming by heat processing, the transparent sheet 26 side is placed in a concave mold having a temperature of about 50 to 80 ° C. so that the transparent sheet 26 side is in contact with the mold surface, and the temperature is about 100 to 120 ° C. from the base sheet 28 side. It is performed by pressing with a convex mold.

Subsequently, the preformed topsheet 20
Is attached to the mold of the rear large wheel 120 in such a direction that the base sheet 28 side is in contact with the resin to be injected and filled next in the step 2300 of attaching the sheet to the mold, and the base resin is injected into the mold. In step 2400, as shown in FIG. 7, a PP resin to be the base 10 is injection-molded so as to form a structure in which the topsheet 20 and the base 10 are laminated and integrated.
The step 2400 of injecting the base resin into the mold will be described in detail with reference to FIGS. 5 and 6.

FIG. 5 is a sectional view showing the outline of the injection molding die, and FIG. 6 is a central sectional perspective view showing the outline of the vicinity of the gate of the injection molding die. In the figure, the injection molding die is composed of a die A on which the topsheet 20 is mounted and a die B having a gate 50, and the melted base resin is transferred from the cylinder 52 through the gate 50. Supplied into the mold cavity. In this injection molding, the topsheet 20
The temperature of the mold A which is in contact with is 160 ° C. or lower, for example, 5
The temperature of the mold B on the substrate side is set to 10 ° C by setting it from 0 ° C to 80 ° C.
0 ℃ to 120 ℃, cylinder temperature from 150 ℃ to 18 ℃
The temperature is set to 0 ° C., the surface sheet 20 is attached to the mold A, and the tip portion 5 from the cylinder 52 as shown in FIG.
1 spreads continuously from the sprue side toward the cavity side, that is, spreads in a fan shape, and the tip portion 51 crosses the resin from 500 kg / cm ² through the gate 50 having a substantially oblong rectangular shape. Injection is performed at an injection pressure of 1000 kg / cm ² to integrally mold.

Here, in this embodiment, since the thickness of the topsheet 20 is set to be small, the gate 50 having a substantially horizontally long rectangular cross section in which thin slits are formed on both sides of a small circular hole is used. doing. A circular pin gate 60 (Fig. 6
In the case of using the above-described gate 50 adjacent to the gate 50, the base resin supplied from the cylinder 52 hits the narrow range Q2 of the base sheet 28 through the thin pin gate 60 according to the arrow Y2 and spreads around. Flow into the cavity. Therefore, if the topsheet 20 is thick, there is no problem, but for the topsheet 20 that is thin as in this embodiment, the range of the base sheet 28 that directly receives the pressure of the inflowing base resin is the range Q2. Since it becomes narrower, depending on the injection pressure, the range Q
It is conceivable that a portion of the second base sheet 28 is damaged, for example, the base sheet 28 becomes thinner than other portions due to melting, and the printed surface 32 and the embossed surface 24 on the back surface of the transparent sheet 26 are affected. As measures against these problems, it is conceivable to reduce the injection pressure or thicken the base sheet 28. However, if the injection pressure is decreased, it takes a long time for the inflow to cause welds. Thickening results in surface sheet 2
0 will increase the thickness. Furthermore, it is possible to increase the diameter of the pin gate 60 or increase the number thereof, but this increases the number of man-hours for removing the gate, resulting in poor efficiency.

On the other hand, according to the gate 50 as described above,
The base resin supplied from the cylinder gradually spreads in a fan shape along the inner wall of the gate according to the arrow Y1, collides with a wide area Q1 of the base sheet, spreads around, and smoothly flows into the cavity without causing turbulent flow. Therefore, as compared with the conventional example, the range Q1 of the base sheet 28 that directly receives the pressure of the inflowing base resin is widened, so that the influence of the injection pressure is received with a wide Q1, and the influence on the surface sheet 20 is affected. Can be reduced. Furthermore, the remaining material of the gate 50 remaining on the substrate 10 is in the form of a thin plate, and can be easily removed.

As described above, according to this embodiment, since the embossed surface 24 of the transparent sheet 26 comes into contact with the mold having a low temperature, the uneven pattern is less likely to be deformed, and
The printed surface 32 is protected by the base sheet 28 and is not damaged by the injected resin, and the resin base side of the base sheet 28 is melted and integrally formed with the base 20. In addition, the tip such as the gate 50 is continuously expanded from the sprue side toward the cavity side, and by adopting a gate having an elongated cross-sectional shape, the die can be easily changed. The obstacles of the base sheet 28 can be reduced, and as a result, the topsheet 20 can be made thinner. In this embodiment, the gate 50 as described above is used to form the surface cover 137 in which the surface sheet 20 used in the portable word processor is thinned. However, the thickness of the surface sheet may be increased, or For other large molded products, the conventional pin gate 60
Or other gates may be used.

FIG. 7 is an external view of a large rear wheel on which the tire body 136 is not laminated, FIG. 8 is an external view of a large rear wheel on which the tire body 136 is laminated, and FIG. 9 is a tire of the large rear wheel. FIG. 6 is a cross-sectional view of the vicinity of the body support portion 140. After the above-mentioned injection molding, in the structure completion step 2500, as shown in FIGS.
As shown in FIG. 5, the base body 10 serving as the base structure of the large rear wheel 120 on which the topsheet 20 is laminated is mounted on the mold for stacking the tire body 136 again, and the tire body 136 is attached to the tire body supporting portion 140. The ethylene-vinyl acetate copolymer, which is the material of, is injection molded. At this time, the tire body 136
As shown in FIG. 9, one end of the rib 1 has an outer side of the base body 10.
The tire body 136 is formed so as to wrap around the inner side of the tire body 42 and the other end of the tire body 136 so as to wrap around the tire body supporting portion 140 so that the resin flows into holes 141 provided in the base body 10 around the surface sheet 20 at a plurality of equal intervals. To be done. Further, the end portion of the tire body 136 that is in contact with the topsheet 20 is formed so as to bite the ribs 21 around the topsheet 20 at the time of forming. For this reason, it is possible to keep the top sheet 20 and the substrate 10 laminated and integrated, and to prevent the edge portion of the top sheet 20 from being turned up.

At the end of the structure completing step 2500, the gate portion 50a, burrs and the like are removed to complete the rear large wheel 120 for the cleaner. In this way, the structure manufacturing process 2
In 000, a large rear wheel 120 for a vacuum cleaner having a pattern with a sense of depth in the center and a tire body 136 for improving traveling performance around the periphery could be obtained.

The structure 1 of the PP resin has been described above based on the large rear wheel 120, but in the present embodiment, the large rear wheel 1 is used.
It is not limited to 20 and can be adopted for other components. For example, FIG. 10A is a schematic sectional view of the bumper portion 134 for the cleaner, and FIG. 10B is a schematic partial sectional view of the lid cover 116. When the bumper portion 134 is also created, the surface sheet 20 having a U-shaped cross section is created, the surface sheet 20 is attached to a mold, and the base body 10 having the ribs 135 for mounting the main body is injection-molded. create. At this time, by wrapping the end portion of the topsheet 20 inward, it is possible to keep the topsheet 20 and the base body 10 laminated and integrated, and prevent the end portion of the topsheet 20 from being turned up. Also, the lid cover 11
6, in the sheet cutting step 2100, the topsheet 20 is cut in conformity with the outer shape of the lid cover 116, and a predetermined position of the attachment port 128 of the suction hose portion is cut off. Then, in the sheet pre-processing in the sheet forming step 2200, the mounting port 128 is aligned and pre-processed, and the subsequent steps are similarly performed, so that the lid cover 116 can be created.

Next, the electric vacuum cleaner 100 is assembled by assembling the respective parts and other electrical products created in the manufacturing process 2000 of the structure at predetermined positions with screws or the like in the product assembly process 3000. Finalize.

Thus, the electric vacuum cleaner 1 according to the present embodiment.
According to No. 00, since the inexpensive PP resin is used as the molding resin, the cost of the molded product can be reduced, and the PP resin is lightweight, so that the vacuum cleaner 100 can be manufactured.
Since the overall weight can be reduced, the handle portion 1
In the electric vacuum cleaner 100, which is often transported through 24 or pulled, it is very advantageous to improve the transportability and the traveling performance. Further, in this embodiment, since the sink mark and the weld at the time of molding are hidden by the topsheet 20, the vacuum cleaner 100 has a shape in which curved surfaces are frequently used, and further, a reinforcing rib is provided inside in order to maintain strength. It is very suitable for the external appearance of the electric vacuum cleaner 100 having a curved surface-based form in which a plurality of sink marks and welds are easily noticeable. Conversely, since sink marks and welds can be made inconspicuous, the vacuum cleaner 100 having a large curved surface can be easily manufactured. Moreover, the electric vacuum cleaner 100 is a product that often hits furniture or the like during traveling or transportation, but with the structure according to the present embodiment, the surface of the molded product is less likely to be scratched, and even if scratched. Even if it is, it is very inconspicuous. Furthermore, when a stress is generated in the resin material, a phenomenon called whitening (hatching) in which the stressed portion of the resin is turbid and remains after that tends to occur. Although a phenomenon in which a ring-shaped white cloudy portion is generated easily occurs, this whitening can be made inconspicuous in this structure. In addition, the vacuum cleaner 100 is generally designed to develop a plurality of models by developing the exterior design in multiple colors. The vacuum cleaner 1 including the structure according to the present embodiment is also used.
According to 00, various colors or patterns can be developed without changing other steps such as changing the printing of the topsheet 20 or changing the pigment of the base sheet 28. Moreover, since the base material that serves as the base material is hidden by the topsheet 20, the appearance will not be affected even if recycled resin is used. In particular, the appearance of this embodiment can provide a surface (pattern) with a sense of depth that cannot be expressed by the conventional one.

[Embodiment 2] This embodiment describes the present invention based on an electric washing machine equipped with a PP resin structure. FIG. 11 is an external view of the electric washing machine according to the present embodiment. In the figure, an electric washing machine is generally denoted by reference numeral 200, and is composed of a main body casing 202 that constitutes a lower portion and an upper cover 204 that is an upper portion. Body housing 202
Is a main casing 20 made of a steel plate in which both side surfaces and a back surface, which house a washing / dehydrating tank (not shown), a motor, etc., are formed by bending.
6 and a front panel 208 made of a steel plate that is configured as a front surface and is detachably attached to the main housing. The upper cover 204 is composed of a main upper cover 210 having a structure similar to that of the structure 1 shown in FIG. 1, and a lid cover 212 attached to the center of the upper surface of the main upper cover 210 so as to be openable and closable. The main upper cover 210 has a horizontally elongated strip-shaped operation display portion 214 at the front portion of the upper surface, and a flat portion 216 having a water inlet and a detergent inlet at the rear portion of the upper surface.

Next, the structure used in the electric washing machine according to this embodiment will be described with reference to the schematic sectional view of the lid cover shown in FIG. In the figure, the lid cover 212 includes a first lid cover 218 and a second lid cover 2 which have substantially the same size.
The first lid cover 218 has a rear end portion which is openably and closably attached to the main upper cover 210 via a hinge portion (not shown), and the second lid cover 220 has a rear end portion which has a rear end portion. It is attached to the front end portion of the first lid cover 218 so as to be openable and closable via a hinge portion (not shown). Then, the lid cover 212 is attached to the recess 224 having the clothes insertion opening 222 provided at the center of the main upper cover 210 so as to be flush with the main upper cover 210 in the closed state.
By sliding the lid cover 220 of
The joint portion of the first and second lid covers 218 and 220 moves upward, and the first and second lid covers 218 and 220 can be folded and opened.

The first and second lid covers 218 and 220 are
By forming a thin-walled box having an open inside and a U-shaped cross section, a surface sheet 20 having a U-shaped cross section is mounted in a mold, and a PP resin material is injection-molded. It can be manufactured. However, regarding the second lid cover 220, the handle portion 2 formed of a transparent PP resin material is used.
26, the top sheet 20 is provided with an opening 228 having the same size as the handle portion 226 at a position corresponding to the handle portion 226 for injection molding, and then the handle portion 226. Glue in place. Of course, the handle portion 226 and the second lid cover 220 may be formed by injection molding similarly to the tire body 136 described in the embodiment of the vacuum cleaner. Also, the top sheet 20
In this embodiment, the end portions are folded inward or the end portions are formed so as to be hidden by the handle portion 226 in order to strengthen the integral integration of the substrate 10 and the base body 10 and prevent the end portions from being curled.

Although the electric washing machine according to this embodiment has been described based on the lid cover 212, in the electric washing machine 200, the main cover 210 is also made of the PP resin in which the surface sheet 20 is laminated on the outer surface similarly. It is molded with a case structure. Although the upper cover 204 is the PP resin structure 1 in the present embodiment, the front panel 208 or the entire main body housing 202 may be the same PP resin structure 1.

As described above, according to the electric washing machine 200 of the present embodiment, since the weight of the lid cover 212 can be reduced, the opening and closing can be facilitated and the manufacturing cost can be reduced. Since the lid cover 212 of the electric washing machine 200 has a wide flat portion, a plurality of reinforcing ribs are formed on the inside to maintain strength, and welds and sink marks are easily noticeable. However, according to this embodiment, Since the sink marks and welds at the time of molding are hidden by the surface sheet 20, the appearance quality of a wide flat surface can be improved. Further, in the case structure according to the present embodiment, the surface of the molded product is not easily scratched, and even if it is scratched, it is extremely inconspicuous. Further, similar to the vacuum cleaner 200, it is possible to change the printing of the surface sheet 20 or change the pigment of the base sheet 28 without changing other steps, so that various colors or a feeling of depth can be obtained. Can be deployed,
Recyclability can also be improved. In particular, the electric washing machine 200 using the conventional PS resin has been problematic in terms of corrosion due to liquid detergent, particularly damage to the hinge portion, but according to the present embodiment, it is formed of the PP resin material. The problem can be reduced. Further, in the above-mentioned conventional example, color unevenness due to sunburn is regarded as a problem when it is installed outdoors, but this problem can be alleviated in the present example.

[Embodiment 3] This embodiment describes the present invention based on an air cleaner provided with a PP resin structure. First, FIG. 13 is an external view of the air purifier according to the present embodiment. In the figure, reference numeral 300 is an air purifier as a whole, which has a thin box-shaped exterior having a substantially square front surface, and a front panel 3 provided on the front surface.
Slide 02 back and forth to move the front panel 30
2 has a structure in which room air is sucked in from an opening 304 formed around the air cleaner 2, dust is removed through an internal filter 306, and then blown out from a blowout portion 308 provided on the upper surface. The air purifier 300 includes a front cover 310 that covers the front surface, a rear cover 312 that covers the back surface, and a front panel 302 that is movably attached to the front cover 310 in the front-rear direction. Reference numeral 314 is an operating portion provided on the upper surface of the front cover 310, and 316 is a filter portion attached to the opening 304 so as to be laterally drawn out.

FIG. 14 shows a cross-sectional view of the air purifier 300. FIG. 14A shows a state in which the front panel 302 is closed, and FIG. 14B shows a state in which the front panel 302 is moved. . This air cleaner 300 has a power supply of 0
In the N state, the front panel drive motor 318 is driven to operate the slide mechanism portion 320 to move the front panel 302 forward, and the blower fan 322 is driven to operate. When the power is turned off, the blower fan 322 is stopped and the front panel drive motor 318 is driven to store the front panel 302 in the state shown in FIG.

In the air purifier 300 according to this embodiment, the front panel 302 has a PP resin structure 1 as shown in FIG. The structure is formed by mounting a surface sheet 20 having a U-shaped cross section in a mold and injection-molding a PP resin material to be the base 10. Then, both ends of the topsheet 20 are also wrapped around the backside to be molded, thereby preventing the peeling of the end portion of the topsheet 20.
Although the front panel 302 is the PP resin structure 1 in this embodiment, the other front cover 310, the rear cover 312, and the like may be the same PP resin structure 1.

According to this embodiment, the front panel 302
By using the PP resin structure 1, the pattern of the front panel 302 can be changed easily and at low cost. Furthermore, since the above-mentioned pattern has a sense of depth, and the pattern used for wallpaper or the like can be easily printed, it is necessary to match the large front panel 302 that stands out in the installed state with the same type of wall pattern. Therefore, the air purifier 300 can be matched to the interior. In addition, it is hard to be scratched and is relatively strong against detergents etc.
Since it is formed of the P resin material, the cleanability of the surface of the front panel 302, which is easily soiled by the air flow, can be improved.

[Embodiment 4] In this embodiment, the present invention will be described based on the manufacture of a home electric appliance provided with a structure 2 having a structure different from that of the structures 1 employed in the first to third embodiments. is there. FIG. 15 is a side view showing the structure of the structure 2.
First, in FIG. 15, the structure 2 is a translucent surface made of a PP resin having a base 10 made of a PP resin and an embossed surface 24 having an unevenness formed by embossing on one surface. The surface sheet 72 includes a printing surface 32 on which printing is performed on the back surface of the textured surface 24, and the sheet 20 and the substrate 10 are arranged so that the printing surface 32 and the substrate 10 are in contact with each other. The structure is a laminated and integrated structure. The thickness of the topsheet 72 is about 100 μm to 1000 μm, and the thickness of the base body is appropriately set according to each part of the home electric appliance. In addition, the topsheet 72 is
If a curved surface or a large bend is required, set the thickness to 1
The wrinkles during the pre-processing of the sheet 72 are reduced by setting the thickness of the sheet 72 to about 300 μm. In addition, a thick sheet may be used to obtain a pattern that is stacked on a flat surface and further emphasizes the depth feeling.

The one-layer type surface sheet 7 as described above is also used.
When 2 is used, it is advisable to add a filler having a heat resistance effect to the raw material resin so as to reduce the thermal influence on the sheet during injection molding. By doing so, the accuracy of embossing can be improved and the thickness of the sheet can be reduced. As a filling material, for example, calcium carbonate, kaolin, mica, talc or other fine particle material having a heat-resisting effect is blended in an amount of 5 to 10% by weight with respect to the base material so that recycling and environmental friendliness can be prevented. be able to. Further, if the influence on the environment is excluded, aluminum flakes, mineral substances such as glass fibers, asbestos, glass fiber substances, materials such as carbon black may be used.

FIG. 16 shows a manufacturing process of a home electric appliance including the structure 72. In this manufacturing process, the manufacturing process of the surface sheet in the manufacturing process shown in FIG. 4 is different. In the surface sheet manufacturing process 1000a in this embodiment, the polyolefin resin melting process 11
Only the transparent sheet 72 is made in the sheet making step 1200a by calendering the PP resin melted at 00, and the sheet is completed through the sheet printing processing step 1300 and the sheet embossing step 1400. Therefore, the number of manufacturing steps of the topsheet 72 can be reduced by two steps as compared with the topsheet 20 of FIG. Note that other manufacturing steps are omitted because they are similar to those in FIG.

In FIG. 17, the surface sheet manufacturing process is the same as the process shown in FIG. 16, and the structure manufacturing process is different from the structure manufacturing process 2000 of FIGS. 4 and 16. In the manufacturing process 2000a of this structure, the sheet 72 cut according to the size of the product in the sheet cutting process 2100 is formed into a sheet forming process 220 shown in FIGS. 4 and 16.
The step of attaching the sheet to the mold 2300, in which 0 is omitted and the sheet is directly attached to the mold, is performed. The mold used here is an injection mold provided with an exhaust hole and further provided with a vacuum mechanism for exhausting air from the mold cavity. Then, in a sheet vacuum forming step 2250, the sheet is pre-processed by an injection molding die by vacuum evacuation to bring the sheet into close contact with the die. After that, the manufacturing process 2000a for the structure is completed after the step 2400 of injecting the base resin into the mold and the structure completion step 2500. According to this manufacturing process, it is possible to reduce two processes as compared with the processes shown in FIGS. 4 and 16. This manufacturing process is suitable for molding a large number of molded products.

The structure 2 manufactured by the manufacturing process shown in FIGS. 16 and 17 is used as a member of the electric vacuum cleaner, the electric washing machine, the air cleaner, etc. as exemplified in the first to third embodiments. can do. Further, the home electric appliances provided with the PP resin structure according to the present invention are not limited to these manufacturing methods, and for example, the sheet manufacturing process 100 in FIG.
0 and the manufacturing process 2000a of the structure shown in FIG. 17 may be combined.

Further, in FIGS. 1 and 15, the sheet surface material is made of a transparent material, but if the outer surface is provided with a textured surface by embossing, it is hard to be scratched, and the environment and recycling are good. Can be obtained.

[0071]

EFFECTS OF THE INVENTION The household electric appliance of the present invention has the following effects particularly since it has a polyolefin resin substrate on which a polyolefin resin sheet having an embossed surface is laminated. (1) Even if the member is made of recycled resin, the sheet covers the sink marks, weld lines, etc.
The appearance will be excellent. (2) Since the surface is embossed, scratches are less likely to occur and whitening can be prevented. (3) Since the sheet material and the base material are the same polyolefin-based resin, no adhesive is required when laminating and integrating, and the recycling is easy and the recycling efficiency is improved. (4) Coloring can be performed by printing the sheet, and since spray coating using an organic solvent is not required, it does not pollute the environment and is advantageous in cost. (5) Since a polyolefin resin is used, the weight can be reduced. (6) The design can be changed by changing only the color and pattern of the sheet without changing the color and pattern of the base. Further, according to the manufacturing method of the present invention, it is possible to efficiently and economically manufacture a home electric appliance that exhibits the above effects.

[Brief description of the drawings]

FIG. 1 is a side view showing a structure of a structure 1 adopted in Examples 1 to 3.

FIG. 2 is an external view of a vacuum cleaner.

FIG. 3 is a central cross-sectional view (a) of the large rear wheel of the vacuum cleaner, a front view (b) of the top sheet, and a side view (c) of the top sheet.

FIG. 4 is a diagram showing an example of a manufacturing process of a home appliance of the present invention.

FIG. 5 is a cross-sectional view showing an outline of an injection molding die.

FIG. 6 is a central cross-sectional perspective view schematically showing the vicinity of the gate of the injection molding die.

FIG. 7 is an external view of a large rear wheel in which tire bodies are not stacked.

FIG. 8 is an external view of a large rear wheel in which tire bodies are stacked.

FIG. 9 is a cross-sectional view near a tire body supporting portion of a large rear wheel.

FIG. 10 is a schematic sectional view of a bumper portion of the electric vacuum cleaner (a).
FIG. 3B is a schematic partial sectional view (b) of the lid cover of the electric vacuum cleaner.

FIG. 11 is an external view of an electric washing machine.

FIG. 12 is a schematic cross-sectional view of a lid cover of an electric washing machine.

FIG. 13 is an external view of an air purifier.

FIG. 14 is a cross-sectional view (a) in a state in which a front panel of the air purifier is closed and a cross-sectional view (b) in a state in which the front panel is exposed to the front.

FIG. 15 is a side view showing the structure of a structure 2 adopted in Example 4;

FIG. 16 is a diagram showing an example of a process for manufacturing a home appliance of the present invention.

FIG. 17 is a diagram showing an example of a manufacturing process of the home electric appliance of the present invention.

FIG. 18 is a view showing a sectional shape of a gate of an injection molding die.

FIG. 19 is a diagram showing a cross-sectional shape of a gate of an injection molding die.

[Explanation of reference numerals] 10 ... Base, 20 ... Surface sheet, 24 ... Concavo-convex processed surface, 2
6 ... Transparent sheet, 28 ... Base sheet, 32 ... Printing surface,
50 ... Gate, 60 ... Gate, 72 ... Surface sheet

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Shigehiko Suzuki 1-1-1 Higashitaga-cho, Hitachi-shi, Ibaraki Hitachi Ltd. Electric Appliance Division

Claims (13)

[Claims] 1. A base material made of a polyolefin resin and a surface sheet made of a polyolefin resin having an unevenness by embossing on one surface, wherein the surface sheet having no unevenness is in contact with the base material. A home appliance including a structure in which the sheet and the base are laminated and integrated. 2. The surface sheet has a thickness of 100 to 300 μm.
The household appliance according to claim 1, which is m. 3. The surface sheet is transparent, and printing is performed on a surface having no unevenness.
Home appliances described in. 4. A laminated sheet in which a transparent sheet having one surface thereof provided with unevenness by embossing and having a printed surface having no unevenness is laminated on a base sheet having color. The home electric appliance according to claim 1 or 2, which is 5. The product according to claim 1, which is a vacuum cleaner.
The household appliance according to any one of 1. 6. The product of claim 1, wherein the product is an electric washing machine.
The household appliance according to any one of 1. 7. The product according to claim 1, which is an air purifier.
The household appliance according to any one of 1. 8. The method for manufacturing a home electric appliance according to claim 1, wherein the molten polyolefin resin for the surface sheet is formed into a sheet by calendering (A- 1), and the step of making unevenness on one side of the sheet by embossing (A-
2), including the manufacturing step (A) of the surface sheet, and the step
(A) the step of cutting the topsheet obtained in (B-1), the step of preforming the cut topsheet (B-2), and the preformed topsheet, the uneven surface of the sheet The surface sheet and the substrate are attached to the injection molding die with the opposite surface in contact with the resin to be injected and filled, and then the molten polyolefin resin for the substrate is injected and filled into the cavity of the mold. A method of manufacturing a home electric appliance, comprising the step (B) of manufacturing a structure including the step (B-3) of integrally molding. 9. The method for producing a household electric appliance according to claim 1, wherein the molten polyolefin resin for the surface sheet is formed into a sheet by calendering (A- 1), and the step of making unevenness on one side of the sheet by embossing (A-
2), including the manufacturing step (A) of the surface sheet, and the step
Step (B-1) of cutting the topsheet obtained in (A), the cut topsheet is injection-filled into an injection molding die provided with an exhaust hole on the surface opposite to the uneven surface of the sheet. After being mounted in such a direction as to come into contact with the resin, the surface sheet is preformed by evacuation, and then the molten polyolefin resin for the substrate is injection-filled into the cavity of the mold to form the surface sheet. Step of integrally molding with the substrate
A method for producing a household electric appliance, comprising the step (B) for producing a structure, which comprises (B-4). 10. In the step (B-3) of the step (B), the gate for introducing the molten polyolefin resin is on the side of the substrate opposite to the surface sheet, and the tip of the gate is a sprue. 9. The method for producing a household appliance according to claim 8, wherein the tip portion has a slender shape, and the tip portion has a continuous shape extending from the side toward the cavity side. 11. In the step (B-3) of the step (B), the gate for introducing the molten polyolefin resin is on the side of the substrate opposite to the surface sheet, and the tip of the gate is a sprue. 9. The method for manufacturing a household appliance according to claim 8, wherein the tip portion has a cruciform cross section, which is continuously expanded from the side toward the cavity side. 12. In the step (B-4) in the step (B), the gate for introducing the molten polyolefin resin is on the side of the substrate opposite to the surface sheet, and the tip of the gate is a sprue. 10. The method for manufacturing a household appliance according to claim 9, wherein the tip portion has a slender shape, and the tip portion has a continuous shape extending from the side toward the cavity side. 13. In the step (B-4) in the step (B), the gate for introducing the molten polyolefin resin is on the side of the substrate opposite to the surface sheet, and the tip of the gate is a sprue. 10. The method for manufacturing a home appliance according to claim 9, wherein the tip portion has a cruciform cross section, which is continuously expanded from the side toward the cavity side.