JPH10264277A - Laminated foam sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce cut debris generated in forming work or punching out work by coating only part to be worked with a thermoplastic resin film except forwarding margins of both side peripheries applied by forwarding force in a foam sheet material. SOLUTION: The laminated foam sheet 10 is formed such that the width 13 of a sheet material 11 becomes wider than the width 14 of a film 12, and the film 12 is set at the central part of the sheet material 11. In this manner, the laminated foam sheet 10 has a part 15 being laminated with the film 12 and parts 17 not being laminated with film 12 and thus having the sheet exposed thereon. The parts 17 having the exposed sheet material 11 are both side peripheral parts along the longitudinal direction in the both side peripheral parts of the laminated foam sheet 10. In addition, the part being laminated of the laminated foam sheet 10 forms a part 15 to be worked, and parts (both side peripheral parts) not being laminated with the film 12 forms the forwarding parts 17.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated foam sheet used as a raw material of a sheet molded product.

[0002]

2. Description of the Related Art In recent years, molded articles using a foamed resin have been widely used in various applications such as electric equipment, automobiles and foods. Such foamed resin molded products are produced by various methods. As one of the production methods, by using a long foamed sheet made of foamed resin as a raw material of a foamed resin molded article, while feeding the foamed sheet in the longitudinal direction, by performing molding processing on the foamed sheet, There is a method of continuously producing a foamed resin molded product having a desired shape.

[0003] Such a laminated foam sheet is usually manufactured by a manufacturing line as shown in FIG. That is, the foamed resin sheet material 1 having a predetermined thickness is continuously fed along the direction of the arrow 3 using the rollers 2 for conveyance. Then, a thermoplastic resin film 4 is applied to the entire surface of the foamed resin sheet material 1 fed in this way, and a laminated foamed sheet 5 having a printed pattern as disclosed in, for example, Japanese Patent Publication No. 63-27170 is obtained. Form. This laminated foam sheet 5
Is cut to a predetermined length (for example, about 300 m),
As shown in the figure, it is wound into a roll and shipped as a product.

The resin molded article is formed by subjecting the laminated foamed sheet 5 to, for example, thermoforming or punching as shown in FIG. That is,
While the laminated foamed sheet 5 is fed in the longitudinal direction (the direction of arrow 6), a molding process or a punching process is performed on the processing region, whereby a resin molded product is continuously formed.

Here, a feeding force is applied to the laminated foamed sheet 5 by a processing device for performing a forming process or the like.
Feeding of the laminated foam sheet is usually performed by piercing the feed claws into both side edges 7 along the longitudinal direction of the laminated foam sheet 5 and driving the feed claws in the feed direction in this state.

[0006]

However, when the laminated foamed sheet 5 is fed, the feed claws pierce both side edges 7 of the laminated foamed sheet 5, so that the feed claws make holes in the side edges of the laminated foamed sheet 5. At this time, foamed resin sheet material 1
The chips of the thermoplastic resin film 4 are generated together with the chips. If the chips of the thermoplastic resin film 4 are mixed with the resin molded product, the resin molded product may be defective.

More specifically, for example, in the case where a resin molded product is manufactured by performing a forming process or a punching process on the laminated foamed sheet 5 using a processing device, the above-mentioned chips adhere to a die of the processing device. Then, a small concave portion is formed on the surface of the molded product.
For example, when a curved surface is printed on the molded product, the ink is not applied to the concave portion of such a molded product, and the concave portion becomes conspicuous as white spots. For this reason, it is necessary to remove the above-mentioned swarf with great care and certainty. Therefore, there is a demand to reduce the swarf generated by the feed claw as much as possible.

As shown in FIG. 5, a laminated foamed sheet 5 is formed by laminating a film 4 on one entire surface 1 a of a foamed resin sheet material 1. However, since the portion of the laminated foam sheet 5 which is a raw material of the resin molded product is actually processed in the region between the both side edges 7, the feed margin 9 which is the both sides is not provided. There is no need to laminate the film 4. However, in practice, the film 4 is laminated to the feed margin 9 in this way, so that the resin molded product is more expensive than necessary.

The present invention has been made under such a background, and it is possible to reduce chips generated at the time of processing such as molding and punching, and to further reduce the cost. It is an object to provide a foam sheet.

[0010]

A laminated foam sheet according to the present invention (claim 1) is provided on a surface of a long foam sheet material.
A thermoplastic resin film is laminated, and while feeding the foamed sheet material in the longitudinal direction by applying a feeding force to both side edges along the longitudinal direction of the foamed sheet material, the foamed sheet material is formed between the both side edges of the foamed sheet material. It is a laminated foam sheet for producing a resin molded product by performing a processing process on the processed portion formed in the above, the foamed sheet material, except for the feed margin of both side edges to which the feeding force is given It has a structure in which only the processed portion is covered with the thermoplastic resin film.

According to a second aspect of the present invention, in the laminated foamed sheet according to the first aspect, the dimension of the feed margins on both side edges of the sheet member in the direction orthogonal to the longitudinal direction is set to 10%.
mm to 30 mm.

[0012]

Embodiments of the present invention will be described below. FIG. 1 is a perspective view showing a structure of a laminated foam sheet 10 according to one embodiment of the present invention. As shown in the figure, the laminated foam sheet 10 has a sheet material 11 made of a foamed resin, and a film 12 made of a thermoplastic resin,
The film 12 is laminated (laminated) on the upper surface (or lower surface) of the sheet material 11 by heat fusion. In the present embodiment, the sheet material 11 is made of a polystyrene resin, and the film 12 is made of a polystyrene resin.

The laminated foam sheet 10 is used as a material which is subjected to a predetermined processing and is used to produce a final resin molded product. As such predetermined processing,
For example, heating is performed at a molding temperature while feeding the laminated foamed sheet 10 in the longitudinal direction (the direction of arrow 16), and thermoforming or punching with a vacuum forming machine, a compression molding machine, a press machine, or the like can be given. Although only the main part of the laminated foamed sheet 10 is shown in the drawing, the laminated foamed sheet 10 is actually a long one that is rolled and wound to about 300 m.

The structure of the laminated foamed sheet 10 will be described in more detail. The laminated foamed sheet 10 is formed so that the width 13 of the sheet material 11 is larger than the width 14 of the film 12. Sheet material 1
1 is located at the center. As a result, the laminated foam sheet 10 has a portion 15 on which the film 12 is laminated.
And the sheet material 1 where the film 12 is not laminated
A portion 17 where 1 is exposed is formed. The portions 17 where the sheet material 11 is exposed are both side edges along the longitudinal direction on both side edges of the laminated foam sheet 10. Further, the laminated portion of the laminated foam sheet 10 constitutes a later-described processed portion 15, and the portion on which the film 12 is not laminated (side edges) is a feed margin 17.
Is configured. In the present embodiment, the feed margin 17
Is set to 20 mm. However, the dimension of the feed margin 17 can be changed to another dimension (10 mm to 30 mm) according to the purpose.

Next, a method of manufacturing the laminated foam sheet 10 will be described. The laminated foam sheet 10 is manufactured on a manufacturing line as shown in FIG. That is, the sheet material 11 previously foamed and formed by the sheet material manufacturing apparatus (not shown)
Is transported by a transport roller, and the film 12 is laminated by a laminating device 20 during the transport. The details will be described below.

FIG. 2 is a schematic view showing a step of laminating the film 12 on the sheet material 11. In the figure, 2
Reference numeral 0 denotes a laminating apparatus for the film 12, which has an extruder 21 for extruding the raw material of the film, and a forming die (so-called T die) 22 for adjusting the film 12 to a predetermined width W and sending it out.

The film extruder 21 is for producing the film 12, and has a main body 23 and a raw material charging section 24 provided therein. This film extruder 2
1 melts the raw material of the film 12 supplied from the raw material charging section 24 in the main body 23 and extrudes the raw material from the discharge section 25. The raw material is generally a granular thermoplastic resin, and in the present embodiment, a polystyrene resin is used.

The molten resin (film 12) melted in the main body 23 is extruded by a spiral screw provided in the main body 23. The extruded molten resin is sent to the molding die 22 via the pipe 26. A substantially T-shaped groove 27 is formed inside the molding die 22 as shown in the figure. Exit 2 of this groove 27
8 is set so that its width dimension becomes the above W. Therefore, the molten resin is squeezed by the groove 27 and the dimension W
1 (that is, the width 14 of the film 12 shown in FIG. 1).

The discharged film 12 is positioned so as to be located at the center of the sheet material 11 to be fed, and the film 12 is pressed against the sheet material 11 by the rollers 2 shown in FIG. At this time, by further applying heat, the film 12 can be attached by heat fusion. As a result, the film 12 is
Are laminated to obtain a laminated foam sheet 10 having the above-described processed portion 15 and the feed margin portion 17. As described above, since the laminated foamed sheet 10 is a material of a resin molded product, the laminated foamed sheet 10 is wound in a roll shape to a predetermined length, and is shipped in that state.

According to the laminated foam sheet 10 of the present embodiment, the following operation and effect can be obtained. With reference to FIG. 1, it is possible to form a resin molded product by subjecting the laminated foam sheet 10 to a longitudinal direction while applying a molding process to a portion where the film 12 is laminated, that is, a processed portion 15. it can. At this time, the laminated foam sheet 10
Is sent by a molding machine. This laminated foam sheet 1
As a mechanism for feeding 0, a feed claw is used to feed
In other words, it is possible to employ a mechanism that pierces a portion where the film 12 is not laminated and moves the feed claw in the feed direction in this state.

The laminated foam sheet 10 has a feed margin 17 for applying a feed force to the laminated foam sheet 10.
Is formed, but in this feed margin 17,
Film 12 is not laminated. When the feed claws are sequentially pierced into the portion where the film 12 is not laminated as described above, the cut portion of the sheet material 11 is generated at the portion where the feed claws are pierced.
The feed margin 17 into which the feed claw is pierced is
Since the film 12 is not covered, no chips of the film 12 are generated. It was also found that the amount of chips generated was smaller than in the case where the feed claw pierced the portion covered with the film 12.

That is, as in the present embodiment, the feed allowance unit 1
When the film 7 is not covered with the film 12, the generation of chips in the film 12 can be avoided, and the generation of chips in the sheet material can be suppressed. It is possible to suppress the entry of debris,
As a result, it is possible to suppress occurrence of defective products in a resin product as a final product obtained by processing the laminated foam sheet 10.

In addition, since the film 12 is not laminated on the feed margin 17, a minimum necessary area (the work 1
The film 12 will be laminated only in 5),
There is also an effect that the cost of the laminated foam sheet 10 can be reduced.

Further, the dimension of the feed margin 17 is 10 mm
By setting the thickness in the range of from 30 mm to 30 mm, the configuration of the foam sheet of the present invention can be applied to a sheet-like member processed by a general-purpose processing apparatus.

In the case of a laminated polystyrene foam sheet on which a polystyrene resin film is laminated, since the sheet is deformed during heating for molding, the length and width directions are within 5% of the length before heating. A shrinkage ratio of is preferable in thermoforming.

[0026]

According to the laminated foamed sheet according to the present invention (claim 1), only the processed portion of the foamed sheet material except the surface portions of both side edges to which the feeding force is applied is a thermoplastic resin film. Even when feeding the laminated foamed sheet by moving the feed claws in the feed direction while piercing the laminated foamed sheet with a feed claw or the like of a processing device, film chips are generated. In addition, the amount of chips in the foamed sheet material can be suppressed.
As a result, it is possible to suppress occurrence of defective products in a resin molded product obtained by processing the laminated foamed sheet. Also,
Since no film is formed on both side edges of the foamed sheet material, the amount of film used can be reduced, and the cost of the laminated foamed sheet can be reduced.

According to the present invention (claim 2), the same effect as that of the invention according to claim 1 can be obtained. In addition, by setting the width of the feed margin to 10 mm to 30 mm, various processing devices for processing a laminated foam sheet can also be used.
There is an effect that chips generated by the feed claw piercing the feed margin can be suppressed.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a structure of a laminated foam sheet according to an embodiment of the present invention.

FIG. 2 is a schematic view showing a step of laminating a film on a sheet material constituting the laminated foamed sheet.

FIG. 3 is a view schematically showing a conventional manufacturing process of a laminated foamed sheet.

FIG. 4 is a plan view showing material removal of a conventional laminated foam sheet.

FIG. 5 is a perspective view showing the structure of a conventional laminated foam sheet.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Laminated foam sheet 11 Sheet material 12 Film 15 Worked part 17 Feed margin

Claims (2)

[Claims] A thermoplastic resin film is laminated on the surface of a long foamed sheet material, and a feeding force is applied to both side edges along the longitudinal direction of the foamed sheet material to form the foamed sheet material. While feeding in the longitudinal direction, a laminated foamed sheet for producing a resin molded product by performing a processing process on the processed portion formed between both side edges of the foamed sheet material, the foamed sheet material, A laminated foamed sheet having a structure in which only the processed portion is covered with the thermoplastic resin film except for a feed margin on both side edges to which a feeding force is applied. 2. The laminated foam sheet according to claim 1, wherein the feed margins on both side edges of the foam sheet material have a dimension in a direction perpendicular to the longitudinal direction of 10 mm to 30 mm. Laminated foam sheet.