JPS6327181B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Object of the Invention (Field of Industrial Application) The present invention relates to a method for manufacturing a foamed bead molded product whose surface is bonded with a breathable soft material such as cloth or a porous synthetic resin sheet. It is something.

(Prior Art) Foamed bead molded products are lightweight, flexible, and have high impact strength, so there is an increasing demand for them in interior parts for automobiles, where weight reduction is sought. In addition, a skin material made of synthetic resin is attached to the surface of the molded product for decorative purposes. Conventionally, this skin material is usually shaped and attached by vacuum forming or pressure forming to match the surface shape of a foamed bead molded article whose surface is coated with an adhesive.

(Problem to be solved by the invention) However, cloth made of synthetic fibers or natural fibers,
In the case of breathable materials such as nonwoven fabrics, flocked cloth, or porous synthetic resin sheets, the vacuum forming or pressure forming method described above cannot be used, so it has not been possible to use them as the skin material of the foamed bead molded product. For this reason, at present, foamed bead molded products with breathable skins have not yet been used in a wide range of applications. Moreover, the conventional skin material adhesion method has the drawback of requiring a large number of steps as described above.

In addition, the present inventors have developed a method in which a skin material is in-molded in a mold for molding foam beads, and molding of foam beads and bonding of the skin material are performed simultaneously. However, the wall surface of the mold is provided with a large number of core vents through which steam passes for foaming and fusing the beads. For this reason, it has been found that due to the heat of the steam and the foaming pressure of the beads, traces of the shape of the slit cross section of the core vent may remain on the surface of the skin material depending on the material, which may cause product defects.

The present invention aims to solve the above-mentioned problems and provide a method for manufacturing a foamed bead molded product with a skin, which can be used for a wide range of purposes by bonding skin materials made of various materials to the surface of the foamed bead molded product. It is something.

(Means for solving the problem) In order to solve the above problem, two sheets of soft skin material having a predetermined shape and having air permeability are installed inside the mold equipped with a core vent, and one of the skin materials is By placing synthetic resin foam beads on the back side of the latter skin material and heating and foaming them with high temperature steam from the core vent, the latter skin material is brought into contact with the inner wall and overlaid with another one. A method was adopted in which the skin material and the synthetic resin foam beads were bonded together and the foam beads were molded at the same time, and then the former skin material was peeled off.

(Function) In other words, the manufacturing method of the present invention enables the simultaneous molding of a foamed bead molded product with a skin without leaving any core vent marks by in-molding two sheets of breathable skin material into a mold and molding the foamed beads. did.

(Example) Hereinafter, an example in which the first and second inventions are embodied in a console box slide of an automobile will be described.

As shown in Fig. 3, the console box slid consists of a core material 1 made of synthetic resin molded into foam beads in a predetermined shape, a skin material 2 bonded to the surface of the core material 1, and a vinyl material affixed to the back surface. It is composed of a sheet 3.

The core material 1 is formed by foam-molding a polyolefin synthetic resin such as polypropylene or polyethylene or a thermoplastic synthetic resin such as polystyrene or polyvinyl chloride together with a foaming agent. especially,
Polyolefin-based synthetic resins are often used because they have excellent impact recovery properties, strength, etc. as foamed molded products.

The skin material 2 may be made of synthetic or natural fiber cloth, nonwoven fabric, porous synthetic resin sheet, etc.
Any soft material that is breathable and relatively heat resistant can be appropriately selected and used depending on the purpose.

A sheet 3 made of polyvinyl chloride or the like is adhered or sewn to the back surface of the core material 1, and a support plate 4 made of polypropylene, polyamide, etc. may also be provided.

Next, a method of manufacturing the console box slid will be explained with reference to FIGS. 1 and 2.

The skin material 2 having a predetermined shape, for example, a synthetic fiber non-woven fabric 2 is placed inside the mold 5 for molding foam beads.
Lay them together and in-mold them. At this time, an adhesive 7 may be applied to the overlapping surfaces of the two nonwoven fabrics 2a and 2b at appropriate intervals to prevent the nonwoven fabrics from shifting.

After that, synthetic resin foam beads are loaded into the same mold 5, and further heated at 150℃ 5-7 from the core vent 6.
Foam beads are formed by press-fitting steam at Kg/cm ² pressure. At this time, a part of the synthetic resin foamed and softened by the heat of the steam is fused to the nonwoven fabric 2a, and the core material 1
and the nonwoven fabric 2a are firmly joined.

Depending on the material of the skin material, the adhesive force to the core material made of polyolefin synthetic resin may be weak, but in this case, by applying an adhesive to the back side of the skin material in advance, Adhesive strength can be strengthened.

In addition, if the steam press-fitted from the core vent 6 does not flow into the entire inside of the mold 5, the fusion of the beads will deteriorate, so the nonwoven fabric 2b on the mold side should be coarser than the nonwoven fabric 2a on the inside. , it is desirable to smooth the inflow of steam.

Next, the core material 1 molded into a predetermined shape is placed in a mold 5.
By taking it out and peeling off the outer skin material 2b, a skinned foamed bead molded product without leaving any core vent marks is manufactured.

Effects of the Invention As described above, the manufacturing method of the present invention performs foam bead molding by overlapping two air permeable skin materials and in-molding them in a mold. This is an excellent manufacturing method that enables simultaneous bonding and does not leave core vent marks on the surface of the skin material.

[Brief explanation of the drawing]

Figure 1 is a cross-sectional view of a mold for molding foam beads in which two skin materials are in-molded, Figure 2 is a cross-sectional view of the same mold loaded with synthetic resin foam beads, and Figure 3 is a console box slid. FIG. 2 is a cross-sectional view of a concrete foamed bead molded product with a skin. 1: core material, 2a, 2b: skin material, 5: mold,
6: Core vent, 8: Foamed bead filling hole.

Claims (1)

[Claims] 1. Two sheets of soft skin material 2a, 2b having a predetermined shape and having air permeability are installed inside a mold 5 equipped with a core vent 6, and one of the skin materials 2a, 2b is attached to the inner wall of the mold 5. The synthetic resin foam beads 1 are loaded on the back side of the latter skin material 2a, and heated and foamed with high-temperature steam from the core vent 6. skin material 2
A and synthetic resin foam beads 1 are bonded and foam beads are molded at the same time, and after that, the former skin material 2
A method for producing a foamed bead molded product with a skin, characterized by peeling off b. 2. The method for producing a skinned foam bead molded product according to claim 1, wherein the skin material 2b that contacts the inner wall of the mold 5 has a rougher texture than the other one.