200817170 九、發明說明： 【發明所屬之技術領域】 本發明係涉及發泡產品的製造方法，尤其涉及如何制 造具有塑膠表皮之發泡產品的技術。 衣 【先前技術】 一般常見的發泡產品係具有一發泡板或發泡核心以及 至少一表皮；其中，該發泡板係由一種發泡原料而發泡开3 成，且該表皮係藉一結合媒介而另外貼附於該發泡板。 台灣新型專利第M269181號係揭示一種多層複合板， 其特徵在於一發泡層的一表面共擠設有一層硬質塑膠層。 此外，台灣發明專利第580424號更揭露一具耐磨立體^泡 物之製法，其係利用一具有圖樣之外層膜與一發泡物纟士人 成一體’而得一發泡物成品。再者，台灣發明專利第124扣78 號係揭示一種將軟墊與硬板一體成型之製造方法，其係矛 用數種模具使一軟墊、發泡材料及硬板一體成型。”】200817170 IX. DESCRIPTION OF THE INVENTION: TECHNICAL FIELD The present invention relates to a method of manufacturing a foamed product, and more particularly to a technique for producing a foamed product having a plastic skin. [Prior Art] A commonly used foaming product has a foamed sheet or a foamed core and at least one skin; wherein the foamed sheet is foamed by a foaming material, and the skin is borrowed. A foaming plate is additionally attached to the medium in combination with the medium. Taiwan Patent No. M269181 discloses a multilayer composite panel characterized in that a surface of a foamed layer is coextruded with a layer of a hard plastic layer. In addition, Taiwan Patent No. 580424 discloses a method for manufacturing a wear-resistant three-dimensional foam which is obtained by using a film having a pattern and a foamed gentleman to obtain a finished foam product. Furthermore, Taiwan Invention Patent No. 124, No. 78 discloses a manufacturing method in which a cushion and a hard plate are integrally molded, and the spear is formed by integrally molding a cushion, a foamed material and a hard plate with several kinds of molds. ”
在US 的8, 179及US 4, 850, 913號專利案中，伟 露-種運動用的板子，它具有—發泡核心及包覆住該^ 核心的上表纽下表皮。該發難^用是發泡原料:、、= 成後，再切割成預定的形狀，然後再將該上表皮及；:^ 以熱£貼合方式結合至該發泡心板的上、下表面與^皮 且US 5’ 2U’ 593號專利案’更揭露—種具有壓印圖案= 泡核心結構，它的結構及製造方法雖與上 相务 但較複雜。此外，%奎& 寻巧案相似， 匕外耶4,693,856就專利，係揭露_種_ 6 200817170 性物件的製造方法，它提供多量第―:欠發泡的合成樹脂顆 粒，並引進/膨脹劑而形成第二次發泡的顆粒 ，然後，將 第二次發泡_粒置於-模具内，並引人減體至該模具 内，使得第二次發泡的顆粒膨脹並相互黏結。 【發明内容】 本發明主要描述一種具有表皮之發泡產品的製作方 法，更詳而言之’-種具有圖膜及表皮之發泡產品。該發 泡產品包括-發泡核心、至少—頂皮以及—第一塑膠圖 膜；其中，該發泡核心具有—頂面、—底面及複數周邊， 該發泡核心包括複數個發泡顆粒，且該些發泡顆粒係緊密 地相互結合，且該頂面具有至少一凹部；此外，該頂皮係 結合且填滿該發泡核心之凹部，該第—塑膠圖膜係全面地 結合於該發泡核心之頂面、周邊及該頂皮。 而該發泡產品的製作方法，係主要包括下列步驟 供一模具，該模具内部具有一成型模穴；且將一第一 圖膜置於該成麵穴巾；然後將適當A小及數量之 ^ 於該第一塑膠圖膜之内面的預定位置；再將適當數量之 泡顆粒注人該成翻穴内；並將熱蒸氣勤注人該成型: 穴内，以使該些發泡顆粒本身、該第—轉圖臈及該頂= 相互之間緊密地結合’而形成—發泡產品；以及取出"該發 泡產品，據此，該發泡產品係具有該第—塑膠圖膜、 皮以及一發泡面。 、貝 本發明的最大好處是，該發泡產品形狀的形成，即該 7 200817170 發泡顆粒、該頂皮及該第一塑膠圖膜之結合是同時形成 的，因而具有製造簡單、快速、及廉價之優點。再者，本 發明該頂皮及該第一塑膠圖膜與該發泡核心係可進一步藉 一結合膜之形成，進而產生良好結合且具有不易分離的優 【實施方式】 第一圖係顯示本發明之一第一較佳實施例，其揭示 电泡產ΠΠ ( 1 ) ’且該發泡產品（1 )包括一發泡核心（1 0 )、至少一頂皮（1 1)以及一第一塑膠圖膜（1 2); 其中，該發泡核心（1 〇)具有一頂面（丄〇〇)、一底面 (1 0 1)及複數周邊（1 〇 2 )，該發泡核心（1 〇)包 括複數個發泡顆粒，且該些發泡顆粒係緊密地相互結合， 且該頂面（1 〇 〇)具有至少一凹部（丄〇3 );此外，該 貝皮（1 1 )係結合且填滿該發泡核心（1 〇 )之凹部（1 〇 3 )，該第一塑膠圖膜（丄2 )係全面地結合於該發泡核 心（1 〇 )之頂面（1 〇 〇 )、周邊（1 〇 2 )及該頂皮（1 1 )’其中，该第一塑膠圖膜（丄2)内具有可見之圖案（工 、2 於本發明中，該第一塑膠圖膜（1 2)可為一單片 ’且其面向該發泡核心（i ◦)之—面印有該圖案 2 〇 )，或可為一複合式多層塑膠膜，且其中係印有該 :月暖回1 2 0 ) ’其厚度約為〇. 03〜L 5mm ;其中，該第一 = ΐ(12)不但可印有《，更可印有顏色，以進 乂又侍具有底色之塑膠圖膜；此外，該第一塑膠圖膜（工 8 200817170 2 )較佳厚度為〇· 03〜0· lmm ;且實際厚度則視其使用領 域可更為增加或減少。 7 其中，該發泡顆粒係可為PP、PE、PS等相關材質之發 泡顆粒，且該些發泡顆粒是預先發泡完成而呈珠狀；、該丁^ 皮（1 1 )係包括一發泡層（1 1 〇 )，其最佳發泡密度為 1· 5〜12PCF，且厚度為1〜25mm。該發泡層（1丄〇 ) ^ 密度係高於該發泡核心（X 〇 )，而可提高該發泡產品（工） 之觸感及其整體表面平整度；此外，該發泡層（丄1 〇) 可為一 PE、PP、PS或TPU層等相關材質，且該發泡層（1 1〇)可依该發泡顆粒材質，而選擇與其物性相似材料。 於本發明第一較佳實施例中，該發泡產品（丄）不但 可被視為成品，也可以視為半成品（丄），且該發泡產品（G 2可運用於多種領域，如運動用品、娛樂器材或緩衝塾等 等例如，當該發泡產品（！）運用於滑雪板、風帆板或 滑水板等相關運動用板時，則屬半成品狀態，因為該發泡 核心（10)所裸露之底面（1Q1)需另與其他底層或 附加物相結合，以達到保護該底面（1 0 1)之目的，且 号使用者藉該底層在—表面上平穩地滑行；再者，當該發 ^產品口（ 1 )運用於自行車椅墊或其他墊狀物時，那麼言= 包產品（1 )就可視為_個成品，因為該裸露之底面（1 ，即自行車椅墊的底面，有沒有底層覆蓋並不重要。 恭、治f者’本發明之頂皮（1 1)可供分散該發泡產品（1) 二\、、亥心（1 〇)表面與外界接觸所承受的力量，以避免 包(10)因長期受力而變形，且可進而使該發 9 200817170In U.S. Patent No. 8, 179 and U.S. Patent No. 4,850, 913, the disclosure of the utility model is incorporated herein by reference. The foaming material is used for foaming raw materials:,, =, and then cut into a predetermined shape, and then the upper skin and the surface of the foamed core sheet are bonded to the upper and lower surfaces of the foamed core sheet by heat bonding. It is further disclosed that it has an embossed pattern = a bubble core structure, and its structure and manufacturing method are more complicated than those of the above. In addition, the % Kui & 寻 案 相似 , , 4 4 4 4 4 4 4 4 4 4 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 The second foamed granules are formed, and then the second foaming granules are placed in the mold and introduced into the mold so that the second foamed granules expand and bond to each other. SUMMARY OF THE INVENTION The present invention mainly describes a method for producing a foamed product having a skin, and more specifically, a foamed product having a film and a skin. The foamed product comprises a foamed core, at least a top skin and a first plastic film; wherein the foamed core has a top surface, a bottom surface and a plurality of peripheral edges, the foam core comprising a plurality of foamed particles, And the foamed particles are closely combined with each other, and the top surface has at least one concave portion; further, the top skin is bonded and fills the concave portion of the foamed core, and the first plastic film is fully bonded to the The top surface of the foamed core, the periphery and the top skin. The method for manufacturing the foamed product mainly comprises the following steps for a mold, the mold has a molding cavity inside; and a first film is placed on the faceted towel; then the appropriate A small and quantity is ^ at a predetermined position on the inner surface of the first plastic film; then injecting an appropriate amount of the foam particles into the turning hole; and molding the hot steam into the hole to make the foamed particles themselves, a first-to-figure sheet and the top layer = closely combined with each other to form a foamed product; and a foamed product, according to which the foamed product has the first plastic film, skin and A foaming surface. The biggest advantage of the invention is that the shape of the foamed product, that is, the combination of the 7 200817170 foamed granules, the top skin and the first plastic film is simultaneously formed, thereby having a simple and fast manufacturing process. The advantage of cheap. Furthermore, the top skin and the first plastic film and the foam core of the present invention can be further formed by a bonding film, thereby producing a good bond and having difficulty in separation. A first preferred embodiment of the invention discloses a bubble generation (1)' and the foamed product (1) comprises a foamed core (10), at least one top skin (1 1) and a first a plastic film (1 2); wherein the foam core (1 〇) has a top surface (丄〇〇), a bottom surface (1 0 1), and a plurality of perimeters (1 〇 2 ), the foam core (1) 〇) comprising a plurality of foamed particles, and the foamed particles are closely bonded to each other, and the top surface (1 〇〇) has at least one concave portion (丄〇3); further, the pebbled (1 1 ) system Combining and filling the concave portion (1 〇3) of the foamed core (1 〇), the first plastic film (丄2) is fully bonded to the top surface of the foamed core (1 〇) (1 〇〇 ), the periphery (1 〇 2 ) and the top skin (1 1 )', wherein the first plastic film (丄2) has a visible pattern (Working, 2 in the present invention, the first The plastic film (12) may be a single piece 'and the surface of the foamed core (i ◦) is printed with the pattern 2 〇), or may be a composite multilayer plastic film, and the printed thereon is printed The: month warm back 1 2 0) 'The thickness is about 〇. 03~L 5mm; among them, the first = ΐ (12) can not only be printed ", but also can be printed with color, to enter the 乂 and serve the bottom In addition, the first plastic film (Work 8 200817170 2 ) preferably has a thickness of 〇·03~0·lmm; and the actual thickness can be increased or decreased depending on the field of use. 7 wherein the foamed particles are foamed particles of related materials such as PP, PE, PS, etc., and the foamed particles are pre-expanded and formed into a bead shape; and the dipped skin (11) includes A foamed layer (1 1 〇) having an optimum foaming density of 1.5 to 12 PCF and a thickness of 1 to 25 mm. The foam layer (1丄〇) ^ density is higher than the foam core (X 〇), and the touch feeling of the foamed product and its overall surface flatness can be improved; in addition, the foam layer (丄1 〇) can be a PE, PP, PS or TPU layer and other related materials, and the foam layer (1 1 〇) can be selected according to the material of the foamed granules. In the first preferred embodiment of the present invention, the foamed product can be regarded not only as a finished product but also as a semi-finished product, and the foamed product (G 2 can be used in various fields such as sports). Supplies, entertainment equipment or cushions, etc. For example, when the foamed product (!) is applied to a sports board such as a snowboard, a windsurfing board or a water ski, it is in a semi-finished state because the foaming core (10) The exposed bottom surface (1Q1) needs to be combined with other bottom layers or add-ons to protect the bottom surface (1 0 1), and the user uses the bottom layer to smoothly slide on the surface; When the product mouth (1) is applied to a bicycle seat cushion or other cushions, then the package product (1) can be regarded as a finished product because the bare bottom surface (1, that is, the bottom surface of the bicycle seat cushion, It is not important to have the underlying cover. Christine and the ruler's top skin (1 1) can be used to disperse the foamed product (1), and the surface of the heart (1 〇) is exposed to the outside world. Strength to avoid deformation of the bag (10) due to long-term stress, and 9200817170
泡產品（1 )具有較強之結構而大幅增長其使用壽命·且 该頂皮（1 1 )因被該第一塑膠圖膜（12)包覆於内， 並與該凹部（1 〇 3)及第一塑膠圖膜（1 2)互相結合， 所以該頂皮（1 1)不會有可移動空間。所以，如第一圖 所示，當該發泡產品（i)運用於一滑板製造時，該頂: (1 1)係設置於一使用者之使用區域或乘坐部，即該發 泡核心（1 〇 )之頂面（1 0 0 ) 0 X 此外，為加強該發泡產品（1 )、頂皮（丄丄）及第一 塑膠圖膜（1 2)相互之結合強度，該第一塑膠圖膜（1 2 )更可包括-第-結合膜（i 2丄），係供與該發泡核心 (1 0)之頂面（1 〇 〇)及周邊（1 〇 2)產生良好結 合，且该頂皮（11)更可包括一第二結合膜（1 1 1 )， 係供該第一發泡層（1 10 )與該發泡核心（丄〇 )之凹 部（1 0 3)產生良好結合。需要額外指出的是，本發明 之結合膜的材料特性是根據該發泡顆粒材料而決定，且該 結合膜為一種能與上述發泡顆粒作良好結合之材料，像是 混合有一些PE材料及PS材料等多重物性之共聚物 (copolymer) 〇 第一圖係顯示本發明之一第二較佳實施例，其同樣地 揭示一發泡產品（1 a );相同於上述之第一較佳實施例， 該發泡產品（1 a )包括一發泡核心（丄〇 a )、兩頂皮（工 1 a )以及一第一塑膠圖膜（丄2 a )。如圖所示，該第二 較佳貫施例之頂皮（1 1 a )係包括兩發泡層（丄丄〇 a ); 因此，該發泡核心（1 〇 a )之頂面（丄〇 〇 a )具有兩 10 200817170The foam product (1) has a strong structure and greatly increases its service life, and the top skin (1 1 ) is covered by the first plastic film (12), and the concave portion (1 〇 3) And the first plastic film (12) is combined with each other, so the top skin (11) does not have a movable space. Therefore, as shown in the first figure, when the foamed product (i) is applied to the manufacture of a skateboard, the top: (1 1) is disposed in a user's use area or seat portion, that is, the foam core ( 1 〇) top surface (1 0 0 ) 0 X In addition, in order to strengthen the bonding strength between the foamed product (1), the top skin (丄丄) and the first plastic film (12), the first plastic The film (12) may further comprise a -th-bonding film (i2丄) for providing a good bond with the top surface (1 〇〇) and the periphery (1 〇2) of the foamed core (10). And the top skin (11) further includes a second bonding film (1 1 1 ) for generating the first foam layer (1 10 ) and the concave portion (103) of the foam core (丄〇) Good combination. It should be additionally noted that the material properties of the bonding film of the present invention are determined according to the foamed particle material, and the bonding film is a material which can be well combined with the above-mentioned foamed particles, such as a mixture of PE materials and Copolymer of PS material, etc. The first figure shows a second preferred embodiment of the present invention, which likewise discloses a foamed product (1 a ); the same as the first preferred embodiment described above For example, the foamed product (1 a ) comprises a foamed core (丄〇a ), two top skins (work 1 a ) and a first plastic film (丄 2 a ). As shown, the top skin (11a) of the second preferred embodiment comprises two foam layers (丄丄〇a); therefore, the top surface of the foam core (1 〇a) 〇〇a) has two 10 200817170
凹部Q 滿其對應之凹部Q。母7了'皮(乂 系分別結合且填 〇 3 a )’此外，5亥第—塑膠圖膜（工 ^面地結合於該發泡核心（l〇a)之頂面U a、周邊（1 0 2 a )及該頂皮（；[工a ) 圆膜（1 2 a )内具有可見之圖案（工2 外，該些發泡声f 1 n 、 认 ’匕 相關材質。 10a)可為PE、pp、mpu^ ==上述之第—較佳實㈣，該第二較佳實施例之 頁皮jlla)及第一塑膠圖膜（123)亦可包括第一 較佳實施例之結合膜，以加強其本身與該發泡核心（ a )之結合強度。且如第—圖及第二圖所示，本發明之頂 束（1 1)(1 1 Ο係可置料適當地分佈於該發泡核心 (10)(100 頂面（ 1 0 0 )( 1 0 0 a)的任一處， 且其較佳位置係可為該發泡產品（1)預定受力之位置。 例如’若該發泡產口口σ (1)運用於獨木舟、小船、小艇等 a 製作上，該舟體、船體等本身則需與複數頂皮（1 相配合。 一第二圖係顯不本發明之一第三較佳實施例，即同樣地 揭示-發泡產品（1 b );相同於上述之第—較佳實施例， 該發泡產品（1 b )除包括一發泡核心（i 〇 b )、一頂皮 (1 1 b)及一第一塑膠圖膜（丄2 b)外，更包括一底 皮（1 3 )’係結合於該發泡核心（i 0 b )之底面；因此_， 該發泡核心（1 〇 b)可完全地被該第一塑膠圖膜（工2 b)及該底皮（1 3)所包覆，以進-步地保護該發泡核 11 200817170 心（1 0 b )，而延長其使用壽命。 如先前所述之發泡產品的運用方式，第三圖係進一步 地顯示該發泡產品（1 )運用於運動用板之相關結構，因 該發泡核心（1 0 b)所裸露之底面需被用在滑行於一表 面上，如水面、雪地或沙地等表面，所以該底面係可藉該 底皮（1 3)之設置，來保護該底面，並可讓使用者藉該 底皮（1 3)在該表面上平穩地滑行。 此外，第四圖及第五圖係分別進一步地顯示該底皮（工 3 )之較佳實施例。如第四圖所示，該底皮（ -發泡層⑴〇)及一塑膠板(131);二3 = 層（1 3 0 )’係供結合於該發泡核心之底面，且該發泡層 (1 3 0 )之最佳發泡密度為i 5〜12pcF，且厚度為 25麵；而該塑膠板（1 3 1)，係結合於該發泡層（1 3〇)。 再者，该底皮（1 3 )更可包括一結合膜（1 3 2 )，係供 。亥赉泡層（1 3 0 )與該發泡核心之底面產生良好結合； 且該結合膜（1 3 2)係相同於上述實施例之結合膜。此 外’该發泡層（1 3 0 )可為一 pe、pp、ps或TPU層，而 该塑膠板（1 3 1 )係為耐磨材料，其較佳厚度為〇· 1〜 1mm，其貫際厚度則視其使用領域可更為增加或減少。 第五圖所示，该底皮（1 3)除可包括第四圖所示之 發泡層（1 3 〇)、塑膠板（1 3 1 )及結合膜（1 3 2) 外，更可包括一第二塑膠圖膜（丄3 3 )，其係設於該發泡 層（1 3 0)及該塑膠板（1 3丄）間，並與該發泡層（工 3 0)及該塑膠板（1 3 1 )相互結合；相同於上述之第 200817170 一塑膠圖膜，該第二塑膠圖膜（2 3 3)可為一單一膜或 複合膜，且其具有從該塑膠板（丄3 L)外可見之圖案。The recess Q is filled with its corresponding recess Q. The mother 7 has a 'skin (the scorpion is combined and filled 3 a). In addition, the 5 haidi-plastic film is bonded to the top surface U a and the periphery of the foam core (l〇a). 1 0 2 a ) and the top skin (; [work a) round film (1 2 a) has a visible pattern (in addition to the work 2, the foaming sound f 1 n , recognized '匕 related material. 10a) can The skin of the second preferred embodiment and the first plastic film (123) may also comprise a combination of the first preferred embodiment. The first preferred embodiment is a combination of the first preferred embodiment (b). a film to strengthen the bonding strength of itself to the foamed core (a). And as shown in the first and second figures, the top bundle (1 1) of the present invention (1 1 可 can be properly distributed on the foamed core (10) (100 top surface (100) ( Any position of 1 0 0 a), and its preferred position is the position at which the foamed product (1) is intended to be stressed. For example, 'If the foaming mouth σ (1) is applied to canoes, boats In the production of a small boat, etc., the boat body, the hull, etc. itself need to cooperate with a plurality of top skins (1). A second figure shows a third preferred embodiment of the invention, that is, the same is disclosed - a foamed product (1b); similar to the above-described preferred embodiment, the foamed product (1b) comprises, in addition to a foamed core (i 〇b), a top skin (1 1 b) and a first a plastic film (丄2 b), further comprising a bottom skin (1 3 )' bonded to the bottom surface of the foamed core (i 0 b ); thus, the foam core (1 〇b) can be completely The ground is covered by the first plastic film (working 2 b) and the bottom skin (13) to further protect the foaming core 11 200817170 core (1 0 b ) and prolong its service life. The operation of the foamed product as described previously, the third system Further showing that the foamed product (1) is applied to a structure related to a sports board, since the exposed bottom surface of the foamed core (10 b) needs to be used for sliding on a surface such as water, snow or sand. The ground surface is so that the bottom surface can be protected by the bottom skin (13) to protect the bottom surface, and the user can smoothly slide on the surface by the bottom skin (13). The figure and the fifth figure further respectively show a preferred embodiment of the bottom skin (Work 3). As shown in the fourth figure, the bottom skin (-foam layer (1) 〇) and a plastic plate (131); 3 = layer (1 3 0 )' is bonded to the bottom surface of the foamed core, and the foamed layer (130) has an optimum foaming density of i 5 to 12 pcF and a thickness of 25 faces; The plastic sheet (1 3 1) is bonded to the foam layer (13 〇). Further, the bottom layer (13) may further comprise a bonding film (1 3 2 ) for supplying the enamel layer. (1 3 0 ) produces a good bond with the bottom surface of the foamed core; and the bonding film (1 3 2) is the same as the bonding film of the above embodiment. Further, the foamed layer (1 3 0 ) may be a pe , pp, ps or TPU The plastic plate (1 31) is a wear-resistant material, and the preferred thickness is 〇·1~1 mm, and the thickness of the cross-section can be further increased or decreased depending on the field of use. The bottom skin (13) may include a second plastic film in addition to the foam layer (1 3 〇), the plastic plate (1 3 1 ) and the bonding film (1 3 2) shown in the fourth figure. (丄3 3 ), which is disposed between the foam layer (130) and the plastic plate (13 丄), and the foam layer (working 30) and the plastic plate (1 3 1 ) The second plastic film (23 3) may be a single film or a composite film, and has a pattern visible from the plastic plate (丄3 L), which is the same as the above-mentioned plastic film of 200817170. .
第六圖係顯示本發明之一第四較佳實施例，亦揭示一 種發泡產品（1 c )，其不但包括第_或第二較佳實施例所 不之务泡核心（1〇、1“）、頂皮（ii、iia)以 及第-塑膠圖膜（i 2、i 2 a )外，更包括一發泡結構 (2 )，係結合於該發泡核心（丄〇、丄〇 a )之底面（工 〇 1、1 0 1 a )。該發泡結構（2 )包括一發泡基板（2 〇)’係有-頂面（2〇0)、一底面（2〇1)及複數周 邊（2 0 2 ) ’該發泡基板（2 〇 )之底面 合於該發泡核心（lG、1Qa)之底面UQ1 t 1 a )，其中’该發》包基板（2 q)包括複數個發泡顆粒， 且該些發泡顆粒係緊密地相互結纟；此夕卜該發泡基板（2 0 )之發泡騎材質’係同上述實施例巾所述之材質，例 如 PP、PE、PS 等。 、 再者，如第六圖所示，該發泡產品（丄C )更可包括 -第二塑卵m闕板（2 2)，係全面地結合於該 發泡基板（2 0)之頂面（2 〇 〇)及周邊（2 〇 2);其 中，該第二塑膠圖膜或一塑膠薄板（2 2)内係具有可見 之圖案，類似先前所述之第一塑膠圖膜（1 2、1 2 a 其中，該塑膠板為耐磨材料，且其較佳厚度為Q 〇3〜 ^ 5mm。此外，該發泡結構（2 )更可包括一結合膜（2 3 )， 係供該發泡基板（2Q)之底面（20 1)與該發泡核心 (1 〇、1 〇 a )之底面（i i、工0工a )產生良好 13 200817170 結合。 第七圖及第八圖係顯示本發明之一第五較佳實施例， 亦揭示一種相似於第四較佳實施例之發泡產品（丄d)，其 包括發泡核心（1〇、1〇3)、頂皮（11、113)、 第一塑膠圖膜（1 2、1 2 a )以及發泡結構（2 )之發 泡基板（2 0 )外，更包括至少-皮層（2丄），結合於該 發泡基板（20)之頂面（200);其中，該發泡基板（2 〇 )之頂面（2 0 〇 )具有至少一容槽（2 0 3 )，供容置 該皮層（2 1 )。此外，該發泡產品（χ d )更可包括一第 二塑膠圖膜或一塑膠薄板（2 2 d )，供全面地結合或覆蓋 該發泡基板（2 0 )之頂面（2 0 0 )、周邊（2 〇 2 )及 皮層（2 1 )，其中，該第二塑膠圖膜或塑膠薄板（2 2己） 係相似於前述之第二塑膠圖膜或塑膠薄板（2 2)。 如第八圖所示，該發泡基板（2 〇)之頂面（2 〇 〇 ) 及周邊（202)具有相互連通之容槽（2 〇 3 d )，供容 置该皮層（2 1 )，且該皮層（2 1 )亦可被該第二塑膠圖 膜或一塑膠薄板（2 2 d)所覆蓋。 ★於該第四及第五較佳實施例中，該第二塑膠圖膜或塑 膠薄板（2 2、2 2 d)更可包括一結合膜（2 3 〇 )，係 供該第二塑膠圖膜或塑膠薄板（2 2、2 2 d)與該發泡 基板（2 0 )之頂面（2 0 0 )、周邊（2 〇 2 )及該皮層 (2 1 )產生良好結合。 詳而言之，本發明第四及第五較佳實施例之結構，有 些部份實際上係運用該第第二較佳實施例所完成之半 14 200817170 成品，相互結合而成；其中，該第四及第五較佳實施例雖 顯示該發泡結構（2)係完全地結合於該發泡核心（1 0、 1 0 a )之底面（1 〇 1、1 〇 1 a )，但其實際運用，並 不以此為限；例如，視實際需要將該發泡結構結合於該發 泡核心底面之部份區域。 此外，第九圖係進一步顯示製作上述發泡產品的方 法；其中，該方法包括下列步驟： a )提供一模具，該模具内部具有一成型模穴；其中， 該模具係由可合模之一第一模與一第二模所組成。該第一 模與第二模中分別具有一第一成型模穴及一第二成型模 穴，以供組成該成型模穴，該成型模穴係對應該發泡產品 之形狀。此外，該第一模另連接有一第一輸送管及一第二 輸送管，並藉由該第一、二輸送管與一射出裝置連接；該 射出裝置包括一料筒及一供氣設備，且該料筒連接該第一 輸送管，供注入隨後步驟所需要的發泡顆粒，例如PP、PE、 PS等相關材質之發泡顆粒；而該供氣設備係藉該第二輸送 管與該模具連接，用以供應熱蒸氣壓力。 b )將一第一塑膠圖膜置於該成型模穴中；其中，該 第一塑膠圖膜係以足夠涵蓋該成型模穴之方式而固定於該 模具内；例如，先將該第一塑膠圖膜設置於該第二模上， 然後將該第一模與第二模合模，而使該第一塑膠圖膜可固 定於該模具内。 c)將適當大小及數量之頂皮置於該第一塑膠圖膜之 内面的預定位置； 15 200817170 d)將適當數量之發泡顆粒注人該成型模穴内；即驅 動該射出裝置並藉該第-輪送管，將該些發侧粒送 模具内； e )將熱蒸氣壓力注μ成型敎内，以使該些發泡 顆粒本身、㈣—㈣_及該頂皮相互之間緊密地結 ^而形成-發泡產品：更詳而言之，也就是利用該第二 輸送管將適當地減氣壓力仏職具之成麵穴内，以 3些發泡顆粒受熱再次些微地膨脹，並使該些發泡顆粒 ^，產生祕且具純，並相互且完全沒有間隙地緊密 ^在—起，且#該些發—互誠黏結而成型時， :::接f到的該第一塑膠圖膜及頂皮，也會相互緊密地黏 結在一起；以及 圖膜f it ^發缝品’該發泡產品係具有該第一塑膠 =撼该頂皮以及-發泡面；其中，該發泡顆粒黏 係根據該成型模穴而形成—旅 膜及該頂皮相結合；因此，心’並與該第—塑膠圖 皮之發泡顆粒，則形成該發2觸到該第—塑膠圖膜及頂 所亍根據上述之方法則可製作出如第—圖及第二圖 斤不之發泡產品。此外，上述之方法更可包括一步驟： =)將-底皮結合至該發泡面上；亦即利賴壓貼合 式’將皮結合至該錢面。因此，除·上述方 品。再加此—步驟，即可製作出如第三_示之發泡產 另外，如第十圖所示，本發明之第一塑膠圖膜則可藉 16 200817170 下列步驟而完成；首先，提供一塑膠膜，係具有可見之圖 案；然後，於該塑膠膜之一面形成一結合膜，該結合膜係 供該塑膠膜與該發泡顆粒產生良好結合。更詳而言之，即 先提供一張透明或半透明的塑膠膜，且其内部預先印有圖 案或顏色；接著，於該塑膠膜的一面以淋膜方式形成一層 厚度約0. 01〜0· lmm之結合膜，該結合膜係同於上述實施 例中之結合膜。 第Η 圖更進一步顯示，該具有圖案之塑膠膜的製作 方式，係包括下列步驟；首先，提供一第一層膜；然後， 以印刷方式在該第一層膜上形成該圖案或顏色；接著，以 淋膜（extrusion)或層壓（lamination)方式於該第一層 膜上形成一第二層膜，以覆蓋該圖案，即將該圖案設於該 第一層膜及第二層膜間。 第十二圖係指出該底皮之製作方法；首先，提供一發 泡層，其材質如上述實施例所示且其發泡密度為1.5〜 12PCF，厚度為1〜25腿；然後，於該發泡層的一面形成一 塑膠板；接著，於該發泡層的另一面形成一結合膜，該結 合膜係供該發泡層與該發泡面產生良好結合；其中，該結 合膜及塑膠板係以淋膜或層壓方式於分別形成於該發泡層 之兩相對面。據此，便可製作出如第四圖所示之底皮。 第十三圖係顯示製作第五圖所示之底皮的方法；首 先，提供一發泡層，其發泡密度為1, 5〜12PCF，厚度為1 〜25腿；然後，提供一第二塑膠圖膜，係具有可見之圖案； 接著，將該第二塑膠圖膜之一面結合於該發泡層的一面； 17 200817170 i1 过後於邊第一塑膠圖膜之另一面形成一塑膠板，該塑膠 板較該第二塑膠圖膜；最後，於該發泡層的另一面形 • 成、、、ϋ &膜，该結合膜係供該發泡層與該發泡面產生良好 結合。相似於上述之方法，該結合膜及塑膠板係以淋膜或 ·· 層壓方式於分別形成於該發泡層。 由上述說明可知，本發明的最大好處是，該發泡產品 形狀=形成及其發泡核心與該頂皮及第一塑膠圖膜之結合 是同時形成的，因而具有製造簡單、快速、及廉價之優點。 再者γ本發明之頂皮及第一塑膠圖膜與該發泡核心係可進 〆少藉該結合膜之形成，而產生良好結合且具有不易分離 的摄點。無論如何，這些產品因為其核心是由發泡顆粒所 構成的，所以具有重量輕的好處。再者，該頂皮、第一塑 膠圖膜及底皮更是可增加該發泡核心的結構強度而增長其 使用身叩。另外，印刷圖案或模製成型之立體圖案的呈現 更熊提昇适些產品的市場競爭力。更重要的是，本發明的 雙造過程相當簡單、快速。 細上所述’本發明之生產流程完全突破改革制 生多效率低、品質不良率劣化的問題，是一技術理念:的 . 高度發明，應符專利申請要件，爰依法提出申請。 18 200817170 【圖式簡單說明】 第一圖，係顯示本發明之一第一較佳實施例，其揭示 一發泡產品之部份剖面示意圖。 第二圖，係顯示本發明之一第二較佳實施例，其揭示 另一發泡產品之部份剖面示意圖。 第三圖，係顯示本發明之一第三較佳實施例，其揭示 一發泡產品包括一底皮。 弟四圖’係顯示該底皮之一較佳實施例。 弟五圖’係顯不该底皮之另一較佳實施例。 第六圖，係顯示本發明之一第四較佳實施例，其揭示 一發泡產品包括一發泡結構。 第七圖，係顯不本發明之一第五較佳實施例，其揭示 ^ 一發泡產品包括一發泡結構。 第八圖，係顯示該發泡產品之皮層係結合於一發泡基 板之頂面及周邊。 =九圖，係顯示製作本發明發泡產品的流程示意圖。 十圖，係顯示製作本發明第一塑膠圖膜的流程示意 圖。 第'Ή ^ 第圖，係顯示製作本發明塑膠膜的流程示意圖。 十一圖，係顯示製作本發明底皮的流程示意圖，以 ^ ‘作第四圖所示之底皮。 十二圖’係顯示製作本發明底皮的流程示意圖，以 製作第五圖所示之底皮。 19 200817170 【主要元件符號說明】 (1 )發泡產品 (1 0 0 )頂面 (1 0 2 )周邊 (1 1 )頂皮 (1 1 1 )第二結合膜 (1 2 0 )圖案 (1 a )發泡產品 (100a)頂面 (1 0 3 a )凹部 (1 1 a )頂皮 (12a)第一塑膠圖膜 (1 b )發泡產品 (1 1 b )頂皮 (1 3 )底皮 (1 3 1 )塑膠板 ·( 1 3 3 )第二塑膠圖膜 (2 )發泡結構 (2 0 0 )頂面 (2 0 2 )周邊 (10)發泡核心 (1 0 1 )底面 (1 0 3 )凹部 (110)發泡層 (12)第一塑膠圖膜 (1 2 1 )第一結合膜 (1 0 a )發泡核心 (1 0 2 a )周邊 (1 1 0 a )發泡層 (120a)圖案 (1 0 b )發泡核心 (12b)第一塑膠圖膜 (1 3 0 )發泡層 (1 3 2 )結合膜 (1 c )發泡產品 (2 0 )發泡基板 (2 0 1 )底面 (2 0 3 ) ( 2 0 3 d )容槽 (21)皮層 (22)(22d)塑膠薄板 (2 3 )結合膜 20The sixth drawing shows a fourth preferred embodiment of the present invention, and also discloses a foamed product (1 c ) which comprises not only the foam core of the first or second preferred embodiment (1, 1, 1) "), the top skin (ii, iia) and the first-plastic film (i 2, i 2 a ), further comprising a foamed structure (2) bonded to the foamed core (丄〇, 丄〇a) The bottom surface (working area 1, 1 0 1 a ). The foamed structure (2) comprises a foamed substrate (2 〇)' with a top surface (2〇0) and a bottom surface (2〇1) and a plurality of periphery (2 0 2 ) 'the bottom surface of the foamed substrate (2 〇) is bonded to the bottom surface UQ1 t 1 a ) of the foamed core (lG, 1Qa), wherein the 'the hair' package substrate (2 q) includes a plurality a foamed granule, and the foamed granules are closely bonded to each other; the foaming material of the foamed substrate (20) is similar to the material described in the above embodiment, such as PP, PE , PS, etc. Further, as shown in the sixth figure, the foamed product (丄C) may further comprise a second plastic egg m plate (2 2), which is fully integrated on the foamed substrate (2) 0) top surface (2 〇〇) and surrounding (2 〇 2); wherein the second plastic film or a plastic sheet (2 2) has a visible pattern, similar to the first plastic film previously described (1 2, 1 2 a, wherein the plastic plate is resistant Grinding material, and preferably having a thickness of Q 〇 3 to ^ 5 mm. Further, the foamed structure (2) may further comprise a bonding film (23) for the bottom surface of the foamed substrate (2Q) (20 1 The bottom surface (ii, work 0) of the foamed core (1 〇, 1 〇a ) is combined with good 13 200817170. The seventh and eighth figures show a fifth preferred embodiment of the present invention, Also disclosed is a foamed product (丄d) similar to the fourth preferred embodiment, which comprises a foamed core (1〇, 1〇3), a top skin (11, 113), and a first plastic film (1 2 And a foamed substrate (20) of the foamed structure (2), further comprising at least a skin layer (2) bonded to a top surface (200) of the foamed substrate (20); The top surface (20 〇) of the foamed substrate (2 〇) has at least one receiving groove (203) for accommodating the skin layer (2 1 ). Further, the foamed product (χ d ) may further comprise a second plastic film or a a plastic sheet (2 2 d ) for fully combining or covering the top surface (200) of the foamed substrate (20), the periphery (2 〇2) and the skin layer (2 1 ), wherein the second plastic The film or plastic sheet (2 2) is similar to the second plastic film or plastic sheet (2 2). As shown in the eighth figure, the top surface of the foamed substrate (2 〇) (2 〇〇) And the periphery (202) has interconnecting receptacles (2 〇 3 d ) for receiving the skin layer (2 1 ), and the skin layer (2 1 ) can also be used by the second plastic film or a plastic sheet ( 2 2 d) covered. In the fourth and fifth preferred embodiments, the second plastic film or plastic sheet (2 2, 2 2 d) may further comprise a bonding film (23 〇) for the second plastic drawing. The film or plastic sheet (2 2, 2 2 d) and the top surface (200) of the foamed substrate (20), the periphery (2 〇 2) and the skin layer (2 1 ) are well bonded. In detail, the structures of the fourth and fifth preferred embodiments of the present invention are actually partially combined with the finished products of the second embodiment of the second preferred embodiment; The fourth and fifth preferred embodiments show that the foamed structure (2) is completely bonded to the bottom surface (1 、1, 1 〇1 a ) of the foamed core (10, 10 a ), but The practical application is not limited thereto; for example, the foamed structure is bonded to a part of the bottom surface of the foamed core as needed. Further, the ninth drawing further shows a method of producing the above-mentioned foamed product; wherein the method comprises the following steps: a) providing a mold having a molding cavity inside the mold; wherein the mold is one of the moldable molds The first mold is composed of a second mold. The first mold and the second mold respectively have a first molding cavity and a second molding cavity for forming the molding cavity, and the molding cavity corresponds to the shape of the foamed product. In addition, the first mold is further connected with a first conveying pipe and a second conveying pipe, and is connected to the injection device by the first and second conveying pipes; the injection device comprises a barrel and a gas supply device, and The cartridge is connected to the first conveying pipe for injecting the foaming particles required for the subsequent step, such as foamed particles of related materials such as PP, PE, PS, etc.; and the gas supply device borrows the second conveying pipe and the mold Connection to supply hot vapor pressure. b) placing a first plastic film in the molding cavity; wherein the first plastic film is fixed in the mold in a manner sufficient to cover the molding cavity; for example, the first plastic is first The film is disposed on the second mold, and then the first mold and the second mold are combined, so that the first plastic film can be fixed in the mold. c) placing a suitable size and quantity of the top skin at a predetermined position on the inner surface of the first plastic film; 15 200817170 d) injecting an appropriate amount of foamed particles into the molding cavity; that is, driving the injection device and borrowing a first-wheel feeding tube, which sends the side particles into the mold; e) molding the hot vapor pressure into the crucible so that the foaming particles themselves, (4)-(iv)_ and the top skin are closely adjacent to each other Forming - foaming product: in more detail, that is, using the second conveying pipe, the gas pressure is appropriately reduced in the surface of the tool, and the three foaming particles are slightly expanded by the heat, and The foamed particles are made to be secret and pure, and are closely and completely free of each other without gaps, and #: these hairs are formed by mutual bonding, ::: The plastic film and the top skin are also closely bonded to each other; and the film f it is the first plastic = the top skin and the foaming surface; wherein The foamed granules are formed according to the forming cavity - the film and the top skin are combined; therefore, the heart 'and The foamed granule of the first plastic film forms the hair 2 and touches the first plastic film and the top layer. According to the above method, the foamed product such as the first image and the second image can be produced. . Further, the above method may further comprise a step of: =) bonding a - a skin to the foamed face; that is, a tie-up press-bonding the skin to the face. Therefore, in addition to the above products. In addition, this step can be used to produce a foaming product as shown in the third embodiment. As shown in the tenth figure, the first plastic film of the present invention can be completed by the following steps: 16 200817170; The plastic film has a visible pattern; then, a bonding film is formed on one side of the plastic film, and the bonding film is used to provide a good bond between the plastic film and the foamed particles. 1〜0。 The thickness of the film is formed on the one side of the plastic film to form a thickness of about 0. 01~0 A lmm bonding film which is the same as the bonding film in the above embodiment. The figure further shows that the patterned plastic film is formed by the following steps; firstly, a first film is provided; then, the pattern or color is formed on the first film by printing; Forming a second film on the first film by an extrusion or lamination method to cover the pattern, that is, the pattern is disposed between the first film and the second film. Figure 12 is a view showing a method of fabricating the base; first, a foamed layer is provided, which has a material as shown in the above embodiment and has a foaming density of 1.5 to 12 PCF and a thickness of 1 to 25 legs; Forming a plastic sheet on one side of the foam layer; then forming a bonding film on the other side of the foam layer, the bonding film is for the foam layer to form a good bond with the foaming surface; wherein the bonding film and the plastic film The plates are respectively formed on the opposite faces of the foamed layer by lamination or lamination. According to this, the bottom skin as shown in the fourth figure can be produced. The thirteenth figure shows the method of making the bottom skin shown in the fifth figure; firstly, a foaming layer having a foaming density of 1, 5 to 12 PCF and a thickness of 1 to 25 legs; and then providing a second The plastic film has a visible pattern; then, one side of the second plastic film is bonded to one side of the foam layer; 17 200817170 i1 then forms a plastic plate on the other side of the first plastic film. The plastic sheet is closer to the second plastic film; finally, the other side of the foam layer is formed into a film, and the film is used to provide a good bond between the foam layer and the foamed surface. Similar to the above method, the bonding film and the plastic sheet are separately formed on the foam layer by lamination or lamination. It can be seen from the above description that the biggest advantage of the present invention is that the shape of the foamed product = formation and the combination of the foamed core and the top skin and the first plastic film are simultaneously formed, thereby being simple, fast, and inexpensive to manufacture. The advantages. Further, γ of the top skin and the first plastic film of the present invention and the foamed core system can be formed by the formation of the bonding film, resulting in good bonding and having a separation point which is not easily separated. In any case, these products have the advantage of being lightweight because their core is composed of foamed granules. Moreover, the top skin, the first plastic film and the bottom skin can increase the structural strength of the foamed core and increase the use of the body. In addition, the appearance of printed patterns or molded three-dimensional patterns is more important for the market competitiveness of some products. More importantly, the dual manufacturing process of the present invention is relatively simple and fast. The above-mentioned production process completely breaks through the problems of low efficiency and low quality defect rate of reform and production, and is a technical concept: Highly invented, should meet the requirements of patent applications, and apply in accordance with the law. 18 200817170 BRIEF DESCRIPTION OF THE DRAWINGS The first drawing shows a first preferred embodiment of the present invention which discloses a partial cross-sectional view of a foamed product. The second drawing shows a second preferred embodiment of the present invention which discloses a partial cross-sectional view of another foamed product. The third figure shows a third preferred embodiment of the present invention which discloses that a foamed product comprises a base. The fourth figure shows a preferred embodiment of the base. The fifth figure shows another preferred embodiment of the bottom. Fig. 6 is a view showing a fourth preferred embodiment of the present invention, which discloses that a foamed product comprises a foamed structure. The seventh figure shows a fifth preferred embodiment of the present invention, which discloses that a foamed product comprises a foamed structure. The eighth figure shows that the skin layer of the foamed product is bonded to the top surface and the periphery of a foamed substrate. = Nine diagrams showing a schematic diagram of the process for making the foamed product of the present invention. Fig. 10 is a schematic flow chart showing the production of the first plastic film of the present invention. The first figure is a schematic flow chart showing the production of the plastic film of the present invention. The eleventh figure shows a schematic flow chart for making the base of the present invention, and is ‘the base shown in the fourth figure. The twelfth figure shows a schematic flow chart for making the base of the present invention to produce the base shown in the fifth figure. 19 200817170 [Description of main component symbols] (1) Foamed product (1 0 0) top surface (1 0 2 ) periphery (1 1 ) top skin (1 1 1 ) second bonding film (1 2 0 ) pattern (1 a) foamed product (100a) top surface (1 0 3 a) concave portion (1 1 a) top skin (12a) first plastic film (1 b) foamed product (1 1 b ) top skin (1 3 ) Bottom (1 3 1 ) plastic plate · ( 1 3 3 ) second plastic film (2 ) foam structure (200) top surface (2 0 2 ) peripheral (10) foam core (1 0 1 ) Bottom (1 0 3 ) recess (110) foam layer (12) first plastic film (1 2 1 ) first bonding film (10 a ) foam core (1 0 2 a ) periphery (1 1 0 a ) foam layer (120a) pattern (10b) foam core (12b) first plastic film (1 30) foam layer (1 3 2 ) bond film (1 c) foam product (2 0 ) Foamed substrate (2 0 1 ) bottom surface (2 0 3 ) ( 2 0 3 d ) cavity (21) skin layer (22) (22d) plastic sheet (2 3 ) bonding film 20