【発明の詳細な説明】本発明は発泡性ポリプロピレン等の樹脂ビーズを型内で
加熱発泡せしめてなる成形体のうち、特に部分的に硬度
が異なるようにしたものに関する。DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a molded article formed by heat-foaming resin beads such as expandable polypropylene in a mold, particularly one having partially different hardness.
従来から５発泡剤を含んだ樹脂ビーズを型内で加熱発泡
せしめて一定の形に成形した発泡樹脂成形体は、軽量で
あるとともに、断熱性、耐衝撃性に優れるため、各種機
器の包装緩衝材、浮力材或いは自動車用部品等に用いら
れている。Foamed resin molded products, which are made by heating and foaming resin beads containing five foaming agents in a mold and molding them into a certain shape, are lightweight and have excellent heat insulation and impact resistance, so they are used as packaging cushions for various equipment. It is used for materials, buoyancy materials, automobile parts, etc.
しかしながら、発泡樹脂成形体を上記の如き用途として
用いる際、部分的に軟かくしなければならないとか、逆
に硬くしなければならない場合がある。このような場合
、従来にあっては、必要な硬度が要求される部分に、そ
の硬度を有する他の材料を貼り付けるようにしている。However, when a foamed resin molded article is used for the above purposes, it may be necessary to partially soften it or, conversely, to make it hard. In such cases, conventionally, another material having the required hardness is pasted on the part where the necessary hardness is required.
しかしながら、斯る手段によると製作が面倒であるばか
りでなく、接着部が剥れたり、接着部において折損しや
すくなるという不利がある。However, such a method is disadvantageous in that it is not only complicated to manufacture, but also that the adhesive portion is likely to peel off or break at the adhesive portion.
本発明者等は上述の如き従来の問題点に鑑み、これを有
効に解決すべく本発明をなしたものであり、その目的と
する処は、部分毎に要求される硬度が異なる場合であっ
ても、それに応じることができる発泡樹脂成形体を提供
するにある。In view of the above-mentioned conventional problems, the present inventors have devised the present invention to effectively solve the problems. The object of the present invention is to provide a foamed resin molded article that can meet these demands.
斯る目的を達成すべく本発明は、発泡樹脂成形体を、発
泡倍率の異なる発泡性ビーズを型内で発泡せしめること
で、連続する或いは層状をなす複数の硬度が異なる部分
によって構成したことをその要旨としている。In order to achieve such an object, the present invention proposes that a foamed resin molded article is made up of a plurality of continuous or layered parts having different hardness by foaming expandable beads with different expansion ratios in a mold. This is the summary.
以下に本発明の実施の一例を添付図面に従って詳述する
。An example of the implementation of the present invention will be described in detail below with reference to the accompanying drawings.
第１図は本発明に係る成形体としての自動車のインナパ
ネルを示したものであり、サイドライニング１は車室内
側への膨出部２を形成するとともに、この膨出部２の裏
側にダクトとなる溝３を形成している。そして上記膨出
部２の内側の約半分は発泡倍率の高い樹脂ビーズ、例え
ば発泡性ポリプロピレンビーズ４・・・によって構成さ
れ、他の部分５は発泡倍率の低い発泡性ポリプロピレン
ビーズ６によって構成し、運転者或いは同乗者の肘が泡
倍率の異なる発泡性ポリプロピレンビーズ４゜６を充填
し、同時に加熱発泡せしめればよい。FIG. 1 shows an inner panel of an automobile as a molded article according to the present invention, in which a side lining 1 forms a bulge 2 toward the inside of the vehicle interior, and a duct is provided on the back side of the bulge 2. A groove 3 is formed. Approximately half of the inside of the bulging portion 2 is made up of resin beads with a high expansion ratio, such as foamable polypropylene beads 4, and the other part 5 is made up of foamable polypropylene beads 6 with a low expansion ratio, The driver's or fellow passenger's elbow may be filled with foamable polypropylene beads 4.6 of different foam magnification and heated and foamed at the same time.
また第２図は成形体として自動車のインストルメントパ
ネルを示したものであり、インストルメントパネル７Ｖ
ｉ、薄く且つ硬度を必要とする部分、例えばデフロスタ
用の空気吹出口の取付部或いはメータ類の取付部８及び
グローブボックスの取付部９を発泡倍率の低い発泡性ポ
リプロピレンビーズ１０・・・によって構成し、その他
の部分１１を発泡倍率の高い発泡性ポリプロピレンビー
ズ１２・・・によって構成するようにしている。而して
メータ類等はインストルメントパネル７に強固に取り付
けることができるとともに、インストルメントパネル７
は緩衝材としても有効に作用する。Fig. 2 shows an automobile instrument panel as a molded body, and the instrument panel 7V
i. Parts that require thinness and hardness, such as the mounting part for the air outlet for the defroster, the mounting part 8 for meters, and the mounting part 9 for the glove box, are made of expandable polypropylene beads 10 with a low expansion ratio. However, the other portions 11 are made of expandable polypropylene beads 12 with a high expansion ratio. Therefore, meters etc. can be firmly attached to the instrument panel 7, and the instrument panel 7
also acts effectively as a buffer material.
上記インストルメントパネル７は第３図に示す如き装置
によって製造される。即ち装置１６は中空状の固定型１
４と中実の移動型１５．１６とからなり、これら型１４
．１５．１６の突き合せ面に成形用のキャビティ１７が
形成される。そして固定型１４の中空部１８内には蒸気
入口１９及び蒸気出口２０を取り付けるとともに、キャ
ビティ１７を形成する面には多数の孔２１・・・全穿設
している。また固定型１４には樹脂ビーズ注入バイブ２
２・・・全貫通して設け、これら注入パイプ２２の先端
がキャビティ１７内に臨むようにしており、更に仕切り
板２６を取り付けたシリンダユニット２４を固定型１４
の近傍に配設し、シリンダユニット２４の作動で仕切り
板２３がキャビティ１７内を区切るようにしている。The instrument panel 7 is manufactured by an apparatus as shown in FIG. That is, the device 16 is a hollow fixed mold 1.
4 and a solid moving mold 15.16, these molds 14
．． A molding cavity 17 is formed on the abutting surfaces of 15 and 16. A steam inlet 19 and a steam outlet 20 are installed in the hollow part 18 of the fixed mold 14, and a large number of holes 21 are completely bored in the surface forming the cavity 17. In addition, the fixed mold 14 has a resin bead injection vibe 2.
2...The injection pipes 22 are completely penetrated so that the tips of the injection pipes 22 face the inside of the cavity 17, and the cylinder unit 24 with the partition plate 26 attached is attached to the fixed mold 14.
The partition plate 23 partitions the inside of the cavity 17 by the operation of the cylinder unit 24.
以上において、先ずシリンダユニット２４゜２４を作動
せしめてキャビティ１７内を仕切り板２３．２６で区切
り、この仕切り板で区切られたキャビティ１７の中央区
画内には注入パイプ２２を介して発泡倍率の低い発泡性
ポリプロピレンビーズ１０・・・を充填し、両側の区画
内には発泡倍率の高い発泡性ポリプロピレンビーズ１２
・・・を充填する。In the above process, first, the cylinder unit 24 24 is operated, the inside of the cavity 17 is divided by partition plates 23 and 26, and the central section of the cavity 17 separated by the partition plates is filled with a material having a low foaming ratio through the injection pipe 22. Filled with expandable polypropylene beads 10..., expandable polypropylene beads 12 with a high expansion ratio are filled in the compartments on both sides.
Fill it with...
次いで、仕切板２６．２３’ｅ移動させてキャビティ１
７から拍き抜き、蒸気人口１９から１２０Ｃ程度の蒸気
を導入し、孔２１・・・を介してキャビティ１７内に蒸
気を送り込み、発泡性ポリプロピレンビーズ１０．１２
’ｅ加熱する。するとビーズ内の発泡剤が分解し、有機
ガス又はＮ２ガス等を発生し７ビーズ１０．１２は夫々
の発泡倍率でもって膨張する。その後型１５を図中上方
へ、また型１６を側方へ移動せしめることで、第２図に
示したインストルメントパネル７が得られる。Next, move the partition plates 26 and 23'e to open the cavity 1.
7, steam with a steam population of about 19 to 120C is introduced, and the steam is sent into the cavity 17 through the holes 21... to expandable polypropylene beads 10.12.
'eHeat. Then, the foaming agent in the beads decomposes and generates organic gas or N2 gas, and the 7 beads 10 and 12 expand with their respective expansion ratios. Thereafter, the mold 15 is moved upward in the figure, and the mold 16 is moved laterally, thereby obtaining the instrument panel 7 shown in FIG. 2.
第４図及び第５図はインナパネル２５及びインストルメ
ントパネル２６の別実施例を示すものであり、インナパ
ネル２５は車内側となる部分２７を高発泡ビーズ２８に
よって構成し、外側になる部分２９を低発泡ビーズ６０
によって構成し、層状をなすようにしている。またイン
ストルメントパネル２６は外側部分３１を低発泡ビーズ
３２によって構成し、充分な硬度を持たせるようにし、
またこの内側となる部分６６を高発泡ビーズ６４によっ
て構成して軟かくシ、前記同様に断面が層状をなすよう
にしている。4 and 5 show another embodiment of the inner panel 25 and the instrument panel 26. The inner panel 25 has a portion 27 on the inside of the vehicle made of highly foamed beads 28, and a portion 29 on the outside. The low foam beads 60
It is made up of layers and has a layered structure. In addition, the outer portion 31 of the instrument panel 26 is made of low foam beads 32 to have sufficient hardness.
The inner portion 66 is made of highly foamed beads 64 to be soft and have a layered cross section as described above.
このような層状の成形体を製造するには二工程で成形す
るか、又は発泡倍率の異なる複数の樹脂ビーズを予じめ
型内に積層しておき、一工程で成形すれば良い。第６図
に示すものは、同一型でこのような積層体を成形するた
めの有利な方法を示す。先ず、第６図イに示す如く型３
５．３６間のキャビティ３７に高発泡のポリプロピレン
ビーズ２８を充填し、加熱発泡せしめ、次いで第６図口
に示す如く型３６を移動し、この移動によって形成され
る空間内に低発泡のポリプロピレンビーズ３０を充填し
、加熱発泡せしめる。このようにすることで、硬度の異
なる部分が明確に区分けされ且つ一体的な成形体が得ら
れる。In order to produce such a layered molded article, it may be molded in two steps, or a plurality of resin beads with different expansion ratios may be laminated in advance in a mold and molded in one step. What is shown in FIG. 6 shows an advantageous method for molding such a laminate in the same mold. First, as shown in Figure 6A, type 3
5. Fill the cavity 37 between 36 and 36 with highly foamed polypropylene beads 28, heat and foam them, then move the mold 36 as shown in the opening in Figure 6, and fill the space formed by this movement with low foamed polypropylene beads. 30 and heated and foamed. By doing so, parts having different hardness can be clearly separated and an integral molded body can be obtained.
尚、以上の実施例にあっては発泡性樹脂ビーズとしてポ
リプロピレンを用いたものを説明したが、ポリスチレン
或いはポリエチレン等を用いてもよい。ただし、ポリプ
ロピレンは他の樹脂に比較し耐熱性、耐油性、耐薬品性
に優れ、且つ機械的強度も太きいため自動車のインスト
ルメントパネル或いはインナパネルには発泡性ポリプロ
ピレンビーズを用いることが最適である。In the above embodiments, polypropylene was used as the foamable resin beads, but polystyrene, polyethylene, etc. may also be used. However, polypropylene has superior heat resistance, oil resistance, and chemical resistance compared to other resins, and has greater mechanical strength, so it is best to use foamed polypropylene beads for automobile instrument panels or inner panels. be.
以上の説明で明らかな如く本発明によれば、発泡倍率が
夫々異なる発泡性ビーズを１つの型内で発泡せしめて連
続する或いは層状をなす硬度の異なる部分によって発泡
樹脂成形体を構成するようにしたので、異なる硬度の発
泡樹脂成形体を所定の形状に切′断したり削ったりして
貼着する必要がなく、且つ強度的にも優れた゛成形体を
得ることができ、更に製造も容易である等多大の利点を
有する。As is clear from the above description, according to the present invention, expandable beads having different expansion ratios are foamed in one mold, and a foamed resin molded body is constructed by continuous or layered parts having different hardness. Therefore, there is no need to cut or scrape foamed resin molded bodies of different hardness into predetermined shapes and paste them together, and it is possible to obtain a molded body with excellent strength, which is also easy to manufacture. It has many advantages such as:
図面は本発明の実施の一例を示すものであり、第１図は
本発明に係る成形体であるサイドライニングの一部の断
面図、第２図は同インストルメントパネルの断面図、第
３図は同インストルメントパネルを製造する装置の断面
図、第４図及び第５図は別実施例の断面図、第６図（イ
）及び（ロ）は層状の成形体の特殊な製造方法における
型の断面図である。尚、図面中１．７．２５．２６は発泡樹脂成形体、４，
６．１０，１２．２８．３０．３２゜３４は発泡性樹脂
ビーズ、５．８，９，２９゜３１は硬い部分、１１．２
７．３３は軟かい部分、１４．１５．１６，３５．３７
Ｓは型である。２３９（）Ｌｒ＞ＮＱ：））〜へThe drawings show an example of the implementation of the present invention, and FIG. 1 is a cross-sectional view of a part of the side lining, which is a molded article according to the present invention, FIG. 2 is a cross-sectional view of the same instrument panel, and FIG. 4 and 5 are sectional views of another embodiment, and FIGS. 6 (a) and 6 (b) are molds in a special manufacturing method for a layered molded body. FIG. In addition, 1.7.25.26 in the drawing is a foamed resin molded product, 4,
6.10, 12.28.30.32゜34 are foamed resin beads, 5.8, 9, 29゜31 are hard parts, 11.2
7.33 is the soft part, 14.15.16, 35.37
S is type. 239 () Lr>NQ:) ) to ~
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP57055012AJPS58171946A (en) | 1982-04-02 | 1982-04-02 | Foamed resin molded body |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP57055012AJPS58171946A (en) | 1982-04-02 | 1982-04-02 | Foamed resin molded body |
| Publication Number | Publication Date |
|---|---|
| JPS58171946Atrue JPS58171946A (en) | 1983-10-08 |
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP57055012APendingJPS58171946A (en) | 1982-04-02 | 1982-04-02 | Foamed resin molded body |
| Country | Link |
|---|---|
| JP (1) | JPS58171946A (en) |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4756859A (en)* | 1985-05-31 | 1988-07-12 | Plastbau A.G. | Method for manufacturing elements of expanded synthetic material having layers of particularly high strength and a plant for implementing said method |
| US5466405A (en)* | 1992-12-18 | 1995-11-14 | Gerb. Happich Gmbh | Method for the manufacture of a sun visor |
| JP2009286031A (en)* | 2008-05-30 | 2009-12-10 | Asahi Kasei Kk | Method of manufacturing expanded resin material and molding machine used for this method |
| WO2018105394A1 (en)* | 2016-12-07 | 2018-06-14 | 三菱電機株式会社 | Foamed heat-insulating material production method and foamed heat-insulating material |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5147966A (en)* | 1974-10-23 | 1976-04-24 | Tokai Kogyo Co Ltd | Nan hankoshitsusokaranaru kutsushontaino dojiitsutaiseikeiho oyobi sochi |
| JPS54110286A (en)* | 1978-02-17 | 1979-08-29 | Sekisui Plastics | Coomolding product from different raw materials |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4756859A (en)* | 1985-05-31 | 1988-07-12 | Plastbau A.G. | Method for manufacturing elements of expanded synthetic material having layers of particularly high strength and a plant for implementing said method |
| US5466405A (en)* | 1992-12-18 | 1995-11-14 | Gerb. Happich Gmbh | Method for the manufacture of a sun visor |
| JP2009286031A (en)* | 2008-05-30 | 2009-12-10 | Asahi Kasei Kk | Method of manufacturing expanded resin material and molding machine used for this method |
| WO2018105394A1 (en)* | 2016-12-07 | 2018-06-14 | 三菱電機株式会社 | Foamed heat-insulating material production method and foamed heat-insulating material |
| CN110023386A (en)* | 2016-12-07 | 2019-07-16 | 三菱电机株式会社 | Manufacturing method of foamed thermal insulation material and foamed thermal insulation material |
| JPWO2018105394A1 (en)* | 2016-12-07 | 2019-07-18 | 三菱電機株式会社 | Method for producing foam insulation and foam insulation |
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