JP2000254992A - Foamed molding and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent a foamed molding comprising a foamed layer and a reinforcing material from becoming warped and the peeling of the foamed layer from the reinforcing material from occurring. SOLUTION: When the foamed molding is manufactured, a layer of foaming beads 30 is arranged on both first and second surface sides of a reinforcing material 13. Thus the foamed layers 11, 12 are molded by making the foaming beads 30 foam and at the same time, are firmly bonded to both first and second surfaces of the reinforcing material 13.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foam molded article comprising a resin foam layer and a reinforcing material for reinforcing the same, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, foam moldings 1 as shown in FIG. 6 have been used as interior materials for vehicles such as door trims and lids of glove boxes provided on instrument panels. The foamed molded article 1 is composed of a foamed layer 2 formed by foaming a resin and a reinforcing material 3 for reinforcing the foamed layer 2, and the foamed layer 2 and the reinforcing material 3 are fixed to each other.

[0003] In the case of manufacturing the foamed molded article 1 as described above, first, the reinforcing material 1 is placed in a cavity of a mold (not shown).
Is set in contact with the inner surface of the cavity. Thereafter, a resin to be foamed is charged into the cavity.
Then, the foamed layer 2 is formed by foaming the resin. During foaming, part of the resin melts. When the molten resin is solidified, the foam layer 2 and the reinforcing material 3 are fixed to each other, and the foam molded article 1 is manufactured.

[0004]

After the completion of molding, the foamed layer 2 slightly contracts with a decrease in temperature. On the other hand, the reinforcing material 3 hardly shrinks. For this reason, as shown in FIG.
Alternatively, there has been a problem that the warp causes the foam layer 2 and the reinforcing material 3 to peel off.

[0005]

In order to solve the above-mentioned problems, a foam molded article according to the present invention comprises a foam layer formed by foaming a resin and a plate-like reinforcing material for reinforcing the foam layer. By foaming the resin together with the reinforcing material in a mold, the foam layer is fixed to the foamed layer and the reinforcing material. It is characterized by being provided in. In this case, it is desirable that the thickness of the foam layers provided on both the front and back sides of the reinforcing material be substantially the same. It is desirable to form a through-hole into which the resin can enter, in the reinforcing material. Preferably, the foam layer and the reinforcing material are formed of the same material, and more preferably, a polypropylene resin. In order to solve the above problem, the manufacturing method according to the present invention comprises, after charging a resin and a reinforcing material to be foamed into a cavity of a mold, by foaming the resin, a foam layer fixed to each other. A method for producing a foamed molded article comprising a reinforcing material is characterized in that the resin is foamed in a state where the resin is arranged on both front and back surfaces of the reinforcing material. In this case, it is desirable that the thickness of the resin layer disposed on both the front and back surfaces of the reinforcing material be substantially the same. It is desirable to form a through-hole into which the resin can enter, in the reinforcing material. It is desirable to use the same material as the material of the resin and the reinforcing material,
More preferably, a polypropylene resin is used. It is desirable that the resin has a bead shape before foaming.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. FIG. 1 shows a foam molded article 1 according to one embodiment of the present invention. This foam molded article 1 is used as an interior material for a vehicle such as a door trim or a glove box lid, and includes two foam layers 11 and 12 and a reinforcing material 13 disposed therebetween. ing. In addition, the foam molded body 1 is formed in a simple rectangular flat plate shape, but is formed in an appropriate shape according to a use in actual use.

The foam layers 11 and 12 are made by foaming a resin, and give a soft touch. On the other hand, reinforcing material 1
Numeral 3 is for maintaining the shape-retaining property of the entire foam molded body 10, and foam layers 11 and 12 are fixed to both front and back surfaces thereof. Thereby, the foam layers 11, 12 and the reinforcing material 1
3 are integrated. Moreover, a through-hole 13a is formed in the reinforcing material 13, and the foamed layers 11, 12 and the reinforcing material 13 are further connected by connecting the foamed layers 11, 12 with each other by the resin that has entered the through-hole 13a. It is more firmly fixed. The foam layers 11, 12 and the reinforcing material 13 are desirably formed of the same resin, for example, an olefin-based resin, and more desirably formed of a polypropylene resin among them for the reasons described later.

FIGS. 2 and 3 show a foamed molded article 1 having the above-described structure.
FIG. 6 is a diagram illustrating an example of a manufacturing method for manufacturing the No. 0. In this manufacturing method, a pair of dies 21 and 22 are used.
A concave portion 21 a having a shape corresponding to the foamed molded body 10 is formed in one mold 21. By closing the recess 21 a with the other mold 22, a pair of molds 2 are formed.
A cavity 23 for molding the foamed molded body 10 is formed between 1 and 22.

When the foamed molded article 10 is molded using the pair of dies 21 and 22, first, as shown in FIG. 2A, the foamed layer 11 (or the foamed layer 12) is formed at the bottom of the recess 21a. ) Is charged. It is desirable to use a resin which is formed in a small ball shape in advance (hereinafter, referred to as foam beads 30). The size of the foam beads 30 is made smaller than the size so as to be able to enter the through holes 13 a of the reinforcing material 13. The foam beads 30 are spread all over the bottom of the recess 21a so as to form a uniform layer as a whole. The layer thickness of the spread foam beads 30 is adjusted so that the layer thickness after foaming is the same as the thickness of the foam layer 11.

Next, as shown in FIG.
The reinforcing material 13 is placed on the foamed beads 30 inserted in a. The reinforcing member 13 is positioned when its outer peripheral surface contacts the inner surface of the concave portion 21a. Thereafter, the foam beads 30 to form the foam layer 12 (or the foam layer 11) are formed.
Is placed in the concave portion 21a and is spread over the reinforcing member 13 in a layered manner. Of course, the layer thickness of the foam beads 30 is adjusted so that the layer thickness after foam molding is the same as the layer thickness of the foam layer 12. When the foam beads 30 are spread on the reinforcing material 13, some of the foam beads 30 enter the through holes 13a, and the reinforcing material 1
3 contacts the lower foam beads 30.

Next, the concave portion 21a is closed by the mold 22. Thereafter, steam or other high-temperature gas is supplied into the cavity 23 to foam the foam beads 30. Thereby, the foam layers 11 and 12 are formed. Here, at the time of foaming of the foam beads 30, their surfaces are melted and solidified after molding. Therefore, after the molding is completed, the expanded beads 3
0 is fixed to the reinforcing member 13. That is, the foam layers 11 and 12
Adhere to the reinforcing member 13. In this case, if the foam beads 30 and the reinforcing material 13 are made of the same material, the surfaces of the both are melted and fused, so that the foam layers 11, 12 and the reinforcing material 13 are firmly fixed. In addition, the foam beads 30 that have entered the through holes 13a are fixed to the foam beads 30 forming the foam layers 11 and 12, and the foam layers 11 and 12 are
Connect via 3a. Therefore, the foam layers 11, 12
And the reinforcing material 13 is further firmly fixed.

In the foamed molded article 10 produced by the above-described production method, the foamed layers 11 and
Since the foam layer 12 is fixed, even if the foam layers 11 and 12 shrink after the completion of molding, they do not warp as a whole. In particular, since the thicknesses of the foam layers 11 and 12 are the same, warpage due to shrinkage can be almost completely eliminated. Further, since no warpage occurs, the foamed layers 11, 12 and the reinforcing material 13 do not peel off. In particular, the foam layers 11, 12 and the reinforcing material 13
Are formed of the same resin, and a part of their surfaces are melted and fused at the time of foaming. Thereby, the foam layer 1
1, 12 and the reinforcing material 13 are more firmly fixed.
Moreover, the expanded beads 30 that have entered the through holes 13a
Connects the foam layers 11 and 12 to each other. Therefore, separation between the foam layers 11 and 12 and the reinforcing material 13 can be more reliably prevented. When the foam layers 11, 12 and the reinforcing material 13 are made of a polypropylene resin, the whole can be recycled without separating them.

Next, another embodiment of the manufacturing method of the present invention shown in FIGS. 4 and 5 will be described. In this embodiment, only differences from the above-described embodiment will be described, and the same components will be denoted by the same reference numerals and description thereof will be omitted.

In this embodiment, the reinforcing member 1 shown in FIG.
4 is used. The reinforcing member 14 is formed in a frame shape by forming a large through hole 14a at the center thereof, a small through hole 14b is formed on the inner peripheral side of each side, and a notch is formed on the outer peripheral side. (Through hole) 14c is formed.

Protrusions 14d and 14e are formed on the inner peripheral portions of both surfaces of the reinforcing member 14, respectively. Projection 1
The heights of 4d and 14e are almost the same as the thickness of the foam layers 11 and 12. Therefore, the distance from the tip of one protrusion 14d to the tip of the other protrusion 14e is the same as the depth of the recess 21a of the mold 21.

When a foamed molded article is manufactured using the above-described reinforcing material 14, as shown in FIG.
Is inserted into the concave portion 21a, and the concave portion 21a is closed by the mold 22. At this time, the outer peripheral surface of the reinforcing member 14 contacts the inner peripheral surface of the concave portion 21a, and the protruding portions 14d and 14e contact the bottom surface of the concave portion 21a and the mold 22. Thereby, the reinforcing material 14
Is fixed at the center of the concave portion 21a.

Thereafter, the foam beads 30 are charged into the cavity 23 from a charging port (not shown) formed in the mold 22. The inserted foam beads 30 not only enter between the reinforcing member 14 and the mold 22 but also penetrate the through holes 14a, 14a.
b and the notch 14c and the reinforcing member 14 and the recess 21
a between the bottom of a. The charging amount of the foam beads 30 is adjusted to an amount corresponding to the foam layers 11 and 12. next,
The foam beads 30 are foamed to obtain a foam molded article.

In the foam molded article manufactured as described above, since the foam layers 11 and 12 are integrally formed through the large through-holes 14a, the gap between the foam layers 11 and 12 and the reinforcing material 13 is formed. Peeling can be more reliably prevented.

[0019]

As described above, according to the present invention, it is possible to prevent the warpage of the foamed molded product and to prevent the peeling between the foamed layer and the reinforcing material. Can be

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one embodiment of a foam molded article according to the present invention.

FIG. 2 is a view for explaining a method for producing the foamed molded article shown in FIG. 1; FIG. 2 (A) shows a state in which foam beads for molding one foam layer are spread in a concave portion of a mold; Indicates that
FIG. 2B shows a state in which a reinforcing material is placed on the expanded beads, and FIG. 3C shows a state in which all the expanded beads are expanded after the expanded beads are spread on the reinforcing material. I have.

FIG. 3 is a perspective view showing a pair of molds and a reinforcing material used in the manufacturing method according to the present invention.

FIG. 4 is a perspective view showing another example of a reinforcing material used in the manufacturing method according to the present invention.

5A and 5B are views for explaining a manufacturing method using the reinforcing material shown in FIG. 4, wherein FIG. 5A shows a state in which the reinforcing material is mounted in a concave portion of a mold, and FIG. Indicates a state in which the foamed beads injected into the cavity are foamed.

FIG. 6 is a sectional view showing an example of a conventional foam molded article.

7 is a cross-sectional view showing a state in which the foam molded article shown in FIG. 6 is warped.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Foam molded object 11 Foam layer 12 Foam layer 13 Reinforcement 13a Through hole 14 Reinforcement 14a Through hole 14b Through hole 14c Notch (through hole) 21 Mold 22 Mold 23 Cavity 30 Foam beads (resin to be foamed)

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification code FI Theme coat ゛ (Reference) B29K 105: 04 F term (Reference) 4F100 AK01A AK01C AK07A AK07B AK07C BA03 BA06 BA10A BA10C BA16 DC11B DH00B DJ01A DJ01C DJ05A DJ05CEJ022 GB33 JK06 JL04 4F212 AA11 AD05 AD08 AD23 AG03 AG20 AH26 UA01 UB01 UB11 UB22 UF05 UG02 UG05

Claims (11)

[Claims] 1. A foamed layer formed by foaming a resin, and a plate-like reinforcing material for reinforcing the foamed layer, wherein the resin is foamed in a state of being charged in a mold together with the reinforcing material. And a foam molded article in which the foam layer and the reinforcing material are fixed, wherein the foam layer is provided on both front and back sides of the reinforcing material. 2. The foam molded article according to claim 1, wherein the thickness of the foam layers provided on both sides of the reinforcing material is substantially the same. 3. The foamed molded article according to claim 1, wherein a through-hole through which the resin can enter is formed in the reinforcing material. 4. The foam molded article according to claim 1, wherein said foam layer and said reinforcing material are formed of the same material. 5. The foam molded article according to claim 4, wherein said foam layer and said reinforcing material are formed of a polypropylene resin. 6. A method for producing a foam molded article comprising a foam layer and a reinforcing material fixed to each other by charging a resin to be foamed and a reinforcing material into a cavity of a mold and then foaming the resin. 3. The method for producing a foamed molded article according to claim 1, wherein the resin is foamed in a state where the resin is arranged on both front and back surfaces of the reinforcing material. 7. The method according to claim 6, wherein the thickness of the resin layer disposed on both the front and back surfaces of the reinforcing material is substantially the same. 8. The method according to claim 6, wherein a through-hole through which the resin can enter is formed in the reinforcing material. 9. The method according to claim 6, wherein the same material is used for the resin and the reinforcing material. 10. The method according to claim 9, wherein polypropylene is used as a material of the resin and the reinforcing material. 11. The method according to claim 6, wherein the shape of the resin before foaming is a ball.