Manufacturing method and manufacturing device for foamed synthetic resin molded products

Abstract

To provide a method and device for manufacturing a foamed synthetic resin molded product that can easily remove unnecessary portions of the foamed synthetic resin molded product.SOLUTION: The method for manufacturing a foamed synthetic resin molded product 10 includes an application process of applying a liquid that swells a foamed synthetic resin to a foamed synthetic resin protrusion 12 formed protruding from the foamed synthetic resin molded product 10.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates to a method and an apparatus for producing a foamed synthetic resin molded product. [Background technology]

[0002] As a manufacturing method and manufacturing apparatus for foamed synthetic resin molded products, Patent Document 1 discloses a trimming method and trimming apparatus that can use an ultrasonic cutter to remove burrs (unnecessary parts) formed when manufacturing foamed synthetic resin molded products (urethane foam molded products). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2008-207391 A Summary of the Invention [Problem to be solved by the invention]

[0004] The manufacturing method and manufacturing device for foamed synthetic resin molded products disclosed in the above-mentioned Patent Document 1 have a problem in that it is difficult to cut off relatively hard burrs (unnecessary parts) with an ultrasonic cutter.

[0005] The present invention has been made to solve the above-mentioned problems, and has an object to provide a method and an apparatus for manufacturing foamed synthetic resin molded products, which can easily remove unnecessary portions of foamed synthetic resin molded products. [Means for solving the problem]

[0006] In order to solve the above problems, the manufacturing method of the foamed synthetic resin molded product of the present invention is characterized by including a coating step of coating a foamed synthetic resin protrusion formed by protruding from the foamed synthetic resin molded product with a liquid that swells the foamed synthetic resin.

[0007] According to the manufacturing method of the foamed synthetic resin molded product of the present invention, when the protruding portion of the foamed synthetic resin molded product is an unnecessary portion, the protruding portion of the foamed synthetic resin molded product is swelled by applying a liquid that swells the foamed synthetic resin in the application step, so that the swollen protruding portion, i.e., the unnecessary portion, can be easily removed. Therefore, it is possible to provide a manufacturing method of the foamed synthetic resin molded product that can easily remove the unnecessary portion of the foamed synthetic resin molded product.

[0008] In the method for producing a foamed synthetic resin molded product according to the present invention, it is preferable that the liquid is applied to the foamed synthetic resin molded product in a state where the foamed synthetic resin molded product is placed on a member in the application step, which makes it possible to appropriately apply the liquid to the protruding portion of the foamed synthetic resin molded product.

[0009] In the method for producing a foamed synthetic resin molded product according to the present invention, it is preferable that in the application step, the liquid is applied to the wall surface of the member on which the foamed synthetic resin molded product can be placed with the protruding portion in contact with the wall surface of the member. This makes it possible to reliably support the protruding portion by the wall surface of the member, and makes it possible to more appropriately apply the liquid to the protruding portion supported by the wall surface of the member.

[0010] In the manufacturing method of the foamed synthetic resin molded product according to the present invention, the member is a metal mold for molding the foamed synthetic resin molded product, and the coating step is preferably carried out after the molding step of molding the foamed synthetic resin molded product using the metal mold. This makes it possible to add the coating step by utilizing conventional manufacturing equipment for molding foamed synthetic resin molded products using a metal mold as it is.

[0011] In the method for producing a foamed synthetic resin molded product according to the present invention, it is preferable that the protruding portion is formed with a recess capable of receiving the liquid, so that the recess can reliably receive the liquid that swells the foamed synthetic resin, and the liquid can be reliably dispensed to the protruding portion.

[0012] In addition, in the method for producing a foamed synthetic resin molded product according to the present invention, it is preferable to further provide a groove for cutting off the protruding portion. With this, the groove makes it possible to reliably cut off the protruding portion.

[0013] In the method for producing a foamed synthetic resin molded product according to the present invention, it is preferable to apply the liquid by spraying in the application step. This makes it possible to apply the liquid that swells the foamed synthetic resin appropriately and reliably to a desired area. Furthermore, by controlling the supply amount of the liquid to be sprayed, it becomes possible to reliably control the application amount of the liquid that swells the foamed synthetic resin, making it possible to apply the desired amount appropriately and reliably.

[0014] In addition, the manufacturing apparatus for foamed synthetic resin molded products according to the present invention is characterized in that it is provided with an application section that applies a liquid that swells the foamed synthetic resin to a foamed synthetic resin protrusion formed by protruding from the foamed synthetic resin molded product.

[0015] According to the manufacturing device for foamed synthetic resin molded products of the present invention, when the protruding portion of the foamed synthetic resin molded product is an unnecessary portion, the application unit applies a liquid that swells the foamed synthetic resin to the protruding portion of the foamed synthetic resin molded product to cause it to swell, so that the swollen protruding portion, i.e., the unnecessary portion, can be easily removed. Therefore, it is possible to provide a manufacturing device for foamed synthetic resin molded products that can easily remove the unnecessary portion of the foamed synthetic resin molded product.

[0016] In addition, the manufacturing apparatus for foamed synthetic resin molded products according to the present invention preferably further comprises a groove forming unit for forming a groove for cutting off the protruding portion, whereby the groove forming unit can reliably and easily form the groove, and thus the protruding portion can be reliably cut off by the groove. Effect of the Invention

[0017] According to the present invention, it is possible to provide a method and an apparatus for manufacturing a foamed synthetic resin molded product, which can easily remove unnecessary portions of the foamed synthetic resin molded product. [Brief description of the drawings]

[0018] [Figure 1A] 1 is a plan view showing one embodiment of a foamed synthetic resin molded product 10 manufactured by a method for manufacturing a foamed synthetic resin molded product 10 according to the present invention. [Figure 1B] 1B is a cross-sectional view taken along line 1B-1B of the foamed synthetic resin molded product 10 shown in FIG. 1A. [Figure 2A] 1 is a plan view showing an intermediate molded product 15 of a foamed synthetic resin molded product 10. FIG. [Figure 2B] 2B is a cross-sectional view taken along line 2B-2B of the intermediate molded product 15 shown in FIG. 2A. [Diagram 3] 1 is a cross-sectional view showing a method for producing a foamed synthetic resin molded product 10 according to the present invention (a step of injecting raw urethane foam material). [Figure 4] 1 is a cross-sectional view showing a method for producing a foamed synthetic resin molded product 10 according to the present invention (foaming step). [Diagram 5] 1 is a cross-sectional view showing a method for producing a foamed synthetic resin molded product 10 according to the present invention (foaming step). [Figure 6] 1 is a cross-sectional view showing a method for producing a foamed synthetic resin molded product 10 according to the present invention (a coating step). [Figure 7] 1 is a cross-sectional view showing a method for producing a foamed synthetic resin molded product 10 according to the present invention (a coating step). [Figure 8] 1 is a cross-sectional view showing a method for producing a foamed synthetic resin molded product 10 according to the present invention (a coating step). [Figure 9] 1 is a cross-sectional view showing a method for producing a foamed synthetic resin molded product 10 according to the present invention (demolding step). [Figure 10] 1 is an explanatory diagram showing a manufacturing apparatus 30 for a foamed synthetic resin molded product 10 according to the present invention. [Figure 11] 1 is a side view showing one embodiment of an adsorption device 60 of an apparatus 30 for producing a foamed synthetic resin molded product 10 according to the present invention. [Figure 12] 1 is a side view showing an embodiment of a gripping device 70 of a manufacturing apparatus 30 for a foamed synthetic resin molded product 10 according to the present invention. [Figure 13] 2 is a cross-sectional view showing a groove forming section 24 of an apparatus 30 for manufacturing a foamed synthetic resin molded product 10 according to the present invention. FIG. [Figure 14] 2 is a cross-sectional view showing another embodiment of the foamed synthetic resin molded product 10 according to the present invention. [Figure 15] 2 is a plan view showing an intermediate molded product 115 of the foamed synthetic resin molded product 10. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Hereinafter, an embodiment of a method and an apparatus for manufacturing a foamed synthetic resin molded product 10 according to the present invention will be described with reference to the drawings. However, the present invention is not limited to this embodiment, and can be embodied in various forms with various modifications and improvements based on the knowledge of those skilled in the art.

[0020] (Foamed synthetic resin moldings) As shown in Fig. 1, the foamed synthetic resin molded product 10 is a molded product having a foamed synthetic resin part. The foamed synthetic resin molded product 10 may or may not have an embedded member. In this embodiment, the foamed synthetic resin molded product 10 does not have an embedded member (insert member). The embedded member is a member that is embedded in the foamed synthetic resin molded product.

[0021] In this embodiment, the foamed synthetic resin molded product 10 is molded using a metal mold 20. The foamed synthetic resin molded product 10 does not have to be integrally molded using a metal mold, and may be integrally molded, for example, by laminating foamed synthetic resin (for example, using a 3D printer or a foamed synthetic resin spraying device). The foamed synthetic resin molded product 10 may be formed by manufacturing a foamed synthetic resin molded product main body provided with an embedding portion for embedding an embedding member in advance, and then embedding the embedding member in the embedding portion.

[0022] The foamed synthetic resin molded product 10 is intended to be used as a base material for vehicle interior components such as a seat back, which is a backrest portion of a seat, and a seat cushion, which is a seating portion of a seat. In this embodiment, a seat cushion is taken as an example of the foamed synthetic resin molded product 10. As shown in FIG. 1A, the seat cushion 10 is formed in a substantially rectangular shape, and as shown in FIG. 1B, the seat cushion 10 has a predetermined thickness. The seat cushion 10 is molded using a mold 20.

[0023] The foamed synthetic resin molded product 10 is formed by foaming a foamed synthetic resin raw material. The foamed synthetic resin molded product 10 is made of a porous synthetic resin (foamed synthetic resin) with fine air bubbles retained inside, and is a foam with a synthetic resin skeleton. For the foamed synthetic resin, urethane foam (polyurethane foam) made from polyurethane can be used. The urethane foam may be soft polyurethane foam, hard polyurethane foam, or semi-hard polyurethane foam. For the foamed synthetic resin, foamed synthetic resin such as polyethylene foam, EVA foam, or melamine resin foam can be used. Polyethylene foam is made from polyethylene, and EVA foam is made from ethylene vinyl acetate copolymer. Melamine resin foam is made from a synthetic resin produced by polycondensation of melamine and formaldehyde.

[0024] For example, the urethane foam raw material contains polyol, polyisocyanate, a blowing agent, a catalyst, etc., and is a known material that foams by the reaction of polyol and polyisocyanate, and has a density of 40 kg / m 3 ~95kg / m 3 It is preferable to use a material that forms a urethane foam.

[0025] In the middle of the manufacturing process of the foamed synthetic resin molded product (seat cushion) 10, which is the final product, an intermediate molded product 15 made of foamed synthetic resin, which is an intermediate product, is formed. That is, the intermediate molded product 15 is processed to finally form the foamed synthetic resin molded product 10. As shown in Figs. 2A and 2B, the intermediate molded product 15 includes a main body 11 (which will finally become the foamed synthetic resin molded product 10) and a protruding portion 12. The protruding portion 12 is provided so as to protrude outward from the main body 11. The protruding portion 12 is a portion made of foamed synthetic resin formed so as to protrude from the foamed synthetic resin molded product 10. Therefore, the protruding portion 12 is cut off from the intermediate molded product 15 to finally form the foamed synthetic resin molded product 10.

[0026] Furthermore, the protruding portion 12 is formed with a recess 13 capable of receiving a liquid (hereinafter, sometimes referred to as a swelling liquid) that swells the foamed synthetic resin. This allows the recess 13 to reliably receive the swelling liquid, and the swelling liquid received by the recess 13 can be reliably administered (permeated (impregnated)) to the protruding portion 12. Specifically, the recess 13 is preferably formed so as to open upward. This allows the swelling liquid to be easily supplied to the recess 13 and thus to the protruding portion 12. In addition, the recess 13 is preferably formed so as to be able to store only a predetermined amount of swelling liquid. This allows the swelling liquid to be reliably prevented from reaching the main body 11 by simply supplying a predetermined amount of swelling liquid, which is a liquid amount equal to or less than the amount of liquid that can be stored, to the recess 13, and allows the protruding portion 12 to swell sufficiently. In addition, the protruding portion 12 is preferably substantially plate-shaped (approximately rectangular in cross section). This allows the swelling liquid to permeate early and uniformly in the thickness direction. One or more protrusions 12 are provided partially around the periphery of the main body 11, and are formed corresponding to protrusion forming portions 23 of the mold 20 described later.

[0027] Furthermore, the intermediate molded product 15 may be provided with a groove 14 for separating the protruding portion 12 (see FIG. 13). The groove 14 is preferably formed at the base end of the protruding portion 12, and the thickness of the protruding portion 12 having the groove 14 formed therein is made thinner than the thickness of the protruding portion 12 not having the groove 14 formed therein. This makes it possible to prevent the swelling liquid from passing through the thin portion having the groove 14 and infiltrating into the main body 11. As a result, only the protruding portion 12 on the tip side of the groove 14 is caused to swell, and the protruding portion 12 can be accurately and easily separated along the groove 14.

[0028] (Manufacturing method for foamed synthetic resin molded products (manufacturing process)) Next, a method (manufacturing process) for producing the foamed synthetic resin molded product 10 described above will be described with reference to Figs. 3 to 10. In this embodiment, a case where a mold 20 is used for production will be described. The method (manufacturing process, molding process) for producing the foamed synthetic resin molded product 10 includes a urethane foam raw material injection process (Fig. 3), a foaming process (Figs. 4 and 5), a coating process (Figs. 6 to 8), and a demolding process (Fig. 9). The mold 20 has two or more divided molds, i.e., at least a cavity (concave mold) 21 and a core (convex mold) 22.

[0029] (Urethane foam raw material injection process) In the urethane foam raw material injection process, a required amount of urethane foam raw material (foamed synthetic resin raw material) 10a is injected into a mold 20 (cavity 21 in this embodiment) (see FIG. 3). The injection amount of urethane foam raw material 10a is determined so that the density of the urethane foam formed by foaming is a predetermined density (for example, 40 kg / m 3 ~95kg / m 3 ) is preferably used. With mold 20 (core 22 in this embodiment) open, urethane foam raw material 10a is injected into mold 20, and then cavity 21 and core 22 are closed (see FIG. 4). If mold 20 has a raw material injection port (not shown), urethane foam raw material 10a can be injected into mold 20 through the raw material injection port with mold 20 closed, thereby forming the molded product.

[0030] (Foaming process) In the foaming process, the urethane foam raw material 10a is foamed in the mold 20 by the progress of reaction to form the intermediate molded product 15. The urethane foam raw material 10a foams in the space 20a between the cavity 21 and the core 22, filling the space 20a, and the main body 11 of the intermediate molded product 15 is formed. The foamed urethane foam raw material 10a further enters the protrusion forming portion 23 formed between the cavity 21 and the core 22 and fills the protrusion forming portion 23, forming the protrusion 12 of the intermediate molded product 15. The protrusion forming portion 23 is preferably provided in an air escape flow path for releasing the gas in the space 20a to the outside, at the boundary between the molds 21 and 22, at the raw material injection port, etc. The foaming process described above can be said to be a molding process in which the main body 11 of the intermediate molded product 15, i.e., the foamed synthetic resin molded product 10, is molded using the mold 20.

[0031] (coating process) Next, a coating process is performed in which a swelling liquid that causes the foamed synthetic resin to swell is applied to the protrusion 12 to cause it to swell (see FIG. 7). The swelling liquid swells the foamed synthetic resin by penetrating into the numerous pores formed in the foamed synthetic resin. The swelling liquid is preferably a solvent that is as polar as the polar molecular bonds that form the foamed synthetic resin, and the polar swelling liquid is attracted to the polar molecular bonds of the foamed synthetic resin, so it penetrates into the numerous pores formed in the foamed synthetic resin.

[0032] In this embodiment, the foamed synthetic resin is made of polyurethane and has a urethane bond (-NH·CO·O-). The swelling liquid preferably has a polarity that attracts the urethane bond, and for example, ethanol is used. Ethanol is represented by CH3CH2OH, has a polar hydroxyl group (R-OH), and has polarity as a whole. Incidentally, water (H2O) also has polarity, but does not swell the foamed synthetic resin because it has high hydrophilicity and low non-hydrophilicity. The swelling liquid is preferably a solvent with low hydrophilicity and high non-hydrophilicity, and for example, limonene (a monocyclic monoterpene), orange oil containing limonene, or a monoterpene other than limonene may be used. Limonene is represented by CH3-C6H8-C(CH3)=CH2, has polarity as a whole, and is highly non-hydrophilic. Monoterpene is one of the classifications of terpenes, contains two isoprene units, and is C 10 H 16 It has the molecular formula: Monoterpenes can be linear (acyclic) or cyclic. Other monoterpenes besides limonene include geranyl diphosphate, cineole, and pinene.

[0033] In this embodiment, the swelling liquid is applied by spray application. The spray application is performed by a spray device 50 (application device). The spray device 50 can spray the swelling liquid in the storage tank from a nozzle 51. The nozzle 51 has high directivity and can spray the swelling liquid accurately to a desired range. Furthermore, the nozzle 51 can spray a desired amount of swelling liquid accurately. It is also possible to use a nozzle with low directivity, and in this case, it is preferable to adopt a cover that can cover the desired range. In addition, as the application method, application with a brush or the like, application by injection using an injector (syringe), application by immersion, application by electrostatic coating, or other application methods can be adopted.

[0034] The hardness (hardness) of the main body 11 and the protrusions 12 of the intermediate molded product 15 is ILD25% 50 to 150 N (Newtons), and the hardness of the swollen protrusions 12 is ILD25% 30 to 100 N (Newtons). The hardness can be measured by a hardness test specified in 6.7 "D method (method of determining the force after 20 seconds of constant compression of 25%)" of JIS K6400-2 (Soft foamed materials-Physical properties-Part 2: Method of determining hardness and compressive stress-strain characteristics).

[0035] In the application step, it is preferable to apply the swelling liquid in a state where the main body 11 of the intermediate molded product 15, i.e., the foamed synthetic resin molded product 10, is placed in a metal mold 20 (member). Specifically, in the application step, it is more preferable to apply the swelling liquid in a state where the protruding portion 12 is in contact with the wall surface of the metal mold 20 (member) in which the main body 11 of the intermediate molded product 15, i.e., the foamed synthetic resin molded product 10 can be placed.

[0036] In the application step, as shown in Fig. 6, the core 22 is opened and the mold 20 is in an open state (mold open). Then, as shown in Fig. 7, a predetermined amount of the swelling liquid described above is supplied (sprayed) from the nozzle 51 to the recess 13. The swelling liquid stored in the recess 13 impregnates the protrusion 12, and the protrusion 12 is swelled by the swelling liquid (see Fig. 8). The swollen protrusion 12 is soft and brittle compared to the main body 11.

[0037] The above-mentioned application step is preferably carried out after the foaming step, which is a molding step in which the body 11 of the intermediate molded product 15, i.e., the foamed synthetic resin molded product 10, is molded using the mold 20. The mold 20 is a member in which the body 11 of the intermediate molded product 15, i.e., the foamed synthetic resin molded product 10, is placed in order to apply the swelling liquid in the application step. The foamed synthetic resin molded product 10 can be placed inside or outside the member. In this embodiment, the mold 20 is adopted as one embodiment of the member, but is not limited thereto, and any container in which the body 11 of the intermediate molded product 15, i.e., the foamed synthetic resin molded product 10, is placed in order to apply the swelling liquid can be adopted as the member.

[0038] (Demolding process) In the demolding step, the main body 11 of the intermediate molded product 15, i.e., the foamed synthetic resin molded product 10, is taken out. At this time, the foamed synthetic resin molded product 10 may be held by being sucked by the suction device 60, or may be held by the gripping device 70. For example, it is preferable that the suction device 60 is of a negative pressure type (vacuum type) and the gripping device 70 is of a robot hand type, and both the suction device 60 and the gripping device 70 are end effector units that can be attached to the tip of a robot (robot arm). It is also possible to turn the mold 20 (cavity 21) upside down and point the opening of the cavity 21 downwards so that the main body 11 of the intermediate molded product 15 falls by its own weight without using an end effector unit.

[0039] When the main body 11 is removed, the main body 11 is separated from the cavity 21, but a part of the protrusion 12 is likely to adhere to the wall surface of the cavity 21 (indicated by a dashed line in FIG. 9). Furthermore, when the main body 11 is moved away from the cavity 21, the swollen and brittle protrusion 12 can be separated from the main body 11. At this time, the groove portion 14 functions to make it easier to separate the protrusion 12 from the main body 11. That is, the protrusion 12 can be easily separated from the main body 11 by the groove portion 14. The separated protrusion 12 either remains adhered to the wall surface of the cavity 21, or is separated during the movement associated with the removal of the main body 11, and falls into the cavity 21, etc.

[0040] Furthermore, if the protrusion 12 is not separated from the main body 11 when the main body 11 is removed, the protrusion 12 may be separated from the main body 11 after the main body 11 is removed. At this time, the protrusion 12 is fragile, so it can be blown off with an air blower or easily torn off by an operator manually or using a tool. Furthermore, the protrusion 12 may be separated from the main body 11 by the above-mentioned method using a robot equipped with a robot hand as an end effector part of a robot arm.

[0041] (Production equipment for foamed synthetic resin moldings) Furthermore, the manufacturing apparatus 30 for the foamed synthetic resin molded product 10 described above will be described with reference to Fig. 10 to Fig. 12. The manufacturing apparatus 30 is a manufacturing apparatus for manufacturing the foamed synthetic resin molded product 10, and includes a mold 20 and a robot 40. An application device 50, a suction device 60, and a gripping device 70 can be detachably attached (mounted) to the robot 40 as end effectors.

[0042] As described above, the mold 20 has the cavity 21 and the core 22. The mold 20 has the protrusion forming portion 23 (see FIG. 4). The mold 20 has the groove forming portion 24 for forming the groove 14 (see FIG. 13). The groove forming portion 24 is provided in the protrusion forming portion 23. In this embodiment, the groove forming portion 24 is provided so as to protrude from the wall surface of the cavity 21, but it may be provided so as to protrude from the wall surface of the core 22.

[0043] As shown in FIG. 10, the robot 40 is a so-called articulated robot, and is a vertical articulated robot having six drive axes. The robot 40 is a so-called serial link type robot arm in which a plurality of drive axes (or arms) are arranged in series. The robot 40 operates an end effector attached to the tip to a desired position and angle. In FIG. 10, a coating device 50 is attached as the end effector. The robot 40 is not limited to a vertical articulated robot, and a horizontal articulated robot, an orthogonal robot, a parallel link robot (SCARA robot), etc. may also be used.

[0044] The coating device 50 is a device suitable for use in the coating step described above. The coating device 50 is a coating section that coats the foamed synthetic resin protruding portion 12 formed by protruding from the foamed synthetic resin molded product 10 with a liquid that swells the foamed synthetic resin. For example, a spray device can be used as the coating device 50. As shown in FIG. 10, the coating device 50 includes a nozzle 51 that sprays the swelling liquid, and a main body 52 that has a pressure-feeding section (not shown) that pressure-feeds the swelling liquid from a storage tank (not shown) that stores the swelling liquid to the nozzle 51.

[0045] The operation of the coating device 50 will be described. The coating device 50 is moved from the original position to a predetermined coating position by the robot 40. The pressure feed unit is driven and the swelling liquid in the storage tank is sprayed from the nozzle 51. Since the nozzle 51 has high directionality, it is possible to spray a predetermined amount of swelling liquid with good precision onto the desired coating range, i.e., the protruding portion 12, and especially the recessed portion 13. This allows the protruding portion 12 to swell. Thereafter, the coating device 50 is moved from the predetermined coating position back to the original position by the robot 40.

[0046] The suction device 60 is an apparatus suitable for use in the demolding step described above. As shown in Fig. 11, the suction device 60 includes a suction section 61 for suctioning an object to be suctioned (in this embodiment, the main body 11 of the intermediate molded product 15, and thus the foamed synthetic resin molded product 10), and a main body 62 having a negative pressure section (not shown).

[0047] The operation of the suction device 60 will be described. The suction device 60 is moved from the original position to a predetermined suction position (a position where the suction part 61 contacts the main body 11) by the robot 40. The negative pressure part of the suction device 60 moved to the suction position is driven, and the suction part adheres to the main body 11 and grasps the main body 11. Thereafter, the suction device 60 is moved to a predetermined destination by the robot 40 while still adhering to the main body 11.

[0048] The gripping device 70 is a device suitable for use in the demolding step described above. As shown in Fig. 12, the gripping device 70 includes a pair of claws 71, 71 for pinching and gripping an object to be gripped (in this embodiment, the main body 11 of the intermediate molded product 15 or the protruding portion 12 remaining on the main body 11), and a main body 72 having a drive unit (not shown) for driving the pair of claws 71, 71.

[0049] The operation of the gripping device 70 will be described. The gripping device 70 is moved from an original position to a predetermined gripping position by the robot 40. The drive unit is driven, and the pair of claws 71, 71 are in an open state (shown by solid lines in FIG. 12). The drive unit of the gripping device 70 moved to the gripping position is driven, and the pair of claws 71, 71 in the open state are closed, and the gripping device 70 clamps and grabs the object to be gripped. The gripping device 70 is then moved to a predetermined destination by the robot 40 while still clamping the object to be gripped.

[0050] In the above-described manufacturing apparatus 30, the coating device 50 and the suction device 60 or the gripping device 70 are attached to the robot 40, but the present invention is not limited to this, and the coating device 50 and the suction device 60 or the gripping device 70 may be installed separately. In the above-described embodiment, the coating device 50 and the suction device 60 or the gripping device 70 are attached to different robots 40, but they may be attached to one robot 40 together.

[0051] (Actions and Effects of the Embodiments) The manufacturing method of the foamed synthetic resin molded product 10 according to the above-mentioned embodiment includes a coating process in which a liquid that swells the foamed synthetic resin is applied to the foamed synthetic resin protrusion 12 formed protruding from the foamed synthetic resin molded product 10.

[0052] According to this manufacturing method for the foamed synthetic resin molded product 10, if the protruding portion 12 of the foamed synthetic resin molded product 10 is an unnecessary portion, a liquid that swells the foamed synthetic resin is applied to the protruding portion 12 of the foamed synthetic resin molded product 10 in the application step to cause the protruding portion 12 to swell, so that the swollen protruding portion 12, i.e., the unnecessary portion, can be easily removed. Therefore, it is possible to provide a manufacturing method for the foamed synthetic resin molded product 10 that can easily remove the unnecessary portion of the foamed synthetic resin molded product 10.

[0053] In the manufacturing method of the foamed synthetic resin molded product 10, it is preferable to apply the liquid (swelling liquid) to the foamed synthetic resin molded product 10 in a state where the foamed synthetic resin molded product 10 is placed on a member in the application step. This makes it possible to appropriately apply the liquid to the protruding portion 12 of the foamed synthetic resin molded product 10.

[0054] In the manufacturing method of the foamed synthetic resin molded product 10, it is preferable that in the application step, the liquid is applied in a state where the protruding portion 12 is in contact with the wall surface of the member on which the foamed synthetic resin molded product 10 can be placed. This makes it possible to reliably support the protruding portion 12 by the wall surface of the member, and makes it possible to more appropriately apply the liquid to the protruding portion 12 supported by the wall surface of the member.

[0055] In the manufacturing method of the foamed synthetic resin molded product 10, the member is a mold 20 for molding the foamed synthetic resin molded product 10, and the coating step is preferably carried out after the molding step of molding the foamed synthetic resin molded product 10 using the mold 20. This makes it possible to add the coating step by utilizing the conventional manufacturing equipment for molding the foamed synthetic resin molded product 10 using the mold 20 as is.

[0056] In the manufacturing method of the foamed synthetic resin molded product 10, it is preferable that the protruding portion 12 is formed with a recessed portion 13 capable of receiving the liquid. This allows the recessed portion 13 to reliably receive the liquid that swells the foamed synthetic resin, and allows the liquid to be reliably dispensed to the protruding portion 12.

[0057] Moreover, in the manufacturing method of the foamed synthetic resin molded product 10, it is preferable to further provide a groove portion 14 for cutting off the protruding portion 12. In this way, the groove portion 14 makes it possible to reliably cut off the protruding portion 12.

[0058] In addition, in the manufacturing method of the foamed synthetic resin molded product 10, it is preferable to apply the liquid by spraying in the application step. This makes it possible to apply the liquid that swells the foamed synthetic resin appropriately and reliably to the desired range. Furthermore, by controlling the supply amount of the liquid to be sprayed, it becomes possible to reliably control the application amount of the liquid that swells the foamed synthetic resin, and it becomes possible to apply the desired amount appropriately and reliably.

[0059] In addition, the manufacturing apparatus 30 for the foamed synthetic resin molded product 10 is equipped with an application section (application device) 50 that applies a liquid that swells the foamed synthetic resin to the foamed synthetic resin protrusion 12 formed by protruding from the foamed synthetic resin molded product 10.

[0060] According to the manufacturing apparatus 30 for the foamed synthetic resin molded product 10, when the protruding portion 12 of the foamed synthetic resin molded product 10 is an unnecessary portion, the application device 50 applies a liquid that swells the foamed synthetic resin to the protruding portion 12 of the foamed synthetic resin molded product 10 to cause it to swell, so that the swollen protruding portion 12, i.e., the unnecessary portion, can be easily removed. Therefore, it is possible to provide the manufacturing apparatus 30 for the foamed synthetic resin molded product 10 that can easily remove the unnecessary portion of the foamed synthetic resin molded product 10.

[0061] In addition, the manufacturing apparatus 30 for the foamed synthetic resin molded product 10 preferably further includes a groove forming section 24 for forming the groove 14 for cutting off the protruding section 12. This makes it possible to reliably and easily form the groove 14 by the groove forming section 24, and therefore makes it possible to reliably cut off the protruding section 12 by the groove 14.

[0062] In the above embodiment, the protrusion 12 extends obliquely upward from the main body 11, but as shown in Fig. 14, a protrusion 112 extending horizontally may be provided. In this case, a recess 113 recessed upward may be provided on the upper surface of the protrusion 112.

[0063] In the above-mentioned embodiment, the foamed synthetic resin molded product 10 is a molded product without an embedded member, but the foamed synthetic resin molded product may be an integrally molded product formed integrally with an embedded member. An example of an integrally molded product is one used as a base material for interior components for vehicles, such as a headrest, which is a headrest on the upper part of the backrest provided in a seat, and an armrest, which is an armrest on a seat. When a foamed synthetic resin molded product is molded using a mold 20, the embedded member is loaded into the mold 20, and is then integrally molded when the foamed synthetic resin molded product is molded.

[0064] In the above-mentioned embodiment, one or more protrusions 12 are provided partially around the periphery of the main body 11, but as shown in FIG. 15, the protrusions 112 may be provided around the entire periphery of the main body 111. In this case, the intermediate molded product 115 includes the main body 111 (which will eventually become the foamed synthetic resin molded product 10) and the protrusions 112. The protrusions 112 are foamed synthetic resin parts formed to protrude from the foamed synthetic resin molded product 10. Thus, the foamed synthetic resin molded product 10 is finally formed by cutting the protrusions 112 from the intermediate molded product 115. Furthermore, the protrusions 112 are formed with recesses 113 (similar to the recesses 13) capable of receiving a swelling liquid, similar to the protrusions 12. The recesses 113 are provided along the entire periphery of the protrusions 12. [Explanation of symbols]

[0065] 10... foamed synthetic resin molded product, 12... protrusion, 13... recess, 14... groove, 20... mold (member), 24... groove forming section, 30... foamed synthetic resin molded product manufacturing apparatus, 50... coating device (coating section).

Claims

1. A method for producing a foamed synthetic resin molded product, comprising the steps of: A method for manufacturing a foamed synthetic resin molded product, comprising a coating step of coating a foamed synthetic resin protrusion formed by protruding from the foamed synthetic resin molded product with a liquid that swells the foamed synthetic resin.

2. 2. The method for producing a foamed synthetic resin molded product according to claim 1, wherein in the coating step, the liquid is coated on the foamed synthetic resin molded product in a state where the foamed synthetic resin molded product is placed on a member.

3. 3. The method for manufacturing a foamed synthetic resin molded product according to claim 2, wherein in the application step, the liquid is applied to the wall surface of the member on which the foamed synthetic resin molded product can be placed with the protrusion in contact with the wall surface.

4. the member is a mold for molding the foamed synthetic resin molded product, 4. The method for producing a foamed synthetic resin molded product according to claim 2, wherein the coating step is carried out after a molding step of molding the foamed synthetic resin molded product using the mold.

5. 5. The method for producing a foamed synthetic resin molded product according to claim 1, wherein the protruding portion is formed with a recess capable of receiving the liquid.

6. 6. The method for producing a foamed synthetic resin molded product according to claim 1, further comprising a groove for separating the protruding portion.

7. 7. The method for producing a foamed synthetic resin molded product according to claim 1, wherein the liquid is applied by spraying in the application step.

8. An apparatus for manufacturing foamed synthetic resin molded products, comprising:

2. A foamed synthetic resin molded product manufacturing apparatus comprising: a foamed synthetic resin protrusion formed to protrude from the foamed synthetic resin molded product; and a coating section for coating the foamed synthetic resin with a liquid that swells the foamed synthetic resin.

9. 9. The apparatus for producing foamed synthetic resin molded products according to claim 8, further comprising a groove forming section for forming a groove for cutting off said protruding section.

Images