Insert molded products, insert molding methods

Abstract

To provide hygienic insert molded products that are not limited to specific footwear. [Solution] An insert molded product 1 for laying on a floor surface by connecting multiple sheets, comprising a surface material 20 and a resin part 10 disposed on the back surface 20b of the surface material 20, wherein the resin part 10 is disposed on at least a part of the outer surface 20s of the surface material 20 and has an outer joint part 14 that covers the joint 2 formed between the surface materials 20 when multiple sheets are connected. The surface material 20 consists of multiple adjacent second surface materials 25, and the resin part 10 has an inner joint part 15 that is disposed in the second joint 6 formed between the second surface materials 25.

Description

TECHNICAL FIELD

[0001] The present invention relates to an insert-molded article in which a face material and a resin are integrated, and an insert molding method. BACKGROUND ART

[0002] Conventionally, decorative floor materials are sometimes laid on balconies of condominiums and the like to improve design properties. Some decorative floor materials are insert-molded articles in which a face material such as inorganic tile or glass and a resin are integrated. As an insert molding method for such a decorative floor material, a method has been proposed in which the face material is placed in an insert holder, the insert holder is loaded into a mold, and then a resin is injected onto the back surface of the face material to obtain the decorative floor material (see Patent Document 1). PRIOR ART DOCUMENTS PATENT DOCUMENTS

[0003] PATENT DOCUMENT 1 Japanese Unexamined Patent Application Publication No. 2000-218651 SUMMARY OF THE INVENTION PROBLEM TO BE SOLVED BY THE INVENTION

[0004] In the insert-molded article of Patent Document 1, since concave joints are formed between the face materials, dust and dirt may get stuck therein, making it feel unsanitary. In addition, due to the influence of these joints, walking in footwear with sharp heels such as stiletto heels is hindered, so the article could only be used on balconies and the like where footwear is restricted.

[0005] In the insert molding method of Patent Document 1, it is necessary to perform the operation of placing the face material into the insert holder in an external setup in parallel with the injection molding operation. This external setup is complicated, which causes a problem of reduced work efficiency.

[0006] This invention has been made in consideration of these circumstances, and aims to provide a hygienic insert molded product and an insert molding method that are not limited to footwear. [Means for solving the problem]

[0007] To solve the aforementioned problems, the present invention proposes the following means. "1" The insert molded product according to this embodiment is an insert molded product that is laid on a floor surface by connecting a plurality of pieces, and comprises a surface material and a resin part disposed on the back surface of the surface material, wherein the resin part is disposed on at least a part of the outer surface of the surface material and has an outer joint part that covers the joint formed between the surface materials when a plurality of pieces are connected.

[0008] With the aforementioned insert molded products, when multiple insert molded products are connected and laid on the floor surface, the joints formed between the surface materials are covered by an outer joint made of resin. As a result, dirt and debris are less likely to accumulate in the joints, reducing the feeling of unsanitary conditions. In addition, because the joints are covered by the outer joint, it is possible to walk without difficulty even with pointed-heeled footwear.

[0009] "2" The insert molded product according to this embodiment is characterized in that the surface material consists of a plurality of adjacently arranged second surface materials, and the resin portion has an inner joint portion that is placed in the second joint formed between the second surface materials.

[0010] In the case of the insert molded product described above, even if the surface material consists of multiple adjacent second surface materials, the second joint formed between these second surface materials is covered by an inner joint made of resin. As a result, dirt and debris are less likely to accumulate, and walking is possible without difficulty even with pointed-heeled footwear.

[0011] "3" An insert molded product according to this embodiment, characterized in that the surface material has a chamfered portion on the outer peripheral edge on the surface side.

[0012] With the aforementioned insert molded product, the outer and inner joint portions made of resin are properly positioned.

[0013] "4" An insert molded product according to this embodiment, characterized in that the outer joint portion is arranged on the entire outer surface of the surface material.

[0014] With the aforementioned insert-molded product, the outer joint is positioned across the entire outer surface of the panel, making it less prone to clogging with dirt and debris, and thus not limiting the types of footwear that can be used.

[0015] "5" An insert molded product according to this embodiment, characterized in that the outer joint portion is arranged on half of the outer surface of the surface material.

[0016] With the aforementioned insert-molded products, when multiple pieces are connected and laid on the floor, the outer joints are positioned across the entire outer surface of the panel, making it difficult for dirt and debris to accumulate and allowing for the use of any type of footwear.

[0017] "6" The insert molding method according to this embodiment is a method for molding an insert molded product having resin on the back surface of a surface material and being laid on a floor surface by connecting multiple pieces, characterized in that an elastic body is placed in a surface material insertion recess formed in a mold core, the elastic body is in close contact with at least a part of the outer peripheral edge on the surface side of the surface material from the side of the surface material, the surface material is inserted into the surface material insertion recess and brought into contact with the elastic body, and while pressing the back surface of the surface material with the mold cavity, resin is injected onto the upper surface of the elastic body to form an outer joint portion on at least a part of the outer surface of the surface material that covers the joint formed between the surface materials when multiple pieces are connected.

[0018] With the insert molding method described above, the elastic body is pre-positioned in the recess for inserting the surface material of the mold core. This eliminates the need for tasks such as performing external setup in parallel with the injection molding process, allowing for efficient molding of insert molded products. Further, an elastic body is disposed at a position that serves as a joint formed between face materials when a plurality of the face materials are connected and laid on a floor surface. As a result, the joint is covered by the outer joint portion, so that dust and dirt are less likely to be clogged in the joint, the perception of unsanitary conditions is reduced, and walking can be performed without trouble even in footwear with sharp heels.

[0019] [7] In the insert molding method according to the present embodiment, the face material is composed of a plurality of second face materials, and the elastic body shields a second joint formed between the second face materials from below and molds an inner joint portion disposed at the second joint.

[0020] With the insert molding method described above, even when the face material is composed of a plurality of adjacently arranged second face materials, the second joint formed between the second face materials is covered by the inner joint portion made of resin. For this reason, dust and dirt are less likely to be clogged, and walking can be performed without trouble even in footwear with sharp heels.

[0021] [8] In the insert molding method according to the present embodiment, the elastic body has an inclined surface that abuts against the outer peripheral edge.

[0022] With the insert molding method described above, the elastic body is satisfactorily brought into close contact with the outer peripheral edge on the surface side of the face material, so that the outer joint portion and the inner joint portion made of resin can be satisfactorily molded.

[0023] [9] In the insert molding method according to the present embodiment, the elastic body is disposed so as to be in close contact with the entire outer peripheral edge.

[0024] With the insert molding method described above, since the outer joint portion is disposed on the entire outer side surface of the face material, dust and dirt are less likely to be clogged, and there is no restriction on the type of footwear that can be used.

[0025]

[10] In the insert molding method according to the present embodiment, the elastic body is disposed so as to be in close contact with half of the outer peripheral edge.

[0026] With the insert molding method described above, when a plurality of the molded articles are connected and laid on a floor surface, the outer joint portions are arranged on all of the outer side surfaces of the face material, so that dust and dirt are less likely to be clogged, and no restriction is imposed on footwear.

Effects of the Invention

[0027] According to the present invention, it is possible to provide an insert molded article that is hygienic and does not impose restrictions on footwear. Further, it is possible to provide an insert molding method capable of efficiently molding such an insert molded article.

Brief Description of the Drawings

[0028] [Figure 1] Fig. 2 is a view showing an insert molded article 1 according to the first embodiment of the present invention, where (a) is a plan view and (b) is a side view. [Figure 2] Fig. 3 is a view showing the insert molded article 1 according to the first embodiment of the present invention, where (a) is a rear view, (b) is a cross-sectional view, and (c) is a partially enlarged view. [Figure 3] Fig. 4 is a view showing a state in which a plurality of the insert molded articles 1 are connected. [Figure 4] Fig. 5 is a schematic view showing an insert molding die 50, where (a) is a cross-sectional view and (b) is a plan view. [Figure 5] Fig. 6 is a view showing the insert molding method according to the first embodiment of the present invention in the order of steps. [Figure 6] Fig. 7 is a view showing steps subsequent to Fig. 5 in the order of steps. [Figure 7] Fig. 8 is a view showing an insert molded article 3 according to the second embodiment of the present invention, where (a) is a plan view, (b) is a cross-sectional view, and (c) is a partially enlarged view. [Figure 8] Fig. 9 is a schematic view showing an insert molding die 60, where (a) is a cross-sectional view and (b) is a plan view. [Figure 9] Fig. 10 is a view showing an insert molded article 5 according to the third embodiment of the present invention, where (a) is a plan view, (b) is a cross-sectional view, and (c) is a partially enlarged view. [Figure 10]A schematic diagram showing an insert molding die 70, (a) a cross-sectional view and (b) a plan view. [Figure 11] This figure shows an insert molded product 7 according to a fourth embodiment of the present invention, (a) a plan view, (b) a cross-sectional view, and (c) a partially enlarged view. [Figure 12] A schematic diagram showing an insert molding die 80, wherein (a) is a cross-sectional view and (b) is a plan view. [Figure 13] This is a cross-sectional view showing the arrangement of the outer joint portion 14 and the inner joint portion 15 relative to joint 2 and the second joint 6. [Modes for carrying out the invention]

[0029] The following describes an insert molded product and an insert molding method according to one embodiment of the present invention, with reference to the drawings.

[0030] [First Embodiment: Insert Molded Product 1] Figure 1 shows an insert molded product 1 according to the first embodiment of the present invention. Figure 1(a) is a plan view, and Figure 1(b) is a side view. Figure 2 shows an insert molded product 1 according to the first embodiment of the present invention, where (a) is a rear view, (b) is a cross-sectional view, and (c) is a partially enlarged view. Figure 3 shows a configuration in which multiple insert molded parts 1 are connected. In Figure 3, five insert molded parts 1 are connected in a cross shape. In the following explanation, the vertical direction in Figures 1(a), 2(a), and 3 is referred to as the vertical direction, and the horizontal direction is referred to as the horizontal direction. Also, the vertical direction in Figures 1(b) and 2(b) and (c) is referred to as the thickness direction.

[0031] The insert molded product 1 is a building surface material that is laid on a floor surface by connecting multiple pieces together, and comprises a resin part 10 and a surface material 20. The insert molded product 1 is formed by integrating the resin part 10 and the surface material 20 by placing the surface material 20 inside the mold when molding the resin part 10, and then injecting molten plastic onto it and allowing it to solidify.

[0032] The resin part 10 is installed on the balcony floor and supports the facing material 20. The resin part 10 is roughly plate-shaped and formed in a rectangular shape. The resin part 10 is molded from a resin such as polypropylene, polyethylene, or polyamide.

[0033] As shown in Figure 1(b), the resin portion 10 is arranged in a mesh pattern on the back surface 20b of the surface material 20. In other words, the resin portion 10 is not arranged to cover the entire back surface 20b of the surface material 20, but rather to cover an area of ​​about half of the back surface 20b. The resin part 10 has a covering part 11, a leg part 12, a connecting part 13, and an outer joint part 14.

[0034] The covering portion 11 is the part of the resin portion 10 that is in close contact with the back surface 20b of the surface material 20, and as described above, it covers the back surface 20b of the surface material 20 in a mesh-like manner and supports the surface material 20. The legs 12 are the parts that come into contact with the floor surface when the insert molded product 1 is laid on the floor surface, and have a cylindrical shape that protrudes downward from the covering portion 11. The legs 12 are arranged at multiple locations on the covering portion 11 and are regularly arranged so that the horizontal position of the surface material 20 can be maintained when a load is applied to the surface 20a of the surface material 20. In the insert molded product 1, six legs 12 are arranged along each of the four surfaces 20a of the surface material 20. In addition, six legs 12 are arranged along the vertical center and the horizontal center of the surface material 20. Furthermore, five legs 12 are arranged in each of the four regions surrounded by these legs 12.

[0035] The connecting portion 13 is a part for connecting multiple insert molded products 1 and has a ring shape that protrudes laterally from the outer surface 20s of the surface material 20. The connecting portion 13 is arranged along two adjacent (intersecting) outer surface 20s of the four outer surface 20s of the surface material 20. In the insert molded product 1, six connecting portions 13 are arranged along the lower vertical and right horizontal outer surface 20s1, 20s2, respectively. The legs 12 of other insert molded products 1 that are positioned adjacent to each other are inserted into the ring-shaped connecting portion 13. Specifically, the six legs 12 that are positioned along the upper vertical outer surface 20s of other insert molded products 1 that are positioned below the vertical side of insert molded product 1 are inserted into the six connecting portion 13 that are positioned along the lower vertical side of the outer surface 20s. Also, the six legs 12 that are positioned along the left horizontal outer surface 20s of other insert molded products 1 that are positioned to the right horizontal side of insert molded product 1 are inserted into the six connecting portion 13 that are positioned along the right horizontal side of the outer surface 20s. By inserting the leg portion 12 into the connecting portion 13, multiple insert molded products 1 are connected in such a way that they cannot move relative to one another.

[0036] The outer joint portion 14 is the part that covers the joint 2 formed between the surface materials 20 of each insert molded product 1 when multiple insert molded products 1 are connected. In other words, the outer joint portion 14 is positioned at the joint 2, which is the seam between adjacent insert molded products 1. The outer joint portion 14 is positioned to cover the four outer surfaces 20s of the facing material 20 from the bottom to the top in the thickness direction. The outer joint portion 14 is the outer edge of the resin portion 10 and has a rectangular frame shape that surrounds the covering portion 11 and the facing material 20 from the side. Furthermore, the outer joint portion 14 does not necessarily have to completely cover the outer surface 20s, but may also cover only a part of it.

[0037] When multiple insert molded products 1 are connected, if the joint 2 formed is, for example, a 4 mm wide concave groove, the width (thickness in the vertical or horizontal direction) of the outer joint portion 14 is 2 mm. The width of the outer joint portion 14 is constant along the outer surface 20s (over the entire length or width). Two outer joint portions 14 are placed in close contact with the joint 2 to fill the joint 2. In other words, the outer joint portion 14 of one insert molded product 1 and the outer joint portion 14 of the other insert molded product 1 placed adjacent to it are in close contact to form a 4 mm wide outer joint portion 14, and the 4 mm wide joint 2 is filled without any gaps.

[0038] The surface material 20 is a single flat plate-shaped component placed on the resin part 10. The surface material 20 is formed in a rectangular shape from an inorganic fired body (so-called fired tile). In the insert molded product 1, one surface material 20 is placed on one resin part 10. The surface material 20 is covered by the resin part 10 on all sides except the surface 20a. In other words, the back surface 20b and the four outer surfaces 20s of the surface material 20 are covered by the resin part 10.

[0039] The surface material 20 has a chamfered portion 21 on the outer peripheral edge on the surface 20a side. This chamfered portion 21 is not covered by the resin portion 10 and is exposed toward the upper side in the thickness direction. The chamfered portion 21 is a surface that intersects the surface 20a and the outer surface 20s. The chamfered portion 21 is formed over the entire outer edge on the surface 20a side of the facing material 20. The chamfered portion 21 may be, for example, a surface where the outer edge is cut into a flat shape (so-called C chamfer) or a surface where the outer edge is cut into an arc-shaped curved surface (so-called R chamfer). By providing a chamfered portion 21 on the outer peripheral edge of the surface 20a side of the facing material 20, the outer surface 20s of the facing material 20 can be positioned to be covered by the outer joint portion 14 when molding the resin portion 10.

[0040] [Insert molding die 50] Figure 4 shows an insert molding die 50, with (a) a cross-sectional view and (b) a plan view. The insert molded product 1 is manufactured by injection molding using an insert mold 50. The insert mold 50 comprises a mold core 51 located on the movable side of the injection molding machine and a mold cavity 56 located on the fixed side.

[0041] The mold core 51 has a surface material insertion recess 52 for inserting the surface material 20, and an elastic body 54 disposed inside the surface material insertion recess 52. The panel insertion recess 52 is a flat recess (cavity) into which the panel 20 is housed. The panel insertion recess 52 has a flat bottom surface 52a into which the surface 20a of the panel 20 is in close contact with the entire surface, and an inner surface 52s that is slightly separated from the outer surface 20s of the panel 20. The depth of the recess 52 for inserting the facing material is equal to the thickness of the facing material 20. In other words, the distance from the parting line L to the bottom surface 52a is equal to the thickness of the facing material 20. The length of the recess 52 in the vertical and horizontal directions is slightly greater than the length of the facing material 20 in the vertical and horizontal directions. When the facing material 20 is placed in the facing material insertion recess 52, a small gap 53 is formed between the outer surface 20s and the inner surface 52s of the facing material 20 (see Figures 5(b), 6(a), etc.). This gap 53 is a space facing each of the four outer surfaces 20s of the facing material 20 and is provided to form the outer joint portion 14 described above. The gap 53 has a constant width along each of the four outer surfaces 20s of the facing material 20 (over the entire area in both the vertical and horizontal directions). The width of the gap 53 (distance between the outer surface 20s and the inner surface 52s) is set to, for example, 2 mm.

[0042] The elastic body 54 is positioned at the intersection (inner periphery) of the bottom surface 52a and inner surface 52s of the surface material insertion recess 52. The elastic body 54 is provided to adhere closely to the surface material 20 from the side and to block the molten resin during insert molding. The elastic body 54 is made of heat-resistant rubber, such as nitrile rubber or chloroprene rubber. The elastic body 54 is positioned so as to extend from the inner periphery of the surface material insertion recess 52 toward the outer surface 20s of the surface material 20. In other words, the elastic body 54 is positioned so as to face the gap 53 formed between the outer surface 20s of the surface material 20 and the inner surface 52s of the surface material insertion recess 52. The elastic body 54 is positioned along each of the four inner surfaces 52s of the surface material insertion recess 52 (the four outer surfaces 20s of the surface material 20) (over the entire length). The elastic body 54 has a rectangular frame shape that surrounds the bottom surface 52a of the surface material insertion recess 52. When the facing material 20 is placed in the facing material insertion recess 52, the elastic body 54 adheres closely to the outer peripheral edge (chamfered portion 21) on the surface 20a side of the facing material 20. The elastic body 54 may also adhere closely to the surface 20a or outer surface 20s of the facing material 20.

[0043] When the facing material 20 is placed in the facing material insertion recess 52, the elastic body 54 supports the facing material 20 from the surface 20a side. During molten resin injection, the elastic body 54 is compressed by the clamping force and adheres tightly to the outer peripheral edge (chamfered portion 21) on the surface 20a side of the facing material 20. The elastic body 54, when compressed, covers (shields) the gap 53 formed between the outer surface 20s and inner surface 52s of the facing material 20 from below (on the surface 20a side of the facing material 20). As the elastic body 54 is compressed and covers the gap 53 from below, when molten resin is injected into the gap 53, the outer joint portion 14 described above is formed.

[0044] The elastic body 54 has a beveled surface 54c on its inner periphery on the upper side in order to ensure secure contact with the outer periphery on the surface 20a side of the facing material 20. The beveled surface 54c of the elastic body 54 corresponds to (contacts) the chamfered portion 21 of the facing material 20. The beveled surface 54c may be, for example, a surface whose outer periphery is cut into a flat shape (so-called C-chamfer) or a surface whose outer periphery is cut into an arc-shaped curved surface (so-called R-chamfer).

[0045] The mold core 51 is provided with an ejector 55 for removing the insert molded product 1. The ejector 55 contacts the surface 20a of the surface material 20, pushing the surface material 20 out of the mold core 51.

[0046] The mold cavity 56 has a recess 57 for molding the resin part 10 and a protrusion 58 that adheres closely to the surface 20a of the surface material 20. The recessed portion 57 is a recess (cavity) in the resin portion 10 for molding the covering portion 11, the leg portion 12, and the connecting portion 13. The protruding portion 58 is positioned between the recesses for molding the covering portion 11, and its tip surface coincides with the parting line L. The mold cavity 56 also includes a spool and runner into which molten resin is injected.

[0047] [Insert molding method] Figure 5 is a diagram showing the insert molding method according to the first embodiment of the present invention in order of steps. Figure 6 is a diagram showing the steps following Figure 5 in order of steps. The insert molding method of the first embodiment includes an elastic body placement step S1, a surface material placement step S2, a mold clamping and resin injection step S3, and a molded product removal step S4.

[0048] As shown in Figure 5(a), in the elastic body placement step S1, the elastic body 54 is placed in the surface material insertion recess 52 that has been formed in the mold core 51 in advance. The elastic body 54 is placed at the intersection (inner periphery) of the bottom surface 52a and the inner surface 52s of the surface material insertion recess 52.

[0049] Next, as shown in Figure 5(b), in the panel material placement step S2, the panel material 20 is inserted into the panel material insertion recess 52 and placed on the elastic body 54. The panel material 20 is accommodated in the panel material insertion recess 52 such that the surface 20a of the panel material 20 faces the bottom surface 52a of the panel material insertion recess 52. At this time, the outer peripheral edge of the panel material 20 on the surface 20a side is brought into contact with the elastic body 54. Specifically, the chamfered portion 21 of the panel material 20 is brought into contact with the inclined surface 54c of the elastic body 54 to ensure close contact. As a result, a gap 53 is formed between the outer surface 20s of the facing material 20 and the inner surface 52s of the facing material insertion recess 52. Furthermore, the upper surface of the elastic body 54 is exposed on the lower side (bottom surface 52a side) of this gap 53. In other words, the elastic body 54 is positioned so as to face the gap 53.

[0050] As shown in Figure 6(a), in the mold clamping and resin injection process S3, the mold core 51 is pressed against the mold cavity 56, and the insert molding die 50 is closed by applying high clamping pressure. As a result, the protrusion 58 of the mold cavity 56 comes into close contact with the back surface 20b of the surface material 20, pressing the surface material 20 toward the surface material insertion recess 52 of the mold core 51. When the insert molding die 50 is clamped, the surface 20a of the surface material 20 comes into close contact with the bottom surface 52a of the surface material insertion recess 52. At the same time, the surface material 20 presses against the elastic body 54, causing the elastic body 54 to be crushed. The elastic body 54 comes into close contact with the outer peripheral edge of the surface material 20a side without any gaps. Next, molten resin is injected toward the back surface 20b of the surface material 20. This supplies (fills) the molten resin into the recess 57 of the mold cavity 56, and the resin part 10 is formed on the back surface 20b of the surface material 20. That is, the covering part 11, the leg part 12, and the connecting part 13 are formed. Simultaneously, molten resin is supplied to the gap 53 formed between the outer surface 20s of the facing material 20 and the inner surface 52s of the facing material insertion recess 52. In other words, the molten resin fills the concave groove (gap 53) surrounded by the outer surface 20s of the facing material 20, the inner surface 52s of the facing material insertion recess 52, and the upper surface of the elastic body 54. This forms the outer joint portion 14 of the resin portion 10. Then, as the molten resin solidifies and the outer joint portion 14 is formed, the surface material 20 is firmly held in place with respect to the resin portion 10.

[0051] Finally, as shown in Figure 6(b), in the molded product removal process S4, the insert molding die 50 is opened to separate the mold core 51 and the mold cavity 56. Next, the ejector 55 of the mold core 51 is activated to press the surface 20a of the surface material 20, thereby pushing the insert molded product 1 out of the mold core 51. Through the above process, insert molded product 1 is formed.

[0052] [Second Embodiment: Insert Molded Product 3] Figure 7 is a plan view showing an insert molded product 3 according to the second embodiment of the present invention. In the second embodiment, the same reference numerals are used for parts that are the same as those in the first embodiment, and their descriptions are omitted. Only the differences will be described.

[0053] In the insert molded product 3, the outer joint portion 14 is positioned on at least some of the four outer surfaces 20s of the facing material 20. Specifically, the outer joint portion 14 is positioned on half of the outer surfaces 20s of the facing material 20, 20s1 and 20s2. In other words, the outer joint portion 14 is not positioned on the remaining half of the outer surfaces 20s of the facing material 20, 20s3 and 20s4. Outer surface 20s1 is the upper outer surface in the vertical direction among the four outer surfaces 20s, and outer surface 20s2 is the right outer surface in the horizontal direction. On the other hand, outer surface 20s3 is the lower outer surface in the vertical direction, and outer surface 20s4 is the left outer surface in the horizontal direction.

[0054] In the insert molded product 3, the outer joint portion 14 has a width that matches the width of the joint 2. If the joint 2 is, for example, a concave groove with a width of 4 mm, then the width of the outer joint portion 14 is also 4 mm. As a result, when multiple insert molded products 3 are connected, the outer joint portions 14 adhere closely to the surface material 20 of the adjacent insert molded product 1. Specifically, the outer joint portions 14 located on the outer surface 20s1 of insert molded product 3 adhere closely to the outer surface 20s3 of the adjacent insert molded product 1 where there are no outer joint portions 14. The outer joint portions 14 located on the outer surface 20s2 of insert molded product 3 adhere closely to the outer surface 20s4 of the adjacent insert molded product 1 where there are no outer joint portions 14. On the other hand, the outer surface 20s3 of insert molded product 3 is in close contact with the outer surface 20s1 of the adjacent insert molded product 1, which has an outer joint portion 14. The outer surface 20s4 of insert molded product 3 is in close contact with the outer surface 20s2 of the adjacent insert molded product 1, which has an outer joint portion 14. In this way, when multiple insert molded products 3 are connected, one outer joint portion 14 with a width of 4 mm is positioned in relation to the 4 mm wide joint 2 formed between the insert molded products 3 (between the surface materials 20).

[0055] [Insert molding die 60, insert molding method] Figure 8 is a schematic diagram showing an insert molding die 60, with (a) a cross-sectional view and (b) a plan view. The insert molded product 3 is manufactured using an insert molding die 60 which has a mold core 51 and a mold cavity 56. In the insert molding die 60, the elastic body 54 is positioned on one of the four inner surfaces 52s of the surface material insertion recess 52, the surface facing the outer surfaces 20s1 and 20s2 of the surface material 20. The elastic body 54 is in close contact with half of the outer peripheral edge on the surface 20a side of the surface material 20 (the outer peripheral edges of the outer surfaces 20s1 and 20s2). On the other hand, the elastic body 54 is not provided on the surface facing the outer surfaces 20s3 and 20s4 of the facing material 20. The molding method for insert molded product 3 is the same as the molding method for insert molded product 1.

[0056] [Third Embodiment: Insert Molded Product 5] Figure 9 shows an insert molded product 5 according to the third embodiment of the present invention. In the third embodiment, the same reference numerals are used for parts that are the same as those in the first and second embodiments, and their descriptions are omitted. Only the differences will be described.

[0057] The insert molded product 5 comprises multiple adjacently arranged second facing materials 25 instead of a single facing material 20. The four second facing materials 25 are arranged in a grid pattern. Each of the second facing materials 25 is provided with a chamfered portion 26, similar to the chamfered portion 21. In the insert molded product 3, a second joint 6 is formed between the second surface materials 25. In the insert molded product 5, the second joint 6 has an elongated cross shape.

[0058] The resin part 10 has an inner joint part 15 in addition to the covering part 11, leg part 12, connecting part 13, and outer joint part 14. The inner joint portion 15 is positioned between the covering portions 11 that cover the back surfaces 25b of each of the four second facing materials 25. The inner joint portion 15 is positioned in the second joint 6 formed between the second facing materials 25. In other words, the inner joint portion 15 has an elongated cross shape that divides the back surface of the insert molded product 5 in half vertically and horizontally.

[0059] [Insert molding die 7] Figure 10 shows an insert molding die 70, with (a) a cross-sectional view and (b) a plan view. The insert molded product 5 is manufactured using an insert molding die 70 which has a mold core 71 and a mold cavity 56.

[0060] The mold core 71 has a surface material insertion recess 52 for inserting the surface material 20, and an elastic body 74 disposed inside the surface material insertion recess 52. The elastic body 74 has a square frame-shaped portion (corresponding to the elastic body 54) that surrounds the bottom surface 52a of the surface material insertion recess 52, and a cross-shaped portion that divides the surface material insertion recess 52 in the vertical and horizontal directions, respectively. In other words, the elastic body 74 has a grid shape (a grid shape). Similar to the elastic body 54, the elastic body 74 has a sloped surface 74c formed on the upper side edge.

[0061] [Insert molding method] The insert molding method of the third embodiment is similar to the insert molding methods of the first and second embodiments in that it includes an elastic body placement step S1, a surface material placement step S2, a mold clamping and resin injection step S3, and a molded product removal step S4.

[0062] In the elastic body placement step S1, the elastic body 74 is placed in the surface material insertion recess 52 that has been previously formed in the mold core 71. In the panel placement step S2, four second panel materials 25 are inserted into the panel material insertion recesses 52 and placed on the elastic body 74. At this time, the outer peripheral edge on the surface 25a side of each second panel material 25 is brought into contact with the elastic body 74. Specifically, the chamfered portion 26 of the second panel material 25 is brought into contact with the inclined surface 74c of the elastic body 74 to ensure close contact.

[0063] In the mold clamping and resin injection process S3, the mold core 71 is pressed against the mold cavity 56, closing the insert molding die 70. The protrusions 58 of the mold cavity 56 make close contact with the back surface 25b of each second surface material 25, pressing down on the second surface material 25. The surface surface 25a of each second surface material 25 makes close contact with the bottom surface 52a of the surface material insertion recess 52. At the same time, each second surface material 25 presses down on the elastic body 74, causing the elastic body 74 to be crushed. The elastic body 74 makes close contact with the outer peripheral edge on the surface 25a side of each second surface material 25 without any gaps. Next, molten resin is injected onto the back surface 25b of each second facing material 25. This forms the covering portion 11, leg portion 12, connecting portion 13, and outer joint portion 14 of the resin portion 10 on the back surface 25b of each second facing material 25. Simultaneously, the inner joint portion 15 of the resin portion 10 is also formed. In other words, molten resin is also supplied to the second joint 6 formed between the four second surface materials 25. Molten resin is filled into the concave groove (second joint 6) surrounded by the outer surfaces 20s of two adjacent second surface materials 25 and the upper surface of the elastic body 74. This forms the inner joint portion 15 of the resin portion 10.

[0064] In the molded product removal process S4, the insert molding die 70 is opened to separate the mold core 71 and the mold cavity 56. Next, the ejector 75 of the mold core 71 is activated to press the surface 25a of the second facing material 25, thereby pushing the insert molded product 5 out of the mold core 71. Through the above process, the insert molded product 5 is formed.

[0065] [Fourth Embodiment: Insert Molded Product 7] Figure 10 is a plan view showing an insert molded product 7 according to the fourth embodiment of the present invention. In the fourth embodiment, the same reference numerals are used for parts that are the same as those in the first, second, and third embodiments, and their descriptions are omitted. Only the differences will be described.

[0066] Similar to insert molded product 3, insert molded product 7 has an outer joint portion 14 positioned on at least a portion of the outer surface 25s of the second facing material 25. Specifically, the outer joint portion 14 is positioned on half of the outer surface 25s of the second facing material 25, 25s1 and 25s2. Outer surface 20s1 is the upper outer surface in the vertical direction of the outer surface 25s, and outer surface 25s2 is the right outer surface in the horizontal direction.

[0067] In the insert molded product 7, the outer joint portion 14 has a width that matches the width of the joint 2. As a result, when multiple insert molded products 7 are connected, the outer joint portion 14 adheres closely to the second surface material 25 of the other insert molded products 7 that are placed adjacent to it. In a multi-piece insert molded product 7, for example, a 4 mm wide joint 2 is formed between the insert molded products 7 (between the second surface materials 25), and one 4 mm wide outer joint portion 14 is positioned therein.

[0068] [Insert molding die 80, insert molding method] Figure 12 is a schematic diagram showing an insert molding die 80, with (a) a cross-sectional view and (b) a plan view. The insert molded product 7 is manufactured using an insert molding die 80 which has a mold core 71 and a mold cavity 56. In the insert molding die 80, the elastic body 74 is positioned on one of the four inner surfaces 52s of the surface material insertion recess 52, specifically on the surface facing the outer surfaces 25s1 and 25s2 of the second surface material 25. The elastic body 74 is in close contact with half of the outer peripheral edge on the surface 25a side of the second surface material 25 (the outer peripheral edges of the outer surfaces 25s1 and 25s2). On the other hand, the elastic body 74 is not provided on the surface facing the outer surfaces 20s3 and 20s4 of the second surface material 25. The molding method for insert molded product 7 is the same as the molding method for insert molded product 5.

[0069] As explained above, according to the insert molded products 1 and 3 of the first and second embodiments, when multiple pieces are connected and laid on the floor surface, the joints 2 formed between the insert molded products 1 and 3 (between the surface materials 20) are covered by the outer joint portion 14 made of resin. As a result, dirt and debris are less likely to get stuck in the joints 2, reducing the feeling of unsanitary conditions. In addition, because the joints 2 are covered by the outer joint portion 14, it is possible to walk without difficulty even with pointed-heeled footwear.

[0070] Furthermore, according to the insert molding method of the first and second embodiments, the elastic body 54 is pre-positioned in the surface material insertion recess 52 of the mold core 51 of the insert molding die 50, 60. Therefore, tasks such as performing external setup in parallel with the injection molding operation become unnecessary, and insert molded products 1, 3 can be molded efficiently. Furthermore, as the molten resin solidifies and the outer joint portion 14 is formed, the surface material 20 is firmly held in place relative to the resin portion 10.

[0071] According to the insert molded products 5 and 7 of the third and fourth embodiments, when multiple insert molded products 5 and 7 are connected and laid on a floor surface, the joints 2 formed between the insert molded products 5 and 7 (between the second surface materials 25) are covered by the outer joint portion 14 made of resin. In addition, the second joints 6 formed between the second surface materials 25 are also covered by the inner joint portion 15 made of resin. As a result, dirt and debris are less likely to accumulate in joint 2 and the second joint 6, reducing the feeling of unsanitary conditions. In addition, since joint 2 and the second joint 6 are covered by the outer joint portion 14 and the inner joint portion 15, it is possible to walk without difficulty even with pointed-heeled footwear.

[0072] Furthermore, according to the insert molding method of the third and fourth embodiments, the elastic body 74 is pre-positioned in the surface material insertion recess 52 of the mold core 71 of the insert molding die 70, 80. Therefore, tasks such as performing external setup in parallel with the injection molding operation become unnecessary, and insert molded products 5, 7 can be molded efficiently. Furthermore, as the molten resin solidifies and the outer joint portion 14 and the inner joint portion 15 are formed, the second facing material 25 is firmly held in place with respect to the resin portion 10.

[0073] It should be noted that the technical scope of the present invention is not limited to the embodiments described above, and various modifications can be made without departing from the spirit of the invention. In other words, the specific shapes and configurations given in the embodiments are merely examples and can be modified as appropriate.

[0074] For example, this is not limited to connecting insert molded parts of the same shape. Insert molded parts of different shapes may also be connected. For example, insert molded part 1 and insert molded part 3 may be connected, or insert molded part 5 and insert molded part 7 may be connected. Insert molded parts 1, 3, 5, and 7 are not limited to being connected in a grid pattern. They may also be connected with a 50 / 50 offset in either the vertical or horizontal direction.

[0075] The insert molded product 3,7 is not limited to having four second surface materials 25. It may have multiple second surface materials 25, for example, two or nine.

[0076] The facing material 20 and the second facing material 25 are not limited to inorganic fired materials (so-called fired tiles). The facing material 20 and the second facing material 25 may be made of materials such as stone, wood, resin, metal, or composite materials thereof. The shape of the front panel 20 and the second front panel 25 is not limited to a square. The shape of the front panel 20 and the second front panel 25 may be a rectangle, a triangle, a hexagon, etc. Furthermore, they may be circular, elliptical, or other shapes. Different shapes may be combined. For example, squares and rectangles may be combined.

[0077] Joint 2 and the second joint 6 do not need to be straight, nor do they need to have a uniform width. Similarly, the outer joint section 14 and the inner joint section 15 do not need to be straight, nor do they need to have a uniform width.

[0078] Figure 13 is a cross-sectional view showing the arrangement of the outer joint portion 14 and the inner joint portion 15 relative to joint 2 and the second joint 6. As shown in Figure 13(a), the outer joint 14 and the inner joint 15 may completely fill joint 2 and the second joint 6. As shown in Figures 13(b) and (b), the outer joint 14 and the inner joint 15 only need to fill at least a portion of the joint 2 and the second joint 6. As shown in Figure 13(b), the outer joint 14 and the inner joint 15 may cover the entire outer surfaces 20s and 25s of the facing material 20 and the second facing material 25, or, as shown in Figure 13(c), they may be covered in such a way that the upper side of the outer surfaces 20s and 25s is exposed. In other words, as shown in Figure 13(a), the outer joint portion 14 and the inner joint portion 15 may completely cover the chamfered portions 21 and 26 of the facing material 20 and the second facing material 25, as shown in Figure 13(b), they may cover only a portion (the lower side), or they may be left exposed without being covered, as shown in Figure 13(c).

[0079] The chamfered portions 21 and 26 do not have to be provided on all of the outer peripheral edges on the surface side of the face material 20 and the second face material 25. The chamfered portions 21 and 26 may be provided on only a part of the outer peripheral edge. For example, the chamfered portions 21 and 26 may be provided only on the four vertices (corners) on the surface side of the face material 20 and the second face material 25. It is also possible to omit the chamfered portions 21 and 26 on the facing material 20 and the second facing material 25, and instead provide the beveled surfaces 54c and 74c on the elastic bodies 54 and 74. Conversely, it is also possible to provide the chamfered portions 21 and 26 on the facing material 20 and the second facing material 25, and not provide the beveled surfaces 54c and 74c on the elastic bodies 54 and 74. [Explanation of symbols]

[0080] 1. Insert molded product 2. Joint 3. Insert molded product 5. Insert molded products 6 Second joint 7 Insert molded products 10 Resin part 11 Covering part 12 Legs 13 Connecting part 14 Outside joint area 15. Inner joint area 20 Surface material 20s outer surface 21 Chamfered section 25 Second side material 25s outer surface 26 Chamfered section 50 Insert molding dies 51 Mold core 52 Recesses for inserting facing material 53 gaps 54 Elastic body 54c Slope 55 Mold Cavity 60 Insert molding dies 70 Insert molding dies 74 Elastic body 80 Insert molding dies L parting line

Claims

1. An insert molded product that is laid on the floor surface by connecting multiple pieces, Surface material and, A resin part is placed on the back surface of the aforementioned surface material, Equipped with, The insert molded product is characterized in that the resin portion is arranged on at least a part of the outer surface of the surface material and has an outer joint portion that covers the joint formed between the surface materials when multiple pieces are connected together.

2. The aforementioned surface material consists of multiple adjacent second surface materials. The insert molded product according to claim 1, characterized in that the resin portion has an inner joint portion that is disposed in a second joint formed between the second surface materials.

3. The insert molded product according to claim 1, characterized in that the surface material has a chamfered portion on the outer peripheral edge on the surface side.

4. The insert molded product according to claim 1, characterized in that the outer joint portion is arranged on the entire outer surface of the facing material.

5. The insert molded product according to claim 1, characterized in that the outer joint portion is arranged on half of the outer surface of the facing material.

6. A method for molding insert molded products having resin on the back surface of the surface material, which are laid on a floor surface by connecting multiple pieces, An elastic body is placed in a recess for inserting a surface material formed in the mold core, and is in close contact with at least a portion of the outer peripheral edge on the surface side of the surface material from the side of the surface material. Insert the facing material into the facing material insertion recess and bring it into contact with the elastic body. An insert molding method characterized by pressing the back surface of the surface material with a mold cavity and injecting resin onto the upper surface of the elastic body to form an outer joint portion on at least a part of the outer surface of the surface material that covers the joint formed between the surface materials when multiple surface materials are connected.

7. The aforementioned surface material consists of multiple second surface materials, The elastic body shields the second joint formed between the second surface materials from below, The insert molding method according to claim 6, characterized by forming an inner joint portion to be placed in the second joint.

8. The insert molding method according to claim 6, characterized in that the elastic body has an inclined surface that abuts against the outer edge.

9. The insert molding method according to claim 6, characterized in that the elastic body is arranged to be in close contact with the entire outer edge.

10. The insert molding method according to claim 6, characterized in that the elastic body is arranged to be in close contact with half of the outer edge.

Images