Manufacturing method and manufacturing device for foamed synthetic resin molded products, and foamed synthetic resin molded products

Abstract

To provide a method and equipment for manufacturing foamed synthetic resin molded products from which unnecessary portions of foamed synthetic resin can be easily removed, as well as foamed synthetic resin molded products.SOLUTION: A method for manufacturing a foamed synthetic resin molded article 10 having foamed synthetic resin 11 comprises a removal step S3 in which a liquid that swells the foamed synthetic resin 11 is applied to an unwanted portion 11a, which is the unwanted foamed synthetic resin 11, to cause the same to swell, and the swollen unwanted portion 11a is removed.SELECTED DRAWING: Figure 3

Description

[Technical Field]

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

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

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2008-207391 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 has a problem in that it is difficult to cut off relatively hard burrs (unwanted parts) with an ultrasonic cutter.

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

[0006] In order to solve the above problems, the method for manufacturing a foamed synthetic resin molded product according to the present invention is a method for manufacturing a foamed synthetic resin molded product having a foamed synthetic resin, and is characterized by comprising a removal step of applying a liquid that swells the foamed synthetic resin to the unnecessary part, which is the unnecessary foamed synthetic resin, to cause it to swell, and then removing the swollen unnecessary part.

[0007] According to the method for manufacturing a foamed synthetic resin molded product of the present invention, it is possible to apply a liquid that swells the foamed synthetic resin to the unnecessary portion of the foamed synthetic resin, thereby causing the unnecessary portion to swell and removing the swollen unnecessary portion. Thus, it is possible to provide a method for manufacturing a foamed synthetic resin molded product that can easily remove the unnecessary portion of the foamed synthetic resin.

[0008] Furthermore, the method for manufacturing a foamed synthetic resin molded product according to the present invention preferably further comprises a range setting step of forming a notch to set the range for removing the unnecessary portion. According to this, after forming the notch, a liquid that swells the foamed synthetic resin is applied, thereby making it possible to reliably swell and remove the unnecessary portion. At the same time, it is possible to reliably prevent the liquid that swells the foamed synthetic resin from seeping into the essential portions of the foamed synthetic resin, thereby reliably preventing the essential portions of the foamed synthetic resin from swelling.

[0009] In the method for producing a foamed synthetic resin molded product according to the present invention, the incisions are preferably formed using a hot blade, which ensures that the incisions are reliably formed, the liquid that swells the foamed synthetic resin is reliably permeated, and ultimately the unnecessary parts are reliably swelled.

[0010] 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 removing step. This makes it possible to apply the liquid that swells the foamed synthetic resin appropriately and reliably to the desired area. Furthermore, by controlling the supply amount of the liquid to be sprayed, it is possible to reliably control the amount of liquid that swells the foamed synthetic resin to be applied, making it possible to apply the desired amount appropriately and reliably.

[0011] In the method for manufacturing a foamed synthetic resin molded product according to the present invention, it is preferable that the foamed synthetic resin molded product has an embedded member integrally molded therein, and the removing step removes the unnecessary part adhering to the embedded member. This makes it possible to reliably and easily remove the unnecessary part adhering to the embedded member.

[0012] In the method for manufacturing a foamed synthetic resin molded product according to the present invention, it is preferable that the removal range of the unnecessary part is set to be an inner range of a predetermined portion of the embedding member, thereby making it possible to more reliably and easily remove the unnecessary part attached to the embedding member.

[0013] In addition, the manufacturing apparatus for foamed synthetic resin molded products according to the present invention is a manufacturing apparatus for foamed synthetic resin molded products having foamed synthetic resin, and is characterized by comprising an application unit that applies a liquid that swells the foamed synthetic resin to the unnecessary portion, which is the unnecessary foamed synthetic resin, and a removal unit that removes the swollen unnecessary portion.

[0014] According to the manufacturing device for foamed synthetic resin molded products of the present invention, the application unit applies a liquid that swells the foamed synthetic resin to the unnecessary portion, which is the unnecessary foamed synthetic resin, and the removal unit removes the swollen unnecessary portion. 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.

[0015] In addition, the foamed synthetic resin molded product according to the present invention is a foamed synthetic resin molded product having foamed synthetic resin, characterized in that a liquid that swells the foamed synthetic resin is applied to the unnecessary part, which is the unnecessary foamed synthetic resin, causing it to swell, and the product has a notch for setting a removal range within which the swollen unnecessary part should be removed.

[0016] According to the foamed synthetic resin molded product of the present invention, it is possible to apply a liquid that swells the foamed synthetic resin to the unnecessary portion of the foamed synthetic resin, thereby causing the unnecessary portion to swell and removing the swollen unnecessary portion, thereby providing a foamed synthetic resin molded product from which the unnecessary portion of the foamed synthetic resin has been easily removed. [Effects 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 foamed synthetic resin, and a foamed synthetic resin molded product. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is an external perspective view showing an embodiment of a foamed synthetic resin molded product 10 according to the present invention. [Figure 2A] FIG. 2 is a plan view showing the embedded member 12 shown in FIG. [Figure 2B] FIG. 2 is a side view showing the embedded member 12 shown in FIG. [Figure 3] 1 is a manufacturing process diagram showing one embodiment of a method for manufacturing a foamed synthetic resin molded product 10 according to the present invention. [Figure 4A] 1 is a partial plan view showing an unnecessary portion 11a of the foamed synthetic resin 11. FIG. [Figure 4B] 4B is a partial cross-sectional view taken along line 4B-4B, showing an unnecessary portion 11a of foamed synthetic resin 11. FIG. [Figure 5] 1 is a side view showing an embodiment of a manufacturing apparatus 30 for a foamed synthetic resin molded product 10 and a slit forming apparatus 50 according to the present invention. [Figure 6] 1 is a side view showing an embodiment of an application device 60 of an apparatus 30 for manufacturing a foamed synthetic resin molded product 10 according to the present invention. [Figure 7] 1 is a side view showing an embodiment of a gripping device 70 of an apparatus 30 for manufacturing a foamed synthetic resin molded product 10 according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0019] Hereinafter, an embodiment of a method and apparatus for manufacturing a foamed synthetic resin molded product 10 according to the present invention, and a foamed synthetic resin molded product 10 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] (Foam synthetic resin molded products) As shown in FIG. 1, the foamed synthetic resin molded product 10 is an integrally molded product formed by integrating a foamed synthetic resin 11 and an embedding member 12. In this embodiment, the foamed synthetic resin molded product 10 is molded using a mold. Note that the foamed synthetic resin molded product 10 does not have to be integrally molded using a mold, and may be integrally molded, for example, by laminating a foamed synthetic resin on an embedding member 12 (for example, using a 3D printer or a foamed synthetic resin spraying device). Alternatively, the foamed synthetic resin molded product 10 may be formed by manufacturing a foamed synthetic resin 11 with an embedding portion provided in advance, and then embedding the embedding member 12 in the embedding portion.

[0021] The foamed synthetic resin molded product 10 is used as a base material for vehicle interior components such as a headrest, which is a headrest on the upper part of a seat back, and an armrest, which is an armrest for a seat. In this embodiment, an armrest will be taken as an example of the foamed synthetic resin molded product 10.

[0022] The foamed synthetic resin 11 is formed by foaming a foamed synthetic resin raw material. The foamed synthetic resin 11 is a porous synthetic resin with fine air bubbles trapped inside, and is a foam with a synthetic resin skeleton. The foamed synthetic resin 11 can be urethane foam (polyurethane foam) made from polyurethane. The urethane foam may be soft polyurethane foam, hard polyurethane foam, or semi-hard polyurethane foam. The foamed synthetic resin 11 can be polyethylene foam, EVA foam, melamine resin foam, or other foamed synthetic resin. 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. The foamed synthetic resin 11 may also be referred to as a main body made of foamed synthetic resin (foamed synthetic resin part).

[0023] 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 Preferably, the urethane foam is formed as follows.

[0024] The embedding member 12 is a member that is embedded in the foamed synthetic resin 11. When the foamed synthetic resin 11 is molded using a mold, the embedding member 12 is loaded into the mold and is integrally molded when the foamed synthetic resin 11 is molded. When the foamed synthetic resin 11 is formed without using a mold, the embedding member 12 is integrally molded by laminating (shaping) the foamed synthetic resin 11, or is integrally molded by being attached to the foamed synthetic resin 11 after it has been molded into a desired shape.

[0025] 2A and 2B, the embedded member 12 has a protruding portion 21, a fixing portion 22, and an additional portion 23. The embedded member 12 is a member that is embedded in foamed synthetic resin 11. When manufactured using a mold, an insert member is the embedded member 12. The embedded member 12 is made of metal, synthetic resin, or the like, and the protruding portion 21, the fixing portion 22, and the additional portion 23 are integrally formed.

[0026] The protrusion 21 protrudes outward from the surface of the foamed synthetic resin 11 (foamed synthetic resin molded product 10). The protrusion 21 is used to exert a predetermined function of the foamed synthetic resin molded product 10, and functions, for example, as a rotation axis or fixing foot of the foamed synthetic resin molded product 10. The fixing part 22 is a part for fixing the embedding member 12 to the foamed synthetic resin 11, and is embedded inside the foamed synthetic resin 11.

[0027] The additional portion 23 is a portion for adding a predetermined function (for example, strengthening fixation) to the embedded member 12. In this embodiment, the additional portion 23 is formed in a plate shape and is a portion for firmly and stably fixing the embedded member 12 to the foamed synthetic resin 11, and is embedded in the foamed synthetic resin 11. Note that the embedded member 12 only needs to have the protruding portion 21 and the fixing portion 22, and the additional portion 23 may be omitted in some cases. Furthermore, the foamed synthetic resin molded product 10 may be a foamed synthetic resin molded product formed only from foamed synthetic resin without the embedded member 12 provided therein.

[0028] (Method of manufacturing foam synthetic resin molded products) Next, a method for producing the foamed synthetic resin molded product 10 will be described with reference to Fig. 3. In this embodiment, a case where the foamed synthetic resin molded product 10 is integrally molded using a mold will be described. First, a foamed synthetic resin molded product 10 is molded in a mold (not shown) (molding in a mold (molding process S1)). The mold has two or more separate molds, i.e., at least a cavity (concave mold) and a core (convex mold). The molding process includes an embedding member placement process, a urethane foam raw material injection process, a foaming process, and a demolding process.

[0029] In the embedding member placement step, the embedding member 12 is placed at a predetermined position in the mold. In the urethane foam raw material injection step, a required amount of urethane foam raw material (foamed synthetic resin raw material) is injected into the mold for the embedding member 12. The injection amount of the urethane foam raw material is determined so that the density of the urethane foam formed by foaming becomes a predetermined density (for example, 40 kg / m 3 ~95kg / m 3 ) is preferable. After the urethane foam raw material is injected into the mold with the mold open, the cavity and core are closed. If the mold has a raw material injection port (not shown), the embedding member 12 can be placed in the mold, and then the urethane foam raw material can be injected into the mold through the raw material injection port with the mold closed to form the mold.

[0030] In the foaming step, the urethane foam raw material is foamed in the mold by the progress of a reaction to form foamed synthetic resin 11, and the embedded member 12 is integrated with the foamed synthetic resin 11. Then, in the demolding step, the mold is opened and the foamed synthetic resin molded product 10 in which the embedded member 12 and the foamed synthetic resin 11 are integrated is taken out.

[0031] After molding, the foamed synthetic resin molded product 10 has unnecessary portions 11a of the foamed synthetic resin 11. The unnecessary portions 11a are formed in parts of the foamed synthetic resin 11 that correspond to the raw material injection port of the mold, the boundary between the molds, and the recessed portions (concave portions) formed in the inner wall surface of the mold to allow the protruding portion 21 of the embedded member 12 to escape. As an example of the unnecessary portions 11a, unnecessary portions 11a corresponding to the recessed portions are shown in Figures 4A and 4B. Examples of the unnecessary portions 11a include unnecessary portions 11a1 formed and attached to the surfaces of the protruding portion 21 and the additional portion 23, and burr-like unnecessary portions 11a2 formed corresponding to the boundary between the split molds.

[0032] Next, a removal step S3 is performed to remove the unnecessary portion 11a of the foamed synthetic resin 11. The removal step S3 begins with a range setting step S31 in which a removal range for the unnecessary portion 11a is set (defined; defined). Specifically, in the range setting step S31, a slit 15 for setting the removal range for the unnecessary portion 11a is formed in the foamed synthetic resin 11. The slit 15 is made along the outline (contour) of the removal range. For example, the slit 15 is made by a thermal blade 51 (described later), which is a cutting tool with a blade heated by a heat source. In this embodiment, the blade of the thermal blade 51 is formed in a shape corresponding to the slit 15 (i.e., a shape that follows the outline of the removal range). The formed slit 15 can facilitate and promote the penetration of the swelling liquid into the unnecessary portion 11a of the foamed synthetic resin 11. The slit 15 can also reliably prevent the swelling liquid from seeping into areas outside the removal range of the foamed synthetic resin 11, i.e., into essential parts of the foamed synthetic resin 11. Furthermore, the notch 15 defines the range to be cut off when cutting (picking) the unnecessary portion 11a, making it possible to cut off the unnecessary portion 11a reliably and accurately.

[0033] The thermal blade may have a cutting edge, in which case the notch 15 is formed by the cutting edge. In this embodiment, the notch 15 is formed by the thermal blade 51, but it may also be formed by a laser device that irradiates a laser instead of the thermal blade 51.

[0034] The removal range is preferably set to be within the inner range of a predetermined portion of the embedding member 12. In this embodiment, the predetermined portion is the additional portion 23, and the inner range of the predetermined portion is the range inside the outer periphery of the additional portion 23. This makes it possible to form the notch 15 in the unnecessary portion 11a1 present on the surface of the embedding member 12, so that although the swelling liquid described below reaches the surface of the embedding member 12, it is possible to reliably prevent the swelling liquid from penetrating into the necessary portion of the foamed synthetic resin 11. In other words, it is possible for the swelling liquid to penetrate only into the unnecessary portion 11a1 attached within the inner range of the predetermined portion.

[0035] Next, an application step S33 is performed in which a swelling liquid, which is a liquid that swells the foamed synthetic resin 11, is applied to the unnecessary portion 11a to cause it to swell. The swelling liquid swells the foamed synthetic resin 11 by penetrating into the numerous pores formed in the foamed synthetic resin 11. The swelling liquid is preferably a solvent that is as polar as the polar molecular bonds that form the foamed synthetic resin 11, and the polar swelling liquid is attracted to the polar molecular bonds of the foamed synthetic resin 11, so it penetrates into the numerous pores formed in the foamed synthetic resin 11.

[0036] In this embodiment, the foamed synthetic resin 11 is made of polyurethane and therefore has a urethane bond (—NH·CO·O—). The swelling liquid preferably has a polarity that attracts the urethane bond, and ethanol, for example, is used. Ethanol, represented by CH3CH2OH, has a polar hydroxyl group (R—OH) and is polar overall. Water (H2O) also has polarity, but because it has high hydrophilicity and low hydrophobicity, it does not swell the foamed synthetic resin 11. The swelling liquid is preferably a solvent with low hydrophilicity and high hydrophobicity, and examples of such solvents include limonene (a monocyclic monoterpene), orange oil containing limonene, and monoterpenes other than limonene. Limonene, represented by CH3-C6H8-C(CH3)=CH2, is polar overall and highly hydrophobic. Monoterpenes are a type of terpene that contains two isoprene units and are 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.

[0037] In this embodiment, spray application is used as the method for applying the swelling liquid. Spray application is performed by a spray device 60 (described later). The spray device 60 can spray the swelling liquid from the storage tank from a nozzle 61. The nozzle 61 has high directionality and can spray the swelling liquid accurately over the desired area. It is also possible to use a nozzle with low directionality, in which case it is preferable to employ a cover that can cover the desired area. In addition, as the application method, application with a brush or the like, application by injection using a syringe, application by immersion, application by electrostatic coating, or other application methods can be used.

[0038] The unnecessary portion 11a may be harder than the portion other than the unnecessary portion 11a (the necessary portion of the foamed synthetic resin 11). In this case, in order to easily remove the unnecessary portion 11a, the unnecessary portion 11a can be swelled to make it softer than the necessary portion of the foamed synthetic resin 11. The necessary portion (main portion) of the foamed synthetic resin 11 has a hardness of 1 to 10 Shore A, and the unnecessary portion 11a of the foamed synthetic resin 11 has a hardness of 15 to 30 Shore A. The swollen unnecessary portion 11a has a hardness of 8 to 15 Shore A.

[0039] Furthermore, an unnecessary part removing step S35 is performed to remove the swollen unnecessary part 11a. Specifically, the softened unnecessary part 11a is gripped by a gripping device 70 (described later). In this case, since the unnecessary part 11a is soft, the gripping force by the gripping device 70 can be reduced compared to when the unnecessary part 11a is not swollen. This makes it possible to reduce the size of the gripping device 70 itself, reduce the driving force required for the gripping device 70, and ultimately achieve size and energy savings in the driving unit of the gripping device 70.

[0040] Although most of the unnecessary portions 11a can be removed by the gripping device 70, some unnecessary portions 11a remain. In order to remove the remaining unnecessary portions 11a, a brush or the like may be used.

[0041] (Foam synthetic resin molding manufacturing equipment) Furthermore, the manufacturing apparatus 30 for the foamed synthetic resin molded product 10 described above will be described with reference to Figures 5 to 7. The manufacturing apparatus 30 is a manufacturing apparatus for manufacturing the foamed synthetic resin molded product 10, and in particular a manufacturing apparatus for removing the unnecessary portion 11a of the foamed synthetic resin molded product 10.

[0042] The manufacturing device 30 includes a robot 40. To the robot 40, an incision forming device 50, an application device 60, and a gripping device 70 can be detachably attached (mounted) as end effectors.

[0043] As shown in FIG. 5, the robot 40 is a so-called articulated robot, a vertical articulated robot having six drive axes. The robot 40 is a so-called serial link type robot arm in which multiple drive axes (or arms) are arranged in series. The robot 40 includes a first joint axis 41a to a sixth joint axis 41f, an arm base 42a, a first arm 42b, a second arm 42c, and a tip 42d. The robot 40 operates the first joint axis 41a to the sixth joint axis 41f to move the arm base 42a, the first arm 42b, the second arm 42c, and the tip 42d, thereby operating an end effector attached to the tip 42d to a desired position and angle. In FIG. 5, a notch forming device 50 is attached as the end effector.

[0044] The first joint shaft 41a to the sixth joint shaft 41f are each driven by a drive source (for example, an electric motor). The first joint shaft 41a is installed on a base (not shown) and causes the arm base 42a to rotate (horizontally rotate) around the rotation axis (vertical) of the first joint shaft 41a. The second joint shaft 41b is provided on the arm base 42a and causes the first arm portion 42b to rotate around the rotation axis of the second joint shaft 41b. The third joint shaft 41c is provided at the tip of the first arm portion 42b and causes the second arm portion 42c to rotate around the rotation axis of the third joint shaft 41c.

[0045] The fourth joint shaft 41d is provided at the tip of the second arm portion 42c and rotates (twists) the first tip portion 42d1 around the rotation axis of the fourth joint shaft 41d. The first tip portion 42d1, together with the second tip portion 42d2, forms the tip portion 42d. The fifth joint shaft 41e is provided at the first tip portion 42d1 and rotates the second tip portion 42d2 around the rotation axis of the fifth joint shaft 41e. The sixth joint shaft 41f is provided at the second tip portion 42d2 and rotates (twists) the end effector around the rotation axis of the sixth joint shaft 41f. An end effector is detachably attached to the sixth joint shaft 41f.

[0046] The robot 40 is not limited to a vertical articulated robot, but may also be a horizontal articulated robot, a Cartesian robot, or a parallel link robot (SCARA robot). A horizontal articulated robot is a robot whose arms (links) move horizontally. A Cartesian robot is composed of two or three orthogonal sliding axes. A parallel link robot (SCARA robot) is a robot having a mechanism in which multiple connecting chains made of links and joints are arranged in parallel between an output link and a base.

[0047] The incision forming device 50 is suitable for use in the range setting step S31 described above. As shown in Fig. 5, the incision forming device 50 includes a hot blade 51 for forming the incision 15, a heating unit 52 (heater) for heating the hot blade 51, and an advancing / retracting unit 53 for advancing and retracting the hot blade 51. The advancing / retracting unit 53 reciprocates the hot blade 51 between an advanced position (shown by a dashed line in Fig. 5) and a retracted position (shown by a solid line in Fig. 5).

[0048] The operation of the slit forming device 50 will be described. The slit forming device 50 is moved by the robot 40 from the original position to a predetermined slit forming position. The hot blade 51 is heated by the heating unit 52, and the heated hot blade 51 is advanced by the advancing / retracting unit 53 toward the portion of the foamed synthetic resin molded product 10 where the slit is to be formed. When the hot blade 51 comes into contact with the portion of the foamed synthetic resin molded product 10 where the slit is to be formed, the slit 15 is formed in that portion. The hot blade 51 is then retracted by the advancing / retracting unit 53 from the portion of the foamed synthetic resin molded product 10 where the slit is to be formed. The slit forming device 50 is moved by the robot 40 from the predetermined slit forming position to the original position.

[0049] The incision forming device 50 may be configured to omit the advancing / retreating unit 53. In this case, the robot 40 may be driven to advance and retract the hot blade 51.

[0050] The thermal blade 51 may have a cutting edge. In this case, the robot 40 may be driven to move the incision forming device 50 so that the cutting edge moves along a desired path corresponding to the incision 15. The incision forming device 50 may also be configured as a laser device. In this case, the robot 40 may be driven to move the incision forming device 50 so that the laser emitted from the laser device moves along a desired path corresponding to the incision 15.

[0051] The coating device 60 is a device suitable for use in the coating step S33 described above. For example, a spray device can be used as the coating device 60. As shown in Fig. 6, the coating device 60 includes a nozzle 61 that sprays the swelling liquid, and a main body 62 that has a pressure-feeding unit (not shown) that pressure-feeds the swelling liquid from a storage tank (not shown) that stores the swelling liquid to the nozzle 61.

[0052] The operation of the coating device 60 will now be described. The coating device 60 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 61. Because the nozzle 61 has high directionality, it is possible to spray a predetermined amount of swelling liquid accurately onto the removal range (desired range) of the unnecessary part 11a. This makes it possible to swell the unnecessary part 11a within the removal range of the unnecessary part 11a. Thereafter, the coating device 60 is moved from the predetermined coating position to the original position by the robot 40.

[0053] The coating device 60 may be provided with a cover 63 that can cover the removal range (desired range) of the unnecessary part 11a. In this case, when the coating device 60 is moved to a predetermined coating position by the robot 40, the opening of the cover 63 may be positioned to cover the removal range of the unnecessary part 11a.

[0054] The gripping device 70 is a device suitable for use in the unnecessary part removal step S35 described above. As shown in Fig. 7, the gripping device 70 includes a pair of claws 71, 71 for clamping and gripping an object to be gripped (in this embodiment, the swollen unnecessary part 11a), and a main body 72 having a drive unit (not shown) for driving the pair of claws 71, 71.

[0055] The operation of the gripping device 70 will be described. The gripping device 70 is moved from its 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 Figure 7). 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 swollen unwanted part 11a. The gripping device 70 is then returned to its original position by the robot 40, still clamping the swollen unwanted part 11a. This allows the gripping device 70 to grab and remove the unwanted part 11a.

[0056] In the above-described manufacturing apparatus 30, the incision forming device 50, the coating device 60, and the gripping device 70 are each attached to the robot 40, but this is not limiting, and the incision forming device 50, the coating device 60, and the gripping device 70 may each be installed independently. In this case, the manufacturing apparatus has the incision forming device 50, the coating device 60, and the gripping device 70 arranged in this order. In addition, in the above-described embodiment, the incision forming device 50, the coating device 60, and the gripping device 70 are each attached to separate robots 40, but they may also be attached together to a single robot 40.

[0057] (Actions and Effects of the Embodiments) The manufacturing method of the foamed synthetic resin molded product 10 according to the embodiment described above is a manufacturing method of a foamed synthetic resin molded product 10 having foamed synthetic resin 11 (formed from foamed synthetic resin 11), and includes a removal step S3 in which a liquid that swells the foamed synthetic resin 11 is applied to the unnecessary portion 11a, which is the unnecessary foamed synthetic resin 11, causing it to swell, and the swollen unnecessary portion 11a is removed.

[0058] According to this manufacturing method for the foamed synthetic resin molded product 10, it is possible to apply a liquid that swells the foamed synthetic resin 11 to the unnecessary portion 11a, which is the unnecessary foamed synthetic resin 11, to cause it to swell, and then remove the swollen unnecessary portion 11a. Therefore, it is possible to provide a manufacturing method for the foamed synthetic resin molded product 10 that can easily remove the unnecessary portion 11a of the foamed synthetic resin 11.

[0059] Furthermore, the manufacturing method for the foamed synthetic resin molded product 10 preferably further includes a range setting step S31 of forming slits 15 to set the removal range of the unnecessary portion 11a. According to this, after forming the slits 15, a liquid that swells the foamed synthetic resin 11 is applied, thereby making it possible to reliably swell and remove the unnecessary portion 11a. At the same time, it is possible to reliably prevent the liquid that swells the foamed synthetic resin 11 from seeping into the essential portion of the foamed synthetic resin 11, and to reliably prevent the essential portion of the foamed synthetic resin 11 from swelling.

[0060] In the method for manufacturing the foamed synthetic resin molded product 10, the slits 15 are preferably formed using a hot blade 51. This ensures that the slits 15 are reliably formed, the liquid that swells the foamed synthetic resin 11 is reliably permeated, and the unnecessary portion 11a is reliably swelled.

[0061] Furthermore, in the manufacturing method of the foamed synthetic resin molded product 10, it is preferable to apply the liquid that swells the foamed synthetic resin 11 by spraying in the removal step S3. This makes it possible to properly and reliably apply the liquid that swells the foamed synthetic resin 11 to the desired area. Furthermore, by controlling the supply amount of the liquid to be sprayed, it becomes possible to reliably control the amount of application of the liquid that swells the foamed synthetic resin, making it possible to properly and reliably apply the desired amount.

[0062] In the manufacturing method of the foamed synthetic resin molded product 10, the foamed synthetic resin molded product 10 is preferably formed integrally with the embedding member 12, and the removing step S3 preferably removes the unnecessary part 11a attached to the embedding member 12. This makes it possible to reliably and easily remove the unnecessary part 11a attached to the embedding member 12.

[0063] In the manufacturing method of the foamed synthetic resin molded product 10, the removal range of the unnecessary part 11a is preferably set to be the inner range of a predetermined part of the embedding member 12. This makes it possible to more reliably and easily remove the unnecessary part 11a attached to the embedding member 12.

[0064] In addition, the manufacturing apparatus 30 for a foamed synthetic resin molded product 10 according to the present invention is a manufacturing apparatus 30 for a foamed synthetic resin molded product 10 having a foamed synthetic resin 11, and is characterized in that it is equipped with an application section (application device 60) that applies a liquid that swells the foamed synthetic resin 11 to the unnecessary part 11a, which is the unnecessary foamed synthetic resin 11, and a removal section (gripping device 70) that removes the swollen unnecessary part 11a.

[0065] According to this manufacturing apparatus 30 for foamed synthetic resin molded products 10, the application device 60 applies a liquid that swells the foamed synthetic resin 11 to the unnecessary portion 11a, which is the unnecessary foamed synthetic resin 11, and the gripping device 70 removes the swollen unnecessary portion 11a. Therefore, it is possible to provide a manufacturing apparatus 30 for foamed synthetic resin molded products 10 that can easily remove the unnecessary portion 11a of the foamed synthetic resin molded product 10.

[0066] In addition, the foamed synthetic resin molded product 10 of the present invention is a foamed synthetic resin molded product 10 having foamed synthetic resin 11, and is characterized in that a liquid that swells the foamed synthetic resin 11 is applied to the unnecessary part 11a, which is the unnecessary foamed synthetic resin 11, causing it to swell, and the product has a notch 15 for setting a removal range in which the swollen unnecessary part 11a should be removed.

[0067] According to this foamed synthetic resin molded product 10, it is possible to apply a liquid that swells the foamed synthetic resin 11 to the unnecessary portion 11a, which is the unnecessary foamed synthetic resin 11, to cause it to swell, and then remove the swollen unnecessary portion 11a. Thus, it is possible to provide a foamed synthetic resin molded product 10 from which the unnecessary portion 11a of the foamed synthetic resin 11 has been easily removed. [Explanation of symbols]

[0068] 10...foamed synthetic resin molded product, 11...foamed synthetic resin, 11a...unwanted part, 12...embedded member, 15...notch, 30...manufacturing device, 51...heat blade, 60...applying part (applying device), 70...removing part (gripping device), S3...removing process, S31...range setting process.

Claims

1. A method for producing a foamed synthetic resin molded product having a foamed synthetic resin, comprising: A method for manufacturing a foamed synthetic resin molded product, comprising a removal step of applying a liquid that swells the foamed synthetic resin to an unnecessary portion of the foamed synthetic resin, thereby causing the unnecessary portion to swell, and removing the swollen unnecessary portion.

2. 2. The method for manufacturing a foamed synthetic resin molded product according to claim 1, further comprising a range setting step of forming a notch for setting the range for removing the unnecessary portion.

3. 3. The method for manufacturing a foamed synthetic resin molded product according to claim 2, wherein the incisions are formed by a hot blade.

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

5. The foamed synthetic resin molded product has an embedded member integrally molded therein, 5. The method for producing a foamed synthetic resin molded product according to claim 1, wherein the removing step removes the unnecessary part adhering to the embedding member.

6. 6. The method for manufacturing a foamed synthetic resin molded product according to claim 5, wherein the range of removal of the unnecessary portion is set to be an inner range of a predetermined portion of the embedded member.

7. An apparatus for manufacturing a foamed synthetic resin molded product having a foamed synthetic resin, an application unit that applies a liquid that swells the foamed synthetic resin to the unnecessary portion that is the unnecessary foamed synthetic resin; a removal section for removing the swollen unnecessary portion.

8. A foamed synthetic resin molded product having a foamed synthetic resin, A foamed synthetic resin molded product characterized in that a liquid that swells the foamed synthetic resin is applied to the unnecessary portion, which is the unnecessary foamed synthetic resin, causing it to swell, and the product has a notch for setting a removal range for the swollen unnecessary portion to be removed.

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