JP5297513B2 - Foam molding - Google Patents

Description

  The present invention relates to a foam molded article, and more particularly to a foam molded article used by forming a three-dimensional shape.

  The foam material has properties of heat insulation and buffering properties. As the foam material, for example, bead method expanded polystyrene (EPS), bead method expanded polypropylene (Expanded Polypropylene: EPP), bead method expanded polyethylene (Expanded Polyethylene: EPE), and the like are known. . Conventionally, foam is formed to cover the objects to insulate the objects to be insulated by using the heat insulating property of the foam material or to protect the objects to be protected from shock by using the cushioning property. A material molded product is used. At this time, if the object is three-dimensional, a foam molded product covering the object is used by forming a three-dimensional shape so as to match the shape of the object.

  For example, when a tank T of a water heater having a cylindrical shape as shown in FIG. 5 is covered with a foamed polystyrene molded product M as a heat insulation object, as shown in FIG. The expanded polystyrene molded product M and the two semi-cylindrical expanded polystyrene molded products M covering the side surfaces are combined. By covering the tank T with these polystyrene foam molded products M, the entire surface of the tank T is covered with the polystyrene foam as shown in FIG.

  FIG. 8 is a perspective view of a conventional foamed polystyrene molded product M covering the side surface of the tank T of the water heater. As shown in FIG. 8, the expanded polystyrene molded product M covering the curved surface such as the side surface of the tank T has a curved surface and is three-dimensionally formed. Even when the surface of the object is not a curved surface, for example, if there is a corner, the expanded polystyrene molded product M covering the corner is bent at the corner and becomes a three-dimensional shape.

  As prior arts related to the present invention, there are prior arts described in the following prior art documents.

JP 2010-091134 A

  However, when the expanded polystyrene molded article is formed three-dimensionally, there is a problem that a space required for storage and transportation increases. Further, at the time of storage and transportation, concentrated stress may be applied to a part of the foamed polystyrene molded product and it may break. This will be specifically described below.

  FIG. 9 is a view showing a state in which a plurality of the polystyrene foam molded products shown in FIG. 8 are stacked for storage or transportation. Since the polystyrene foam molded product M attached to the side surface of the tank T of the water heater has a semi-cylindrical shape, the space between the two becomes large when stacked, and a relatively large space S1 is required. In addition, when a load is applied from above, stress concentrates in the central portion, and cracks and cracks are likely to occur.

  The present invention has been made to solve the above-described conventional problems, and an object of the present invention is to provide a foamed molded article that forms a three-dimensional shape during use and is not bulky during storage or transportation. Another object of the present invention is to provide a foamed molded article that is less prone to cracking or cracking during storage or transportation.

  The foamed material molded product of the present invention is a foamed material molded product used by forming a three-dimensional shape, and has a configuration having a slit portion for folding or expanding the foamed material molded product. With this configuration, a foam molded product molded in a shape close to a flat surface is bent at the slit portion to form a solid, or a foam molded product molded into the target three-dimensional shape is expanded at the slit portion (expanded). By forming a shape close to a plane, a desired three-dimensional shape can be formed at the time of use, and a space required for a shape close to a plane can be kept small during storage and transportation.

  In the above foamed material molded product, the slit portion may be formed from one end to the other end of the foamed material molded product. With this configuration, it is possible to fold or unfold the foam molded product using the slit portion as a hinge.

  Further, in the foamed material molded product, the slit portion includes an inner slit formed on the inner side, an outer slit formed on the outer side, and a thin portion formed between the inner slit and the outer slit. It may be. With this configuration, the thin-walled portion is deformed, so that the foamed molded product can be folded inward or expanded outward. In addition, since the slit is formed on both the inside and the outside, it is possible to avoid the occurrence of stress in the slit part in both the folded state and the expanded state, and the foam material molding when forming a three-dimensional shape The crack of the product can be prevented.

  Further, in the foamed molded article, the inner slit and the outer slit may be formed so as to be shifted from each other. With this configuration, it is possible to disperse the stress generated during bending or unfolding.

  In the foamed material molded product described above, the thin portion may be formed obliquely from one outer side to the other inner side of the portions on both sides of the slit portion. With this configuration, it is possible to more effectively disperse the stress generated during bending or unfolding.

  Moreover, in said foamed material molded product, the base part with respect to each of the part of the both sides of the said slit part may be formed thicker than a center. With this configuration, cutting and cracking in the thin portion can be effectively prevented.

  Further, the foamed molded product may be bent at the slit portion to form the entire circumference of the cylindrical shape or a part thereof. With this configuration, the cylindrical object can be covered with the foam material product.

  The foamed material molded product may be any one of a beaded foamed polystyrene molded product, a beaded foamed polypropylene molded product, or a beaded foamed polyethylene molded product. With this configuration, the foamed molded product can be used as a heat insulating material.

  The present invention relates to a foam molded article molded in a shape close to a flat surface, bent at a slit portion to form a desired three-dimensional shape, or a foam molded article molded into a target three-dimensional shape at a slit portion. By unfolding and forming a shape close to a plane, a target solid can be formed at the time of use, and a space required for a shape close to a plane can be kept small during storage and transportation.

The expanded sectional view of the slit part of the polystyrene foam molded product of embodiment of this invention The perspective view of the polystyrene foam molded product (at the time of storage and transportation) of an embodiment of the invention The perspective view of the polystyrene foam molded product (at the time of use) of embodiment of this invention The figure which shows the state which piled up the plurality of the polystyrene molded articles of this invention for storage or transportation. Perspective view of a tank of a water heater having a cylindrical shape covered with a polystyrene foam molded product Exploded view of a water heater tank having a cylindrical shape and a conventional polystyrene foam molded product covering it A perspective view of a tank of a water heater covered with a conventional foamed polystyrene molded product Perspective view of a conventional foamed polystyrene molded product covering the side surface of a water heater tank The figure which shows the state where two or more conventional polystyrene moldings were put on top of each other for storage or transportation

  Hereinafter, a foamed material molded product according to an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is an enlarged cross-sectional view of a slit portion of a foamed polystyrene molded product according to an embodiment of the present invention, and FIG. 2 is a perspective view of the foamed polystyrene molded product (during storage and transportation) of the embodiment of the present invention. FIG. 3 is a perspective view of the expanded polystyrene molded product (in use) according to the embodiment of the present invention.

  A beaded polystyrene foam molded article 1 (hereinafter simply referred to as “foam polystyrene molded article 1”) as a foam molded article according to an embodiment of the present invention is attached to a side surface of a tank T as a heat insulating material covering the tank T of a water heater. Used. A tank T that is an object covered with the expanded polystyrene molded product 1 has a cylindrical shape with a height of 1500 mm and a diameter of 700 mm. The expanded polystyrene molded article 1 does not cover the entire circumference of the side surface of the tank T, but covers only half. Therefore, as shown in FIG. 3, the expanded polystyrene molded product 1 forms a semi-cylindrical shape at the time of use. Note that the other half of the tank T is covered with another expanded polystyrene molded product having the same configuration, so that the entire circumference of the tank T is covered with the expanded polystyrene molded product as a heat insulating material.

  In the following description, terms indicating directions such as up / down / left / right, vertical / horizontal, inside / outside, etc. indicate directions in a state in which the expanded polystyrene molded product 1 is attached to the tank T. In the expanded polystyrene molded article 1, four slit portions 11 are formed in the vertical direction from the upper end to the lower end. In the foamed polystyrene molded article 1, five portions of the left connecting portion 12a, the left portion 12b, the central portion 12c, the right portion 12d, and the right connecting portion 12e are formed in order from the left with the four slit portions 11 as a boundary. .

  The left connecting portion 12a, the left portion 12b, the central portion 12c, the right portion 12d, and the right connecting portion 12e are each projected outward so as to match the outer surface of the tank T when attached to the cylindrical tank T. And has a curved shape. The expanded polystyrene molded product 1 has four slit portions 11 as hinges, and both side portions thereof are bent inward at a predetermined angle to form a semi-cylindrical shape as a whole, and the inner side surface thereof is a cylindrical shape. The shape matches the outer surface of the tank T. The polystyrene foam molded product 1 is appropriately formed with notches and holes in order to escape the legs, the operation unit, the pipes and the like provided in the tank T.

  The foamed polystyrene molded product 1 has a shape close to a plane as shown in FIG. 2 so as to reduce the space occupied during storage and transportation, in particular, the space occupied when a plurality of foamed polystyrene molded products 1 are stacked. Is done. Moreover, when using, as shown in FIG. 3, it is set as the desired three-dimensional shape (namely, semi-cylindrical shape).

  FIG. 4 is a diagram showing a state in which a plurality of foamed polystyrene molded products 1 are placed in piles for storage or transportation. As apparent from the case of the conventional foamed polystyrene molded article of FIG. 8, when the foamed polystyrene molded article 1 is in a shape close to a plane for storage or transportation, the occupied space S2 can be reduced.

  As described above, the expanded polystyrene molded product 1 has a semi-cylindrical shape when in use, and the two expanded polystyrene molded products 1 are combined to form a cylindrical shape covering the entire circumference of the tank T. At this time, the left connection part 12a of one expanded polystyrene molded product 1 and the right connection part 12e of the other expanded polystyrene molded product 1 are connected, and the right connection part 12e of one expanded polystyrene molded product 1 and the other expanded polystyrene molded product. 1 right connection part 12a is connected. The two polystyrene foam molded products 1 to be combined basically have the same shape except for a portion where the legs of the tank T are escaped.

  Of these two expanded polystyrene molded articles 1, the left connecting portion 12a of one expanded polystyrene molded article 1 is formed with an uneven shape, and the right connected portion 12e of the other expanded polystyrene molded article 1 is formed with one expanded polystyrene molded article. Irregularities are formed so as to be connected to the response shape of the left connection portion 12a of the product 1. In addition, a concavo-convex shape is also formed in the right connection portion 12e of one of the expanded polystyrene molded products 1, and the response of the right connection portion 12e of the one expanded polystyrene molded product 1 is also formed in the left connection portion 12a of the other expanded polystyrene molded product 1. Irregularities are formed so as to be connected to the shape.

  One foamed polystyrene molded product 1 and the other foamed polystyrene molded product 1 form a semi-cylindrical shape and are combined so as to surround the tank T, so that the entire circumference of the tank T is 8 by a total of eight slit portions 11. It is covered with a cylindrical foamed polystyrene molding consisting of two parts. Each of the expanded polystyrene molded products 1 is bent at the eight slit portions 11 so that the inner surface thereof matches the outer surface of the tank T.

  When such a polystyrene foam molded product 1 is molded, as shown in FIG. 2, it is molded so as to have a shape close to a plane, that is, so that the slit portions 11 are aligned on the plane. . That is, at the time of storage and transportation, the foamed polystyrene molded product 1 has a shape close to a plane as shown in FIG. 2, but at this time, the shape close to this plane is used so that no stress is generated in the slit portion 11. Molded.

  Next, the detailed structure of the slit part 11 is demonstrated with reference to FIG. As shown in FIG. 1, the slit portion 11 includes an outer slit 11 a formed on the outer side (front side) of the expanded polystyrene molded product 1, an inner slit 11 b formed on the inner side of the expanded polystyrene molded product 1, and an outer slit 11 a and an inner slit. It consists of the thin part 11c formed between 11b. The upper side and the lower side in FIG. 1 are the outer side and the inner side of the expanded polystyrene molded article 1, respectively.

  The outer slit 11a and the inner slit 11b have shapes that gradually narrow in the depth direction. Specifically, the outer slit 11a and the inner slit 11b are formed in a triangular shape with rounded vertices. The outer slit 11a and / or the inner slit 11b may be formed in an arc shape, and the outer slit 11a and / or the inner slit 11b are formed in a trapezoidal shape, that is, the bottom surface (the deepest portion in the depth direction) is formed in a plane. May be.

  The outer slit 11a and the inner slit 11b are formed so as to be shifted in the left-right direction so that a part of them is overlapped in the thickness direction. As a result, the outer slit 11a and the inner slit 11b are formed in a shape in which the width is gradually narrowed in the depth direction (the slit cut surface is inclined with respect to the thickness direction). A thin portion 11c is formed obliquely from the outer side of one part on both sides of the upper side to the inner side of the other side. In addition, the outer slit 11a and the inner slit 11b are formed to be shifted in the left-right direction, and the outer slit 11a and the inner slit 11b are formed in a triangular shape with rounded vertices, so that the thin portion 11c. Is formed in a shape in which the roots on both side portions are thicker than the central portion.

  In the example of FIG. 1, the thickness in the vicinity of the slit portion 11 of the expanded polystyrene molded article 1 is 10 mm, and the thinnest portion of the thin portion 11c is located at a position about 7 mm from the inside, and the thickness is 1 mm. The deviation between the outer slit 11a and the inner slit 11b is about 3 mm.

  The structure of the slit part 11 of the expanded polystyrene molded article 1 of this invention is not restricted to this. For example, the thinnest portion of the thin portion 11c may be 0.3 mm to 3 mm, preferably 0.5 mm to 2 mm, and 0.8 mm to 1.5 mm, as a result of experiments by the inventors. Is more preferable. If the thinnest part of the thin part 11c is too thin, it may be cut at that part when it is bent at the slit part 11 in an attachment operation or the like. Conversely, the thinnest part of the thin part 11c is thick. If it is too large, when it is bent at the slit portion 11 in the mounting operation or the like, there is a possibility that a crack will occur at that portion. From these viewpoints, it is desirable that the thickness of the thinnest portion of the thin portion 11c be in the above range.

  The expanded polystyrene molded product 1 formed as described above is bent inward at the slit portion 11, so that the lower end of the inner slit 11 b (the portions on both sides of the inner slit 11 b) abuts and further bending is restricted. The inner surface is along the outer surface of the tank T. Since each part divided by the slit portion 11 of the expanded polystyrene molded product 1 is curved along the outer surface of the tank T, the expanded polystyrene molded product 1 is bent at the slit portion 11 and put on the tank T. The inner surface of the expanded polystyrene molded product 1 is in close contact with the outer surface of the tank T.

  In addition, although there is known a foam molded product that has a hinge portion and can be freely bent at the hinge portion, in such a conventional foam molded product, in order to ensure the strength of the hinge portion, In the hinge portion, the foam material is solid. In order to make a part of the foamed material molded into a solid state, setting at the time of molding in the foamed material molding apparatus is not easy, and in order to maintain high accuracy, the manufacturing cost increases. Even so, when the application is scheduled to be repeatedly bent and unfolded frequently at the hinge part, the foam material is solid at the hinge part in order to ensure the strength that can withstand such an application. It is necessary to take measures such as making

  On the other hand, in this embodiment, it is assumed that the shape is close to a flat surface during storage and transportation, and a three-dimensional shape is formed when mounting, and after mounting, that is, during use. In addition, it is not assumed that folding and unfolding are repeated by the hinge. Therefore, by making the slit portion 11 serving as a hinge as described above, the required strength can be realized without making the slit portion 11 solid, and setting for such molding is easy. Yes, manufacturing costs can be reduced. That is, the expanded polystyrene molded product 1 of the present embodiment is formed by foaming expanded beads under the same conditions throughout the entire thin portion 11 c of the slit portion 11.

  As described above, according to the present embodiment, by providing the slit part 11 as a hinge in the foamed polystyrene molded article 1 that becomes a semi-cylindrical heat insulating material when attached to the tank T, during transportation before attachment and During storage, the shape can be made closer to a flat surface. Therefore, a required space can be reduced as compared with a case where a polystyrene foam molded product as a heat insulating material attached to the tank T is formed into a semi-cylindrical shape as in the prior art.

  In the present embodiment, two combined polystyrene foam articles 1 that cover the entire circumference of the tank T are divided into eight parts by the slit part 11, which is necessary for storage and transportation. However, the slit portion 11 is not provided as in the embodiment of the present invention, but the combination of eight foamed polystyrene molded products obtained by dividing the entire circumference of the tank 11 into eight parts. Even when the entire circumference is covered, the space for storage and transportation can be reduced in the same manner. However, in this case, it becomes complicated which foamed polystyrene molded product is combined with which foamed molded product, which may cause confusion during installation. Further, each of the eight foamed polystyrene molded products has a risk of chipping at the edge during transportation or the like.

  On the other hand, in the present embodiment, two foamed polystyrene molded articles are required to cover the entire circumference of the side surface of the tank T, and confusion is unlikely to occur when the tank T is attached to the tank T. In FIG. 5, no chipping occurs at the portion where the slit portions 11 are connected, and the number of spots where the chipping can occur is reduced.

  In addition, the polystyrene foam molded product 1 has a curved shape in which the portions on both sides of the slit portion 11 are bent and the inner surface of each portion is matched with the outer surface of the cylindrical tank T at the time of attachment work or the like. Since it is formed, a semi-cylindrical shape covering the columnar tank can be formed.

  In the above embodiment, one foamed polystyrene molded product 1 is bent with the slit portion 11 as a hinge to form a semi-cylindrical shape, and two such foamed polystyrene molded products 1 are combined to form a cylindrical tank. The entire circumference of T is covered, but one foamed polystyrene molded product may be bent to form a cylindrical shape, and one foamed polystyrene molded product may cover the entire circumference of the cylindrical tank T. One foamed polystyrene molded product may be bent to form a quarter cylindrical shape, and four such foamed polystyrene molded products may be combined to cover the entire circumference of the tank T.

  Moreover, in said embodiment, although the four slit parts 11 were formed with respect to the foamed polystyrene molded product 1 which forms a semi-cylindrical shape, the number of the slit parts of the foamed material molded product of this invention is more than that. Or less. In particular, the number of slit portions may be increased or decreased depending on the circumferential length of a part of the cylindrical shape formed by the foamed material molded product. For example, when a foamed molded product forms one third of the entire circumference of a cylindrical shape by bending the slit portion as a hinge, such a foamed polystyrene molded product has two or three slits. The part may be formed.

  Further, in the above-described embodiment, the polystyrene foam molded product 1 is molded into a shape during storage or transportation, that is, a shape in which a plurality of slit portions are arranged on a plane (that is, a gold used for molding). The shape of the mold corresponds to a shape close to the plane shown in FIG. 2), and the shape at the time of storage and transportation is molded so that no stress is generated in the slit portion 11, but the present invention is limited to this. Absent. The foamed molded product of the present invention is molded so as to form a desired three-dimensional shape at the time of molding (that is, the shape of the mold used for molding corresponds to the semi-cylindrical shape shown in FIG. 3). ), During storage and transportation, the foamed material molded product is developed at the slit portion, so that the shape close to the plane, that is, the slit portion may be arranged on one plane. In this case, stress is generated in the slit portion during storage and transportation, but no stress is generated in the slit portion during use.

  Further, in the above embodiment, the foamed polystyrene molded product 1 is formed so as to form a cylindrical shape when it is bent at the slit portion 11 so as to cover the columnar tank T, but the foam of the present invention. The material molded product may be molded so as to form a three-dimensional shape other than the cylindrical shape by being bent at the slit portion. For example, a hollow quadrangular prism may be formed by forming three parallel slit portions from the upper end to the lower end on a foamed molded product on a flat plate and using these slit portions as hinges. . In addition, the foamed molded article of the present invention is assembled into a polyhedron (for example, a hexahedron) or a part thereof (a shape excluding one face of the hexahedron) by forming a plurality of slit portions as hinges in a plurality of directions. ) May be formed.

  In the above embodiment, a foamed polystyrene molded product is used as the foamed molded product covering the tank T. However, the foamed molded product of the present invention is a foamed polypropylene molded product or a foamed polyethylene molded product. Also good. In addition, it is desirable that the foamed material molded product is molded by a bead method from the viewpoint of manufacturing cost and the like. From the viewpoint of ensuring strength by having the slit portion of the present embodiment, the foamed molded article of the present invention is molded by a method with a high production cost other than the bead method, or a hinge is formed, or other There is no need to adopt expensive materials.

  As described above, the foamed molded product of the present invention has a slit part, and the slit part is bent as a hinge to form or form a desired three-dimensional shape. It is three-dimensionally formed and has the effect of not being bulky during storage or transportation, and is useful as a foamed molded article used by forming a three-dimensional shape.

DESCRIPTION OF SYMBOLS 1 Styrofoam molded product 11 Slit part 11a Outer slit 11b Inner slit 11c Thin part 12a Left connection part 12b Left part 12c Center part 12d Right part 12e Right connection part

Claims (5)

It is a foam molded product used to form a three-dimensional shape,
The bent foam moldings, or have a slit portion for deployment,
The slit part is composed of an inner slit formed on the inner side, an outer slit formed on the outer side, and a thin part formed between the inner slit and the outer slit,
The inner slit and the outer slit are formed offset from each other,
The foamed article is characterized in that the thin portion is formed obliquely from one outer side to the other inner side of both sides of the slit portion . It is a foam molded product used to form a three-dimensional shape,
The bent foam moldings, or have a slit portion for deployment,
The slit part is composed of an inner slit formed on the inner side, an outer slit formed on the outer side, and a thin part formed between the inner slit and the outer slit,
The inner slit and the outer slit are formed offset from each other,
The thin-walled portion is a foamed molded article , wherein the base portion of each of the portions on both sides of the slit portion is formed thicker than the center . The foamed material molded product according to claim 1 or 2 , wherein the slit portion is formed from one end to the other end of the foamed material molded product. The foamed product according to any one of claims 1 to 3 , wherein the foamed molded product is bent or expanded at the slit portion to form a cylindrical periphery or a part thereof. Material molded product. The foam molded article, beads method polystyrene foam moldings, beads method expanded polypropylene moldings, or of beads method expanded polyethylene molded article according to any one of claims 1 to 4, characterized in that either Foam molded product.

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