JPH07341B2 - Box-shaped container-like molded article provided with surface material layer made of non-stretchable fabric and method for molding the molded article - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a box-shaped container, such as a bag shell, having a flat quadrangle and each corner having curved surfaces, and a molded article having a surface material layer made of a non-stretchable fabric, and its molding. A method of molding an article.

[0002]

2. Description of the Related Art Conventionally, it is possible to form a cloth surface material layer on the surface of a box-shaped container-like three-dimensional object such as a bag shell without causing wrinkles in the layer, by making the cloth stretch. I was there. Therefore, the cloth surface layer can be provided on the surface of the three-dimensional object in the shape of a box-shaped container when the cloth is (1) the yarn itself constituting the cloth has elasticity. (2) When elasticity can be exerted structurally like knitting. (3) When the mutual yarns are misaligned due to a collection of single fibers such as a non-woven fabric. Was limited to.

[0003]

Therefore, a fabric having a structure that is structurally inelastic in the longitudinal and transverse directions, such as a woven fabric, and having fibers that do not have elasticity is also provided as a surface layer. A box-shaped container having no wrinkle on the surface layer has not been provided so far. The present invention has been made in view of the current situation, and the object thereof is a structure such as a woven fabric that is not structurally stretchable, and the fibers themselves are not stretchable. It is intended to provide a box-shaped three-dimensional object as a surface layer.

[0004]

In order to achieve the above object, in a box-shaped container-shaped molded article having a surface material layer made of a non-stretchable woven fabric of the present invention, the shape of the molded article is a plane quadrangle and each corner is A box-shaped container composed of curved surfaces, and a core material made of thermoplastic nonwoven fabric or inorganic fiber nonwoven fabric made of thermoplastic resin as a matrix substantially constitutes the main body of the molded product, and its surface is non-stretchable. The surface material layer made of a woven fabric is integrally provided, and the surface material layer is
In parts other than the corner radius of the molded product, the warp threads and the weft threads are provided so as to be parallel to the vertical and horizontal side edges of the molded product, and within the line connecting both ends of the corner radius of the molded product and the center of curvature of the corner radius. Is that the texture of the surface material is deformed in the bias direction and the yarn density of the portion becomes larger than the yarn density of the other portions, and this yarn density is the maximum on the line connecting the corner radius center and the curvature center of the corner radius, The radius is gradually reduced toward the line connecting the both ends of the corner radius and the center of curvature of the corner radius. Then, in the production of such a molded article, the step of heating and softening the thermoplastic nonwoven fabric or the inorganic fiber nonwoven fabric made of a thermoplastic resin as a core material, the non-stretchable fiber serving as a surface material on the heat-softened core material. Including the step of stacking woven fabrics and press-molding, the material holding force of the clamp that holds the surface material during the press-molding step,
It is strongest in the part corresponding to the line connecting the center of the corner radius and the center of curvature of the corner radius in each corner of the molded product, and becomes gradually smaller as it approaches the part corresponding to the line connecting both ends of the corner radius and the center of curvature of the corner radius. By adjusting so that the part corresponding to the part other than the are is almost free,
It is possible. In the present invention, the non-stretchable woven fabric does not mean only a fabric which does not stretch at all in a strict sense, and even a fabric which is slightly stretched by applying a load higher than a normal one has a very small stretch ratio. If any, it shall be included in this.

[0005]

In the box-shaped container-shaped molded product constructed as described above, the texture in the line connecting both ends of the corner radius of each corner portion and the center of curvature of the corner radius is deformed in the bias direction, and the portion is deformed. The yarn density of is larger than that of the other parts, and this yarn density is maximum on the line connecting the center of the corner radius and the center of curvature of the corner are, and on the side of the line connecting both ends of the corner are and the center of curvature of the corner are. It becomes gradually smaller toward the corner, and a three-dimensional surface shape with no wrinkles is formed at the corners. Further, in the molding method, by adjusting the surface material holding force of the clamp, during the press molding process,
The tension applied to the surface material is strongest in the part corresponding to the line connecting the center of the corner radius and the center of curvature of the corner radius in each corner of the molded product, and approaches the part corresponding to the line connecting both ends of the corner radius and the center of curvature of the corner radius. The surface material gradually becomes smaller in accordance with the above, and almost no tension is applied to the part other than the corner radius, so the surface material is deformed in the bias direction within the line connecting the both ends of the corner radius of the molded product and the curvature center of the corner radius. , The density of the weaving yarn in that portion is made higher than the density of the weaving yarns in the other portions, and this yarn density is maximum on the line connecting the center of the corner radius and the curvature center of the corner radius, and connecting both ends of the corner radius and the curvature center of the corner radius. It can be gradually reduced toward the line side Kill.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. In this example, the molded product A is a bag shell, and is formed into a thin rectangular box-like container having a flat rectangular shape in which each corner portion is curved and the other portions are straight, and the thermoplastic fiber nonwoven fabric or the thermoplastic resin is used. There are two layers of a core material 1 made of a matt inorganic fiber nonwoven fabric, and a surface material 2 made of a non-stretchable fiber woven fabric, that is, a plain woven fabric which is woven by a yarn that does not have elasticity itself and is structurally unstretchable. It has a structure in which it is laminated and bonded together.

The core material 1 is, for example, polypropylene (P
P) is a thermoplastic fiber non-woven fabric composed of fibers and polyester (PET) fibers, which substantially retains the shape of the bag shell A.

On the other hand, the surface material 2 is, for example, a plain weave of polyester fiber and has a constant load elongation of 2.6% in the longitudinal direction,
The woven fabric has a lateral direction of 1.8% and a bias direction of 33.0%, and is provided integrally with the core material 1 so as to cover the surface of the core material 1. The surface material 2 is provided so that the warp threads 2a and the weft threads 2b are parallel to the longitudinal and lateral side edges of the bag shell A, respectively. Of the portion A1 surrounded by the lines a-c and b-c connecting the centers of curvature c of the portions A1 and A2 are deformed in the bias direction as shown in an enlarged view in FIG. The weaving yarn density is higher than the weaving yarn density of the other portion A2, which is the maximum on the line cd connecting the corner radius center d and the curvature center c of the corner radius, and the corner edges a and b and the corner radius. A line connecting the center of curvature c of
It gradually decreases toward the bc side.

A method of manufacturing the bag shell A will be described below. First, the thermoplastic non-woven fabric of PP and PET serving as the core material 1 is spread and set on the transfer device 3 (a in FIG. 3), and this is carried to the heater zone, and is heated by the heater 4 from above and below to a molding temperature, for example, 190 ° C. Then, it is softened to be suitable for molding (FIG. 3b). On the other hand, the polyester plain weave as the surface material 2 is set on the clamp 5 and placed between the upper die 6 and the lower die 7 for press molding in the molding zone (c in FIG. 3).

Next, the core material 1 which has been softened by heating to the molding temperature is moved to the molding zone, and is superposed on the lower side of the surface material 2 already set in the clamp 5 in the zone, and the upper and lower molds 6, 7 and press-mold (FIG. 3 c,
d). At this time, an adhesive such as a hot melt film is interposed between the core material 1 and the surface material 2 if necessary.

In the molding step, the tension applied to the surface material 2 is strongest at the portion corresponding to the center d of the bag shell corner radius in the planar shape of the molding portion provided on the molding dies 6 and 7, and both ends of the corner radius are strong. It is gradually reduced as it approaches the portions corresponding to a and b, and the tension is adjusted so that almost no tension is applied to the straight portion e continuous to the corner radius. The tension applied to the surface material 2 is adjusted by the clamp 5 which holds the surface material 2 in the molding zone.

As shown in the figure, the clamp 5 is integrally provided on the lower end of the upper mold 6 so as to surround the upper mold 6 and is formed in a quadrangular ring shape. The surface material 2 is formed on the inner peripheral surface of the clamp 5. A slit for inserting the peripheral edge of the woven fabric is provided, and at each corner, a clamp pressure adjusting device is provided at least at three positions corresponding to the center radius center d of the bag shell A and the corner radius ends a and b. 9, and the surface pressure material 2 is held by the clamp pressure adjusting device 9. That is, according to this clamp 5, the surface material 2 is free from being gripped except for the corner-corresponding portion.

The clamp pressure adjusting device 9 is a pressing plate made of hard rubber or the like by an air or hydraulic cylinder 10.
The pressing member 11 is moved up and down in the slit 8 to hold the surface material 2 by the pressing plate 11 and the inner bottom surface of the slit 8. The pressing plate 11 presses the surface material 2 against the inner bottom surface of the slit 8. The cylinder 10 can be adjusted. And this clamp pressure adjusting device 9
Adjusts the surface material holding force by the one provided at the portion corresponding to the center d of the corner radius to be the strongest, and adjusts the surface material holding force by the one provided at both ends a and b of the corner radius slightly less than that. Incidentally, it is of course optional to provide the clamp pressure adjusting device 9 at three or more places in the corner-corresponding portion,
In that case, the holding force is adjusted to be smaller as the corners are closer to both ends a and b.

After the molding is completed, the mold is removed (e in FIG. 3) and the periphery is trimmed to obtain the product bag shell A (f in FIG. 3).

In the embodiment described above, the molded product A has a two-layer structure of the core material 1 and the surface material 2, but the molded product A may have a three-layer structure including an interior material. It is also possible to simultaneously form three layers containing material. The interior material may be a non-stretchable fabric similar to the surface material 2, or may be a stretchable fabric. Further, the non-stretchable woven fabric serving as the surface material 2 is not limited to the cloth, and may be a woven metal wire or the like.

[Effect] Since the present invention is configured as described above, the following effects can be obtained. (1). Claim 1: The surface material layer is deformed in the bias direction in a line connecting both ends of the corner radius of the molded product and the center of curvature of the corner radius, and the yarn density of the portion is higher than the yarn density of other portions. And, moreover, this yarn density is the maximum on the line connecting the center of the corner radius and the center of curvature of the corner radius,
Since the corner radius is gradually reduced toward the line connecting the center of curvature of the corner radius and the center of curvature of the corner radius, a three-dimensional surface shape is partially formed in the corner portion, and a non-stretchable fiber woven fabric is used as the surface material. Despite being a box-shaped container, wrinkles do not occur on the surface material at the corners. (2). Claim 2; The material holding force of the clamp for holding the surface material at the time of molding is strongest at the portion corresponding to the line connecting the center of the corner radius and the curvature center of the corner radius at each corner of the molded product, and both ends of the corner radius. And the corner radius of curvature are approached to the part corresponding to the line connecting the center of curvature, and gradually become smaller, and the part corresponding to the part other than the corner radius is adjusted to be almost free, and the tension applied to the surface material is It is the strongest in the part corresponding to the line connecting the center of the corner radius and the center of curvature of the corner are in each corner part of, and becomes gradually smaller as it approaches the part corresponding to the line connecting the both ends of the corner radius and the center of curvature of the corner are. Make sure that almost no tension is applied to the parts other than Therefore, even if a woven fabric woven of non-stretchable fibers is used as the surface material, the texture of the surface material is deformed in the bias direction within the line connecting the both ends of the corner radius of the molded product and the center of curvature of the corner radius, The weaving yarn density of the part is made higher than that of the other parts, and the weaving yarn density is maximum on the line connecting the center of the corner radius and the curvature center of the corner are, and the line side connecting the both ends of the corner radius and the curvature center of the corner are. It is possible to gradually reduce the size toward the end, and it becomes possible to form a box-shaped container-shaped molded product without generating wrinkles on the surface material.

[Brief description of drawings]

FIG. 1 is a plan view showing an embodiment of a box-shaped container-shaped product of the present invention.

FIG. 2 is an enlarged perspective view of a corner portion of a molded product for explaining the state of the weaving yarn density of the surface material.

FIG. 3 is an explanatory view showing a molding method according to steps.

FIG. 4 is a cross-sectional view showing a clamp pressure adjusting device of a clamp.

FIG. 5 is a plan view of the clamp showing the installation position of the clamp pressure adjusting device.

Claims (2)

[Claims] 1. A box-shaped container-shaped molded product having a flat quadrangular shape and each corner having curved surfaces, wherein a core material made of a thermoplastic non-woven fabric or an inorganic fiber non-woven fabric using a thermoplastic resin as a matrix is substantially formed. configure molded article body, it integrally includes a surface material layer made of fabric weaving non-stretchable fibers on the surface, the surface material layer is a corner a of the molded article
Are provided so that the direction of the thread is parallel to the side edges of the molded product, except for the ruled part, and the texture is in the bias direction within the line connecting both ends of the corner radius of the molded product and the center of curvature of the corner radius. The yarn density of the portion is deformed and becomes higher than the yarn density of the other portion, and this yarn density is the maximum on the line connecting the center of the corner radius and the curvature center of the corner are, and the both ends of the corner are and the corner radius. A box-shaped container-shaped molded article having a surface material layer made of a non-stretchable woven fabric, characterized in that the diameter gradually decreases toward the line connecting the centers of curvature. 2. A method for molding a box-shaped container-shaped molded product having a flat quadrangular shape and each corner having curved surfaces, which comprises a thermoplastic nonwoven fabric as a core material or an inorganic fiber nonwoven fabric made of a thermoplastic resin as a matrix. Includes a step of heat-softening, a step of press-molding a woven fabric of non-stretchable fibers as a surface material on the heat-softened core material, and press-molding the material, and a material holding force of a clamp that holds the surface material during the press-molding step Is the strongest in the part corresponding to the line connecting the center of curvature of the corner radius and the center of curvature of the corner radius in each corner of the molded product, and gradually approaches the part corresponding to the line connecting both ends of the corner radius and the center of curvature of the corner radius. The box-shaped container is characterized in that it becomes smaller and is adjusted to be almost free in parts other than the corner radius. Molding method of goods.