JP2002036276A - Apparatus and method for molding composite foamed molding as well as composite foamed molding obtained by this method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve uniformity of filling, heating and fusion bonding of material beads in a molding cavity in integral molding of a front side member with a foamed member. SOLUTION: The front side member 4 is attached to a front side mold 2 side of a foam molding cavity 6, and a material bead filler 61 is arranged on a back surface side of another rear side mold 3. Further, a plurality of utility nozzles a21, a31, a41, b21, b31 and b41 are opened at their nozzle ports with the cavity 6 and disposed. The utility nozzles a21 to b41 are respectively connected to a utility supply unit (not shown in Fig.) capable of supplying one or more types of utilities such as exhaust gas, heated steam, pressurized air, vacuum, cooling water, drain or the like through piping systems a2, a3, a4, b2, b3 and b4 solely or by partitioning into a plurality of groups.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improved molding apparatus and a molding method for a foam composite molded article obtained by integrating a front member and a foam member.

[0002]

2. Description of the Related Art As a technique similar to the present invention, there is known a method for producing a foam composite molded article in which a front member and a back member are integrated via a foam member. For example, JP-A-4-
Japanese Patent Application Laid-Open No. 344227/1994 or Japanese Patent Application Laid-Open No. 6-210753 has been proposed. An outline of a molding apparatus used in the method will be described with reference to FIG. 5. First, a space 16 for molding a foamed member is formed between the lower surface of the upper mold 11 and the upper surface of the lower mold 15. I have. The upper surface of the lower mold 15 is formed of a gas-permeable porous member 18, and the outer skin 17 attached to the upper surface of the lower mold 15 is configured to be adsorbed and fixed to the upper surface of the lower mold 15 by decompression from a lower exhaust space 19. I have.

The inside of the upper mold 11 is provided with a left steam pipe 11c.
And a right steam chamber 11b having a right steam pipe 11d. A vent hole 12a and a raw material bead supply pipe 13a are provided on the lower surface of the left steam chamber 11a, and a lower surface of the right steam chamber 11b. Is provided with a vent hole 12b and a raw material bead supply pipe 13b.

In the molding method using such an apparatus, first, the skin 17 is disposed in a state of being adsorbed to the air-permeable porous member 18 of the lower die 15, and then the substrate 1 is placed on the lower surface of the upper die 11.
4, the upper die and the lower die are closed, and a space 16 for forming a foam member is prepared. In this case, the substrate 14 is provided with the air holes 12 a and 12 b and the raw material bead supply pipe 13.
a, holes 14c, 14d corresponding to the openings of 13b, 1
4a and 14b are respectively provided through.

Here, the raw material beads are supplied to the space 16 through the raw material bead supply pipes 13a and 13b while supplying the filling air.
In this case, the steam chambers 11a, 1
1b maintains the reduced pressure without supplying steam,
By exhausting the air in the space 16 through the ventilation holes 12a and 12b, the filling air fed together with the raw material beads can be forcibly exhausted, and only the raw material beads can be left in the space 16 and filled.

However, in this molding apparatus,
Since all the ventilation holes 12a and 12b are simultaneously operated to reduce the pressure, the peripheral portion in the space 16 is difficult to be filled with the raw material beads, and especially when the space 16 is thin and large in area. The holes 14 of the raw material bead supply pipes 13a and 13b may be partially closed during filling.
It is difficult for the raw material beads to reach the portions distant from a and 14b. As a result, in the filling method using such a molding apparatus, it is inevitable that uneven filling occurs.

Next, in the heating method in the molding method using this apparatus, the heating steam is applied to the left steam pipe 11 of the upper mold 11.
c, the space 16 in the order of the left steam chamber 11a and the vent hole 12a.
The heated raw material beads are heated and then flowed and discharged from the vent hole 12b in the order of the right steam chamber 11b and the right steam pipe 11d.

In the heating method using such a molding apparatus, the flow of the heating steam in the space 16 tends to make a short path between the ventilation holes 12a and 12b which are closest to each other. Despite the progress of the fusion, the parts near the left and right ends are delayed in the fusion, resulting in uneven heating, resulting in uneven quality of the product, such as specific gravity, appearance, and strength. There was a serious problem that appeared. In addition, although this description is about the foam composite molded body which becomes the combination of the skin, the substrate, and the foam member, the foam member is integrated with the front member not including the substrate, so to speak, as in the present invention. When applied to a foamed composite molded article, exactly the same problem occurred. In addition, the following problems were similarly observed.

Considering these foamed composite moldings from the viewpoint of the material, the conventional combination used for a dashboard of an automobile, for example, has vinyl chloride,
Polypropylene is used for the back side member and urethane is used for the foam member.Each front and back material is bonded and integrated, but each part of the skin, substrate and foam member is made of the same component system material and can be recycled. The need to do so has increased.
From this point, the skin is made of olefin-based elastomer (TP
O) In the case of foamed members, there is an urgent need for technical development to concentrate on olefin-based polypropylene foam (EPP).

In the above publication, the skin 17, the substrate 14
And as the foam member, both olefin-based resin materials, polypropylene-based or polyethylene-based sheet, filler-containing solid resin, it is described that foamable resin beads and the like are used, but also by this method, For example, thin composite foamed molded products with relatively thin thickness, large area, irregularities and bends, such as composite boards used for drain pan members of air conditioners and dashboards of automobiles, etc. It was extremely difficult to produce homogeneously for the reasons described above.

[0011]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to provide a molding method for integrally molding a front side member and a foamed member. In addition to improving the uniformity of the raw material beads filled in the member molding cavity, the uniformity of heating and fusing of the filled raw material beads is also improved. Apparatus and method for producing a thin, irregular and long foam composite molded article having a small target thickness, a large area, and irregularities or bends, or a foam composite molded article obtained therefrom. I do.

[0012]

The above problems can be solved by the following apparatus for forming a foamed composite molded article of the present invention. That is, an apparatus for molding a foamed composite molded article for integrally molding a front side member and a foamed member, wherein one of a pair of molds capable of closing and opening a mold for forming a cavity for foam molding. A mold to which the front member is attached, the other mold is a back mold in contact with the foam member, and the back mold is provided with a filler for feeding raw material beads made of foamable resin, Multiple utility nozzles,
The foam composite molding characterized in that the nozzle port is arranged so as to be opened in the cavity, and the utility nozzle is connected to a utility supply device alone or divided into a plurality of groups. It is a body molding device. The foaming composite molded article molding apparatus includes an exhaust device, a heating steam supply device, a pressurized air device, a vacuum depressurizing device, wherein the utility nozzle is capable of supplying one or more utilities such as heating steam. The present invention can be embodied in a form in which at least one of a cooling water supply device and a drain drainage device and a required utility control device such as a control valve and a switching valve are connected.

Next, the above problem can also be solved by the following method for molding a foamed composite molded article of the present invention. That is, a front member is attached to one mold side of a cavity between a pair of molds capable of closing and opening a mold for forming a cavity for foam molding, and a filling space is provided between the front member and the back mold. The raw material beads made of the expandable resin are fed into the filling space, and the raw material beads are fed when the raw material beads are filled by exhausting the gas from the plurality of utility nozzles provided on the back mold side. After starting the evacuation from the utility nozzle located farthest from the filling device to be filled, the filling is performed by a filling process of sequentially exhausting the utility nozzle at the closest position as the raw material beads are filled, and then the filling is performed. A method of molding a foamed composite molded body, comprising heating and expanding and fusing the raw material beads to integrate the front side member and the foamed member.

In the method for molding a foamed composite molded article, after the filling step, heating steam is supplied from one of the utility nozzles adjacent to the utility nozzle, and the other is discharged from the other utility nozzle to fill the raw material beads. And a heating and fusion step of integrating the front side member and the foaming member by a main heating step of press-fitting the heating steam from all the utility nozzles to heat and fuse the filling material beads. May be embodied.

Further, in the foamed composite molded article of the present invention, that is, in the foamed composite molded article obtained by any one of the above-mentioned methods for molding a foamed composite molded article, wherein the front side member and the foamed member are integrated, the utility nozzle is provided. In the foamed composite molded article, the hole diameter of the utility circulation hole arranged in the rear mold to be arranged is 20 mm or less, and the pitch is set to 5 times or more of the hole diameter. Mold cost can also be reduced. This foamed composite molded article is preferably embodied as a thin irregularly shaped elongated composite foamed article having a small thickness with respect to the area and having an uneven shape or a undulating shape.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of a molding apparatus and a molding method for a foamed composite molded article according to the present invention will be described with reference to FIGS. 1 to 4 by taking a foamed composite molded article constituting a drain pan member of an air conditioner as an example. I will explain it. First, the molding apparatus of the present invention will be described. In this molding apparatus, the space between the front side member and the back side mold placed in the mold is filled with raw material beads made of a foamable resin, and is fused by heating and integrated. This is a molding device for molding the expanded composite molded article.

Referring to FIGS. 1 (schematic sectional view) and FIG. 2 (perspective view), the main part of the molding apparatus of the present invention will be described. First, a front side member made of, for example, a polystyrene resin is prepared in advance. This front side member constitutes the surface layer of the completed foam composite molded article, and has a predetermined appearance, surface texture,
It is manufactured by a known means as a sheet material having a thickness of about 0.3 to 1.0 mm having flexibility and strength.

As shown in FIG. 1, the main part of the present invention is as follows.
Specifically, in the foam molding cavity 6 formed by a set of molds that can be closed and opened. A front member 4 is attached to one mold (hereinafter referred to as a front mold 2), and a foam molding cavity 6 is formed between the mold and the other mold (hereinafter referred to as a back mold 3).

An important feature of the present invention is that the back mold 3 is provided with a filling device 61 for feeding raw material beads made of a foamable resin from the back side thereof, and a plurality of utility nozzles. a21, a31, a41, b21, b31,
are arranged so that their nozzle openings are open toward the cavity 6, and the utility nozzle a
21 to b41,... Are piping systems a2, a3, a4, b
Through b, b4,..., Each of which is capable of supplying one or more utilities such as exhaust gas, heated steam, pressurized air, or drain, individually or in a plurality of groups. It is connected to a supply device (not shown). In this case, the back side mold 3 is provided at a position corresponding to the opening of the filling device 61 and the plurality of utility nozzles a21, etc.
It is assumed that the raw material bead circulation holes 31 and the utility circulation holes 32 are arranged.

Here, the three-dimensional arrangement of the filling device 61 and the plurality of utility nozzles will be described with reference to a case exemplified by FIG. 2 which is a perspective view showing the back surface of the back mold 3. Is one area or divided into a plurality of areas. In this case, the area is divided into three areas a, b, and c. In this area, one filling device 61 mounting hole 6a, 6b, 6c is provided. The utility nozzles are provided for each area. For example, for area b, the utility nozzles 11 in the first row, the utility nozzles 21 to 25 in the second row, and the utility nozzles 31 to 35 in the third row are provided. The utility nozzles in group b, such as the utility nozzles 41 to 45 in the fourth row, are arranged one or more in units of a plurality of rows. Such an array configuration is the same for each of the sections a, b, and c, and thus description thereof is omitted. In the present invention, it is needless to say that the number is not limited to a specific number such as an area consisting of a, b, and c, and first to fourth rows. Moreover, the whole can be put together in one area as needed.

Next, the utility supply device according to the present invention is shown in FIG.
Explaining with reference to the piping system diagram of the molding apparatus, first, utilities such as exhaust gas, heating steam, pressurized air, or drain used in this molding apparatus are as follows. For group b, the main supply valve 7a → the server tank 73a → the individual Supply valves 71a, b,
supplied from the piping system in the order of c and d, and the individual discharge valve 72a,
b, c, d → the server tank 73b → the main discharge valve 7b. The same applies to the groups a and c.

In this case, the exhaust or drain among the utilities is discharged by an exhaust pump, a vacuum pump, or a drain pump provided on the discharge side, and the heating steam, the pressurized air and the like are supplied by a boiler provided on the supply side. Such pressure is supplied from a steam generator or an air compressor, and pressure control is performed as necessary by the supply side and discharge side valves. In the case of the present invention, the main supply valve 7a and the main discharge valve 7b are provided with an exhaust pump, a vacuum pump, or a drain pump for exhaust and drain, or a steam generator such as a boiler for heating steam or pressurized air. And an air compressor that can be arbitrarily switched.

In the piping system configured as described above, the individual supply valves 71a, b, c, d and the individual discharge valves 72a,
Branch lines of piping systems b1, b2, b3, and b4 connecting b, c, and d are connected to the utility nozzles of each row. Therefore, in this embodiment, an arbitrary utility can be supplied to each utility nozzle while controlling an optional utility in units of rows. In other words, the utility nozzles are grouped into one group for each row, and operations such as pressurizing and depressurizing can be individually controlled as well as opening and closing operations of utility supply.

In the present invention, the configuration of the piping system is not limited to those shown in FIGS. 2 and 3, but the arrangement of the groups as individually operated groups, the fillers belonging to the groups, and the utility nozzles The most effective combination may be adopted for the number of the components, the configuration of the rows in the group, and the like, depending on the shape, material, and molding conditions of the molding target. For example, in the cases of FIGS. 2 and 3, utility control is performed in two stages of a group unit and a row unit. However, the piping system may be further subdivided and controlled in units of one utility nozzle. It is possible.

Next, the operation of the above-described molding apparatus of the present invention will be described in detail with reference to FIGS. First, first
Is a method characterized by the filling step, and FIG.
The front member 4 is arranged on one mold 2 side of the cavity between a pair of molds that can close and open the mold for forming the cavity 6 for foam molding, and the front member 4 and the back mold 3 are formed. And a raw material bead made of a foamable resin is fed from the filling device 61 with the filling air into the filling space, and a plurality of utility nozzles a21 provided on the back mold 3 side are provided. ~ A41, exhaust from b21-b41,
The basic operation is to fill the raw material beads.

An important feature is that the exhaust operation of the utility nozzle is performed by the utility nozzle located farthest from the nozzle tip of the filling device 61 (the utility nozzle a41 in FIG. 1).
And b41), in which a filling step is adopted in which the exhausting is started and the exhausting is sequentially performed to the utility nozzles (in the case of FIG. 1, utility nozzles a21 and b21) located closest to each other as the material beads are filled. It is in. After this filling, the filled raw material beads are heated and foam-fused, and the front side member 4 and the foamed member are integrated to obtain a foamed composite molded article.

The behavior of the filling process will be described in detail with reference to FIG. 4 using a combination of the filling device 61 and utility nozzles a21, a31, a41 as an example. Step (1): Of the utility nozzles a21, a31, a41, the utility nozzle a41 furthest from the filling device 61 is exhausted, the utility nozzles a21, a31 in front are turned off to stop the function, and Raw material beads conveyed from a tank (not shown) at a conveying pressure are fed from the filling device 61 to the filling space 63 by the filling air 62. In this case, the raw material beads are deposited near the end of the filling space 63 where the utility nozzle a41 is located.

Step (2): In the state of step (1), the supply of the raw material beads is temporarily stopped, and the pressure of the raw material beads in the vicinity of the position where the utility nozzle a41 is located is supplied by the supply of the filling air 62. , An additional pressure step to facilitate filling. Step (3): Turn on the utility nozzle a31 to set it in the exhaust state, restart feeding of the raw material beads, continue filling, and deposit the raw material beads near the position of the utility nozzle a31.

Step (4): An additional pressure step similar to step (2), in which the raw material beads filled in step (3) are pressurized. Step (5): The utility nozzle a21 is turned on to be in the exhaust state (all the utility nozzles are turned on at this stage), the feeding of the raw material beads is resumed, and the filling is continued. The raw material beads are deposited from to the position of the filling device 61. In each of these steps, the accumulated raw material beads are continually evacuated from the distant utility nozzle, so that the filling is sequentially performed and the packing density is increased as a whole.
Step (6) is a blowback step, in which, at the end of filling, the pressure of the filling air 62 and the conveying pressure of the raw material beads are reversed to feed back the raw material beads in the filling device 61 and the conveying pipe to the raw material tank side.

In the above description, a simple combination of the filling device 61 and the utility nozzles a21, a31, and a41 is taken as an example.
It is needless to say that each of the utility nozzle groups such as the group and the c group can be applied to a large number of individual utility nozzles, that is, by controlling the individual supply valves 71a to 71d and the discharge valves 72a to 72d, A filling operation can be performed for each nozzle or for a group of a plurality of nozzles described above, and a filling step corresponding to a desired shape of the foamed composite molded article can be adopted.

Next, a description will be given of a second embodiment, which is characterized by a heating and fusing step in the method for molding a foamed composite molded article of the present invention. In this method, the following preheating step and main heating step are performed after the above-described filling step. In other words, the preliminary heating step is performed in one of the utility nozzles adjacent to the utility nozzle (for example, the utility nozzle a3 in FIG. 1).
The heating steam is supplied from 1), exhausted from the other utility nozzles (utilizing nozzles a21 and a41 in FIG. 1), and circulates the heating steam to heat the filling material beads. The heating steam is spread over the entire filled raw material beads by reversing the flow direction, sequentially shifting the flow location of the heating steam, and repeating the reversal of the further direction. In this heating step, the heating steam is press-fitted from all the utility nozzles (the utility nozzles a21, a31, and a41 in FIG. 1 in the previous example) to heat and fuse the entire filling material beads. Thus, it is possible to perform a uniform heat fusion process with less temperature unevenness, and to integrate the front side member and the foamed member.

This embodiment is a method applicable to the piping system shown in FIG. 3, that is, heating steam is supplied from the main supply valve 7a, and the main discharge valve 7b is connected to the exhaust system to take out waste steam. The preheating step is performed in such a manner that the supply valve and the discharge valve are controlled for each of the utility nozzle groups such as the group a, the group b, the group c, etc., in units of individual nozzles or in units of rows as described above. And a heat fusion step including a main heating step.

In the case of the conventional method, the length of the path of the heating steam passing through the filling material beads has a large variation in the amount of heat applied to the filling material beads because long and short paths coexist. Irregularity was a cause of uneven fusion of the foamed molded product.However, according to the heat fusion step of the present invention, the distribution path of the heated steam is a distance between the adjacent utility nozzles. Are relatively short and uniform, the variation in the heating conditions is reduced, and uneven fusion of the foam molded article is remarkably improved.

Further, in the preheating step,
It is particularly preferable to further suppress the uneven heating by, for example, appropriately inverting the flow direction of the heating steam, instead of fixing it in one direction, and repeating the inversion. As a pre-stage of the preheating step, a method in which steam at a temperature lower than the fusion temperature is supplied to exhaust air in the filling space, and an exhausting step of previously filling the inside with steam is added. This is more preferable because air that can be an obstacle to the above can be removed and uniform heating in the subsequent stage can be performed more effectively. In this case, not adjacent,
Between the utility nozzles that are separated from each other, for example, the utility nozzle a
Intake and exhaust may be performed between 21 and a41.

The apparatus and method for molding a foamed composite molded article of the present invention are characterized by the points described above, and are used to effectively suppress uneven filling, uneven heating, and uneven fusion. When both the front side member and the raw material beads are made of the same component synthetic resin, the raw material beads form a foam molded body and are simultaneously fused to the front side member and the foam member in the heat fusing step of the raw material beads. Therefore, the molding method and the molding apparatus can be said to be particularly preferable because the whole can be integrated.

In the molding method of the foamed composite molded article of the present invention described above, the front mold 2 and the back mold 3 are different from the conventional one.
Does not have an indispensable structure of a foam molding apparatus having a chamber on each back surface. In particular, a structure such as a steam chamber for heating the inside of the cavity is not required on the front mold 2 side in the present invention. However, as shown in FIG. 6, the present invention provides an apparatus for molding a foamed composite molded article provided with a chamber 5 on the back side of the back mold 3 in FIG. After the step of filling the raw material beads by the above-described operation, heating steam is introduced into the chamber 5 from the introduction port 51, and pressure is controlled so as to be discharged from the discharge port 52. The heating step by the utility nozzle and the main heating step described above may be embodied while performing the mold heating step of heating from the beginning or after performing the mold heating step.

In this case, it is preferable that not only the heating steam but also cooling water and a reduced pressure for cooling (vacuum processing) can be introduced into the chamber 5 so that heating and cooling can be performed. Further, a chamber (not shown) is also provided on the back surface of the front mold 2, and similarly, heating steam, cooling water and / or decompression processing for cooling (vacuum processing) can be introduced so that heating and cooling can be performed. It is good to do. In this way, since the back mold 3 can be efficiently heated to a temperature close to the foaming fusion temperature of the filling material beads, a practical advantage that the molding cycle can be shortened is obtained. It can be said that a similar advantage can be realized for the front mold.

Next, regarding the foamed composite molded article of the present invention,
A description will be given with reference to FIG. The feature of the foamed composite molded article of the present invention is obtained by any one of the above-mentioned methods for molding a foamed composite molded article, and is used in a foamed composite molded article obtained by integrating the front side member 4 and the foamed member. Role nozzle (a2 in FIG. 1)
1, a31, a41) are arranged on the back side mold 3 and the utility flow holes 32a, 32b have a hole diameter of 20 mm.
The size is as follows, and the pitch F is set to be five times or more the hole diameter.

As described above, in the present invention, the arrangement pitch can be set relatively large with respect to the hole diameter of the utility circulation hole. There is no decrease in mechanical strength. Further, in the structure having the conventional steam chamber, core vents for supplying and discharging various utilities through the steam chamber had to be arranged at a pitch of 25 to 40 mm over the entire surface of the mold. In the case of the combination nozzle, the filling operation and the heat welding operation described above can be performed, so that a large interval of 100 to 200 mm pitch can be arranged. For this reason, there is obtained an advantage that the assembling and processing costs of the mold can be greatly reduced, which is advantageous in terms of equipment costs.

Further, the foamed composite molded article of the present invention can be embodied in the form of a thin and irregular long shape having a small thickness with respect to the surface area and having an uneven shape or a undulating shape.
It is particularly suitably used for constituent members of home electric appliances described later, interior members of vehicles such as automobiles, and the like.

Further, among the utility flow holes 32a and 32b provided in the back mold 3, the outer peripheral edge 81a of the foam composite molded article (the front member 4 and the back metal 4 at the end portion 81 of the foam member 8). (Corresponds to the part where mold 3 is directly overlapped)
The distance F between the utility circulation holes 32a excluding the utility circulation holes 32b arranged along the gap is equal to the thickness E of the foamed member 8.
It can be embodied as a form in which the parts are arranged at a pitch of at least 100 mm in a part less than 0 mm and arranged at a pitch of at least 150 mm in a part where the thickness E is 10 mm or more. Thus, the utility circulation hole 32a
Is usually set to be about 10 mm inside and outside, so in this embodiment, the pitch between the utility circulation holes 32a is about 10 times or more the hole diameter, that is, 100 mm or more. There is no danger of lowering the mechanical strength.

The foamed composite molded article of the present invention is particularly preferably applied to each specific application when the thickness of the internal foamed member is set to the conditions described below. (1) If the application is a container, 70% of the surface area of the front side member
The thickness of the foamed member at the above-mentioned portions is set to 30 mm or less. (2) When the application is a constituent member of a household appliance such as an exterior heat insulating member such as an air conditioner, an air purifier, a refrigerator, a drain pan member thereof, and a cool air duct, a foam member in a portion of 70% or more of the surface area of the front member. Is 30mm thick
It is set as follows.

(3) When the application is a building interior material such as a ceiling material, a wall material, a partition wall surface material, and a floor material,
The thickness of the foamed member at a portion of 90% or more of the surface area of the front member is set to 125 mm or less. (4) When the application is an interior member used for an interior part of a vehicle such as an automobile such as a door trim, a glove box, a trunk room, an instrument panel, and a ceiling, the thickness of the foamed member at a portion of 70% or more of the surface area of the front side member. Is set to 30 mm or less.

(5) When the application is a floor member of a vehicle such as an automobile, the thickness of the foamed member at a portion of 70% or more of the surface area of the front side member is set to 150 mm or less. (6) When the application is a shock absorbing member such as a bumper of a vehicle such as an automobile, the front side member is formed in a thick block in a form in which the front side member as a whole bulges in a direction perpendicular to the longitudinal direction. The thickness of the foam member at the corresponding portion is set to 500 mm or less.

The foamed composite molded article obtained by the improved molding apparatus and molding method of the present invention described above is excellent in design, elasticity and touch, heat insulation, sound absorption, strength as a board material, production cost, and the like. As a result, a large member having no variation in quality can be provided at low cost. In particular, it is a material that is particularly useful as a component member of a home appliance, an interior member of a vehicle such as an automobile, or a building interior material as described below. (1) Components of household appliances For example, functional members such as an exterior heat insulating member such as an air conditioner, an air purifier, and a refrigerator, an internal drain pan member, and a cool air duct member.

(2) Interior parts of vehicles such as automobiles Interior parts such as door trims, glove boxes and trunk trims. In particular, since a large area can be handled by integral molding, it is effective in reducing the cost of large parts. (3) Building interior materials For example, excellent livability can be provided in the fields of ceiling materials, wall materials, and floor materials to which conventional synthetic resin products are applied.

[0047]

According to the present invention, the molding apparatus and molding method of the foamed composite molded article of the present invention and the foamed composite molded article obtained by the molding method are constructed as described above. In the integral molding of the expanded composite molded article, uniformity during filling of the raw material beads, or heating and fusion, is improved, and irregularities such as uneven filling and uneven foaming are eliminated. However, there is an excellent effect that a thin, irregular and long-shaped foamed composite molded article having a small thickness, a large surface area, and irregularities or bends can be manufactured without uneven quality, and also contributes to a reduction in equipment costs. Therefore, the present invention has an extremely large industrial value as a foamed composite molded article obtained by the molding apparatus, a molding method, and a molding method of the foamed composite molded article which has solved the conventional problems.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of a molding die for explaining a molding apparatus of the present invention.

FIG. 2 is a perspective view of a main part showing a back surface of a back mold of the molding apparatus of the present invention.

FIG. 3 is a piping diagram of a molding apparatus according to the present invention.

FIG. 4 is an explanatory view of each step for explaining a filling step of the molding method of the present invention.

FIG. 5 is a schematic sectional view of a molding die for explaining a conventional molding method.

FIG. 6 is a schematic sectional view of a molding die for explaining a molding apparatus according to another embodiment of the present invention.

FIG. 7 is a perspective view including a cross section for explaining a molded article according to another embodiment of the present invention.

[Explanation of symbols]

2 Front mold, 3 Back mold, 31 Raw material bead circulation holes, 32 Utility circulation holes, 4 Front members, 5 chambers, 6
Cavity, 6a, 6b, 6c Filler mounting hole, 61
Filler, 7a main supply valve, 7b main discharge valve, 71a,
b, c, d Individual supply valve, 72a, b, c, d Individual discharge valve, 73a, 73b Server tank, a21, a3
1, a41, b21, b31, b41 utility nozzle, a
2, a3, a4, b2, b3, b4 piping system.

 ────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Kiyotaka Ida 2-25 Komabacho, Nakatsugawa-shi, Gifu F-term in Daisen Industry Co., Ltd. (reference) 4F212 AG03 AG20 AH24 AH26 AH33 AH55 AH56 AH58 UA01 UB01 UB13 UB22 UL01 UL06 UN09 UN16 UN17

Claims (18)

[Claims] 1. An apparatus for molding a foamed composite molded article for integrally molding a front side member and a foamed member, wherein one of a pair of molds capable of closing and opening a mold for forming a cavity for foam molding. Is a mold to which the front side member is attached, and the other mold is a back side mold in contact with the foamed member, and the back side mold is provided with a filler for feeding raw material beads made of foamable resin. A plurality of utility nozzles are arranged with their nozzle ports opened in the cavity, and the utility nozzles are connected to the utility supply device individually or in a plurality of groups. An apparatus for forming a foamed composite molded article, comprising: 2. The utility nozzle includes an exhaust gas, a heating steam,
The molding apparatus for a foamed composite molded article according to claim 1, wherein one or more utilities such as pressurized air, vacuum, cooling water, or drain can be supplied to the utility controller. 3. A mold closure for forming a cavity for foam molding,
A front side member is attached to one mold side of a cavity between a pair of molds that can be opened, and a filling space is provided between the front side member and the back side mold. When the raw material beads are fed and exhausted from a plurality of utility nozzles provided on the back mold side to fill the raw material beads, the utility tool located farthest from the filling device for feeding the raw material beads is used. After starting the exhaust from the nozzle, after filling by the filling step of sequentially exhausting to the utility nozzle at the closest position as the raw material beads are filled, the filled raw material beads are heated and foam-fused, A molding method of a foamed composite molded article, wherein a front side member and a foamed member are integrated. 4. The method of molding a foamed composite molded article according to claim 3, wherein both the front side member and the raw material beads are made of the same resin. 5. In the filling step, a feeding / filling step of exhausting gas from a utility nozzle while feeding raw material beads from a filling device, and stopping the feeding of raw material beads and continuing the supply of charging air. The pressure filling step of evacuating from the role nozzle is repeated one or more times.
The method for molding a foamed composite molded article according to the above. 6. After the filling step according to any one of claims 3 to 5, heating steam is supplied from one of the utility nozzles adjacent to the utility nozzle and the other is exhausted from the other. A heating step for heating the front side member and the foaming member by a main heating step for press-fitting the heating steam from all the utility nozzles and heating and fusing the filling material beads. For forming a foamed composite molded article. 7. A method according to claim 1, wherein a heating steam is introduced into the back side of the back side mold, and a chamber capable of heating the back side mold is provided. The foaming composite characterized in that after the filling step, heating steam is introduced into the chamber to heat the back mold, or after the heating, the heating step and the main heating step according to claim 6 are performed. A method for forming a molded body. 8. A foamed composite molded article according to claim 7, wherein a molding apparatus for a foamed composite molded article having a chamber capable of heating said front mold by introducing heating steam is provided on the back side of said front mold. Molding method. 9. A method for molding a foamed composite molded article in which cooling water or reduced pressure treatment is introduced into the chamber according to claim 7 or 8 so that the mold can be cooled. 10. A foamed composite molded body obtained by integrating the front side member and the foamed member obtained by the method for molding a foamed composite molded body according to any one of claims 3 to 9, wherein a utility nozzle is arranged on the back side. The diameter of the utility circulation hole provided in the mold is 2
A foam composite molded article having a diameter of 0 mm or less and a pitch of 5 times or more the pore diameter. 11. The foamed composite molded article according to claim 10, wherein the molded article has a small thickness with respect to an area, and has a thin and irregular long shape having an uneven shape or a undulating shape. 12. Among the utility flow holes provided in the back mold, each of the utility flow holes except for the utility flow hole arranged along the outer peripheral edge of the foamed composite molded article is provided. At least 100 mm where the thickness of the foam member is less than 10 mm
The foamed composite molded article according to claim 10, wherein the foamed composite molded article is arranged at a pitch, and is arranged at a pitch of at least 150 mm in a portion where the thickness is 10 mm or more. 13. The foamed composite molded article according to claim 10, wherein the thickness of the foamed member at a portion of 70% or more of the surface area of the front side member is 30 mm or less, and the use is a container. 14. A foaming member having a thickness of 30 mm or less at a portion of 70% or more of the surface area of the front side member, and is used for an exterior heat insulating member such as an air conditioner, an air purifier, a refrigerator, a drain pan member thereof, and a cool air. The foamed composite molded article according to claim 10, which is a constituent member of a home appliance such as a duct. 15. The thickness of the foamed member at a portion of 90% or more of the surface area of the front side member is 100 mm or less,
Applications are ceiling materials, wall materials, partition wall surface materials,
The foam composite molded article according to claim 10, which is a building interior material such as a floor material. 16. A foam member having a thickness of 30 mm or less at a portion of 70% or more of the surface area of the front member, and is used for door trim, glove box, trunk room,
The foam composite article according to claim 10, which is an interior member used for an interior part of a vehicle such as an automobile such as an instrument panel or a ceiling. 17. The foamed member has a thickness of 150 mm or less in a portion of 70% or more of the surface area of the front side member,
The foamed composite molded article according to claim 10, which is used for floor members of vehicles such as automobiles. 18. A foam composite molded article in which a front member and a foam member are integrated with each other, the front member side is formed by swelling, the thickness of the foam member at the top is 500 mm or less, and the use is for automobiles. The foam composite molded article according to claim 10, which is a shock absorbing member such as a bumper of a vehicle.