JP2004098582A - Injection foam molding machine and method for injection foam molding - Google Patents

Injection foam molding machine and method for injection foam molding Download PDF

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JP2004098582A
JP2004098582A JP2002266231A JP2002266231A JP2004098582A JP 2004098582 A JP2004098582 A JP 2004098582A JP 2002266231 A JP2002266231 A JP 2002266231A JP 2002266231 A JP2002266231 A JP 2002266231A JP 2004098582 A JP2004098582 A JP 2004098582A
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mold
foam molding
die plate
movable
pressure
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JP2002266231A
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JP4169554B2 (en
Inventor
Takashi Mizuno
水野 貴司
Yasuaki Ozeki
大関 泰明
Toshimichi Sugita
杉田 俊道
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Mitsubishi Heavy Industries Ltd
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Mitsubishi Heavy Industries Ltd
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  • Injection Moulding Of Plastics Or The Like (AREA)
  • Molding Of Porous Articles (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide an injection foam molding machine and a method for injection foam molding which suppress intrusion of foaming gas and air between a molded article and a mold, thereby prevent a swirl mark (trace of foaming gas) or a silver (silver streak) and make a movable die plate move parallel in momentary opening (core back) of the mold so as to make uniform the plate thickness of a foam molded article, on the occasion of foam molding by the injection foam molding machine. <P>SOLUTION: When a molten resin filled by injection in a mold cavity is to be foamed by opening the mold momentarily, the speed of the momentary opening is controlled so that an in-mold pressure detected by an in-mold pressure sensor may not become minus. A plurality of ball screw type jacks are used for the momentary opening of the mold on the occasion of foaming and servomotors for driving the jacks are subjected to a tuning control. <P>COPYRIGHT: (C)2004,JPO

Description

【0001】
【発明の属する技術分野】
本発明は、金型キャビティ内に射出充填した溶融樹脂を、金型を寸開することにより発泡させ、発泡成形品が得られるようにした射出発泡成形機の構成と発泡成形方法に関する。
【0002】
【従来の技術】
射出成形機による射出発泡成形品は、表面を硬化させた後、内部を発泡させて外観の見栄えが良く、軽くて丈夫な成形品を得ることを狙いとし、そのために、加熱可塑化した発泡性樹脂を高速で金型内に射出し、射出が終わり金型に接している成形品の表面が冷却して硬化した後、金型の間隔を広げて金型キャビティの容積を拡大し、成形品の内圧を下げ成形品内部を発泡させる射出発泡成形方法が従来から知られている。
しかしこのような射出発泡成形品は、発泡性樹脂の射出時に樹脂圧が急に低下することにより発生する発泡ガスが金型キャビティ内に閉じ込められることや、金型の間隔を開いて金型キャビティを成形品容積まで拡大するときの金型移動速度が早過ぎると、表面の固化層が金型内面の移動に追従できず、金型内面から剥離し、金型内面に沿わない樹脂の自由固化面が生じることにより、外観を損ねるスワールマーク(発泡ガス跡)やシルバー(銀条痕)が発生し易い。これを防止するため、射出直後の未固化成形品を一旦加圧して表面の発泡を抑えた状態で固化後、容積を拡大したり、例えば特許文献1(特開2000−71277号公報)で開示されたように、金型に熱伝導率が低い材料を使用して冷却を遅らせ、固化と発泡の均一化を図った発泡成形方法が工夫されている。
【0003】
また、複数の型締専用シリンダを有する射出発泡成形機による発泡成形工程においては、金型キャビティの容積を拡大するとき、固定側金型と可動側金型とは締め付けていないフリーの状態となるため、金型における発泡成形品の位置や成形品の形状によっては、また、金型に対する発泡成形時の金型内圧力の分布が偏っているような場合は、金型の相対的な傾きを生じ、発泡成形品の厚さの偏りが発生する可能性がある。
このような金型の相対的な傾きを防止し、金型を取付けたダイプレートの平行を保つ機構を有する射出成形機の従来例が、例えば特許文献2(特開2000−351142号公報)に開示されている。この従来例は、固定金型に対して可動金型を進退させる(トグル機構、或いは油圧シリンダ等の)第1の駆動手段と、可動金型を貫通して配設された複数の押圧部材と、この複数の押圧部材を同時に進退させる(油圧シリンダ、又は、圧縮ばね力等の)第2の駆動手段を備えた射出発泡成形機で、発泡樹脂を射出充填後、第1の駆動手段の型締力を緩め(油圧シリンダの場合は油圧切換弁を中立状態にする)、第2の駆動手段により、複数の押圧部材を早い速度で所定のストロークだけ金型のパーティング面を開くようにして、発泡の均質化を得ることを狙いとしたものである。
【0004】
【特許文献1】特開2000−71277号公報
【特許文献2】特開2000−351142号公報
【0005】
【発明が解決しようとする課題】
発泡成形品に外観を損ねるスワールマーク(発泡ガス跡)やシルバー(銀条痕)の発生を防止するための、射出直後の未固化成形品を一旦加圧して表面の発泡を抑えた状態で固化後、容積を拡大したり、特許文献1(特開2000−71277号公報)で公示された、金型に熱伝導率が低い材料を使用して冷却を遅らせ、固化と発泡の均一化を図ったものは、発泡のため金型を開閉するとき、機構が油圧の場合も、トグル機構を使用する場合も、決まった位置に一定速度で金型移動が行われるため、未硬化樹脂の温度条件変化に対応することが困難で、金型移動速度が早すぎるときは、発泡による膨張が間に合わず発泡ガスや空気が成形品と金型の間に入り込み、金型移動速度が遅いときは、発泡膨張中に樹脂が硬化して、発泡が不十分となり、空気が成形品と金型の間に入り込んで、どちらの場合でもスワールマーク(発泡ガス跡)やシルバー(銀条痕)となり易いと同時に冷却時間が掛かり、生産サイクルが長くなる。
【0006】
また、特許文献2(特開2000−351142号公報)に開示された従来例は、金型のパーティング面を開くときは、第2の駆動手段により行なっているので、停止位置の精度は良くなるが、停止位置を調整するには押圧部材を取り替える必要があり、第2の駆動手段が圧縮ばね力を用いているときは、成形速度の調整が容易でなく、また駆動手段が油圧シリンダの作動は停止位置精度が充分でなく、始動停止にロスタイムを生じ、生産のサイクル時間が長くなる問題点を有する。
本発明は、射出発泡成形機による発泡成形時の発泡速度及び発泡倍率を制御できる射出発泡成形機と射出発泡成形方法を提供することを目的とする。また、発泡成形時に、発泡ガスや空気が成形品と金型の間に入り込むことを抑えてスワールマーク(発泡ガス跡)やシルバー(銀条痕)の発生を防止する射出発泡成形機と射出発泡成形方法を提供する。さらにまた、金型の寸開(コアバック)時に可動ダイプレートを平行に移動させて発泡成形品の板厚を均等にできる射出発泡成形機と発泡成形方法を提供することを目的とする。
【0007】
【課題を解決するための手段】
上記の問題点に対し、本発明は以下の構成及び方法を特徴とする。
(1)固定ダイプレートに取付けられた固定側金型と、可動ダイプレートに取付けられた可動側金型と、前記両ダイプレート間の間隔を広げることができる駆動手段と、該駆動手段により可動側金型の移動速度を制御して、前記両金型間に形成される金型キャビティ内に射出充填された溶融樹脂の膨張速度及び膨張率を制御する制御装置とを備えた射出発泡成形機。
(2)前記金型キャビティ内の圧力を検出する型内圧センサをさらに備え、前記制御装置は、該型内圧センサの検出信号に基づき可動側金型の移動速度を制御する上記(1)項の射出発泡成形機。
(3)前記駆動手段は、前記固定ダイプレート又は可動ダイプレートに、他方のダイプレートに対向して取付けられ、同期駆動される複数のジャッキである上記(1)項の射出発泡成形機。
(4)前記駆動手段は、サーボモータ駆動のボールねじ装置である上記(1)項又は(3)項の射出発泡成形機。
(5)固定側金型を取付け基盤に固設された固定ダイプレートと、可動側金型を取付け基盤上を前記固定ダイプレートに対向して移動可能な可動ダイプレートと、可動ダイプレートを往復移動させる可動ダイプレート移動手段と、固定ダイプレートに付属する複数の油圧型締シリンダと、同型締シリンダのピストンロッドと一体で可動ダイプレートの貫通孔に貫通可能な複数のタイバーと、同タイバーと可動ダイプレートを固着可能なタイバー固着手段と、油圧源から各型締シリンダに至る配管に設けられた4方向切換弁と、同4方向切換弁の排出側を閉じると同時に各型締シリンダの型締側、離型側を差動回路にする手段と、油圧源の油圧を設定された低圧に制御可能なリリーフ弁と、可動ダイプレート又は固定ダイプレートに取付けられ、それぞれのサーボモータ駆動によりダイプレートの間隔を広げることができるボールねじ機構を用いた複数のジャッキと、型締、射出充填後、前記リリーフ弁を操作して各型締シリンダの油圧を設定された低圧とした後、前記複数のジャッキのサーボモータを同期駆動して金型の移動速度を制御することにより、樹脂の発泡成形の膨張速度と膨張率を制御する制御装置とを備えてなる射出発泡成形機。
【0008】
(6)固定側金型と可動側金型間に形成される金型キャビティ内に溶融樹脂を射出充填する工程と、該射出充填工程の後に、可動側金型を固定側金型から離れる方向に移動させる工程を有してなり、該可動側金型の移動速度を制御して、金型キャビティ内に射出充填された溶融樹脂の膨張速度及び膨張率を制御する射出発泡成形方法。
(7)前記金型キャビティ内の圧力を検出し、金型キャビティ内の型内圧が負圧にならないように可動側金型の移動速度を制御する上記(6)項の射出発泡成形方法。
(8)上記(5)項の射出発泡成形機を用いて金型のキャビティ内に溶融可塑化し、圧縮した発泡性樹脂を射出充填した後、樹脂圧を減じ、金型キャビティ容積を増大して発泡成形品を成形する発泡成形方法において、発泡性樹脂を射出充填後、前記複数のジャッキの当て板を可動ダイプレート又は固定ダイプレートに当接し、前記リリーフ弁を操作して各型締シリンダの油圧を設定された低圧にした後、前記複数のジャッキをサーボモータにより同期駆動して樹脂の発泡成形の膨張速度を制御しながら可動ダイプレートを平行に移動し(コアバック)て設定位置に停止し、発泡終了後、発泡圧力保持、冷却、降圧、離型を行うようにした射出発泡成形方法。
(9)上記(8)項の射出発泡成形方法において、可動側金型に発泡圧を検出する型内圧センサを設置し、金型キャビティ内の樹脂の発泡成形工程中の型内圧が負圧にならぬような膨張速度に制御する射出発泡成形方法。
(10)上記(8)項又は(9)項の射出発泡成形方法において、可動ダイプレート移動手段にサーボモータ駆動のボールねじ装置を使用し、金型キャビティ内の樹脂の発泡成形工程のとき、前記ジャッキと可動ダイプレート移動手段との移動速度を同期するように制御する射出発泡成形方法。
【0009】
【発明の実施の形態】
本発明の実施の形態の射出発泡成形機と発泡成形方法を図に基づいて説明する。図1は射出発泡成形機の型締装置を示す側面模式図及び型締装置の油圧系統図、図2は図1の射出発泡成形機の型締装置の可動ダイプレートとボールねじ式ジャッキを示す正面図、図3は図1の型締装置の固定金型と可動金型が型締め状態を示す側面断面図、図4は図1の型締装置の固定金型と可動金型が寸開後の状態を示す側面断面図、図5は図1の型締装置の発泡成形工程のタイミングを示すグラフである。
【0010】
図において、1は基盤で、基盤1の一端には固定金型4を取付けた固定ダイプレート2が固設されている。基盤1の上には固定ダイプレート2に対向して可動金型5を取付けた可動ダイプレート3が移動可能に載置される。22は基盤1に固設されたガイドレールであり、可動ダイプレート3に固設されたリニアベアリング21がこのガイドレール22にガイドされ、可動ダイプレート3を支えている。固定ダイプレート2にはストロークが短い断面積の大きな複数(本例では4基)の型締シリンダ9A〜9Dが設けられている。型締シリンダ9C、9D、は固定ダイプレート2の縦の中心断面に対して型締シリンダ9A、9Bと対称に設けられている。この型締シリンダ9A〜9Dの中を摺動するラム6A〜6Dはその一側面にそれぞれタイバー7A〜7Dが直結され、このタイバー7A〜7Dは対向する可動ダイプレート3が型閉のため近づいてきたとき、可動ダイプレート3に明けられた4個の挿通孔を貫通する。
【0011】
タイバー7A〜7Dの先端部は、それぞれ等ピッチの複数のリング溝部を形成し、一方、可動ダイプレート3の反金型側面には、各タイバー7A〜7Dのリング溝部と噛合するようになっていて、対向して対になった4組の割りナット11が、タイバー7A〜7Dの軸直角方向に油圧シリンダ等で移動してタイバー7A〜7Dを挟んで固定するように設けられている。8は射出シリンダを示す。
【0012】
図2に示すように、可動ダイプレート3の金型取付面に、4組のボールねじジャッキ50が、金型5を中にして対称平行に取付けられている(固定ダイプレート2に取付けてもよい)。図1に示すように、ジャッキ本体52は可動ダイプレート3に固設され、ジャッキ本体52に内装する軸受56はボールねじナット53を回転自在に、スラスト方向を拘束して軸支している。ボールを介して螺合するボールねじ51の軸端は当て板58に固設している。ボールねじ51と平行なピン57は、当て板58に設けられた孔に摺動可能に嵌合し、当て板58の回り止めの役割をしている。ボールねじナット53の端部に歯付きベルトプーリー53aが備えられ、サーボモータ54の回転及びトルクは歯付きベルト55を介してボールねじナット53に伝えられる。サーボモータ54は制御装置37により同調回転されるので、各ボールねじ51の移動の速度も、停止位置も同調制御され、ボールねじ51に取付けられた当て板58の停止位置は4組共、可動ダイプレート3の金型取付面から同じ距離となる。
【0013】
可動ダイプレート3を型開の方向に大距離移動させる型開閉手段は、可動ダイプレート3の送行方向に平行に設置され、基盤1に取付けられた軸受箱17と軸受箱18によって回転可能に、軸方向を拘束して支えられ、サーボモータ15により動力伝動ベルト16を介して駆動されるボールねじ軸13と、可動ダイプレート3の下方に固設されたブラケット3aに支持され、ボールねじ軸13に螺合し、ボールねじ軸13の回転により直線移動するボールねじナット14とで構成されている。ボールねじ軸13は制御装置37によりサーボモータ15を介して、回転数、回転速度が制御される。
【0014】
この型締装置は、図1の金型が開いた状態、即ち、可動ダイプレート3が、2点鎖線で示すような、充分に固定ダイプレート2から離れた状態から、実線で示したように金型4と金型5が閉となるまで、可動ダイプレート3はサーボモータ15で駆動されるボールねじ軸13の回転によって移動する。制御装置37に内蔵する型盤移動速度制御回路は可動ダイプレート3をゆっくり加速し、一定速度で移動した後、減速して金型5が金型4に接触する寸前に停止する。
【0015】
この可動ダイプレート3の停止位置で割りナット11が作動して割りナット11の内側リング溝がタイバー7A〜7Dの先端部のリング溝と係合してタイバー7A〜7Dと結合する。次に、型締シリンダ9A〜9Dの型締側室(ポート2a側)を昇圧して型締めした後、4組のボールねじジャッキ50が同時に前進して当て板58を固定ダイプレート2の金型取付面に当接する。型締め後、射出シリンダ8より金型のキャビティ内へ一定量の高圧の溶融発泡樹脂を射出充填し、殆ど間を置かず、型締シリンダ9A〜9Dの型締側室(ポート2a側)を減圧し、4組のボールねじジャッキ50、50、50、50を同調回転駆動し、型締シリンダ9A〜9Dの(低圧の)型締油圧に抗して固定ダイプレート2と可動ダイプレート3の間隔を広げ、金型4と金型5に囲われたキャビティ内の発泡性樹脂の発泡膨張を促す。金型内の樹脂が所定の膨張率に達したら4組のボールねじジャッキ50、50、50、50を同調停止する。樹脂の発泡膨張中、型内圧センサ28が型内圧を検出し、型内圧が負にならぬようにジャッキ50の速度を制限する(型内圧が負になると、発泡ガスや空気が成形品と金型の間に入り込み、スワールマーク(発泡ガス跡)やシルバー(銀条痕)となり易い)。
【0016】
この状態を保持する間に金型キャビティ内の溶融発泡樹脂は金型接触面から冷却固化し、内部が発泡した成形品となり、冷却固化後、型締シリンダ9A〜9Dの油圧回路の油圧をゼロにし、割りナット11が逆作動してタイバー7A〜7Dとの結合を外し、ボールねじ軸13を逆回転して可動金型5と可動ダイプレート3を開側に移動させ、元の全開位置に停止する。成形品が取り出された後、次の型閉工程が始まる。
【0017】
図1に示すように、型締シリンダ9A〜9Dの油圧制御回路は、制御装置37、油圧ポンプ駆動用モータ32、油圧ポンプ31、油圧ポンプ31から送り出される作動油の油圧を高圧、低圧の2段階に切換え可能な電磁比例制御リリーフ弁36、油圧4方向切換弁34、油圧ポンプ31より送り出された作動油を油圧4方向切換弁34まで供給する供給配管44、油圧4方向切換弁34から油圧シリンダ9A〜9Dのポート2a、2cまで配設された型締側配管45A〜45D、供給配管44に設置された開閉弁33、油圧4方向切換弁34から油圧シリンダ9A〜9Dのポート2b、2dまで配設された離型側配管46A〜46D、型締側配管45A〜45Dと離型側配管46A〜46Dとを結んだ差動回路配管に設置された開閉弁35A〜35D、供給配管44に設置された油圧計39とで構成されている。
【0018】
図5に示すこの実施形態の型締装置の発泡成形工程のタイミングを示すグラフにより、射出発泡成形の工程を説明する。
(1)型閉:サーボモータ15によりボールねじ軸13を回転駆動し、可動ダイプレート3を閉側へ高速移動させ、次いでサーボモータ15の回転速度を制御して可動ダイプレート3を減速し、停止させる。
(2)タイバーの結合:4組の割りナット11を作動させてタイバー7A〜7Dと結合する。
(3)型締:油圧ポンプ31を駆動し、電磁比例制御リリーフ弁36を指示して油圧を規定高圧に制御し、4方向切換弁34を型締側に切換え、型締シリンダ9A〜9Dの型締側ポート2a、2cに作動油を送り、金型4と金型5を型締する。4組のボールねじジャッキ50を同調移動して当て板58を固定ダイプレート2の金型取付面2eに当接する。
【0019】
(4)射出充填:金型キャビティ内に加圧した定量の溶融発泡樹脂を射出充填する。
(5)発泡膨張:溶融した発泡樹脂の射出充填後、金型側の樹脂ゲートを閉鎖し、短時間(0.4秒以下)保持した後、電磁比例制御リリーフ弁36を指示して油圧を設定低圧に降圧し(型締力は図5に示すFMとなる)、4組のボールねじジャッキ50を同調移動して当て板58を押出し、固定金型4と可動金型5の間隔を広げ樹脂を発泡膨張させる(図3の状態から図4の状態に間隔s広げる。このときのジャッキ50の押圧力は図5に示すFJであり、FJ≧FM−FB である)。このとき、型内圧センサ28が検出する発泡性樹脂の発泡圧FBがマイナスにならぬように成形品の膨張速度(ジャッキ50のボールねじ移動速度)を制御する。成形品が設定厚さsに膨張したとき、ボールねじジャッキ50を同調停止する。
【0020】
(6)保持冷却:上記のボールねじジャッキ50で固定ダイプレート2と可動ダイプレート3の間隔を保持した状態のまま、設定時間成形品の冷却をする。
(7)離型:成形品の冷却後、油圧4方向切換弁34を離型側に切換え、開閉弁35A〜35Dを開き、型締側配管45と離型側配管46を通にすることにより差動回路を形成し、型締シリンダ9A〜9Dに離型動作をさせる。開閉弁33を閉じ、油圧4方向切換弁34を型締側に切換えて型締シリンダ9A〜9Dの作動油を排油タンクの圧力へ降圧し、割りナット11を逆作動してタイバー7A〜7Dとの結合を外し、ボールねじジャッキ50を型締前の位置に戻し、ボールねじ軸13が型閉のときと逆回転して可動ダイプレート3を開側に移動させ、元の全開位置に停止する。成形品が取り出され、射出発泡成形の工程の1サイクルを終了する。
【0021】
薄肉の成形品の場合、コアバックの移動量sは小さいが、金型の移動速度は所定値に厳密に制御され、停止位置の高精度が要求される。この型締装置のように、金型の寸開手段を複数のボールねじジャッキ50にして、複数のサーボモータ54を同調制御し、コアバック速度と金型停止位置の制御をサーボモータ54の回転数により厳密に行えば、成形品の板厚を揃えると同時に、成形品の板厚を±0.05mmの範囲に納めることが可能となる。即ち、発泡成形においては射出充填完了時に間を置かず(0.4sec以内)、0.5〜5.0mmの移動量を1〜20mm/secの速度でコアバックする必要があり、このような迅速な制御にはサーボモータ駆動のボールねじ装置が最適である。なお、高精度の制御が要求されない場合には、サーボモータ駆動のボールねじジャッキに代えて、油圧シリンダを用いたジャッキとすることもできる。
以上、本発明の好適な実施例について説明したが、本発明は前記実施例に限定されることなく、本発明の精神を逸脱しない範囲内において種々の設計変更をなし得ることは勿論である。
例えば、上記実施形態では、金型の寸開(コアバック)手段としてボールねじジャッキ50を使用しているが、型締シリンダ9A〜9Dとラム6A〜6Dを、或いは、型開閉に用いられるサーボモータ15、ボールねじ軸13を使用することもできる。
【0022】
【発明の効果】
本発明の射出発泡成形機及び射出発泡成形方法によれば、金型キャビティに射出充填した溶融樹脂を、金型を寸開(コアバック)して発泡させる際に、寸開速度を制御することで溶融樹脂の発泡速度及び発泡倍率を制御できるため、良質な発泡成形品を得ることができる。
特に薄肉の発泡成形品の場合、コアバックの移動量は小さいが、金型の移動速度は所定値に厳密に制御され、停止位置の高精度が要求される。発泡時の型寸開(コアバック)に複数のボールねじ式のジャッキを使用し、同ジャッキを駆動するサーボモータを同調制御し、コアバック速度と金型停止位置の制御をサーボモータの回転数により厳密に行えば、成形品の板厚を揃えると同時に、成形品の板厚を±0.05mmの範囲に納めることが可能となる。また、生産サイクルを短くすることができる。
【0023】
また、型内圧センサの検出した型内圧がマイナスにならぬように寸開速度を制御することにより、充填された樹脂は内圧を保った状態で寸開成形することができるので、成形品の表面は常に発泡圧で金型に押し付けられた状態を続け、発泡ガスや空気が成形品と金型の間に入り込むことが抑えられ、成形品の表面にスワールマーク発泡ガス跡)やシルバー(銀条痕)の発生を防止することができる。可動ダイプレート移動手段にサーボモータ駆動のボールねじ装置を使用し、樹脂の発泡成形工程のとき、前記ジャッキと可動ダイプレート移動手段との移動速度を同期するように制御することにより、可動ダイプレート移動手段のボールねじ装置に偏り力が掛かることを防止できる。
【図面の簡単な説明】
【図1】本発明の実施の形態に係る射出発泡成形機の型締装置を示す側面模式図及び型締装置の油圧系統図である。
【図2】図1の射出発泡成形機の型締装置の可動ダイプレートとボールねじ式ジャッキを示す正面図である。
【図3】図1の型締装置の固定金型と可動金型が型締め状態を示す側面断面図である。
【図4】図1の型締装置の固定金型と可動金型が寸開の状態を示す側面断面図である。
【図5】図1の型締装置の発泡成形工程のタイミングを示すグラフである。
【符号の説明】
2…固定ダイプレート
3…可動ダイプレート
4…固定金型
5…可動金型
6A、6B、6C、6D…ラム
7A、7B、7C、7D…タイバー
8…射出ユニット
9A、9B、9C、9D…型締シリンダ
11…割りナット
13…ボールねじ軸
14…ボールねじナット
33、35A、35B、35C、35D…開閉弁
28…型内圧センサ
31…油圧ポンプ
32…モータ
34…4方向切換弁
37…制御装置
50…ボールねじジャッキ
51…ボールねじ
53…ボールねじナット
52…ジャッキ本体
54…サーボモータ
58…当て板
[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a configuration and a foam molding method of an injection foam molding machine in which a molten resin injected and filled into a mold cavity is foamed by slightly opening a mold to obtain a foam molded product.
[0002]
[Prior art]
Injection foam molding by injection molding machine, after hardening the surface, foaming the inside, aiming at obtaining a light and durable molded product with good appearance, heat-plasticized foaming property The resin is injected into the mold at a high speed, and after the injection is finished, the surface of the molded product in contact with the mold cools and cures. An injection foam molding method for lowering the internal pressure of the molded article to foam the inside of the molded article has been conventionally known.
However, such an injection-foam molded product has a problem in that a foaming gas generated by a sudden decrease in resin pressure during injection of a foaming resin is confined in a mold cavity, or a mold cavity is opened by increasing a space between molds. If the mold moving speed is too fast when expanding the mold to the volume of the molded product, the solidified layer on the surface will not be able to follow the movement of the inner surface of the mold, and will be separated from the inner surface of the mold and free solidification of the resin will not follow the inner surface of the mold. When a surface is formed, swirl marks (foaming gas traces) and silver (silver streaks) that impair the appearance are likely to occur. In order to prevent this, the unsolidified molded product immediately after injection is once pressurized and solidified in a state where foaming on the surface is suppressed, and then the volume is increased, or disclosed in, for example, Patent Document 1 (JP-A-2000-71277). As described above, a foam molding method has been devised in which a material having a low thermal conductivity is used for a mold, cooling is delayed, and solidification and foaming are made uniform.
[0003]
In addition, in the foam molding process using an injection foam molding machine having a plurality of cylinders dedicated to mold clamping, when the volume of the mold cavity is increased, the fixed mold and the movable mold are in a free state in which they are not clamped. Therefore, depending on the position of the foam molded product in the mold and the shape of the molded product, and when the distribution of the pressure in the mold during foam molding with respect to the mold is biased, the relative inclination of the mold is changed. This may cause unevenness in the thickness of the foam molded article.
A conventional example of an injection molding machine having a mechanism for preventing such a relative inclination of a mold and maintaining a parallel state of a die plate to which the mold is attached is disclosed in, for example, Japanese Patent Application Laid-Open No. 2000-351142. It has been disclosed. This conventional example includes a first driving means (such as a toggle mechanism or a hydraulic cylinder) for moving a movable mold relative to a fixed mold, and a plurality of pressing members disposed through the movable mold. After injection-filling a foamed resin with an injection foaming molding machine having a second drive means (such as a hydraulic cylinder or a compression spring force) for simultaneously moving the plurality of pressing members back and forth, the mold of the first drive means is The tightening force is loosened (in the case of a hydraulic cylinder, the hydraulic switching valve is set to a neutral state), and the second driving means is used to open the parting surface of the mold by a predetermined stroke at a high speed with a plurality of pressing members. The aim is to obtain homogenization of foaming.
[0004]
[Patent Document 1] JP-A-2000-71277 [Patent Document 2] JP-A-2000-351142
[Problems to be solved by the invention]
In order to prevent the generation of swirl marks (foaming gas traces) and silver (silver streaks) that impair the appearance of the foamed molded product, the unsolidified molded product immediately after injection is once pressurized and solidified while suppressing foaming on the surface Thereafter, the volume is increased or cooling is delayed by using a material having a low thermal conductivity for the mold disclosed in Patent Document 1 (Japanese Patent Application Laid-Open No. 2000-71277) to achieve solidification and uniform foaming. When the mold is opened and closed for foaming, the mold is moved to a fixed position at a constant speed regardless of whether the mechanism is hydraulic or the toggle mechanism is used. If it is difficult to cope with the change and the mold moving speed is too fast, the expansion due to foaming will not be in time, foaming gas or air will enter between the molded product and the mold, and if the mold moving speed is slow, foaming will occur. The resin hardens during expansion and foaming is insufficient. , It enters between the air of the molded product and the mold, swirl mark in either case takes (foaming gas mark) and silver (silver streaks) and easy at the same time cooling time, the production cycle is longer.
[0006]
Further, in the conventional example disclosed in Patent Document 2 (Japanese Patent Laid-Open No. 2000-351142), the opening of the parting surface of the mold is performed by the second driving means, so that the accuracy of the stop position is high. However, in order to adjust the stop position, it is necessary to replace the pressing member. When the second driving means uses a compression spring force, it is not easy to adjust the molding speed and the driving means is The operation has a problem that the stop position accuracy is not sufficient, a loss time is caused in starting and stopping, and a production cycle time is lengthened.
An object of the present invention is to provide an injection foam molding machine and an injection foam molding method that can control the foaming speed and expansion ratio during foam molding by an injection foam molding machine. In addition, during foam molding, injection foam molding machines and injection foaming that suppress the generation of swirl marks (foam gas traces) and silver (silver streaks) by suppressing foam gas and air from entering between the molded product and the mold A molding method is provided. It is still another object of the present invention to provide an injection foam molding machine and a foam molding method that can move a movable die plate in parallel when a mold is opened (core back) to make the thickness of a foam molded product uniform.
[0007]
[Means for Solving the Problems]
In order to solve the above problems, the present invention is characterized by the following configuration and method.
(1) A fixed-side mold attached to a fixed die plate, a movable-side mold attached to a movable die plate, a driving means capable of widening a distance between the two die plates, and a movable means by the driving means. A control device for controlling the moving speed of the side mold to control the expansion rate and expansion rate of the molten resin injected and filled in the mold cavity formed between the two molds. .
(2) The apparatus according to the above (1), further comprising an in-mold pressure sensor for detecting a pressure in the mold cavity, wherein the control device controls a moving speed of the movable mold based on a detection signal of the in-mold pressure sensor. Injection foam molding machine.
(3) The injection foam molding machine according to the above (1), wherein the driving means is a plurality of jacks mounted on the fixed die plate or the movable die plate so as to face the other die plate and driven synchronously.
(4) The injection foam molding machine according to the above item (1) or (3), wherein the driving means is a servo motor driven ball screw device.
(5) A fixed die plate having the fixed mold fixed to the mounting base, a movable die plate movable with the movable mold mounted on the mounting base facing the fixed die plate, and a movable die plate reciprocating. A movable die plate moving means for moving, a plurality of hydraulic clamping cylinders attached to the fixed die plate, a plurality of tie bars which can be integrated with the piston rod of the same clamping cylinder and penetrate through the through hole of the movable die plate; A tie bar fixing means capable of fixing a movable die plate, a four-way switching valve provided in a pipe from a hydraulic pressure source to each mold clamping cylinder, and a mold for each mold clamping cylinder at the same time as closing the discharge side of the four-way switching valve. A means for making a differential circuit between the tightening side and the releasing side, a relief valve capable of controlling the hydraulic pressure of the hydraulic power source to a set low pressure, and a device mounted on a movable die plate or a fixed die plate. A plurality of jacks using a ball screw mechanism that can increase the distance between the die plates by driving each servo motor, and after clamping and injection filling, the relief valve was operated to set the hydraulic pressure of each clamping cylinder. After the pressure is reduced, the servo motors of the plurality of jacks are synchronously driven to control the moving speed of the mold, thereby controlling the expansion speed and expansion rate of the resin foam molding. Molding machine.
[0008]
(6) A step of injecting and filling a molten resin into a mold cavity formed between the fixed mold and the movable mold, and a direction in which the movable mold is separated from the fixed mold after the injection and filling step. An injection foam molding method comprising controlling the moving speed of the movable mold so as to control the expansion speed and expansion rate of the molten resin injected and filled in the mold cavity.
(7) The injection foam molding method according to the above (6), wherein the pressure in the mold cavity is detected, and the moving speed of the movable mold is controlled so that the mold internal pressure in the mold cavity does not become negative.
(8) Using the injection foaming molding machine described in (5) above, melt-plasticize and mold-fill the cavity of the mold by injection, and then reduce the resin pressure and increase the mold cavity volume. In the foam molding method for molding a foam molded article, after injection filling of a foamable resin, the abutment plates of the plurality of jacks are brought into contact with a movable die plate or a fixed die plate, and the relief valve is operated to operate each mold clamping cylinder. After the hydraulic pressure is reduced to the set low pressure, the plurality of jacks are synchronously driven by a servo motor to move the movable die plate in parallel while controlling the expansion speed of the resin foam molding (core back) and stop at the set position. An injection foam molding method in which foaming pressure is maintained, cooling, pressure reduction, and release are performed after foaming is completed.
(9) In the injection foam molding method described in the above (8), an in-mold pressure sensor for detecting a foaming pressure is installed in the movable mold, and the mold internal pressure during the foam molding process of the resin in the mold cavity becomes negative. An injection foam molding method that controls the expansion rate to an unusual level.
(10) In the injection foam molding method according to the above item (8) or (9), when a ball screw device driven by a servo motor is used for the movable die plate moving means, and the resin foam molding process in the mold cavity is performed, An injection foam molding method for controlling the moving speed of the jack and the movable die plate moving means so as to be synchronized.
[0009]
BEST MODE FOR CARRYING OUT THE INVENTION
An injection foam molding machine and a foam molding method according to an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a schematic side view showing a mold clamping device of the injection foam molding machine and a hydraulic system diagram of the mold clamping device. FIG. 2 shows a movable die plate and a ball screw type jack of the mold clamping device of the injection foam molding machine of FIG. Front view, FIG. 3 is a side sectional view showing a fixed mold and a movable mold of the mold clamping device of FIG. 1 in a clamped state, and FIG. 4 is a slightly opened state of the fixed mold and the movable mold of the mold clamping device of FIG. FIG. 5 is a graph showing the timing of the foam molding step of the mold clamping device of FIG. 1.
[0010]
In the figure, reference numeral 1 denotes a base, and a fixed die plate 2 to which a fixed mold 4 is attached is fixedly provided at one end of the base 1. A movable die plate 3 on which a movable mold 5 is mounted is movably mounted on the base 1 so as to face the fixed die plate 2. Reference numeral 22 denotes a guide rail fixed to the base 1, and a linear bearing 21 fixed to the movable die plate 3 is guided by the guide rail 22 and supports the movable die plate 3. The fixed die plate 2 is provided with a plurality (four in this example) of mold clamping cylinders 9A to 9D having a short stroke and a large cross-sectional area. The mold clamping cylinders 9C and 9D are provided symmetrically to the mold clamping cylinders 9A and 9B with respect to the vertical center cross section of the fixed die plate 2. Tie bars 7A to 7D are directly connected to one side surface of rams 6A to 6D that slide in the mold clamping cylinders 9A to 9D, respectively, and the tie bars 7A to 7D approach because the opposed movable die plate 3 is closed. Then, it passes through the four insertion holes opened in the movable die plate 3.
[0011]
The tip portions of the tie bars 7A to 7D form a plurality of ring grooves at the same pitch, respectively, while the opposite die side surface of the movable die plate 3 is engaged with the ring grooves of the tie bars 7A to 7D. Further, four pairs of split nuts 11 facing each other are provided so as to be moved by a hydraulic cylinder or the like in a direction perpendicular to the axes of the tie bars 7A to 7D and fixed with the tie bars 7A to 7D therebetween. Reference numeral 8 denotes an injection cylinder.
[0012]
As shown in FIG. 2, four sets of ball screw jacks 50 are mounted symmetrically in parallel with the die 5 on the die mounting surface of the movable die plate 3. Good). As shown in FIG. 1, the jack main body 52 is fixed to the movable die plate 3, and a bearing 56 provided inside the jack main body 52 rotatably supports a ball screw nut 53 in a thrust direction while supporting the ball screw nut 53. The shaft end of the ball screw 51 screwed via a ball is fixed to a backing plate 58. A pin 57 parallel to the ball screw 51 is slidably fitted in a hole provided in the backing plate 58 and serves to prevent the backing plate 58 from rotating. A toothed belt pulley 53 a is provided at an end of the ball screw nut 53, and the rotation and torque of the servomotor 54 are transmitted to the ball screw nut 53 via a toothed belt 55. Since the servomotor 54 is tuned and rotated by the control device 37, the movement speed and the stop position of each ball screw 51 are also tuned and the stop position of the abutment plate 58 attached to the ball screw 51 is movable in all four sets. The distance from the die mounting surface of the die plate 3 is the same.
[0013]
The mold opening / closing means for moving the movable die plate 3 for a large distance in the mold opening direction is installed in parallel with the moving direction of the movable die plate 3, and is rotatable by a bearing box 17 and a bearing box 18 attached to the base 1. The ball screw shaft 13 is supported by being restrained in the axial direction and driven by a servo motor 15 via a power transmission belt 16, and is supported by a bracket 3 a fixed below the movable die plate 3. And a ball screw nut 14 that moves linearly with the rotation of the ball screw shaft 13. The rotation speed and rotation speed of the ball screw shaft 13 are controlled by the control device 37 via the servomotor 15.
[0014]
This mold clamping device starts from a state where the mold of FIG. 1 is opened, that is, a state where the movable die plate 3 is sufficiently separated from the fixed die plate 2 as shown by a two-dot chain line, as shown by a solid line. Until the mold 4 and the mold 5 are closed, the movable die plate 3 moves by the rotation of the ball screw shaft 13 driven by the servomotor 15. The mold moving speed control circuit built in the control device 37 slowly accelerates the movable die plate 3, moves at a constant speed, then decelerates and stops just before the mold 5 contacts the mold 4.
[0015]
At the stop position of the movable die plate 3, the split nut 11 operates, and the inner ring groove of the split nut 11 engages with the ring groove at the tip of the tie bars 7A to 7D to be connected to the tie bars 7A to 7D. Next, after the mold clamping side chambers (port 2a side) of the mold clamping cylinders 9A to 9D are pressurized and mold-clamped, the four sets of ball screw jacks 50 move forward simultaneously to attach the abutment plate 58 to the mold of the fixed die plate 2. Contact the mounting surface. After the mold clamping, a fixed amount of high-pressure molten foaming resin is injected and filled into the cavity of the mold from the injection cylinder 8, and the mold clamping side chambers (port 2a side) of the mold clamping cylinders 9A to 9D are depressurized with almost no interval. Then, the four sets of ball screw jacks 50, 50, 50, 50 are synchronously driven to rotate, and the distance between the fixed die plate 2 and the movable die plate 3 against the (low pressure) clamping hydraulic pressure of the clamping cylinders 9A to 9D. To expand the foaming resin in the cavity surrounded by the mold 4 and the mold 5. When the resin in the mold reaches a predetermined expansion coefficient, the four sets of ball screw jacks 50, 50, 50, 50 are stopped in synchronization. During foaming expansion of the resin, the mold pressure sensor 28 detects the mold pressure and limits the speed of the jack 50 so that the mold pressure does not become negative. (Swirl marks (foaming gas traces) and silver (silver streaks) easily enter between molds.)
[0016]
While maintaining this state, the molten foamed resin in the mold cavity is cooled and solidified from the mold contact surface to form a foamed product. After cooling and solidifying, the hydraulic pressure of the hydraulic circuit of the mold clamping cylinders 9A to 9D is reduced to zero. The split nut 11 is operated in reverse to release the connection with the tie bars 7A to 7D, the ball screw shaft 13 is rotated in reverse to move the movable mold 5 and the movable die plate 3 to the open side, and return to the original fully open position. Stop. After the molded product is removed, the next mold closing process starts.
[0017]
As shown in FIG. 1, the hydraulic control circuit of the mold clamping cylinders 9A to 9D includes a control device 37, a hydraulic pump driving motor 32, a hydraulic pump 31, and a hydraulic pressure of hydraulic oil delivered from the hydraulic pump 31. An electromagnetic proportional control relief valve 36 that can be switched in stages, a hydraulic four-way switching valve 34, a supply pipe 44 for supplying hydraulic oil sent from the hydraulic pump 31 to the hydraulic four-way switching valve 34, and a hydraulic pressure from the hydraulic four-way switching valve 34 The mold-clamping side pipes 45A to 45D provided to the ports 2a and 2c of the cylinders 9A to 9D, the on-off valve 33 installed in the supply pipe 44, and the ports 2b and 2d of the hydraulic cylinders 9A to 9D from the hydraulic four-way switching valve 34 Release pipes 46A to 46D disposed up to the opening and closing valve 35A installed in a differential circuit pipe connecting the mold clamping side pipes 45A to 45D and the release pipes 46A to 46D. 35D, is constituted by a hydraulic meter 39 installed in the supply pipe 44.
[0018]
The injection foam molding process will be described with reference to FIG. 5, which is a graph showing the timing of the foam molding process of the mold clamping device of this embodiment.
(1) Mold closing: The ball screw shaft 13 is rotationally driven by the servo motor 15 to move the movable die plate 3 toward the closing side at a high speed, and then the rotational speed of the servo motor 15 is controlled to decelerate the movable die plate 3, Stop.
(2) Connection of tie bars: Four sets of split nuts 11 are operated to connect with tie bars 7A to 7D.
(3) Clamping: The hydraulic pump 31 is driven, the electromagnetic proportional control relief valve 36 is instructed to control the hydraulic pressure to a specified high pressure, the four-way switching valve 34 is switched to the mold clamping side, and the mold clamping cylinders 9A to 9D are closed. The hydraulic oil is sent to the mold-side ports 2a and 2c to clamp the mold 4 and the mold 5. The four sets of ball screw jacks 50 are moved synchronously to bring the abutment plate 58 into contact with the mold mounting surface 2 e of the fixed die plate 2.
[0019]
(4) Injection filling: Injecting and filling a fixed amount of molten foamed resin into the mold cavity.
(5) Foaming expansion: After injection filling of the molten foaming resin, the resin gate on the mold side is closed and held for a short time (0.4 seconds or less). The pressure is lowered to the set low pressure (the mold clamping force is FM shown in FIG. 5). The four sets of ball screw jacks 50 are tuned to push out the abutment plate 58, and the distance between the fixed mold 4 and the movable mold 5 is increased. The resin is foamed and expanded (the interval s is increased from the state of FIG. 3 to the state of FIG. 4. At this time, the pressing force of the jack 50 is FJ shown in FIG. 5, and FJ ≧ FM−FB). At this time, the expansion speed of the molded product (the ball screw moving speed of the jack 50) is controlled so that the expansion pressure FB of the expandable resin detected by the in-mold pressure sensor 28 does not become negative. When the molded product expands to the set thickness s, the tuning of the ball screw jack 50 is stopped.
[0020]
(6) Holding and cooling: The molded product is cooled for a set time while the distance between the fixed die plate 2 and the movable die plate 3 is maintained by the ball screw jack 50 described above.
(7) Release: After cooling the molded product, the hydraulic four-way switching valve 34 is switched to the release side, the open / close valves 35A to 35D are opened, and the mold-side piping 45 and the release-side piping 46 are passed through. A differential circuit is formed, and the mold clamping cylinders 9A to 9D are caused to perform a releasing operation. The on-off valve 33 is closed, the hydraulic four-way switching valve 34 is switched to the mold clamping side to lower the hydraulic oil of the mold clamping cylinders 9A to 9D to the pressure of the drainage tank, and the split nut 11 is operated in reverse to tie bars 7A to 7D. The ball screw jack 50 is returned to the position before the mold clamping, and the ball screw shaft 13 is rotated in the reverse direction to when the mold is closed to move the movable die plate 3 to the open side, and stops at the original fully open position. I do. The molded product is taken out, and one cycle of the injection foam molding process is completed.
[0021]
In the case of a thin molded product, the moving amount s of the core back is small, but the moving speed of the mold is strictly controlled to a predetermined value, and high accuracy of the stop position is required. Like the mold clamping device, the mold opening means is a plurality of ball screw jacks 50, the plurality of servomotors 54 are tuned, and the core back speed and the mold stop position are controlled by the rotation of the servomotors 54. If it is strictly performed by the number, it is possible to make the thickness of the molded product uniform and at the same time to keep the thickness of the molded product within the range of ± 0.05 mm. That is, in foam molding, it is necessary to perform a core-back at a speed of 1 to 20 mm / sec with a moving amount of 0.5 to 5.0 mm without a pause (within 0.4 sec) at the time of completion of injection filling. A servo motor driven ball screw device is optimal for quick control. When high-precision control is not required, a jack using a hydraulic cylinder can be used instead of the ball screw jack driven by the servo motor.
The preferred embodiment of the present invention has been described above. However, the present invention is not limited to the above-described embodiment, and it is needless to say that various design changes can be made without departing from the spirit of the present invention.
For example, in the above embodiment, the ball screw jack 50 is used as the die opening (core back) means, but the mold clamping cylinders 9A to 9D and the rams 6A to 6D or the servo used for opening and closing the mold is used. The motor 15 and the ball screw shaft 13 can be used.
[0022]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to the injection foam molding machine and the injection foam molding method of the present invention, when the molten resin injected and filled into the mold cavity is foamed by slightly opening (core backing) the mold, the opening speed is controlled. Thus, the foaming rate and the foaming ratio of the molten resin can be controlled, so that a high-quality foam molded article can be obtained.
In particular, in the case of a thin-walled foam molded product, the moving amount of the core back is small, but the moving speed of the mold is strictly controlled to a predetermined value, and high accuracy of the stop position is required. Using a plurality of ball screw type jacks for opening the mold (core back) during foaming, the servo motor that drives the jack is tuned and the core back speed and the mold stop position are controlled. If it is performed more strictly, it is possible to make the thickness of the molded product uniform and at the same time to keep the thickness of the molded product within the range of ± 0.05 mm. Further, the production cycle can be shortened.
[0023]
In addition, by controlling the opening speed so that the mold pressure detected by the mold pressure sensor does not become negative, the filled resin can be opened while maintaining the internal pressure, so that the surface of the molded product Always keeps pressed against the mold by the foaming pressure, suppressing foaming gas and air from entering between the molded product and the mold, and swirl mark foaming gas traces on the surface of the molded product and silver (silver strip) Scars) can be prevented. By using a ball screw device driven by a servo motor for the movable die plate moving means, and controlling the moving speed of the jack and the movable die plate moving means to be synchronized during the resin foaming step, the movable die plate is moved. It is possible to prevent a biasing force from being applied to the ball screw device of the moving means.
[Brief description of the drawings]
FIG. 1 is a schematic side view showing a mold clamping device of an injection foam molding machine according to an embodiment of the present invention, and a hydraulic system diagram of the mold clamping device.
FIG. 2 is a front view showing a movable die plate and a ball screw type jack of the mold clamping device of the injection foam molding machine of FIG.
FIG. 3 is a side sectional view showing a state in which a fixed mold and a movable mold of the mold clamping device of FIG. 1 are clamped.
FIG. 4 is a side sectional view showing a state where a fixed mold and a movable mold of the mold clamping device of FIG. 1 are slightly opened.
FIG. 5 is a graph showing the timing of a foam molding step of the mold clamping device of FIG. 1;
[Explanation of symbols]
2 ... fixed die plate 3 ... movable die plate 4 ... fixed mold 5 ... movable mold 6A, 6B, 6C, 6D ... ram 7A, 7B, 7C, 7D ... tie bar 8 ... injection unit 9A, 9B, 9C, 9D ... Clamping cylinder 11 Split nut 13 Ball screw shaft 14 Ball screw nut 33, 35A, 35B, 35C, 35D Open / close valve 28 Mold pressure sensor 31 Hydraulic pump 32 Motor 34 4-way switching valve 37 Control Device 50: Ball screw jack 51: Ball screw 53: Ball screw nut 52: Jack body 54: Servo motor 58: Backing plate

Claims (10)

固定ダイプレートに取付けられた固定側金型と、可動ダイプレートに取付けられた可動側金型と、前記両ダイプレート間の間隔を広げることができる駆動手段と、該駆動手段により可動側金型の移動速度を制御して、前記両金型間に形成される金型キャビティ内に射出充填された溶融樹脂の膨張速度及び膨張率を制御する制御装置とを備えてなることを特徴とする射出発泡成形機。A fixed-side mold attached to the fixed die plate, a movable-side mold attached to the movable die plate, a driving unit capable of increasing an interval between the two die plates, and a movable-side mold by the driving unit. And a control device for controlling the moving speed of the molten resin and controlling the expansion rate and expansion rate of the molten resin injected and filled into the mold cavity formed between the two molds. Foam molding machine. 前記金型キャビティ内の圧力を検出する型内圧センサをさらに備え、前記制御装置は、該型内圧センサの検出信号に基づき可動側金型の移動速度を制御することを特徴とする請求項1に記載の射出発泡成形機。2. The apparatus according to claim 1, further comprising an in-mold pressure sensor for detecting a pressure in the mold cavity, wherein the control device controls a moving speed of the movable mold based on a detection signal of the in-mold pressure sensor. The injection foam molding machine as described in the above. 前記駆動手段は、前記固定ダイプレート又は可動ダイプレートに、他方のダイプレートに対向して取付けられ、同期駆動される複数のジャッキであることを特徴とする請求項1に記載の射出発泡成形機。The injection foam molding machine according to claim 1, wherein the driving means is a plurality of jacks attached to the fixed die plate or the movable die plate so as to face the other die plate and driven synchronously. . 前記駆動手段は、サーボモータ駆動のボールねじ装置であることを特徴とする請求項1又は3に記載の射出発泡成形機。The injection foam molding machine according to claim 1, wherein the driving unit is a ball screw device driven by a servo motor. 固定側金型を取付け基盤に固設された固定ダイプレートと、可動側金型を取付け基盤上を前記固定ダイプレートに対向して移動可能な可動ダイプレートと、可動ダイプレートを往復移動させる可動ダイプレート移動手段と、固定ダイプレートに付属する複数の油圧型締シリンダと、同型締シリンダのピストンロッドと一体で可動ダイプレートの貫通孔に貫通可能な複数のタイバーと、同タイバーと可動ダイプレートを固着可能なタイバー固着手段と、油圧源から各型締シリンダに至る配管に設けられた4方向切換弁と、同4方向切換弁の排出側を閉じると同時に各型締シリンダの型締側、離型側を差動回路にする手段と、油圧源の油圧を設定された低圧に制御可能なリリーフ弁と、可動ダイプレート又は固定ダイプレートに取付けられ、それぞれのサーボモータ駆動によりダイプレートの間隔を広げることができるボールねじ機構を用いた複数のジャッキと、型締、射出充填後、前記リリーフ弁を操作して各型締シリンダの油圧を設定された低圧とした後、前記複数のジャッキのサーボモータを同期駆動して金型の移動速度を制御することにより、樹脂の発泡成形の膨張速度と膨張率を制御する制御装置とを備えてなることを特徴とする射出発泡成形機。A fixed die plate having a fixed mold fixed to a mounting base; a movable die plate capable of moving the movable mold on the mounting base in opposition to the fixed die plate; and a movable die plate for reciprocating the movable die plate. Die plate moving means, a plurality of hydraulic mold clamping cylinders attached to the fixed die plate, a plurality of tie bars integral with the piston rod of the mold clamping cylinder, and a plurality of tie bars penetrating through the through hole of the movable die plate, A tie-bar fixing means capable of fixing the same, a four-way switching valve provided in a pipe extending from a hydraulic pressure source to each mold clamping cylinder, a discharge side of the four-way switching valve being closed, Means for making the release side a differential circuit, a relief valve capable of controlling the hydraulic pressure of the hydraulic power source to a set low pressure, and mounted on a movable die plate or a fixed die plate. A plurality of jacks using a ball screw mechanism that can increase the distance between the die plates by driving the servo motors, and after clamping and injection filling, the relief valve was operated to set the hydraulic pressure of each clamping cylinder. A control device for controlling the expansion speed and expansion rate of the resin foam molding by controlling the moving speed of the mold by synchronously driving the servo motors of the plurality of jacks after the low pressure. Injection foam molding machine. 固定側金型と可動側金型間に形成される金型キャビティ内に溶融樹脂を射出充填する工程と、該射出充填工程の後に、可動側金型を固定側金型から離れる方向に移動させる工程を有してなり、該可動側金型の移動速度を制御して、金型キャビティ内に射出充填された溶融樹脂の膨張速度及び膨張率を制御することを特徴とする射出発泡成形方法。Injecting and filling a molten resin into a mold cavity formed between the fixed mold and the movable mold, and moving the movable mold in a direction away from the fixed mold after the injection filling step. An injection foam molding method, comprising the steps of: controlling a moving speed of the movable mold so as to control an expansion speed and an expansion rate of a molten resin injected and filled in a mold cavity. 前記金型キャビティ内の圧力を検出し、金型キャビティ内の型内圧が負圧にならないように可動側金型の移動速度を制御することを特徴とする請求項6に記載の射出発泡成形方法。7. The injection foam molding method according to claim 6, wherein the pressure in the mold cavity is detected, and the moving speed of the movable mold is controlled so that the mold internal pressure in the mold cavity does not become a negative pressure. . 請求項5に記載する射出発泡成形機を用いて金型のキャビティ内に溶融可塑化し、圧縮した発泡性樹脂を射出充填した後、樹脂圧を減じ、金型キャビティ容積を増大して発泡成形品を成形する発泡成形方法において、発泡性樹脂を射出充填後、前記複数のジャッキの当て板を可動ダイプレート又は固定ダイプレートに当接し、前記リリーフ弁を操作して各型締シリンダの油圧を設定された低圧にした後、前記複数のジャッキをサーボモータにより同期駆動して樹脂の発泡成形の膨張速度を制御しながら可動ダイプレートを平行に移動し(コアバック)て設定位置に停止し、発泡終了後、発泡圧力保持、冷却、降圧、離型を行うようにしたことを特徴とする射出発泡成形方法。A foam molded product obtained by melt-plasticizing a mold cavity using the injection foam molding machine according to claim 5 and injecting and filling a compressed foamable resin, then reducing the resin pressure and increasing the volume of the mold cavity. In the foam molding method, the foaming resin is injected and filled, then the abutment plates of the plurality of jacks are brought into contact with a movable die plate or a fixed die plate, and the relief valve is operated to set the hydraulic pressure of each mold clamping cylinder. After the pressure is lowered, the plurality of jacks are synchronously driven by a servo motor to move the movable die plate in parallel while controlling the expansion speed of the resin foam molding (core back), and stop at the set position to stop foaming. After the completion, the foaming pressure is maintained, the cooling, the pressure is reduced, and the mold is released. 請求項8に記載する射出発泡成形方法において、可動側金型に発泡圧を検出する型内圧センサを設置し、金型キャビティ内の樹脂の発泡成形工程中の型内圧が負圧にならぬような膨張速度に制御することを特徴とする射出発泡成形方法。In the injection foam molding method according to claim 8, an in-mold pressure sensor for detecting a foaming pressure is installed in the movable mold so that the mold internal pressure during the resin foam molding process in the mold cavity does not become a negative pressure. An injection foam molding method characterized in that the expansion rate is controlled at a high level. 請求項8又は9に記載する発泡成形方法において、可動ダイプレート移動手段にサーボモータ駆動のボールねじ装置を使用し、金型キャビティ内の樹脂の発泡成形工程のとき、前記ジャッキと可動ダイプレート移動手段との移動速度を同期するように制御することを特徴とする射出発泡成形方法。10. The foam molding method according to claim 8 or 9, wherein a ball screw device driven by a servo motor is used as the movable die plate moving means, and the jack and the movable die plate move during the resin foam molding process in the mold cavity. An injection foam molding method, wherein the moving speed of the injection foam molding is controlled so as to be synchronized with the means.
JP2002266231A 2002-09-12 2002-09-12 Injection foam molding machine and injection foam molding method Expired - Fee Related JP4169554B2 (en)

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