JP2004299262A

JP2004299262A - Method for producing foamed resin molding

Info

Publication number: JP2004299262A
Application number: JP2003095342A
Authority: JP
Inventors: Kazuo Tajima; 一雄田島; Masahiro Tane; 将博太根; Tomoyoshi Onozuka; 智義小野塚
Original assignee: Sekisui Plastics Co Ltd
Current assignee: Sekisui Kasei Co Ltd
Priority date: 2003-03-31
Filing date: 2003-03-31
Publication date: 2004-10-28
Anticipated expiration: 2023-03-31
Also published as: JP3954517B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method which enables production of a foamed resin molding which is homogeneous and excellent in appearance although a synthetic resin sheet or a synthetic resin bag is arranged along a male mold in a cavity. <P>SOLUTION: The foamed resin molding is produced by a process in which the synthetic resin sheet or the synthetic resin bag is arranged along the male mold in the cavity formed between female and male molds, expandable synthetic resin particles are packed in the cavity, preheating steam is supplied into the cavity, the cavity is evacuated, heating steam is supplied into the cavity, and the particles are heated and expanded. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は、合成樹脂層が表面に積層一体化されてなる発泡樹脂成形品を製造することができる発泡樹脂成形品の製造方法に関する。
【０００２】
【従来の技術】
従来から、発泡性スチレン系樹脂粒子を雌雄型間に形成されたキャビティ内に充填し、上記発泡性スチレン系樹脂粒子を加熱、発泡させて所望形状を有する発泡樹脂成形品を製造することが行われている。
【０００３】
そして、上記発泡樹脂成形品の表面に合成樹脂層を積層一体化して表面性を向上させることも行われている。このような表面に合成樹脂層を積層一体化してなる発泡樹脂成形品の製造方法としては、特許文献１に、成形品の表面化粧層となるブランクを用意し、このブランクを雌雄型のうちの何れか一方の型に装着し、次に、この雌雄型を型締めして得られたキャビティ内に発泡性合成樹脂粒子を充填し、この発泡性合成樹脂粒子を加熱、発泡させて、表面に合成樹脂層を積層一体化してなる合成樹脂発泡成形品を製造する製造方法が開示されている。
【０００４】
しかしながら、上記合成樹脂発泡成形品の製造方法では、キャビティ内に合成樹脂層となるブランクを雌雄型の何れか一方の型に装着していることから、ブランクを装着した型部分において、加熱蒸気のキャビティ内への流入及びキャビティ外への流出が規制され、発泡性合成樹脂粒子間に存在する空気の加熱蒸気への置換が円滑に行われず、その結果、加熱蒸気の流通が不充分となって発泡性合成樹脂粒子が充分に発泡せず、得られる発泡樹脂成形品の発泡倍率が部分的に異なってしまって発泡樹脂成形品が不均質となったり或いは発泡粒子間の融着が不均一となるといったことがあった。
【０００５】
【特許文献１】
特公平６−１０４３３８号公報
【０００６】
【発明が解決しようとする課題】
本発明は、キャビティ内において雄型に沿って合成樹脂シート又は合成樹脂製袋体を配設しているにもかかわらず、キャビティ内に加熱蒸気を均一に流通させてキャビティ内に充填した発泡性合成樹脂粒子を均一に且つ充分に発泡させることができ、均質で外観性に優れた発泡樹脂成形品を製造することができる発泡樹脂成形品の製造方法を提供する。
【０００７】
【課題を解決するための手段】
請求項１に記載の発泡樹脂成形品の製造方法は、雌雄型間に形成されたキャビティ内における雄型に沿って合成樹脂シート又は合成樹脂製袋体を配設した状態で上記キャビティ内に発泡性合成樹脂粒子を充填した後、上記キャビティ内に予備加熱蒸気を供給し、次に、上記キャビティ内を真空吸引した上で上記キャビティ内に加熱蒸気を供給して発泡性合成樹脂粒子を加熱、発泡させて発泡樹脂成形品を製造することを特徴とする。
【０００８】
又、請求項２に記載の発泡樹脂成形品の製造方法は、請求項１に記載の発泡樹脂成形品の製造方法において、雄型のチャンバー内に供給された予備加熱蒸気の冷却に伴う体積の減少によって雄型のチャンバー内を減圧し、この減圧力によってキャビティ内を減圧吸引すると共に、雌型のチャンバーを通じてキャビティ内に予備加熱蒸気を供給することを特徴とする。
【０００９】
【発明の実施の形態】
本発明の発泡樹脂成形品の製造方法の一例を図面を参照しつつ説明する。発泡樹脂成形品Ａの製造に用いられる雌雄型１、２における雌型１は、図１に示したように、発泡樹脂成形品の形状に合致した形状を有する凹部１１が凹設されており、この凹部１１には、雌型１のチャンバー１２と凹部１１表面とを連結、連通する貫通孔１１ａが多数、貫設されている。
【００１０】
そして、上記チャンバー１２には、該チャンバー１２内に連通させた状態に蒸気供給管１３が連結されていると共にこの蒸気供給管１３から供給された蒸気に起因する水分をチャンバー１２外に排出するための水分排出管１４をチャンバー１２内に連通させ、更に、上記チャンバー１２内を真空吸引して雌雄型１、２間に形成されるキャビティ３内を真空吸引するための真空吸引管１５がチャンバー１２内に連結、連通されている。
【００１１】
更に、上記チャンバー１２内には、チャンバー１２内に冷却水を供給するための冷却水供給管１６が配設されており、この冷却水供給管１６から冷却水をチャンバー１２内に散水するように構成されている。
【００１２】
又、雄型２は、図１に示したように、発泡樹脂成形品の形状に合致した形状を有する凸部２１が突設されており、この凸部２１には、雄型２のチャンバー２２と凸部２１表面とを連結、連通する貫通孔２１ａが多数、貫設されている。
【００１３】
そして、上記チャンバー２２には、該チャンバー２２内に連通させた状態に蒸気供給管２３が連結されていると共にこの蒸気供給管２３から供給された蒸気に起因する水分をチャンバー２２外に排出するための水分排出管２４をチャンバー２２内に連通させ、更に、上記チャンバー２２内を真空吸引して雌雄型１、２間に形成されるキャビティ３内を真空吸引するための真空吸引管２５がチャンバー２２内に連結、連通されている。
【００１４】
更に、上記チャンバー２２内には、チャンバー２２内に冷却水を供給するための冷却水供給管２６が配設されており、この冷却水供給管２６から冷却水をチャンバー２２内に散水するように構成されている。
【００１５】
このように構成された雌雄型１、２を用いて発泡樹脂成形品を製造する要領について説明する。先ず、図１のように、雌雄型１、２を型開きして、雄型２の凸部２１を露出させた状態とし、この雄型２の凸部２１表面に沿って合成樹脂シート４ａを配設し或いは雄型２の凸部２１に合成樹脂製袋体４ｂを被せた状態に配設する（図では、雄型２の凸部２１に合成樹脂製袋体４ｂを被せた状態を示した）。
【００１６】
上記合成樹脂シート４ａとしては、雌雄型１、２間に形成されたキャビティ３内における雄型２に沿って配設することができれば、雄型２の凸部２１形状に沿って成形されていてもいなくてもよいが、雄型２の凸部２１形状に沿って予め成形された合成樹脂シート４ａが好ましい。
【００１７】
又、上記合成樹脂製袋体４ｂとしては、雄型２の凸部２１形状に合致した形状に成形されておらず、後に続く工程によって、雄型２の凸部２１形状に沿って完全に合致した形状に成形されて発泡樹脂成形品の内面に積層一体化させることができればよく、例えば、雄型２の凸部２１における雌雄型１、２の型開き方向に直交する方向の断面を全て包囲し得る大きさの平面矩形状等の平面多角形状或いは平面円形状の底面部４１ｂと、この底面部４１ｂの四方外周縁から突設され且つ上記雄型２の凸部２１の高さに合致し或いは僅かに高い一定高さを有する周壁部４２ｂとから有底筒状に形成されてなるもの（図２参照）や、折曲線を形成して折畳可能に形成したガゼット袋体や、同形、同大の一対の正面矩形状の合成樹脂シート同士を重ね合わせると共にこれら合成樹脂シートの上端を除いた三方外周縁同士を熱融着してなる袋体等が挙げられる。
【００１８】
又、合成樹脂シート４ａ又は合成樹脂製袋体４ｂを構成する合成樹脂としては、例えば、ポリスチレン、ハイインパクトポリスチレン、スチレン−無水マレイン酸共重合体、スチレン−アクリロニトリル共重合体、スチレン−アクリロニトリル−ブタジエン共重合体等のポリスチレン系樹脂；ポリエチレン、ポリプロピレン、エチレン−酢酸ビニル共重合体等のポリオレフィン系樹脂；ポリエチレンテレフタレート等のポリエステル系樹脂、ナイロン等のポリアミド系樹脂等が挙げられ、必要に応じて、帯電防止剤等の添加剤が添加されていてもよい。
【００１９】
そして、上記雄型２の真空吸引管２５を通じて雄型２のチャンバー２２内を真空吸引して、上記雄型２の凸部２１に沿って配設した合成樹脂シート４ａ又は合成樹脂製袋体４ｂを凸部２１表面に吸着させて、上記雄型２の凸部２１に沿って合成樹脂シート４ａ又は合成樹脂製袋体４ｂが確実に配設された状態を確実に保持する。
【００２０】
なお、上記雄型２のチャンバー２２内に連結、連通された蒸気供給管２３、水分排出管２４及び冷却水供給管２６、並びに、上記雌型１のチャンバー１２内に連結、連通された蒸気供給管１３、水分排出管１４、真空吸引管１５及び冷却水供給管１６は閉止されている。
【００２１】
しかる後、上記雌雄型１、２をクラッキングを残した状態に型締めした上で上記雄型２のチャンバー２２内の真空吸引を停止して真空吸引管２５を閉止した後、上記雌型１に一体的に設けられた樹脂粒子供給管１７を通じて、上記雌雄型１、２間に形成されたキャビティ３内に発泡性合成樹脂粒子５を充填する。なお、上記発泡性合成樹脂粒子５は、合成樹脂に物理発泡剤を含浸させてなり、加熱によって発泡するものであり、予備発泡させたものも含まれる。なお、本発明では、予備発泡させた、所謂、予備発泡粒子を主に使用する。
【００２２】
上記発泡性合成樹脂粒子５を構成する合成樹脂としては、例えば、ポリスチレン、ハイインパクトポリスチレン、スチレン−エチレン共重合体、スチレン改質ポリエチレン系樹脂、スチレン−無水マレイン酸共重合体、スチレン−アクリロニトリル共重合体等のポリスチレン系樹脂、ポリエチレン、ポリプロピレン、エチレン−酢酸ビニル共重合体等のポリオレフィン系樹脂、ポリエチレンテレフタレート等のポリエステル系樹脂等が挙げられる。
【００２３】
又、上記物理発泡剤としては、例えば、プロパン、ブタン、ペンタン、ヘキサン等の脂肪族炭化水素類；シクロペンタン、シクロブタン等の脂肪族環化水素類；トリクロロフルオロメタン、ジクロロジフルオロメタン、ジクロロテトラフルオロメタン、トリクロロトリフルオロエタン、メチルクロライド、メチレンクロライド、エチルクロライド等のハロゲン化炭化水素類等が挙げられる。
【００２４】
そして、図３に示したように、上記雌雄型１、２を完全に型締めして、上記雌雄型１、２間に形成されたキャビティ３内に充填した発泡性合成樹脂粒子５の充填圧力によって、合成樹脂シート４ａ又は合成樹脂製袋体４ｂを雄型２の凸部２１表面に概ね正確に沿った状態とする。
【００２５】
ここで、キャビティ３内には合成樹脂シート４ａ又は合成樹脂製袋体４ｂが配設されていることから、雌雄型１、２のチャンバー１２、２２から供給される後述の加熱蒸気のキャビティ３内での流通が、合成樹脂シート４ａ又は合成樹脂製袋体４ｂによって阻害されてしまい、通常のキャビティ３内における通常の加熱蒸気の流通に比して円滑に行うことができない。
【００２６】
しかも、キャビティ３内の発泡性合成樹脂粒子５間には空気が存在しているが、この空気は熱伝導率が低いと共に後述する加熱蒸気の円滑な流通を阻害する要因にもなることから、キャビティ３内に加熱蒸気を流通させる前に空気をできるだけ除去しておく必要がある。
【００２７】
しかるに、種々検討した結果、キャビティ３内の発泡性合成樹脂粒子５、５間に存在する空気は、単独で真空吸引して除去するよりも、予備加熱蒸気の存在下で真空吸引する方がより確実に吸引除去できることが鋭意研究の結果、判明した。
【００２８】
そこで、上記現象を有効利用すべく、先ず、キャビティ３内に予備加熱蒸気を流入させてキャビティ３内の空気を概ね予備加熱蒸気と置換させた上でキャビティ３内を真空吸引することによって、キャビティ３内の空気を略完全に除去することが可能となり、その結果、発泡性合成樹脂粒子５の発泡のためにキャビティ３内に供給される加熱蒸気を空気の邪魔を受けることなくキャビティ３内に円滑に且つ均一に流通させて、全ての発泡性合成樹脂粒子５を略同一倍率に発泡させると共に発泡性合成樹脂粒子５を発泡させて得られる発泡粒子同士の融着ムラを防止することができる。
【００２９】
上記要領を具体的に説明すると、先ず、上記雄型２の蒸気供給管２３及び水分排出管２４及び上記雌型１の水分排出管１４を開放した後、上記雄型の蒸気供給管２３からチャンバー２２内に予備加熱蒸気を供給する。なお、この雄型２のチャンバー２２内に供給される予備加熱蒸気の温度は、雌雄型１、２が、キャビティ３内に充填した発泡性合成樹脂粒子５の発泡温度以上に加熱されないように調整されている。
【００３０】
そして、上記雄型２のチャンバー２２内の空気が予備加熱蒸気と完全に入れ代わり、雄型２が予備加熱蒸気によって充分に加熱されていない時点で、上記雄型２の蒸気供給管２３を閉止して雄型２のチャンバー２２内への予備加熱蒸気の供給を停止すると同時に上記雄型２の水分排出管２４を閉止して、雄型２のチャンバー２２内をキャビティ３内に連通させている以外は完全に外部から気密的に遮断した状態とする一方、上記雌型１の蒸気供給管１３を開放して雌型１のチャンバー１２内に予備加熱蒸気を供給する。この雌型１のチャンバー１２内に供給される予備加熱蒸気の温度は、雌雄型１、２が、キャビティ３内に充填した発泡性合成樹脂粒子５の発泡温度以上に加熱されないように調整されている。
【００３１】
なお、上記では、上記雄型２のチャンバー２２内への予備加熱蒸気の供給の停止と同時に、上記雌型１の蒸気供給管１３を開放して雌型１のチャンバー１２内に予備加熱蒸気を供給しているが、上記雄型２のチャンバー２２内への予備加熱蒸気の供給と同時に、上記雌型１の蒸気供給管１３を開放して雌型１のチャンバー１２内に予備加熱蒸気を供給してもよい。
【００３２】
すると、雄型２のチャンバー２２内に供給された予備加熱蒸気は、雄型２が充分に予備加熱されていないことから雄型２によって直ちに冷却されて体積が減少し、この予備加熱蒸気の体積の減少に伴って雄型２のチャンバー１２内が減圧状態となる。
【００３３】
そして、上記雄型２のチャンバー２２内の減圧力によって、このチャンバー２２内に唯一、連通した状態となっている貫通孔２１ａを通じてキャビティ３内が減圧吸引され、更に、上記キャビティ３内の減圧吸引によって、上記雌型１のチャンバー１２内の予備加熱蒸気がキャビティ３内に貫通孔１１ａを通じて吸引、供給される。
【００３４】
即ち、上記雄型２のチャンバー２２からの減圧吸引によって、上記雌型１のチャンバー１２内の予備加熱蒸気が、雌型１の貫通孔１１ａを通じてキャビティ３内に流入し、上記キャビティ３内に充填された発泡性合成樹脂粒子５間に存在する空気を雄型２のチャンバー１２側に追い出しながら上記キャビティ３内に置換、充満される。
【００３５】
この時、上記雄型２の凸部２１が部分的に或いは全面的に合成樹脂シート４ａ又は合成樹脂製袋体４ｂによって被覆されており、雄型２におけるチャンバー２２とキャビティ３内とを連通させている貫通孔２１ａの一部或いは大部分が閉塞された状態となっていることから、雄型２のチャンバー２２からキャビティ３に対する減圧吸引は、限定された貫通孔２１ａから集中的に且つ効果的に行われ、キャビティ３内の発泡性合成樹脂粒子５間に存在する空気は、雌型１のチャンバー１２から流入する予備加熱蒸気によって略全面的に且つ円滑に置換される。
【００３６】
しかも、キャビティ３内の減圧吸引は、雌型１側から雄型２側に向かって行われることから、このキャビティ３内の減圧吸引によって該キャビティ３内における雄型２の凸部２１表面に沿って配設された合成樹脂シート４ａ又は合成樹脂製袋体４ｂは、キャビティ３内に供給された予備加熱蒸気によって加熱されつつ雄型２の凸部２１に向かって吸引され、雄型２の凸部２１形状に更に正確に沿った状態となり、合成樹脂シート４ａ又は合成樹脂製袋体４ｂと、これに対向する雄型２の凸部２１との間には殆ど隙間が生じていない状態となっている。
【００３７】
しかる後、上記雌型１の蒸気供給管１３及び水分排出管１４を閉止すると共に、上記雌雄型１、２の真空吸引管１５、２５を開放し、この真空吸引管１５、２５から雌雄型１、２のチャンバー１２、２２内を真空吸引することによって、該チャンバー１２、２２内に貫通孔１１ａ、２１ａを通じて連通しているキャビティ３内を真空吸引し、キャビティ３内に充満された予備加熱蒸気を発泡性合成樹脂粒子５、５間に残存した僅かな空気と共にキャビティ３外に円滑に且つ確実に除去する。
【００３８】
この状態のキャビティ３内は、加熱蒸気の流通及び合成樹脂粒子５の加熱の妨げとなる空気が殆ど残存していない状態となっており、この後にキャビティ３内に供給される加熱蒸気を発泡性合成樹脂粒子５、５間に確実に供給することができると共に、発泡性合成樹脂粒子５の表面を予備加熱蒸気にて覆った状態として加熱蒸気との馴染み性を向上させて、発泡性合成樹脂粒子５、５間における加熱蒸気の流通を全体的に円滑なものとし、各発泡性合成樹脂粒子５を確実に発泡させることができる。
【００３９】
次に、上記雌雄型１、２の真空吸引管１５、２５を閉止すると共に、上記雌雄型１、２の蒸気供給管１３、２３を開放し、雌雄型１、２のチャンバー１２、２２内に、発泡性合成樹脂粒子５を発泡させるのに充分な温度に加熱された加熱蒸気を供給する。
【００４０】
すると、雌雄型１、２のチャンバー１２、２２内に供給した加熱蒸気によって雌雄型１、２が加熱されると共に、雌雄型１、２のチャンバー１２、２２内に供給した加熱蒸気は、空気が殆ど存在しない真空状態に近いキャビティ３内に直ちに流入して該キャビティ３内に充填された発泡性合成樹脂粒子５、５間にくまなく充満し、この加熱蒸気によって残存空気の阻害を受けることなく全ての発泡性合成樹脂粒子５が充分に加熱されて略均一な発泡倍率に発泡して発泡粒子となると共に、これら発泡粒子同士が互いに隙間なく融着一体化して発泡樹脂成形品となる。
【００４１】
これと同時に、キャビティ３内に配設した合成樹脂シート４ａ又は合成樹脂製袋体４ｂは加熱蒸気によって加熱、溶融（軟化）し、発泡性合成樹脂粒子５の発泡圧力によって雄型２の凸部２１の表面形状に沿って成形されると共に、発泡性合成樹脂粒子５の発泡圧力によって発泡樹脂成形品表面に押圧一体化されて、内面に合成樹脂シート４ａ又は合成樹脂製袋体４ｂからなる合成樹脂層Ａ１が積層一体化された発泡樹脂成形品Ａを製造することができる（図４参照）。
【００４２】
なお、上記では、上記雌雄型１、２のチャンバー１２、２２内に同時に加熱蒸気を供給してキャビティ３内の発泡性合成樹脂粒子５を雌雄型１、２の双方側から加熱した場合を説明したが、先ず、上記雌型１の蒸気供給管１３を開放して雌型１のチャンバー１２内に加熱蒸気を供給してキャビティ３内の発泡性合成樹脂粒子５を雌型１側からのみ加熱、発泡させ、発泡した発泡性合成樹脂粒子５を雄型２側に押圧させることによって、雄型２の凸部２１に沿って配設させた合成樹脂シート４ａ又は合成樹脂製袋体４ｂを雄型２の凸部２１の表面に押圧させ、合成樹脂シート４ａ又は合成樹脂製袋体４ｂと雄型２の凸部２１との間の隙間を減少させ、しかる後、上述の要領で雌雄型１、２のチャンバー１２、２２内に加熱蒸気を同時に供給して雌雄型１、２の双方側からキャビティ３内の発泡性合成樹脂粒子５を加熱、発泡させるようにしてもよい。
【００４３】
更に、上記加熱要領では、キャビティ３内の発泡性合成樹脂粒子５の発泡が不充分である場合には、下記の要領でキャビティ３内の加熱を継続する。即ち、上記加熱工程に続いて、上記雄型２の蒸気供給管２３からの雄型２のチャンバー２２への加熱蒸気の供給を継続して行いつつ、上記雌型１の蒸気供給管１３を閉止して、キャビティ３内を雄型２側から所定時間に亘って加熱する。
【００４４】
次に、上記雄型２の蒸気供給管２３を閉止する一方、上記雌型１の蒸気供給管１３を開放して、雌型１のチャンバー１２内に、発泡性合成樹脂粒子５が発泡に充分な温度に加熱された加熱蒸気を供給して、キャビティ３内を雌型１側から所定時間に亘って加熱する。
【００４５】
このように、雌雄型１、２の何れか一方側から順次、別々にキャビティ３内を加熱することによって、キャビティ３内に充填された発泡性合成樹脂粒子５を略完全に発泡させることができる。なお、雌雄型１、２の何れか一方側からの加熱にあたっては、必要に応じて、雌雄型１、２の水分排出管１４、２４を開放させてもよい。
【００４６】
しかる後、図５に示したように、上記雌雄型１、２の蒸気供給管１３、２３を閉止してチャンバー１２、２２内への加熱蒸気の供給を停止した上で、雌雄型１、２の水分排出管１４、２４及び冷却水供給管１６、２６を開放し、この冷却水供給管１６、２６から雌雄型１、２のチャンバー１２、２２内に冷却水を供給してキャビティ３内を冷却する。そして、上記雌雄型１、２を型開きしてキャビティ３内にて所望形状に成形された、合成樹脂層が積層一体化された発泡樹脂成形品Ａを得ることができる。
【００４７】
【発明の効果】
請求項１に記載の発泡樹脂成形品の製造方法は、雌雄型間に形成されたキャビティ内における雄型に沿って合成樹脂シート又は合成樹脂製袋体を配設した状態で上記キャビティ内に発泡性合成樹脂粒子を充填した後、上記キャビティ内に予備加熱蒸気を供給し、次に、上記キャビティ内を真空吸引した上で上記キャビティ内に加熱蒸気を供給して発泡性合成樹脂粒子を加熱、発泡させて発泡樹脂成形品を製造することを特徴とし、雌雄型間に形成されたキャビティ内に、先ず、予備加熱蒸気を供給して発泡性合成樹脂粒子間に存在する空気を予備加熱蒸気で概ね置換した後、この予備加熱蒸気が充満したキャビティ内を真空吸引することによって、キャビティ内の発泡性合成樹脂粒子間に残存する空気を予備加熱蒸気と共にキャビティ内から効率良く略完全に除去している。
【００４８】
従って、その後のキャビティ内への加熱蒸気の流通、充満を空気によって阻害されることなく円滑に且つ均一に行って発泡性合成樹脂粒子の加熱、発泡を全体的に略均一な状態に行うことができ、得られる発泡樹脂成形品は、全体的に略均一な発泡倍率を有し均質なものとなっていると共に発泡性合成樹脂粒子を発泡させて得られる発泡粒子同士が融着ムラなく一体化した良好なものとなっている。
【００４９】
しかも、雌雄型間に形成されたキャビティ内の発泡性合成樹脂粒子を充分に発泡させることができるので、発泡性合成樹脂粒子による発泡圧力を充分に得ることができ、発泡性合成樹脂粒子を発泡、融着一体化させて得られる発泡体を合成樹脂シート又は合成樹脂製袋体に充分に押圧させて、合成樹脂シート又は合成樹脂製袋体を雄型の形状に沿って正確に且つ確実に成形させることができると共に、発泡体の表面に合成樹脂シート又は合成樹脂製袋体からなる合成樹脂層を強固に積層一体化させることができ、得られる発泡樹脂成形品は外観性に優れている。
【００５０】
又、請求項２に記載の発泡樹脂成形品の製造方法は、請求項１に記載の発泡樹脂成形品の製造方法において、雄型のチャンバー内に供給された予備加熱蒸気の冷却に伴う体積の減少によって雄型のチャンバー内を減圧し、この減圧力によってキャビティ内を減圧吸引すると共に、雌型のチャンバーを通じてキャビティ内に予備加熱蒸気を供給することを特徴とするので、雄型からキャビティ内を減圧吸引しつつ雌型のチャンバンーを通じて予備加熱蒸気を円滑にキャビティ内に供給することができ、よって、キャビティ内に充填された発泡性合成樹脂粒子間に存在する空気を予備加熱蒸気に更に効果的に置換することができる。
【図面の簡単な説明】
【図１】本発明の発泡樹脂成形品の製造方法によって発泡樹脂成形品を製造する際の要領の一部を示した断面図である。
【図２】合成樹脂製袋体を示した模式斜視図である。
【図３】本発明の発泡樹脂成形品の製造方法によって発泡樹脂成形品を製造する際の要領の一部を示した断面図である。
【図４】本発明の発泡樹脂成形品の製造方法によって発泡樹脂成形品を製造する際の要領の一部を示した断面図である。
【図５】本発明の発泡樹脂成形品の製造方法によって発泡樹脂成形品を製造する際の要領の一部を示した断面図である。
【符号の説明】
１雌型
１１凹部
１１ａ貫通孔
１２チャンバー
１３蒸気供給管
１４水分排出管
１５真空吸引管
１６冷却水供給管
２雌型
２１凸部
２１ａ貫通孔
２２チャンバー
２３蒸気供給管
２４水分排出管
２５真空吸引管
２６冷却水供給管
３キャビティ
４ａ合成樹脂シート
４ｂ合成樹脂製袋体
５発泡性合成樹脂粒子
Ａ発泡樹脂成形品
Ａ１合成樹脂層[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a foamed resin molded product capable of producing a foamed resin molded product in which a synthetic resin layer is laminated and integrated on the surface.
[0002]
[Prior art]
Conventionally, foamed styrene resin particles are filled into a cavity formed between a male and female mold, and the foamed styrene resin particles are heated and foamed to produce a foamed resin molded product having a desired shape. It has been broken.
[0003]
And the synthetic resin layer is laminated and integrated on the surface of the foamed resin molded product to improve the surface property. As a method for producing a foamed resin molded product in which a synthetic resin layer is laminated and integrated on such a surface, a blank serving as a surface decorative layer of the molded product is prepared in Patent Document 1, and this blank is a male or female mold. Attached to one of the molds, and then filled with foamable synthetic resin particles in the cavity obtained by clamping the male and female molds, and the foamable synthetic resin particles are heated and foamed on the surface. A manufacturing method for manufacturing a synthetic resin foam molded article obtained by laminating and integrating synthetic resin layers is disclosed.
[0004]
However, in the method for producing a synthetic resin foam molded article, since a blank serving as a synthetic resin layer is mounted in one of the male and female molds in the cavity, in the mold portion where the blank is mounted, The inflow into the cavity and the outflow to the outside of the cavity are restricted, and the replacement of the air existing between the foamable synthetic resin particles with the heating steam is not performed smoothly. As a result, the circulation of the heating steam becomes insufficient. The foamable synthetic resin particles are not sufficiently foamed, and the foamed resin molded product obtained is partially different in foaming ratio, resulting in heterogeneous foamed resin molded products or non-uniform fusion between the foamed particles. There was such a thing.
[0005]
[Patent Document 1]
Japanese Examined Patent Publication No. 6-104338 [0006]
[Problems to be solved by the invention]
The present invention has a foaming property in which a heating steam is circulated uniformly in the cavity and filled in the cavity, even though the synthetic resin sheet or the synthetic resin bag body is disposed along the male mold in the cavity. Provided is a method for producing a foamed resin molded product, in which synthetic resin particles can be uniformly and sufficiently foamed, and a foamed resin molded product having a uniform and excellent appearance can be produced.
[0007]
[Means for Solving the Problems]
The method for producing a foamed resin molded article according to claim 1 is a method of foaming in the cavity in a state where a synthetic resin sheet or a synthetic resin bag body is disposed along the male mold in the cavity formed between the male and female molds. After filling the synthetic resin particles, preheated steam is supplied into the cavities, and then the evacuated synthetic resin particles are heated by supplying the heated steam into the cavities after vacuum suction inside the cavities. Foamed resin molded products are produced by foaming.
[0008]
The method for producing a foamed resin molded product according to claim 2 is the method for producing a foamed resin molded product according to claim 1, wherein the volume of the foamed resin molded product according to cooling of the preheated steam supplied into the male chamber is increased. The inside of the male chamber is decompressed by the reduction, and the inside of the cavity is decompressed and sucked by this decompression force, and preheated steam is supplied into the cavity through the female chamber.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
An example of the method for producing a foamed resin molded product of the present invention will be described with reference to the drawings. As shown in FIG. 1, the female mold 1 in the male and female molds 1 and 2 used for manufacturing the foamed resin molded product A is provided with a recess 11 having a shape that matches the shape of the foamed resin molded product. The recess 11 is provided with a large number of through-holes 11 a that connect and communicate the chamber 12 of the female mold 1 and the surface of the recess 11.
[0010]
A steam supply pipe 13 is connected to the chamber 12 so as to communicate with the chamber 12, and moisture caused by the steam supplied from the steam supply pipe 13 is discharged outside the chamber 12. A vacuum suction tube 15 for communicating the inside of the cavity 12 formed between the male and female molds 1 and 2 by vacuum suction in the chamber 12 is connected to the chamber 12. It is connected and communicated inside.
[0011]
Further, a cooling water supply pipe 16 for supplying cooling water into the chamber 12 is disposed in the chamber 12, and the cooling water is sprayed into the chamber 12 from the cooling water supply pipe 16. It is configured.
[0012]
Further, as shown in FIG. 1, the male mold 2 is provided with a protruding portion 21 having a shape that matches the shape of the foamed resin molded product, and the protruding portion 21 has a chamber 22 of the male mold 2. A large number of through-holes 21a that connect and communicate with the surface of the convex portion 21 are provided.
[0013]
A steam supply pipe 23 is connected to the chamber 22 in a state of communicating with the chamber 22, and moisture caused by the steam supplied from the steam supply pipe 23 is discharged outside the chamber 22. A vacuum suction pipe 25 for communicating the moisture discharge pipe 24 in the chamber 22 and vacuuming the inside of the chamber 22 to vacuum the cavity 3 formed between the male and female molds 1 and 2 is provided in the chamber 22. It is connected and communicated inside.
[0014]
Further, a cooling water supply pipe 26 for supplying cooling water into the chamber 22 is disposed in the chamber 22, and the cooling water is sprayed into the chamber 22 from the cooling water supply pipe 26. It is configured.
[0015]
The point which manufactures a foamed resin molded product using the male and female type | molds 1 and 2 comprised in this way is demonstrated. First, as shown in FIG. 1, the male and female molds 1 and 2 are opened so that the convex portion 21 of the male mold 2 is exposed, and the synthetic resin sheet 4 a is formed along the surface of the convex portion 21 of the male mold 2. It arrange | positions or arrange | positions in the state which covered the synthetic resin bag body 4b on the convex part 21 of the male mold 2 (In the figure, the state which covered the synthetic resin bag body 4b on the convex part 21 of the male mold 2 is shown. )
[0016]
If the synthetic resin sheet 4a can be disposed along the male mold 2 in the cavity 3 formed between the male and female molds 1 and 2, the synthetic resin sheet 4a is molded along the shape of the convex portion 21 of the male mold 2. However, the synthetic resin sheet 4a molded in advance along the shape of the convex portion 21 of the male mold 2 is preferable.
[0017]
Further, the synthetic resin bag 4b is not molded into a shape that matches the shape of the convex portion 21 of the male mold 2, and is completely matched along the shape of the convex portion 21 of the male mold 2 by the subsequent process. For example, all the cross-sections in the direction orthogonal to the mold opening direction of the male and female molds 1 and 2 at the convex portion 21 of the male mold 2 are surrounded by the molded resin molded product. A flat polygonal or planar circular bottom surface portion 41b such as a flat rectangular shape having a size that can be formed, and the height of the convex portion 21 of the male mold 2 that protrudes from the four-side outer periphery of the bottom surface portion 41b. Alternatively, it is formed into a bottomed cylindrical shape from a peripheral wall portion 42b having a slightly high constant height (see FIG. 2), a gusset bag body that is formed so as to be foldable by forming a folding curve, Overlapping a pair of front rectangular synthetic resin sheets of the same size Bag, and the like formed by heat sealing the three sides outside peripheral edges except for the upper ends of the synthetic resin sheet causes I.
[0018]
Examples of the synthetic resin constituting the synthetic resin sheet 4a or the synthetic resin bag 4b include polystyrene, high impact polystyrene, styrene-maleic anhydride copolymer, styrene-acrylonitrile copolymer, and styrene-acrylonitrile-butadiene. Polystyrene resins such as copolymers; Polyolefin resins such as polyethylene, polypropylene, and ethylene-vinyl acetate copolymers; Polyester resins such as polyethylene terephthalate, polyamide resins such as nylon, and the like. Additives such as antistatic agents may be added.
[0019]
Then, the inside of the chamber 22 of the male mold 2 is vacuum-sucked through the vacuum suction tube 25 of the male mold 2, and the synthetic resin sheet 4 a or the synthetic resin bag body 4 b disposed along the convex portion 21 of the male mold 2. Is adsorbed on the surface of the convex portion 21 to securely hold the state in which the synthetic resin sheet 4a or the synthetic resin bag body 4b is securely disposed along the convex portion 21 of the male mold 2.
[0020]
In addition, the steam supply pipe 23 connected to and communicated with the chamber 22 of the male mold 2, the moisture discharge pipe 24 and the cooling water supply pipe 26, and the steam supply coupled and communicated with the chamber 12 of the female mold 1. The pipe 13, the water discharge pipe 14, the vacuum suction pipe 15 and the cooling water supply pipe 16 are closed.
[0021]
Thereafter, the male and female molds 1 and 2 are clamped in a state in which cracking is left, the vacuum suction in the chamber 22 of the male mold 2 is stopped and the vacuum suction tube 25 is closed. The foamable synthetic resin particles 5 are filled into the cavity 3 formed between the male and female molds 1 and 2 through the resin particle supply pipe 17 provided integrally. The expandable synthetic resin particles 5 are made by impregnating a synthetic resin with a physical foaming agent and foamed by heating, and include those pre-foamed. In the present invention, pre-foamed particles that have been pre-foamed are mainly used.
[0022]
Examples of the synthetic resin constituting the expandable synthetic resin particle 5 include polystyrene, high impact polystyrene, styrene-ethylene copolymer, styrene-modified polyethylene resin, styrene-maleic anhydride copolymer, and styrene-acrylonitrile copolymer. Examples thereof include polystyrene resins such as polymers, polyolefin resins such as polyethylene, polypropylene, and ethylene-vinyl acetate copolymers, and polyester resins such as polyethylene terephthalate.
[0023]
Examples of the physical blowing agent include aliphatic hydrocarbons such as propane, butane, pentane and hexane; aliphatic cyclized hydrogens such as cyclopentane and cyclobutane; trichlorofluoromethane, dichlorodifluoromethane, dichlorotetrafluoro, and the like. And halogenated hydrocarbons such as methane, trichlorotrifluoroethane, methyl chloride, methylene chloride, and ethyl chloride.
[0024]
Then, as shown in FIG. 3, the filling pressure of the expandable synthetic resin particles 5 filled in the cavity 3 formed between the male and female dies 1 and 2 is completely clamped. Thus, the synthetic resin sheet 4a or the synthetic resin bag body 4b is brought into a state substantially along the surface of the convex portion 21 of the male mold 2.
[0025]
Here, since the synthetic resin sheet 4a or the synthetic resin bag body 4b is disposed in the cavity 3, the inside of the cavity 3 for heating steam to be described later supplied from the chambers 12 and 22 of the male and female molds 1 and 2 is provided. The flow of the water is hindered by the synthetic resin sheet 4a or the synthetic resin bag body 4b, and cannot be smoothly performed as compared with the flow of normal heating steam in the normal cavity 3.
[0026]
Moreover, air exists between the foamable synthetic resin particles 5 in the cavity 3, but this air has a low thermal conductivity and also becomes a factor that hinders the smooth circulation of the heating steam described later. It is necessary to remove air as much as possible before circulating the heating steam in the cavity 3.
[0027]
However, as a result of various studies, it is better to vacuum-suck the air present between the expandable synthetic resin particles 5 and 5 in the cavity 3 in the presence of preheated steam than to remove by vacuum suction alone. As a result of earnest research, it has been found that suction can be removed with certainty.
[0028]
Therefore, in order to effectively use the above phenomenon, first, the preheated steam is caused to flow into the cavity 3 so that the air in the cavity 3 is substantially replaced with the preheated steam, and then the cavity 3 is vacuum-sucked to obtain the cavity. As a result, the heated steam supplied into the cavity 3 for foaming the expandable synthetic resin particles 5 can be removed into the cavity 3 without being obstructed by the air. It is possible to smoothly and uniformly circulate so that all the foamable synthetic resin particles 5 are foamed at substantially the same magnification, and the fusion unevenness between the foamed particles obtained by foaming the foamable synthetic resin particles 5 can be prevented. .
[0029]
The above procedure will be described in detail. First, the steam supply pipe 23 and the moisture discharge pipe 24 of the male mold 2 and the moisture discharge pipe 14 of the female mold 1 are opened, and then the chamber is connected to the chamber from the male steam supply pipe 23. The preheated steam is supplied into 22. The temperature of the preheated steam supplied into the chamber 22 of the male mold 2 is adjusted so that the male and female molds 1 and 2 are not heated above the foaming temperature of the expandable synthetic resin particles 5 filled in the cavity 3. Has been.
[0030]
Then, when the air in the chamber 22 of the male mold 2 is completely replaced with the preheated steam and the male mold 2 is not sufficiently heated by the preheated steam, the steam supply pipe 23 of the male mold 2 is closed. Except that the supply of the preheated steam into the chamber 22 of the male mold 2 is stopped and the moisture discharge pipe 24 of the male mold 2 is closed at the same time so that the chamber 22 of the male mold 2 communicates with the cavity 3. Is completely shut off from the outside, while the steam supply pipe 13 of the female mold 1 is opened to supply preheated steam into the chamber 12 of the female mold 1. The temperature of the preheating steam supplied into the chamber 12 of the female mold 1 is adjusted so that the male and female molds 1 and 2 are not heated above the foaming temperature of the expandable synthetic resin particles 5 filled in the cavity 3. Yes.
[0031]
In the above description, at the same time as the supply of the preheating steam into the chamber 22 of the male mold 2 is stopped, the steam supply pipe 13 of the female mold 1 is opened and preheating steam is supplied into the chamber 12 of the female mold 1. While supplying the preheating steam into the chamber 22 of the male mold 2, the steam supply pipe 13 of the female mold 1 is opened and the preheating steam is supplied into the chamber 12 of the female mold 1. May be.
[0032]
Then, the preheated steam supplied into the chamber 22 of the male mold 2 is immediately cooled by the male mold 2 because the male mold 2 is not sufficiently preheated, and the volume of the preheated steam is reduced. As the pressure decreases, the inside of the chamber 12 of the male mold 2 is in a reduced pressure state.
[0033]
Then, due to the decompression force in the chamber 22 of the male mold 2, the inside of the cavity 3 is decompressed and sucked through the through hole 21a which is in a state of communication with the chamber 22 only. Accordingly, the preheated steam in the chamber 12 of the female mold 1 is sucked and supplied into the cavity 3 through the through hole 11a.
[0034]
That is, the preheated steam in the chamber 12 of the female mold 1 flows into the cavity 3 through the through hole 11a of the female mold 1 by vacuum suction from the chamber 22 of the male mold 2, and fills the cavity 3 The cavity 3 is replaced and filled while the air existing between the foamable synthetic resin particles 5 is expelled to the chamber 12 side of the male mold 2.
[0035]
At this time, the convex portion 21 of the male mold 2 is partially or entirely covered with the synthetic resin sheet 4a or the synthetic resin bag body 4b, and the chamber 22 in the male mold 2 is communicated with the inside of the cavity 3. Since a part or most of the through hole 21a is closed, the vacuum suction from the chamber 22 of the male mold 2 to the cavity 3 is concentrated and effective from the limited through hole 21a. The air existing between the expandable synthetic resin particles 5 in the cavity 3 is replaced almost entirely and smoothly by the preheated steam flowing from the chamber 12 of the female mold 1.
[0036]
Moreover, since the vacuum suction in the cavity 3 is performed from the female mold 1 side toward the male mold 2 side, the vacuum suction in the cavity 3 causes the surface of the convex portion 21 of the male mold 2 in the cavity 3 to follow. The synthetic resin sheet 4a or the synthetic resin bag body 4b disposed in this manner is sucked toward the convex portion 21 of the male mold 2 while being heated by the preheating steam supplied into the cavity 3, and the convex of the male mold 2 is It becomes a state that more accurately follows the shape of the portion 21, and there is almost no gap between the synthetic resin sheet 4 a or the synthetic resin bag body 4 b and the convex portion 21 of the male mold 2 facing this. ing.
[0037]
Thereafter, the steam supply pipe 13 and the moisture discharge pipe 14 of the female mold 1 are closed, and the vacuum suction pipes 15 and 25 of the male and female molds 1 and 2 are opened. By vacuuming the inside of the two chambers 12 and 22, the inside of the cavity 3 communicating with the inside of the chambers 12 and 22 through the through holes 11 a and 21 a is vacuum-sucked, and the preheated steam filled in the cavity 3 Are removed smoothly and reliably to the outside of the cavity 3 together with the slight air remaining between the expandable synthetic resin particles 5 and 5.
[0038]
The inside of the cavity 3 in this state is in a state in which almost no air remains that hinders the flow of the heating steam and the heating of the synthetic resin particles 5, and the heating steam supplied into the cavity 3 thereafter is expanded. The foamable synthetic resin can be reliably supplied between the synthetic resin particles 5 and 5 and the familiarity with the heating steam is improved by covering the surface of the foamable synthetic resin particles 5 with the preheating steam. The flow of the heating steam between the particles 5 and 5 can be made smooth as a whole, and each foamable synthetic resin particle 5 can be reliably foamed.
[0039]
Next, the vacuum suction pipes 15 and 25 of the male and female molds 1 and 2 are closed, and the steam supply pipes 13 and 23 of the male and female molds 1 and 2 are opened, and the chambers 12 and 22 of the male and female molds 1 and 2 are opened. The heated steam heated to a temperature sufficient to foam the expandable synthetic resin particles 5 is supplied.
[0040]
Then, the male and female molds 1 and 2 are heated by the heating steam supplied into the chambers 12 and 22 of the male and female molds 1 and 2, and the heating steam supplied into the chambers 12 and 22 of the male and female molds 1 and 2 Immediately flows into the cavity 3 which is almost in a vacuum state and almost completely fills the foamable synthetic resin particles 5 and 5 filled in the cavity 3 without being disturbed by the remaining air by the heated steam. All of the expandable synthetic resin particles 5 are sufficiently heated to expand to a substantially uniform expansion ratio to form expanded particles, and these expanded particles are fused and integrated with each other without a gap to form a expanded resin molded product.
[0041]
At the same time, the synthetic resin sheet 4 a or the synthetic resin bag body 4 b disposed in the cavity 3 is heated and melted (softened) by heating steam, and the convex portion of the male mold 2 is generated by the foaming pressure of the expandable synthetic resin particles 5. The synthetic resin sheet 4a or the synthetic resin bag 4b is formed on the inner surface of the foamed resin molded product 5 by being pressed and integrated with the surface of the foamed resin molded product 5 by the foaming pressure of the foamable synthetic resin particles 5. A foamed resin molded product A in which the resin layer A1 is laminated and integrated can be manufactured (see FIG. 4).
[0042]
In the above description, a case where heated steam is simultaneously supplied into the chambers 12 and 22 of the male and female molds 1 and 2 to heat the expandable synthetic resin particles 5 in the cavity 3 from both sides of the male and female molds 1 and 2 will be described. However, first, the steam supply pipe 13 of the female mold 1 is opened, heating steam is supplied into the chamber 12 of the female mold 1, and the expandable synthetic resin particles 5 in the cavity 3 are heated only from the female mold 1 side. The synthetic resin sheet 4a or the synthetic resin bag body 4b disposed along the convex portion 21 of the male mold 2 is pressed by pressing the foamed synthetic resin particles 5 to the male mold 2 side. The surface of the convex part 21 of the mold 2 is pressed to reduce the gap between the synthetic resin sheet 4a or the synthetic resin bag body 4b and the convex part 21 of the male mold 2, and then the male and female molds 1 as described above. Heat steam is supplied into the two chambers 12 and 22 simultaneously. The expandable synthetic resin particles 5 inside the cavity 3 from both side of the male 1,2 heating, it may be caused to foam.
[0043]
Further, in the above heating procedure, when the foamable synthetic resin particles 5 in the cavity 3 are insufficiently foamed, the heating in the cavity 3 is continued in the following manner. That is, following the heating step, the steam supply pipe 13 of the female mold 1 is closed while the supply of the heating steam from the steam supply pipe 23 of the male mold 2 to the chamber 22 of the male mold 2 is continued. Then, the cavity 3 is heated from the male mold 2 side for a predetermined time.
[0044]
Next, the steam supply pipe 23 of the male mold 2 is closed, while the steam supply pipe 13 of the female mold 1 is opened, and the foamable synthetic resin particles 5 are sufficiently foamed in the chamber 12 of the female mold 1. Heated steam heated to a certain temperature is supplied to heat the cavity 3 from the female mold 1 side for a predetermined time.
[0045]
Thus, the foamable synthetic resin particles 5 filled in the cavity 3 can be substantially completely foamed by heating the inside of the cavity 3 separately sequentially from either one of the male and female molds 1 and 2. . When heating from either one of the male and female molds 1 and 2, the moisture discharge pipes 14 and 24 of the male and female molds 1 and 2 may be opened as necessary.
[0046]
Thereafter, as shown in FIG. 5, the steam supply pipes 13 and 23 of the male and female dies 1 and 2 are closed to stop the supply of heated steam into the chambers 12 and 22, and then the male and female dies 1 and 2. The water discharge pipes 14, 24 and the cooling water supply pipes 16, 26 are opened, and cooling water is supplied from the cooling water supply pipes 16, 26 into the chambers 12, 22 of the male and female molds 1, 2. Cooling. Then, the foamed resin molded product A, in which the synthetic resin layers are laminated and integrated, can be obtained by opening the male and female dies 1 and 2 and molding them into the desired shape in the cavity 3.
[0047]
【The invention's effect】
The method for producing a foamed resin molded article according to claim 1 is a method of foaming in the cavity in a state where a synthetic resin sheet or a synthetic resin bag body is disposed along the male mold in the cavity formed between the male and female molds. After filling the synthetic resin particles, preheated steam is supplied into the cavities, and then the evacuated synthetic resin particles are heated by supplying the heated steam into the cavities after vacuum suction inside the cavities. A foamed resin molded article is produced by foaming. First, preheated steam is supplied into a cavity formed between the male and female molds, and air existing between the expandable synthetic resin particles is preliminarily heated. After the replacement, the inside of the cavity filled with the preheated steam is vacuumed to suck the air remaining between the expandable synthetic resin particles in the cavity from the cavity together with the preheated steam. The rate may substantially completely removed.
[0048]
Therefore, it is possible to smoothly and uniformly perform the flow and filling of the heated steam into the cavity thereafter without being hindered by air, and to heat and foam the foamable synthetic resin particles in a substantially uniform state as a whole. The resulting foamed resin molded product has a uniform expansion ratio as a whole and is uniform, and the foamed particles obtained by foaming the foamable synthetic resin particles are integrated with each other without fusing unevenness. It has become a good one.
[0049]
In addition, since the foamable synthetic resin particles in the cavity formed between the male and female molds can be sufficiently foamed, it is possible to obtain a sufficient foaming pressure by the foamable synthetic resin particles and foam the foamable synthetic resin particles. The foam obtained by fusing and integrating is sufficiently pressed against the synthetic resin sheet or the synthetic resin bag body so that the synthetic resin sheet or the synthetic resin bag body is accurately and reliably aligned with the male shape. In addition to being able to be molded, a synthetic resin layer composed of a synthetic resin sheet or a synthetic resin bag can be firmly laminated and integrated on the surface of the foam, and the resulting foamed resin molded product has excellent appearance .
[0050]
The method for producing a foamed resin molded product according to claim 2 is the method for producing a foamed resin molded product according to claim 1, wherein the volume of the foamed resin molded product according to cooling of the preheated steam supplied into the male chamber is increased. The inside of the cavity of the male mold is depressurized by the reduction, and the inside of the cavity is sucked and decompressed by this decompression force, and the preheated steam is supplied into the cavity through the female mold chamber. The preheated steam can be smoothly supplied into the cavity through the female chamber while sucking under reduced pressure. Therefore, the air existing between the expandable synthetic resin particles filled in the cavity is more effectively used as the preheated steam. Can be substituted.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a part of a procedure for producing a foamed resin molded product by the method for producing a foamed resin molded product of the present invention.
FIG. 2 is a schematic perspective view showing a synthetic resin bag.
FIG. 3 is a cross-sectional view showing a part of the procedure for producing a foamed resin molded product by the method for producing a foamed resin molded product of the present invention.
FIG. 4 is a cross-sectional view showing a part of the procedure for producing a foamed resin molded product by the method for producing a foamed resin molded product of the present invention.
FIG. 5 is a cross-sectional view showing a part of the procedure for producing a foamed resin molded product by the method for producing a foamed resin molded product of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Female type | mold 11 Recessed part 11a Through-hole 12 Chamber 13 Steam supply pipe 14 Moisture discharge pipe 15 Vacuum suction pipe 16 Cooling water supply pipe 2 Female mold 21 Convex part 21a Through-hole 22 Chamber 23 Steam supply pipe 24 Moisture discharge pipe 25 Vacuum suction pipe 26 Cooling water supply pipe 3 Cavity 4a Synthetic resin sheet 4b Synthetic resin bag 5 Expandable synthetic resin particle A Expanded resin molded product A1 Synthetic resin layer

Claims

After the synthetic resin sheet or the synthetic resin bag body is arranged along the male mold in the cavity formed between the male and female molds, the cavity is filled with expandable synthetic resin particles and then preheated in the cavity. Vapor is supplied, and then the inside of the cavity is vacuumed and heated steam is supplied into the cavity to heat and foam the foamable synthetic resin particles to produce a foamed resin molded product. Manufacturing method of foamed resin molded product.

The inside of the male chamber is depressurized by reducing the volume accompanying cooling of the preheated steam supplied into the male chamber, and the inside of the cavity is vacuumed and sucked into the cavity through the female chamber by this decompression force. Heated steam is supplied, The manufacturing method of the foamed resin molding of Claim 1 characterized by the above-mentioned.