JP2006068919A - Vacuum forming method of thermoplastic resin foamed sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a thermoplastic resin foamed sheet having a high expansion rate and increased in thickness. <P>SOLUTION: This vacuum foaming method of the thermoplastic resin foamed sheet using a pair of molds capable of being sucked under vacuum from the molding surfaces thereof includes a process (1) for heating and softening the thermoplastic resin foamed sheet, a process (2) for supplying the thermoplastic resin foamed sheet obtained in the process (1) to the space between the molds, a process (3) for closing both molds until the clearance between both molds in the outer edge parts of the molding surfaces becomes the thickness of the thermoplastic resin foamed sheet or below while holding the heated and softened thermoplastic resin foamed sheet between the molds, a process (4) for starting the vacuum suction from the molding surfaces of both molds at the arbitrary point of time when the clearance in the process (3) becomes the thickness of the heated and softened thermoplastic resin foamed sheet or after the thickness of the sheet becomes a predetermined thickness, a process (5) for opening the molds until the sheet between both molding surface becomes the desired thickness of a molded product while continuing vacuum suction to shape the sheet and a process (6) for taking out of the vacuum formed product. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a vacuum forming method for a thermoplastic resin foam sheet.

Thermoplastic resin foam molded articles are excellent in light weight, recyclability, heat insulation, and the like, and are therefore used in various applications such as automotive parts materials, building materials, and packaging materials.
When a thermoplastic resin foam molded article is used as described above, after producing a thermoplastic resin foam sheet, the thermoplastic resin foam sheet is shaped into a desired shape by a secondary molding method such as vacuum molding. It is often used as a thermoplastic resin foam molded article. As a method of vacuum forming a thermoplastic resin foam sheet, a thermoplastic resin foam sheet is supplied between a pair of male and female molds having a predetermined gap when the molds are clamped, and both molds are kept clamped. A method is known in which a vacuum pressure is reduced from the surface to shape a foamed sheet into a void shape to obtain a thermoplastic resin foamed molded article (see, for example, Patent Document 1).

JP 54-148863 A

As the foam sheet, a sheet having a high foaming ratio and a large thickness is desired. According to the said method, compared with the raw fabric foam sheet used for vacuum forming, a foam ratio is high and a thick sheet can be obtained. However, in the above method, since the raw foam sheet can be expanded only by the gap formed when the pair of molds are clamped, the thickness of the obtained thermoplastic resin foam sheet is about twice the thickness of the raw sheet. However, the expansion ratio was still not satisfactory.
In order to obtain a thermoplastic resin foam sheet having a sufficiently high foaming ratio and a thicker thickness than the original foam foam sheet by the above method, it is necessary to use a mold having a large void portion. Even if this is done, the voids may not be filled with the original fabric foamed sheet, and it is still difficult to obtain a thermoplastic resin foamed sheet having a higher foaming ratio than that of the original fabric foamed sheet.
The present invention provides a method for producing a thermoplastic resin foam sheet having a high expansion ratio and a large thickness.

That is, the present invention is a vacuum molding method for a thermoplastic resin foam sheet including the following steps using a pair of molds that can be vacuum-sucked from the molding surfaces of the respective molds.
(1) Step of heat-softening the thermoplastic resin foam sheet (2) Step of supplying the thermoplastic resin foam sheet obtained in step (1) between the molds (3) Heat-softened thermoplastic resin foam sheet The clearance in the step (4) and the step (3) is closed by heating and softening until the clearance between the two dies at the outer edge of the molding surface is equal to or less than the thickness of the sheet while being sandwiched between the dies. Step of starting vacuum suction from the molding surfaces of both molding dies at an arbitrary time when the thickness of the thermoplastic resin foam sheet becomes less than or equal to the predetermined thickness (5) While continuing vacuum suction, between the molding surfaces (6) A step of stopping the vacuum suction to open the mold and taking out the molded product until the sheet has a desired molded product thickness.

  According to the method for producing a thermoplastic resin foam sheet of the present invention, it is possible to produce a thermoplastic resin foam sheet having a high foaming ratio and a large thickness.

  Hereinafter, an example of the present invention will be described in detail with reference to FIG. 3, but the present invention is not limited to this example.

  In the present invention, a pair of molds that can be vacuum-sucked from the molding surface of each mold is used. Examples of the mold used include a male mold on one side and a female mold on the other side, a mold between female dies, a pair of plate-shaped molds, and the like.

  Molds that can be vacuum-sucked from the molding surface of each mold include molds in which at least a part of the molding surface is made of a sintered alloy, and molds in which holes are provided in at least a part of the molding surface Illustrated. The number, position, and hole diameter of the previous holes provided in the mold are not particularly limited. By vacuum suction through the holes, the foamed thermoplastic resin sheet supplied between the molds is formed into a mold surface. Anything that can be shaped is acceptable.

The material of the mold is not particularly limited, but is usually made of metal from the viewpoints of dimensional stability, durability, thermal conductivity, and the like, and is preferably made of aluminum from the viewpoints of cost and lightness.
Moreover, it is preferable that a shaping | molding die is a structure which can adjust temperature with a heater, a heat medium, etc. From the viewpoint of enhancing the slipperiness with the foam sheet and from the viewpoint of preventing the foam sheet from being cooled before the completion of molding, the molding surface of the molding die is preferably set to 30 to 80 ° C, and 50 to 60 ° C. More preferably.

It is preferable to use a mold having an airtight holding portion for one or both molds. When such a mold is used, it is easy to maintain the degree of vacuum in the cavity when vacuum suction is performed, and a molded product with extremely small sink marks can be obtained.
Examples of the mold having the hermeticity holding portion include a mold in which the outer edge portion of the molding surface of at least one of the molds is movable in the opposing mold direction. In the case of such a mold, it is preferable that the movable part can be stored in the mold so that the movable part is on the same plane as the outer edge of the molding surface when the mold is closed. In such a mold, the movable part protrudes as the mold is opened, so that the degree of vacuum in the cavity is easily maintained in the mold opening process described later.

As another example of the mold having the airtight holding portion, there is a mold having a buffer material at the outer edge of the molding surface of at least one of the molds as shown in FIG. Usually, the foam sheet has minute irregularities on the surface. In the case of a mold having a cushioning material, the cushioning material comes into close contact with the surface of the foamed sheet having minute irregularities when the mold is closed, so that it is easy to maintain the degree of vacuum in the cavity when vacuum suction is performed. Examples of the buffer material include rubber and foam.
As shown in FIG. 5, it is also possible to use a pair of molds configured such that the other mold is covered by an airtight holding portion provided on the outer periphery of one mold when the mold is closed.

  A member for fixing the foam sheet may be provided on the molding surface and / or the outer edge of the molding surface of the molding die. For example, an adhesive material may be provided on a part or the whole of the molding surface and / or the outer edge of the molding surface, or a pin, hook, clip, slit, or the like may be provided. By using such a mold, it becomes easy to shape the foamed sheet into a molded surface.

  As the mold, it is preferable to use a mold in which the height of the cavity formed when the mold is closed is about 0.8 to 2 times the thickness of the foamed sheet obtained in the step (1). The height of the cavity is the distance between the molding surfaces corresponding to the thickness direction of the foam sheet supplied between the molding dies. The cavity height does not need to be constant, and may be a cavity corresponding to the shape of a desired molded product. If the height of the cavity is too low, bubbles in the foam sheet may be crushed when the mold is closed. If it is too high, the mold surface of the mold and the surface of the foam sheet are brought into contact with each other even if vacuum suction is applied as described later. It becomes difficult to form, and even when brought into contact, bubbles are easily broken.

  FIG. 3- (1) shows the step (1) of heat-softening the thermoplastic resin foam sheet. In the step (1), the foam sheet is usually sandwiched between clamp frames, and the foam sheet is heated by a known heating device such as a far infrared heater, a near infrared heater, or a contact hot plate. It is preferable to use a far infrared heater because it can be efficiently heated in a short time. The heat treatment is preferably performed so that the surface temperature of the foamed sheet is near the melting point of the resin if the resin constituting the foamed sheet is a crystalline resin, and near the glass transition temperature if the resin is an amorphous resin. .

  FIG. 3- (2) shows a state in which the thermoplastic resin foam sheet obtained in step (1) is supplied between a pair of molds that can be vacuum-sucked from the molding surfaces of the respective molds.

  FIG. 3-(3) shows both molds until the heat-softened thermoplastic resin foam sheet is sandwiched between the molds and the clearance between both molds at the outer edge of the molding surface is less than the thickness of the sheet. The closed state is shown. In closing the mold, only one mold may be moved in the direction of the other mold, or both molds may be brought close to each other.

FIG. 3- (4) shows a state where vacuum suction is performed from the molding surfaces of both molds. The vacuum suction starts at any time when the clearance between the two molds at the outer edge of the molding surface becomes equal to or less than the thickness of the heat-softened thermoplastic resin foam sheet or after a predetermined thickness. For example, vacuum suction starts when the clearance between both molds at the outer edge of the molding surface becomes the same as the thickness of the heat-softened thermoplastic foam sheet, and the mold is further closed to a predetermined thickness while vacuum suction is performed. Alternatively, vacuum suction may be started at the same time when the clearance reaches a predetermined thickness or after the clearance has reached the predetermined thickness. When vacuum suction is performed after the predetermined thickness is reached, it is preferable to perform vacuum suction within 3 seconds from the point of time when the foam sheet has reached the predetermined thickness before cooling.
The timing of starting vacuum suction from each mold is preferably the same for obtaining a molded product having a uniform internal structure, but it is also possible to make a time difference as long as the foamed sheet is not cooled. . In the case where vacuum suction is started from the other mold after starting vacuum suction from one mold, the difference in the start times is preferably within 3 seconds.

  The degree of vacuum suction is not particularly limited, but vacuum suction is preferably performed so that the degree of vacuum of the cavity is -0.05 to -0.1 MPa. The degree of vacuum is the pressure in the cavity with respect to atmospheric pressure. That is, “the degree of vacuum is −0.05 MPa” indicates that the pressure in the cavity is 0.95 MPa. The higher the degree of vacuum, the stronger the foam sheet is pressed against the mold, so that the foam sheet can be shaped according to the cavity shape. The degree of vacuum of the cavity is a value measured at the cavity side opening of the hole to be vacuumed.

  FIG. 3- (5) shows a state where the mold is opened and shaped until the sheet between the molding surfaces reaches a desired thickness of the molded product. Open the mold while continuing vacuum suction. The mold opening speed and the degree of vacuum may be adjusted so that the foamed sheet is shaped into a desired molded product shape.

  In the state where the mold is opened to a predetermined thickness, the foamed sheet is sufficiently cooled, then vacuum suction is stopped, the mold is opened, and the molded product is taken out. FIG. 3- (6) shows a state in which a mold (not shown) is opened to take out the molded product.

  In the present invention, a skin material may be placed in advance on the molding surface of one or both molds. As the skin material, the material and thickness are not particularly limited as long as the foamed sheet can be shaped into a molding surface by performing vacuum suction through the skin material. For example, a thermoplastic resin, thermosetting Resins, thermoplastic elastomers and other natural fibers, natural fibers such as rubber and hemp, minerals such as calcium silicate, etc. Examples of the form include films, sheets, nonwoven fabrics and woven fabrics. In addition, paper, synthetic paper made of propylene resin, styrene resin, or the like, a metal thin plate such as aluminum or iron, a metal foil, or the like can be used. The skin material may be a single layer or a multilayer, and may be a textured pattern such as embossed or printed or dyed.

It does not specifically limit as a thermoplastic resin foam sheet used by this invention, A well-known foam sheet can be used.
The resin constituting the thermoplastic resin foam sheet is an olefin homopolymer having 6 or less carbon atoms such as ethylene, propylene, butene, pentene, hexene, or two or more kinds selected from olefins having 2 to 10 carbon atoms. Olefin resins such as olefin copolymers obtained by copolymerizing monomers, ethylene-vinyl ester copolymers, ethylene- (meth) acrylic acid copolymers, ethylene- (meth) acrylic acid ester copolymers, ester-based resins Amide resin, styrene resin, acrylic resin, acrylonitrile resin, ionomer resin and the like. These resins may be used alone or as a blend of a plurality of resins. Among these resins, olefin resins are preferably used from the viewpoints of moldability, oil resistance, cost, and the like, and propylene resins are particularly preferably used from the viewpoint of rigidity and heat resistance of the obtained molded product.

  When using a foamed sheet made of a propylene resin, examples of the propylene resin constituting the foamed layer include a propylene homopolymer and a propylene copolymer containing 50 mol% or more of a monomer unit derived from propylene. The copolymer may be any of a block copolymer, a random copolymer, and a graft copolymer. As an example of the propylene-based copolymer that is preferably used, a copolymer of ethylene or an α-olefin having 4 to 10 carbon atoms and propylene can be given. Examples of the α-olefin having 4 to 10 carbon atoms include 1-butene, 4-methylpentene-1, 1-hexene, and 1-octene. The content of monomer units other than propylene in the propylene-based copolymer is preferably 15 mol% or less for ethylene and 30 mol% or less for α-olefins having 4 to 10 carbon atoms. One type of propylene resin may be used, or two or more types may be mixed and used.

Among the propylene resins, a long chain branched propylene resin or a high molecular weight propylene resin having a weight average molecular weight of 1 × 10 ⁵ or more is used in a finer particle by using 50% by weight or more of the thermoplastic resin constituting the foam layer. A propylene-based resin foam sheet having various bubbles can be obtained. Further, among such propylene resins, non-crosslinked propylene resins are preferably used because gels are unlikely to occur during sheet recycling.

Here, the long-chain branched propylene-based resin refers to a propylene-based resin having a degree of branching index [A] satisfying 0.20 ≦ [A] ≦ 0.98.
An example of a long-chain branched propylene-based resin satisfying the branching index [A] of 0.20 ≦ [A] ≦ 0.98 is propylene PF-814 manufactured by Basel.

The degree of branching index indicates the degree of long chain branching in a polymer, and is a numerical value defined in the following formula.
Branch index [A] = [η] _Br / [η] _Lin
Here, [η] _Br is the intrinsic viscosity of the propylene resin having a long chain branch, and [η] _Lin is a straight chain having the same monomer unit and the same weight average molecular weight as the propylene resin having the long chain branch. It is an intrinsic viscosity of a chain propylene resin.
Intrinsic viscosity, also called intrinsic viscosity, is a measure of the ability of a polymer to enhance solution viscosity. Intrinsic viscosity depends in particular on the molecular weight of the polymer molecules and the degree of branching. Therefore, by comparing the intrinsic viscosity of a polymer having long chain branches with the intrinsic viscosity of a linear polymer having the same weight average molecular weight as that of the polymer having long chain branches, the degree of branching of the polymer having long chain branches can be determined. It can be a scale. The method for measuring the intrinsic viscosity of a propylene resin is described by Elliott et al. Appl. Polym. Sci. , 14, 2947-2963 (1970)], for example, a propylene resin is dissolved in tetralin or orthodichlorobenzene, and the intrinsic viscosity at 135 ° C. Can be measured.
The weight average molecular weight (Mw) of the propylene-based resin can be measured by various commonly used methods. L. The method disclosed by McConnel in American Laboratory, May, 63-75 (1978), that is, a low-angle laser light scattering intensity measurement method is particularly preferably used.
As an example of a method for polymerizing a high molecular weight propylene resin having a weight average molecular weight of 1 × 10 ⁵ or more, as described in JP-A No. 11-228629, a high molecular weight component is first polymerized and subsequently a low molecular weight polymer is used. Examples thereof include a method of polymerizing components.

Among long-chain branched propylene resins or high-molecular-weight propylene resins, propylene resins having a uniaxial melt-extension viscosity ratio η ₅ / η _0.1 measured under the following conditions at around melting point + 30 ° C. are preferably 5 or more, more preferably 10 or more resins. The uniaxial melt extensional viscosity ratio is a value measured using an apparatus such as a uniaxial extensional viscosity measurement apparatus (for example, a uniaxial extensional viscosity measurement apparatus manufactured by Rheometrics, Inc.) at an elongation strain rate of 1 sec ⁻¹ . the uniaxial melt elongation viscosity after 0.1 seconds from the strain initiation and eta _0.1, the uniaxial melt elongation viscosity after 5 seconds and eta _5. By using a propylene-based resin having such uniaxial extensional viscosity characteristics, a foam sheet having finer bubbles can be produced.

  The foaming agent used to form the foamed sheet may be either a so-called chemical foaming agent or a physical foaming agent, or may be used in combination. Examples of the chemical foaming agent include a thermal decomposition type foaming agent that decomposes to generate nitrogen gas (azodicarbonamide, azobisisobutyronitrile, dinitrosopentamethylenetetramine, p-toluenesulfonylhydrazide, p, p'- Oxy-bis (benzenesulfonyl hydrazide) and the like, and pyrolytic inorganic foaming agents that decompose to generate carbon dioxide (sodium hydrogen carbonate, ammonium carbonate, ammonium bicarbonate, etc.) . Specific examples of the physical foaming agent include propane, butane, water, carbon dioxide gas, and the like. Among the above-exemplified foaming agents, water, carbon dioxide, and the like are used because the sheet is not easily deformed by secondary foaming during heating during vacuum forming, is a substance that is inert to high temperature conditions, and fire. Preferably used. The amount of the foaming agent used is appropriately selected according to the type of foaming agent and resin used so that a desired foaming ratio can be obtained. Usually, the foaming agent is used in an amount of 0.5 to 20 with respect to 100 weight of the thermoplastic resin. Parts by weight.

  Although the manufacturing method of the thermoplastic resin foam sheet used in the present invention is not particularly limited, a sheet obtained by extrusion molding using a flat die (T die) or a circular die is preferable, and a resin melted from a circular die is used. A method of extruding while foaming, stretching and cooling along a mandrel or the like is particularly preferably used. When the foamed sheet is produced by extrusion molding, the molten resin can be extruded from a die and solidified by cooling and then stretched. The foamed sheet may be a single layer or a multilayer, but from the viewpoint of preventing foam breakage during sheet production, a multilayered foam sheet having non-foamed layers in both outer layers is preferred. As the resin constituting the non-foamed layer, those described above as examples of the resin constituting the foamed layer can be used, but the same type of resin as that constituting the foamed layer is preferable. In the case of a propylene-based resin, the non-foamed layer is also preferably composed of a propylene-based resin.

The thermoplastic resin foam sheet used in the present invention may be a composite sheet obtained by laminating a single layer or multilayer foam sheet and another material. Such a composite sheet is obtained by laminating a foam sheet and another material by dry lamination, sand lamination, hot roll bonding, hot air bonding, or the like.
Examples of other materials to be laminated with the foamed sheet can be the same as the above-mentioned skin material. Especially when molding an automobile interior material by the molding method of the present invention, a sheet or nonwoven fabric made of a thermoplastic resin. Natural fibers such as woolen fabric and hemp are widely used, and when forming food containers, single-layer or multi-layer gas barrier films having a layer made of an ethylene-vinyl alcohol copolymer and CPP films are widely used. The

  The thermoplastic resin foam sheet used in the present invention may contain an additive. Examples of the additive include a filler (filler), an antioxidant, a light stabilizer, an ultraviolet absorber, a plasticizer, an antistatic agent, a colorant, a release agent, a fluidity-imparting agent, and a lubricant. Specific examples of the filler include inorganic fibers such as glass fibers and carbon fibers, inorganic particles such as talc, clay, silica, titanium oxide, calcium carbonate, and magnesium sulfate.

The molded product obtained by the vacuum forming method of the present invention has a large expansion ratio and thickness, is lightweight and has excellent heat insulation properties, and is used for packaging materials such as food containers, automobile interior parts, building materials, and home appliances. can do. Examples of automobile interior parts include door trims, ceilings, trunk sides, and the like. When the molded product obtained in the present invention is used as such a member, for example, when the temperature inside the vehicle is adjusted, The effect of being able to keep temperature for a long time is acquired. When used as a food container, it can be shaped and used in various shapes such as cups, trays, bowls, etc., and because it has excellent heat insulation properties, it can be used for filling soups heated to high temperatures or cooking in a microwave oven. It is preferably used for food containers.

EXAMPLES Hereinafter, although this invention is demonstrated based on an Example, this invention is not limited to an Example at all.

[Example 1]
By the method shown below, a thermoplastic resin foam sheet of two types and three layers in which a non-foamed layer was laminated on both surfaces of the foamed layer was produced.

(Foam layer material)
With respect to 100 parts by weight of propylene polymer powder having the following physical properties obtained by the method disclosed in JP-A-11-228629, 0.1 part by weight of calcium stearate, phenolic antioxidant (trade name: Irganox 1010, manufactured by Ciba Specialty Chemicals Co., Ltd.) 0.05 parts by weight, phenolic antioxidant (trade name: Sumilyzer BHT, manufactured by Sumitomo Chemical Co., Ltd.) 0.2 parts by weight are added and mixed at 230 ° C. By melt-kneading, propylene polymer pellets (i) were obtained. The melt flow rate (MFR) of the propylene-based polymer pellet (i) measured by JIS K6758 was 12 g / 10 min (230 ° C. 2.16 kgf). The propylene polymer pellet (i) was used as a foam layer material.
Physical properties of propylene polymer Intrinsic viscosity of component (A) (high molecular weight component of two components contained in the propylene polymer obtained by the method disclosed in JP-A-11-228629) ([ η] A) = 8 dl / g, ethylene-derived constituent unit content in component (A) (C2inA) = 0%, intrinsic viscosity of component (B) ([η] B) = 1.2 dl / g, component ( B) Structural unit content (C2inB) derived from ethylene in (low molecular weight component of the two components contained in the propylene-based polymer obtained by the method disclosed in JP-A-11-228629) = 0%. Η ₅ = 71000 Pa · s and η _0.1 = 2400 Pa · s at 180 ° C. and 0.1 sec ⁻¹ measured using a uniaxial extensional viscosity measuring device manufactured by Rheometrics.

(Material for non-foamed layer)
Polypropylene (ii) (Homopolypropylene FS2011DG2 MFR 2.5 g / 10 min (230 ° C. 2.16 kgf) manufactured by Sumitomo Chemical Co., Ltd.), polypropylene (iii) (long-chain branched homopolypropylene PF814 MFR 3 g / 10 min (manufactured by Basel) 230 ° C. 2.16 kgf)), polypropylene (iv) (Propylene-ethylene random copolymer W151 manufactured by Sumitomo Chemical Co., Ltd. W151 ethylene-derived structural unit content 4.5% MFR 8 g / 10 min (230 ° C. 2.16 kgf)) , Talc Masterbatch (v) (Sumitomo Chemical Co., Ltd. Block Polypropylene Base Talc Masterbatch MF110 Talc content 70wt%), Titanium Masterbatch (vi) (Tokyo Ink Co., Ltd. Titanium Masterbatch PPM2924 Titanium content 60wt Random polypropylene base MFR 30 g / 10 min (230 ° C. 2.16 kgf)) at a weight ratio of (ii) / (iii) / (iv) / (v) / (vi) = 12/30/15/43/5 Dry blended to obtain a non-foamed layer material.

(Method for producing foam sheet)
A 50 mmφ twin screw extruder (2) for extruding a foam layer and a 32 mmφ single screw extruder for extruding a non-foamed layer as shown in FIG. 1 and FIG. Extrusion molding was performed by the apparatus (1) in which the 90 mmφ circular die (4) was attached to (3), and a thermoplastic resin foam sheet was obtained as follows.

A raw material obtained by blending 0.1 part by weight of a nucleating agent (MB1023 manufactured by Sankyo Chemical Co., Ltd.) with 100 parts by weight of the foam layer material was put into a hopper of a 50 mmφ twin screw extruder (2) and kneaded in a cylinder heated to 180 ° C did.

A pump (5) connected to a liquefied carbon dioxide gas cylinder when the foam layer material and the nucleating agent are sufficiently melt-kneaded and compatible in the 50 mmφ twin screw extruder (2), and the nucleating agent is decomposed and foamed by heat. Further, 0.5 part by weight of carbon dioxide gas was injected as a physical foaming agent. After carbon dioxide gas injection, the mixture was further kneaded and impregnated with carbon dioxide gas, and then supplied to the circular die (4).
The non-foamed layer material was melt-kneaded by a 32 mmφ single-screw extruder (3) and supplied to the circular die (4).

The material for the foam layer is introduced into the circular die (4) from the head (7) of the 50 mmφ twin screw extruder, is sent in the direction of the die exit through the flow path (9a), and is branched through the path P in the middle. It was also sent to the flow path (9b).
The non-foamed layer material is introduced into the die from the head (8) of the 32 mmφ single screw extruder (3), divided into flow paths (10a) and (10b), and then laminated on both sides of the flow path (9a). While being fed, it was sent in the direction of the die exit and laminated in (11a). The material for the non-foamed layer supplied to the flow paths (10a) and (10b) is branched in the middle by a divided flow path (not shown) similar to the path P and sent to the flow paths (10c) and (10d). Then, while being supplied so as to be laminated on both surfaces of the flow path (9b), it was sent in the direction of the die exit, and was laminated in (11b).
In (11a) and (11b), the molten resin having a cylindrical shape having a two-layer / three-layer structure is extruded from the outlet (12) of the circular die (4), and is released into the foam layer material by opening to the atmospheric pressure. The impregnated carbon dioxide gas expanded, bubbles were formed, and a foam layer was formed.

  The two- and three-layer foam sheet extruded from the die was taken up in a tube shape along a mandrel (6) having a maximum diameter of 700 mm, and expanded and cooled. The sheet-like foamed sheet is cut at two locations on the circumference to form two flat sheets with a width of 1080 mm, taken up by a take-up roll, and heated at a foaming ratio of 3 times and a thickness of 1.5 mm. A plastic resin foam sheet was obtained.

Using the thermoplastic resin foam sheet obtained by the above method, vacuum forming was performed using a vacuum forming machine (VAIM0301 manufactured by Sato Tekko Co., Ltd.) as shown in FIG. The molding dies 16 and 17 are both made of epoxy resin and have a molding surface with a bottom surface of 300 mm × 300 mm, a side surface of 300 mm × 0.5 mm, and a party having a width of 15 mm on the outer edge of the molding surface. A female mold having a curved surface was used. Each mold had four vacuum suction holes with a diameter of 1 mm at intervals of 10 cm on each side constituting the bottom surface of the molding surface. The mold temperature during molding was adjusted to 60 ° C.
The foam sheet (13) was fixed with a clamp frame (14), and was softened by heating with an infrared heater (15) so that the sheet surface was 160 ° C. The thickness of the heat-softened foamed sheet was 1.5 mm.
The foamed sheet softened by heating was fixed between the mold (16) and the mold (17) while being fixed to the clamp frame.
Both molds were brought close to each other until the clearance between the parting surfaces of the mold (16) and the mold (17) was 1 mm, and both molds were closed. Simultaneously with completion of mold closing, vacuum suction was performed from both molds at a vacuum degree of -0.09 MPa.
0.5 seconds after the start of vacuum suction, the molds were each opened at 20 mm / min, and stopped for 5 seconds at a point where the cavity height, that is, the distance between the bottom surfaces of the opposing molding surfaces was 5 mm.
The vacuum suction was stopped, the mold was opened, and the molded product was taken out. The evaluation results of the obtained molded product are shown in Table 1.

[Example 2]
Using the same foamed sheet and vacuum forming machine as those used in Example 1, vacuum forming was performed as shown in FIG. As the mold, a mold having an airtight holding portion (18) over the entire periphery of the parting surface of the mold used in Example 1 was used. The airtight holding portion (18) is a foamed rubber cushioning material having a width of 10 mm, a thickness of 3 mm, and a thickness of 0.2 mm when the mold is closed at a surface pressure of 14 MPa. The mold temperature during molding was adjusted to 60 ° C.
The foam sheet (13) was fixed with a clamp frame (14), and was softened by heating with an infrared heater (15) so that the sheet surface was 160 ° C. The thickness of the heat-softened foamed sheet was 1.5 mm.
The foam sheet heated and softened was supplied between the mold (19) and the mold (20) while being fixed to the clamp frame.
Both molds were brought close to each other until the clearance between the parting surfaces of the mold (19) and the mold (20) reached 1 mm. Simultaneously with completion of mold closing, vacuum suction was performed from both molds at a vacuum degree of -0.09 MPa.
0.5 seconds after the start of vacuum suction, the molds were each opened at 20 mm / min, and stopped for 5 seconds at a point where the cavity height, that is, the distance between the bottom surfaces of the opposing molding surfaces was 5 mm.
The vacuum suction was stopped, the mold was opened, and the molded product was taken out. The evaluation results of the obtained molded product are shown in Table 1.

[Example 3]
By using the same raw materials and equipment as those used in the production of the foam sheet used in Example 1, the amount of carbon dioxide injection, which is a physical foaming agent, is 1.3 parts by weight, so that the expansion ratio is 5 times. A foamed sheet having a thickness of 1.5 mm was obtained. Using this foam sheet, vacuum forming was performed by vacuum forming (VAIM0301 manufactured by Sato Tekko Co., Ltd.) as shown in FIG. As one mold, the mold (17) used in Example 1 is used, and as the other mold, a mold having an airtight holding portion (19) on the outer periphery of the mold (16) ( 20) was used. The mold temperature during molding was adjusted to 60 ° C.
The foam sheet (13) was fixed with a clamp frame (14), and was softened by heating with an infrared heater (15) so that the sheet surface was 160 ° C. The thickness of the heat-softened foamed sheet was 1.5 mm.
While the heat-softened foam sheet was fixed to the clamp frame, it was supplied between the mold (20) and the mold (17).
Both molds were brought close to each other until the clearance between the parting surfaces of the mold (20) and the mold (17) reached 1 mm. Simultaneously with completion of mold closing, vacuum suction was performed from both molds at a vacuum degree of -0.09 MPa.
0.5 seconds after the start of vacuum suction, the molds were each opened at 20 mm / min, and stopped for 5 seconds at a point where the cavity height, that is, the distance between the opposed molding surface bottoms was 6 mm.
The vacuum suction was stopped, the mold was opened, and the molded product was taken out. The evaluation results of the obtained molded product are shown in Table 1.

[Example 4]
Using a foam sheet and a vacuum forming machine similar to those used in Example 3, vacuum forming was performed as shown in FIG. As one mold, the mold (20) having the airtight holding portion (18) used in Example 2 was used, and as the other mold, the airtightness was maintained on the outer periphery of the mold of the mold (19). A mold (23) having a part (19) was used. The mold temperature during molding was adjusted to 60 ° C.
The foam sheet (13) was fixed with a clamp frame (14), and was softened by heating with an infrared heater (15) so that the sheet surface was 160 ° C. The thickness of the heat-softened foamed sheet was 1.5 mm.
The foam sheet heated and softened was supplied between the mold (20) and the mold (23) while being fixed to the clamp frame.
Both molds were brought close to each other until the clearance between the parting surfaces of the mold (20) and the mold (23) reached 1 mm. Simultaneously with completion of mold closing, vacuum suction was performed from both molds at a vacuum degree of -0.09 MPa.
0.5 seconds after the start of vacuum suction, the molds were each opened at 20 mm / min, and stopped for 5 seconds at a point where the cavity height, that is, the distance between the opposed molding surface bottoms was 6 mm.
The vacuum suction was stopped, the mold was opened, and the molded product was taken out. The evaluation results of the obtained molded product are shown in Table 1.

[Comparative Example 1]
Using the same foamed sheet and mold as those used in Example 1, vacuum forming was performed as shown in FIG. The mold temperature during molding was adjusted to 60 ° C.
The foam sheet (13) was fixed with a clamp frame (14), and was softened by heating with an infrared heater (15) so that the sheet surface was 160 ° C. The thickness of the heat-softened foamed sheet was 1.5 mm.
The foamed sheet softened by heating was fixed between the mold (16) and the mold (17) while being fixed to the clamp frame.
Both molds were brought close to each other until the clearance between the parting surfaces of the mold (16) and the mold (17) was 1 mm, and both molds were closed. Simultaneously with completion of mold closing, vacuum suction was performed from both molds at a degree of vacuum of -0.09 MPa and stopped for 10 seconds.
The vacuum suction was stopped, the mold was opened, and the molded product was taken out. The evaluation results of the obtained molded product are shown in Table 1.

[Comparative Example 2]
Using a foam sheet similar to that used in Example 1, vacuum forming was performed. Each of the molds is made of epoxy resin, has a bottom surface of 300 mm × 300 mm square, a side surface of 300 mm × 2 mm, a female surface having a parting surface with a width of 15 mm on the outer edge of the molding surface. A mold was used. Each mold had four vacuum suction holes with a diameter of 1 mm at intervals of 10 cm on each side constituting the bottom surface of the molding surface. The mold temperature during molding was adjusted to 60 ° C.
The foam sheet (13) was fixed with a clamp frame (14), and was softened by heating with an infrared heater (15) so that the sheet surface was 160 ° C. The thickness of the heat-softened foamed sheet was 1.5 mm.
The foamed sheet softened by heating was supplied between the molds while being fixed to the clamp frame.
Both molds were brought close to each other until the clearance between the parting surfaces of both molds reached 1 mm. Simultaneously with completion of mold closing, vacuum suction was performed at a vacuum degree of -0.09 MPa from both vacuum forming molds, and stopped for 10 seconds.
The vacuum suction was stopped, the mold was opened, and the molded product was taken out. The obtained molded product was squeezed due to bubble breakage, so that the surface unevenness was large and the molded surface was not shaped. The evaluation results of the obtained molded product are shown in Table 1.

[Comparative Example 3]
Vacuum forming was performed in the same manner as in Comparative Example 2 except that the same foamed sheet as used in Example 3 was used. The obtained molded product was squeezed due to bubble breakage, so that the surface unevenness was large and the molded surface was not shaped. Table 1 shows the results of evaluation of this molded product.

(Measurement of foaming ratio)
Using a submersible density meter (automatic hydrometer model D-H100 manufactured by Toyo Seiki Seisakusho Co., Ltd.), measure the specific gravity of the product sampled to 20 mm x 20 mm, and foam using the density of each material constituting the product. The magnification was calculated.

(Evaluation of heat transmissibility)
The thermal conductivity was measured based on JIS A1412 with a thermal conductivity measuring device (AUTO-Λ series HC-074) manufactured by Eihiro Seiki Co., Ltd., and the thermal conductivity was calculated based on the obtained results. (Low plate temperature 20 ° C., high temperature plate temperature 30 ° C., Temperature Equirillium 0.2 ° C., Between Block HEM Equil 49 μV, HFM Percent Change 2.0%, Min Number of Block 4, Calblock 3 heat block rate) It can be said that it is excellent in heat insulation.

※１：比較例２と３の成形品は、厚み、発泡倍率ともバラツキが大きかった

* 1: The molded products of Comparative Examples 2 and 3 had large variations in both thickness and foaming ratio.

The figure which showed the example of the apparatus which manufactures a thermoplastic resin foam sheet The figure which showed the example of the section shape of the circular die used when manufacturing a thermoplastic resin foam sheet Schematic of one aspect of the vacuum forming method of the thermoplastic resin foam sheet of the present invention Schematic of another embodiment of the vacuum forming method of the thermoplastic resin foam sheet of the present invention Schematic of another embodiment of the vacuum forming method of the thermoplastic resin foam sheet of the present invention Schematic of another embodiment of the vacuum forming method of the thermoplastic resin foam sheet of the present invention Schematic of conventional vacuum forming method for thermoplastic resin foam sheets

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 The apparatus which manufactures a thermoplastic resin foam sheet 2 50 mmphi biaxial extruder 3 32 mmphi single screw extruder 4 Circular die 5 Carbon dioxide supply pump 6 Mandrel 7 Head of 50 mmphi biaxial extruder 8 Head 9a of 32 mmphi single screw extruder 9b flow path 10a flow path 10b flow path 10c flow path 10d flow path 11a flow path 11b flow path 12 circular die outlet 13 thermoplastic resin foam sheet 14 clip member 15 infrared heater 16 mold 17 mold 18 airtight holding part 19 Mold 20 Mold 21 Airtight holding part 22 Mold 23 Mold

Claims (1)

Vacuum forming method for thermoplastic resin foam sheet including the following steps using a pair of molds that can be vacuum-sucked from the molding surface of each mold (1) Step (2) for softening thermoplastic resin foam sheet by heating Step of supplying the thermoplastic resin foam sheet obtained in step (1) between the molds (3) Both molds at the outer edge of the molding surface while sandwiching the heat-softened thermoplastic resin foam sheet between the molds Step (4) of closing both molds until the clearance between them becomes equal to or less than the thickness of the sheet (4) Any time when the clearance in the step (3) becomes equal to or less than the thickness of the heat-softened thermoplastic resin foam sheet Step (5) of starting vacuum suction from the molding surfaces of both molds after the thickness is reached (5) While continuing the vacuum suction, open the mold until the sheet between the molding surfaces reaches the desired molded product thickness. Open form to step (6) the mold to stop the vacuum suction, the step of removing the molded article

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