JP2008094052A - Multilayer injection molding method of resin, and multilayer injection molding apparatus of resin - Google Patents

Multilayer injection molding method of resin, and multilayer injection molding apparatus of resin Download PDF

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JP2008094052A
JP2008094052A JP2006281396A JP2006281396A JP2008094052A JP 2008094052 A JP2008094052 A JP 2008094052A JP 2006281396 A JP2006281396 A JP 2006281396A JP 2006281396 A JP2006281396 A JP 2006281396A JP 2008094052 A JP2008094052 A JP 2008094052A
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mold
layer
resin
toggle
cavity
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JP4893220B2 (en
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Katsutoshi Fukano
Masataka Mitsui
Kazuaki Miyamoto
Akio Okamoto
正敬 三井
和明 宮本
昭男 岡本
克俊 深野
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Ube Machinery Corporation Ltd
宇部興産機械株式会社
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a multilayer injection molding method of a resin and a multilayer injection molding apparatus of the resin in which enlarging position controlling of a mold cavity volume is improved and a resin molding of a desired multilayer structure is obtained. <P>SOLUTION: When a resin molding material of a first layer is injection filled and molded in the mold cavity, a movable platen is moved backward, the mold cavity is enlarged, a secondary cavity is formed between the resin molding material of the first layer and the mold cavity, and the resin molding material of a second layer is injected and filled in the formed secondary cavity; the formation of the secondary cavity is performed by releasing mold clamping force, then driving a mold thickness regulating mechanism, retreating a toggle mechanism until the movable platen is located at a predetermined mold cavity enlarging position in the locking state of the toggle mechanism, then driving the toggle mechanism, and advancing the movable platen up to the locking state of the toggle mechanism. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

本発明は、少なくとも2種類の樹脂成形材料を多層構造に射出成形する、樹脂の多層射出成形方法及び樹脂の多層射出成形装置に関する。   The present invention relates to a resin multilayer injection molding method and a resin multilayer injection molding apparatus in which at least two kinds of resin molding materials are injection molded into a multilayer structure.
近年、自動車部品や家電製品などに使用される樹脂成形品は、装飾性や多様性を高めたり、あるいは、成形工程時の工程を省略してコストを低減するために、成形と同時にその金型内で樹脂成形材料を多層構造とする成形が実施されるようになった。即ち、
(1)成形品に装飾性や多様性を高めるために成形品の表面に、たとえば、ソフト感を有した樹脂層、あるいは、高級感を有した着色樹脂層を積層した構造体とする積層成形。
(2)リサイクル材の有効利用および成形品の補強のために、樹脂成形品の内部にリサイクル材または補強材入りの樹脂材料などを充填するサンドイッチ成形。などの方法が提案されている。
In recent years, resin molded products used for automobile parts and home appliances have their molds at the same time as molding in order to increase the decorativeness and diversity, or to reduce the cost by omitting the steps during the molding process. Molding with a resin molding material as a multilayer structure has been implemented. That is,
(1) Laminate molding to form a structure in which, for example, a resin layer having a soft feeling or a colored resin layer having a high-class feeling is laminated on the surface of the molded article in order to enhance the decorativeness and diversity of the molded article. .
(2) Sandwich molding in which the inside of a resin molded product is filled with a recycled material or a resin material containing a reinforcing material in order to effectively use the recycled material and reinforce the molded product. Such a method has been proposed.
これらの成形方法は、第1層となる樹脂成形材料を金型キャビティ内に射出充填した後、第2層となる樹脂成形材料を射出充填する際に、金型キャビティ容積を拡大して成形が行われる。そして、これらの成形方法に用いられる型締機構は、金型キャビティ容積の拡大制御が比較的容易とされる油圧式の型締シリンダを備えた直圧式が採用されている。(特許文献1参照)   In these molding methods, when the resin molding material to be the first layer is injected and filled into the mold cavity, the mold cavity volume is enlarged when the resin molding material to be the second layer is injected and filled. Done. As the mold clamping mechanism used in these molding methods, a direct pressure type having a hydraulic mold clamping cylinder in which the expansion control of the mold cavity volume is relatively easy is adopted. (See Patent Document 1)
ところで、これらの成形方法において、金型キャビティ容積の拡大量は成形品の厚みや寸法などに影響を与える重要な因子であり、高精度に再現性高く制御することが要求される。しかしながら、このような従来の直圧式の型締機構を用いた成形方法では、作動油の圧縮性や温度変化による粘度の変化により、油圧シリンダの制御精度が変動する。
また、シリンダストロークが長いことから、制御応答性が低い。さらに、シリンダストロークの制御量と金型の移動量が一対一であるので、位置制御特性の低さから多層射出成形を行うと成形品の厚みが高精度な成形品を得ることができないといった問題があった。
By the way, in these molding methods, the amount of expansion of the mold cavity volume is an important factor affecting the thickness and dimensions of the molded product, and is required to be controlled with high accuracy and high reproducibility. However, in the molding method using such a conventional direct pressure type mold clamping mechanism, the control accuracy of the hydraulic cylinder varies due to the compressibility of the hydraulic oil and the change in viscosity due to a temperature change.
Further, since the cylinder stroke is long, the control response is low. Furthermore, since the control amount of the cylinder stroke and the movement amount of the mold are one-to-one, there is a problem that when the multilayer injection molding is performed due to the low position control characteristics, it is impossible to obtain a molded product with a high thickness of the molded product. was there.
そのため、可動盤の後退制御を可動盤の後退量より大きい運動を行うクロスヘッドで行うことで制御精度を向上させるトグル式型締装置の型盤位置制御方法が開示されている。
この方法によれば、高い精度で可動盤と固定盤との間隔を一定に保つことができる。(特許文献2参照)
For this reason, there is disclosed a mold platen position control method for a toggle type mold clamping device that improves the control accuracy by performing the backward movement control of the movable platen with a cross head that performs a movement larger than the reverse amount of the movable platen.
According to this method, the distance between the movable platen and the fixed platen can be kept constant with high accuracy. (See Patent Document 2)
しかしながら、従来のトグル式型締装置を用いトグル機構を屈曲させて金型キャビティ容積を拡大する成形方法では、依然として以下のような問題があった。
即ち、2層目の樹脂成形材料を射出充填後にトグル機構を駆動して型開を行い、金型キャビティ容積を拡大して2層目の成形樹脂材料の充填空間を確保した際の屈曲状態でのトグル機構では、2層目の射出充填圧力が可動型面に作用すると、可動盤位置を保持して抗するに必要で十分な保持力を得ることができない。このため、充填圧力が可動型面に作用すると、可動盤が後退してさらに金型キャビティ容積が拡大して成形品の厚み精度が維持できないという問題があった。
However, the molding method in which the toggle mechanism is bent using the conventional toggle type mold clamping device to enlarge the mold cavity volume still has the following problems.
That is, after the injection molding of the second layer resin molding material, the toggle mechanism is driven to open the mold, the mold cavity volume is enlarged, and the second layer molding resin material filling space is secured. In this toggle mechanism, when the injection filling pressure of the second layer acts on the movable mold surface, it is not possible to obtain a sufficient holding force necessary to hold and resist the movable platen position. For this reason, when the filling pressure is applied to the movable mold surface, there is a problem that the movable platen retreats, the mold cavity volume is further enlarged, and the thickness accuracy of the molded product cannot be maintained.
特開昭54−86550号公報JP 54-86550 A 特開平8−309779号公報JP-A-8-309779
本発明は、上記従来の問題点に鑑みてなされたもので、その目的は、トグル式の型締機構を用いた金型キャビティ容積の拡大制御において、金型キャビティ容積の拡大位置制御を向上させ、所望する多層構造の樹脂成形品を得る樹脂の多層射出成形方法及び樹脂の多層射出成形装置を提供することにある。   The present invention has been made in view of the above-described conventional problems, and an object of the present invention is to improve mold cavity volume expansion position control in mold cavity volume expansion control using a toggle type mold clamping mechanism. Another object of the present invention is to provide a resin multilayer injection molding method and a resin multilayer injection molding apparatus for obtaining a resin molded article having a desired multilayer structure.
上記の目的を達成するため、本発明の請求項1に係る樹脂の多層射出成形方法は、金型キャビティに少なくとも2種類の樹脂成形材料を射出充填する射出装置と、トグル機構を用いて金型の開閉と型締とを行う型締装置とを用いて、多層成形品を得る樹脂の多層射出成形方法であって、金型キャビティ内に1層目の樹脂成形材料を射出充填して成形した後に、可動盤を後退させ前記金型キャビティを拡大し第1層目の樹脂成形材料と金型キャビティ面との間に2次キャビティを形成して、該形成した2次キャビティに2層目の樹脂成形材料を射出充填するに際し、前記2次キャビティの形成は、型締装置のトグル機構を駆動して型締力を解放し、次いで、前記可動盤がトグル機構のロッキング状態で所定の金型キャビティ拡大位置となるまで型厚調整機構を駆動してトグル機構を後退させた後、前記トグル機構を駆動してトグル機構のロッキング状態まで可動盤を前進させて行うことを特徴とする。   In order to achieve the above object, a resin multilayer injection molding method according to claim 1 of the present invention is a mold using an injection device for injecting and filling at least two kinds of resin molding materials into a mold cavity, and a toggle mechanism. A resin multi-layer injection molding method for obtaining a multi-layer molded product by using a mold clamping device for opening and closing and mold clamping, and molding by molding a first layer resin molding material into a mold cavity Later, the movable platen is moved backward to enlarge the mold cavity to form a secondary cavity between the first layer of the resin molding material and the mold cavity surface, and the second layer is formed in the formed secondary cavity. When the resin molding material is injected and filled, the secondary cavity is formed by driving the toggle mechanism of the mold clamping device to release the mold clamping force, and then the movable plate is locked with the toggle mechanism in a predetermined mold. Until reaching the cavity expansion position After retracting the toggle mechanism drives the thickness adjustment mechanism, and performs to advance the movable platen to the locking state of the toggle mechanism drives the toggle mechanism.
本発明の請求項2に係る樹脂の多層射出成形方法は、金型キャビティに少なくとも2種類の樹脂成形材料を射出充填する射出装置と、トグル機構を用いて金型の開閉と型締とを行う型締装置とを用いて、多層成形品を得る樹脂の多層射出成形方法であって、金型キャビティ内に1層目の樹脂成形材料を射出充填して成形した後に、可動盤を後退させ前記金型キャビティを拡大し第1層目の樹脂成形材料と金型キャビティ面との間に2次キャビティを形成して、第1層目の樹脂成形材料の内部に2層目の樹脂成形材料を射出充填するに際し、前記2次キャビティの形成は、型締装置のトグル機構を駆動して型締力を解放し、次いで、前記可動盤がトグル機構のロッキング状態で所定の金型キャビティ拡大位置となるまで型厚調整機構を駆動してトグル機構を後退させた後、前記トグル機構を駆動してトグル機構のロッキング状態まで可動盤を前進させて行うことを特徴とする。   According to a second aspect of the present invention, there is provided a resin multi-layer injection molding method comprising: an injection device for injecting and filling at least two types of resin molding materials into a mold cavity; and a mold opening / closing and mold clamping using a toggle mechanism. A resin multi-layer injection molding method for obtaining a multi-layer molded article using a mold clamping device, wherein after molding a resin molding material of a first layer into a mold cavity by injection, The mold cavity is enlarged to form a secondary cavity between the first layer resin molding material and the mold cavity surface, and the second layer resin molding material is placed inside the first layer resin molding material. In injection filling, the secondary cavity is formed by driving the toggle mechanism of the mold clamping device to release the mold clamping force, and then the movable platen is in a predetermined mold cavity enlarged position in the locked state of the toggle mechanism. Drive the mold thickness adjustment mechanism until After retracting the glue mechanism, and performs to advance the movable platen to the locking state of the toggle mechanism drives the toggle mechanism.
本発明の請求項3に係る樹脂の多層射出成形方法は、請求項1または請求項2に記載の発明において、前記2層目の樹脂成形材料を射出充填した後、前記可動盤が後退して多層成形品を取り出すための型開の開始から次サイクルの型閉開始までの間で、1層目樹脂充填の際の型締力設定位置となるまで前記型厚調整機構を駆動してトグル機構を前進させることを特徴とする。   According to a third aspect of the present invention, there is provided a resin multi-layer injection molding method according to the first or second aspect of the present invention, wherein after the second layer resin molding material is injected and filled, the movable plate moves backward. Toggle mechanism by driving the mold thickness adjusting mechanism until the mold clamping force setting position at the time of filling the first layer resin is filled between the start of mold opening for taking out the multilayer molded product and the start of mold closing in the next cycle It is characterized by advancing.
本発明の請求項4に係る樹脂の多層射出成形方法は、請求項1乃至請求項3のいずれかに記載の発明において、前記1層目及び/又は2層目が物理発泡剤や化学発泡剤などの発泡剤を含んだ樹脂成形材料であって、前記1層目及び/又は2層目の射出充填後にトグル機構を駆動して前記可動盤を所定の発泡位置まで後退させることを特徴とする。   The multilayer injection molding method for resin according to claim 4 of the present invention is the invention according to any one of claims 1 to 3, wherein the first layer and / or the second layer is a physical foaming agent or a chemical foaming agent. A resin molding material containing a foaming agent such as the above, wherein after the injection filling of the first layer and / or the second layer, the toggle mechanism is driven to retract the movable plate to a predetermined foaming position. .
上記の目的を達成するため、本発明の請求項5に係る樹脂の多層射出成形装置は、金型キャビティに少なくとも2種類の樹脂成形材料を射出充填する射出装置と、トグル機構を用いて金型の開閉と型締とを行う型締装置と、を備え、多層成形品を得る樹脂の多層射出成形装置であって、金型キャビティ内に1層目の樹脂成形材料を射出充填して成形した後に、可動盤を後退させ前記金型キャビティを拡大し第1層目の樹脂成形材料と金型キャビティ面との間に2次キャビティを形成して、該形成した2次キャビティに2層目の樹脂成形材料を射出充填するに際し、前記2次キャビティの形成は、型締装置のトグル機構を駆動して型締力を解放し、次いで、前記可動盤がトグル機構のロッキング状態で所定の金型キャビティ拡大位置となるまで型厚調整機構を駆動してトグル機構を後退させた後、前記トグル機構を駆動してトグル機構のロッキング状態まで可動盤を前進させるように構成したことを特徴とする。   In order to achieve the above object, a multilayer injection molding apparatus for resin according to claim 5 of the present invention is a mold using an injection apparatus for injecting and filling at least two types of resin molding materials into a mold cavity, and a toggle mechanism. A resin multi-layer injection molding apparatus for obtaining a multi-layer molded product, which is molded by injection-filling a first-layer resin molding material into a mold cavity. Later, the movable platen is moved backward to enlarge the mold cavity to form a secondary cavity between the first layer of the resin molding material and the mold cavity surface, and the second layer is formed in the formed secondary cavity. When the resin molding material is injected and filled, the secondary cavity is formed by driving the toggle mechanism of the mold clamping device to release the mold clamping force, and then the movable plate is locked with the toggle mechanism in a predetermined mold. Until reaching the cavity expansion position After retracting the toggle mechanism drives the thickness adjustment mechanism, characterized by being configured to advance the movable platen to the locking state of the toggle mechanism drives the toggle mechanism.
上記の目的を達成するため、本発明の請求項6に係る樹脂の多層射出成形装置は、金型キャビティに少なくとも2種類の樹脂成形材料を射出充填する射出装置と、トグル機構を用いて金型の開閉と型締とを行う型締装置と、を備え、多層成形品を得る樹脂の多層射出成形装置であって、金型キャビティ内に1層目の樹脂成形材料を射出充填して成形した後に、可動盤を後退させ前記金型キャビティを拡大し第1層目の樹脂成形材料と金型キャビティ面との間に2次キャビティを形成して、第1層目の樹脂成形材料の内部に2層目の樹脂成形材料を射出充填するに際し、前記2次キャビティの形成は、型締装置のトグル機構を駆動して型締力を解放し、次いで、前記可動盤がトグル機構のロッキング状態で所定の金型キャビティ拡大位置となるまで型厚調整機構を駆動してトグル機構を後退させた後、前記トグル機構を駆動してトグル機構のロッキング状態まで可動盤を前進させるように構成したことを特徴とする。   In order to achieve the above object, a multilayer injection molding apparatus for resin according to claim 6 of the present invention is a mold using an injection apparatus for injecting and filling at least two types of resin molding materials into a mold cavity, and a toggle mechanism. A resin multi-layer injection molding apparatus for obtaining a multi-layer molded product, which is molded by injection-filling a first-layer resin molding material into a mold cavity. Later, the movable platen is moved backward to enlarge the mold cavity to form a secondary cavity between the first layer resin molding material and the mold cavity surface, and within the first layer resin molding material. When the second layer of resin molding material is injected and filled, the secondary cavity is formed by driving the toggle mechanism of the mold clamping device to release the mold clamping force, and then the movable platen is in the locked state of the toggle mechanism. Becomes a predetermined mold cavity expansion position In after retracting the toggle mechanism drives the mold thickness adjustment mechanism, characterized by being configured to advance the movable platen to the locking state of the toggle mechanism drives the toggle mechanism.
本発明の請求項7に係る樹脂の多層射出成形装置は、請求項5または請求項6に記載の発明において、前記型厚調整機構は、型締装置のリンクハウジング背面の四隅に挿通して架設されタイバーに螺合するタイバーナットそれぞれに設けた駆動手段により四軸が同期または個別に駆動するように構成されたことを特徴とする。   According to a seventh aspect of the present invention, there is provided the resin multilayer injection molding apparatus according to the fifth or sixth aspect, wherein the mold thickness adjusting mechanism is inserted through the four corners on the back surface of the link housing of the mold clamping device. The four axes are configured to be driven synchronously or individually by driving means provided on each tie bar nut screwed to the tie bar.
本発明の請求項8に係る樹脂の多層射出成形装置は、請求項5乃至請求項7に記載の発明において、前記1層目及び/又は2層目が物理発泡剤や化学発泡剤などの発泡剤を含んだ樹脂成形材料であって、前記1層目及び/又は2層目の射出充填後にトグル機構を駆動して前記可動盤を所定の発泡位置まで後退させるように構成したことを特徴とする。   The multilayer injection molding apparatus for resin according to claim 8 of the present invention is the invention according to any one of claims 5 to 7, wherein the first layer and / or the second layer are foamed materials such as a physical foaming agent and a chemical foaming agent. A resin molding material containing an agent, wherein the movable platen is moved back to a predetermined foaming position by driving a toggle mechanism after injection filling of the first layer and / or the second layer. To do.
前記請求項1に係る樹脂の多層射出成形方法では、1層目の樹脂成形材料を金型キャビティ内に射出充填した後に、2層目の樹脂成形材料をトグル機構がロッキング状態で型閉されて形成された2次キャビティ内に射出充填するので、2層目の樹脂充填力が可動型面に作用してもトグル機構のクロスヘッドに樹脂の充填圧力が作用することがなく、したがって、トグル機構が押し戻されて2次キャビティがさらに拡大することがないので、成形品の厚み精度を維持でき成形品に不良が発生することがない。   In the resin multilayer injection molding method according to claim 1, after the first layer of the resin molding material is injected and filled in the mold cavity, the second layer of the resin molding material is closed with the toggle mechanism locked. Since injection filling is performed in the formed secondary cavity, the resin filling pressure does not act on the crosshead of the toggle mechanism even when the resin filling force of the second layer acts on the movable mold surface. Is pushed back and the secondary cavity does not further expand, so that the thickness accuracy of the molded product can be maintained and the molded product will not be defective.
前記請求項2に係る樹脂の多層射出成形方法では、1層目の樹脂成形材料を金型キャビティ内に射出充填した後に、トグル機構がロッキング状態で型閉されて2次キャビティを形成し、第1層目の樹脂成形材料の内部に2層目の樹脂成形材料を射出充填するので、2層目の樹脂充填圧力が可動型面に作用してもトグル機構のクロスヘッドに樹脂の充填力が作用することがなく、したがって、トグル機構が押し戻されて2次キャビティがさらに拡大することがないので、成形品の厚み精度を維持でき成形品に不良が発生することがない。
前記請求項3に係る樹脂の多層射出成形方法では、成形品冷却完了後の型開の開始から次サイクルの型閉開始までの間に、型厚調整機構を駆動してトグル機構を1層目成形の所定位置まで移動させることから、成形サイクルタイムを延長することがない。
In the resin multilayer injection molding method according to claim 2, after the first layer of the resin molding material is injected and filled into the mold cavity, the toggle mechanism is closed in a locked state to form a secondary cavity, Since the resin molding material of the second layer is injected and filled into the resin molding material of the first layer, even if the resin charging pressure of the second layer acts on the movable mold surface, the resin filling force is not applied to the crosshead of the toggle mechanism. Therefore, the toggle mechanism is not pushed back and the secondary cavity does not further expand, so that the thickness accuracy of the molded product can be maintained and no defect occurs in the molded product.
In the resin multi-layer injection molding method according to the third aspect, the mold thickness adjusting mechanism is driven to start the toggle mechanism between the start of mold opening after completion of cooling of the molded product and the start of mold closing in the next cycle. Since it is moved to a predetermined molding position, the molding cycle time is not extended.
前記請求項4に係る樹脂の多層射出成形方法では、1層目及び/又は2層目の樹脂成形材料に発泡剤を含ませたので、発泡層を有する積層成形品、内部や外部あるいは内部と外部を発泡させたサンドイッチ成形品を得ることができる。そして、発泡における金型キャビティ容積の拡大は、トグル機構の倍率特性を利用し、金型タッチ点にある型締装置を型開方向に移動させた際に検出したクロスヘッドと可動盤との関係を位置データとして記憶させ、該記憶した位置データに基づき可動盤の位置を制御する。この方法によれば、所望する発泡倍率、気泡径の発泡層を有する多層射出成形品を得ることができる。   In the resin multilayer injection molding method according to claim 4, since the foaming agent is included in the first layer and / or the second layer resin molding material, the laminated molded product having the foam layer, the inside, the outside, or the inside It is possible to obtain a sandwich molded product in which the outside is foamed. The expansion of the mold cavity volume in foaming uses the magnification characteristics of the toggle mechanism, and the relationship between the cross head and the movable plate detected when the mold clamping device at the mold touch point is moved in the mold opening direction. Is stored as position data, and the position of the movable platen is controlled based on the stored position data. According to this method, it is possible to obtain a multi-layer injection-molded product having a foam layer having a desired expansion ratio and cell diameter.
前記請求項5に係る樹脂の多層射出成形装置では、1層目の樹脂成形材料を金型キャビティ内に射出充填した後に、2層目の樹脂成形材料をトグル機構がロッキング状態で型閉されて形成された2次キャビティ内に射出充填する構成としたので、2層目の樹脂充填圧力が可動型面に作用してもトグル機構のクロスヘッドに樹脂の充填力が作用することがなく、したがって、トグル機構が押し戻されて2次キャビティがさらに拡大することがないので、成形品の厚み精度を維持でき成形品に不良が発生することがない。   In the resin multilayer injection molding apparatus according to claim 5, after the first layer of the resin molding material is injected and filled in the mold cavity, the second layer of the resin molding material is closed with the toggle mechanism locked. Since it is configured to inject and fill the formed secondary cavity, the resin filling force does not act on the crosshead of the toggle mechanism even when the resin filling pressure of the second layer acts on the movable mold surface. Since the toggle mechanism is pushed back and the secondary cavity does not further expand, the thickness accuracy of the molded product can be maintained, and no defect occurs in the molded product.
前記請求項6に係る樹脂の多層射出成形装置では、1層目の樹脂成形材料を金型キャビティ内に射出充填した後に、トグル機構がロッキング状態で型閉されて2次キャビティを形成し、第1層目の樹脂成形材料の内部に2層目の樹脂成形材料を射出充填する構成としたので、2層目の樹脂充填圧力が可動型面に作用してもトグル機構のクロスヘッドに樹脂の充填力が作用することがなく、したがって、トグル機構が押し戻されて2次キャビティがさらに拡大することがないので、成形品の厚み精度を維持でき成形品に不良が発生することがない。   In the multilayer injection molding apparatus for resin according to claim 6, after the first layer of the resin molding material is injected and filled into the mold cavity, the toggle mechanism is closed in a locked state to form a secondary cavity, Since the resin molding material of the second layer is injected and filled inside the resin molding material of the first layer, even if the resin filling pressure of the second layer acts on the movable mold surface, the resin is applied to the crosshead of the toggle mechanism. The filling force does not act, and therefore, the toggle mechanism is pushed back and the secondary cavity does not further expand, so that the thickness accuracy of the molded product can be maintained and the molded product will not be defective.
前記請求項7に係る樹脂の多層射出成形装置では、型厚調整機構を型締装置のリンクハウジング背面の四隅に挿通して架設されたタイバーに螺合するタイバーナットそれぞれに設けた駆動手段により四軸が同期または、個別に駆動するように構成したので、可動盤の平行度調整や金型の平行度に合った可動盤位置調整、また、型締力の微調整、金型キャ
ビティ容積拡大位置の微調整などを高精度に、且つ、再現性高く行うことができる。
In the resin multi-layer injection molding apparatus according to the seventh aspect, the mold thickness adjusting mechanism is inserted into the four corners of the back side of the link housing of the mold clamping apparatus and is driven by driving means provided on each of the tie bar nuts screwed to the tie bar. Since the axes are driven synchronously or individually, the movable platen parallelism adjustment, movable platen position adjustment that matches the mold parallelism, fine clamping force adjustment, mold cavity volume expansion position Can be finely adjusted with high accuracy and high reproducibility.
前記請求項8に係る樹脂の多層射出成形装置では、1層目樹脂に発泡剤を含む樹脂成形材料を用い、第1層目を発泡させた多層射出成形品や1層目及び2層目いずれも発泡剤を含む樹脂成形材料を用いて、発泡層と発泡層を積層した多層射出成形品を得ることができる。   In the multilayer injection molding apparatus for resin according to claim 8, a multilayer injection molded product in which the first layer is foamed using a resin molding material containing a foaming agent in the first layer resin, and either the first layer or the second layer is used. In addition, a multilayer injection molded product in which a foam layer and a foam layer are laminated can be obtained using a resin molding material containing a foaming agent.
以下、図面に基づいて本発明を実施するための最良の形態について詳細に説明する。
図1〜図9は本発明を実施するための最良の形態に係り、図1は本発明実施形態による樹脂の多層射出成形装置の全体構想図、図2は型厚調整機構を概念的に示した構想図面である。図3は成形動作手順を示すフローチャート、図4は2層目の樹脂成形材料を発泡させる成形動作手順を示すフローチャート、図5は成形工程の概略を説明する工程説明図、図6は2層目の樹脂成形材料を発泡させる成形工程の概略を説明する工程説明図である。
図7は他の実施形態を示す樹脂の多層射出成形装置の全体構想図、図8は他の実施形態による成形工程の概略を説明する工程説明図、図9は他の実施形態の2層目樹脂成形材料を発泡させる成形工程の概略を説明する工程説明図である。
Hereinafter, the best mode for carrying out the present invention will be described in detail with reference to the drawings.
1 to 9 relate to the best mode for carrying out the present invention, FIG. 1 is an overall conceptual diagram of a resin multilayer injection molding apparatus according to an embodiment of the present invention, and FIG. 2 conceptually shows a mold thickness adjusting mechanism. It is a conceptual drawing. FIG. 3 is a flowchart showing a molding operation procedure, FIG. 4 is a flowchart showing a molding operation procedure for foaming a second-layer resin molding material, FIG. 5 is a process explanatory diagram for explaining the outline of the molding process, and FIG. It is process explanatory drawing explaining the outline of the molding process which foams the resin molding material of this.
FIG. 7 is an overall conceptual diagram of a multilayer injection molding apparatus for resin showing another embodiment, FIG. 8 is a process explanatory view for explaining the outline of a molding process according to another embodiment, and FIG. 9 is a second layer of another embodiment. It is process explanatory drawing explaining the outline of the molding process which foams a resin molding material.
図1に示すように、本発明における射出成形装置100は、型締装置110と、射出装置120と、型締装置110及び射出装置120を制御する制御装置130と、金型30とを備えている。金型30は、図1に示すように固定型31と可動型32とを備えており、固定型31と可動型32とは半押込み構造であり嵌合部で嵌め合わされ、嵌め合わされた状態で固定型31に形成されたキャビティ面と可動型32に形成されたキャビティ面とが組み合わされて金型キャビティ32を形成する構造となっている。そして、前記半押込み構造の嵌合部は金型全周に亘って形成され、射出充填後に金型キャビティ33の容積を拡大しても金型キャビティ33内に充填した樹脂成形材料が金型30から漏れ出すことを防止している。符合34は、1層目の樹脂成形材料を射出充填した後に可動型32を後退させて形成した2次キャビティである。   As shown in FIG. 1, an injection molding apparatus 100 according to the present invention includes a mold clamping device 110, an injection device 120, a control device 130 that controls the mold clamping device 110 and the injection device 120, and a mold 30. Yes. As shown in FIG. 1, the mold 30 includes a fixed mold 31 and a movable mold 32, and the fixed mold 31 and the movable mold 32 have a half-push structure and are fitted in a fitting portion, and in a fitted state. The cavity surface formed on the fixed mold 31 and the cavity surface formed on the movable mold 32 are combined to form the mold cavity 32. The fitting portion of the half-push structure is formed over the entire circumference of the mold, and even if the volume of the mold cavity 33 is increased after injection filling, the resin molding material filled in the mold cavity 33 is the mold 30. To prevent leakage. Reference numeral 34 denotes a secondary cavity formed by injecting and filling the first layer of resin molding material and then retracting the movable mold 32.
図1に示す型締装置110は、固定型12と可動型13と電動サーボモータ22を駆動源とするリンク駆動機構18と、リンク駆動機構18に駆動されるトグル機構16と、電動サーボモータ22を駆動制御する制御用ドライバとを備え、可動盤13は固定盤12とリンクハウジング11との間に架設したタイバー21により案内されて、トグル機構16により可動型32とともに前後進できるように構成されている。
また、型締装置110に備えたリンク駆動機構18のクロスヘッド駆動軸23には、クロスヘッド17の位置を検出するための位置センサとしてのストロークセンサ24が取付けられており、ストロークセンサ24によってクロスヘッド17の位置を正確に検出することができる。
A mold clamping device 110 shown in FIG. 1 includes a link driving mechanism 18 having a fixed mold 12, a movable mold 13, and an electric servo motor 22 as driving sources, a toggle mechanism 16 driven by the link driving mechanism 18, and an electric servo motor 22. The movable platen 13 is guided by a tie bar 21 installed between the fixed platen 12 and the link housing 11 and can be moved forward and backward together with the movable die 32 by the toggle mechanism 16. ing.
A stroke sensor 24 as a position sensor for detecting the position of the crosshead 17 is attached to the crosshead drive shaft 23 of the link drive mechanism 18 provided in the mold clamping device 110. The position of the head 17 can be accurately detected.
本実施の形態においては、クロスヘッド17の位置を検出するための位置センサとしてストロークセンサ24を配する構成としたが、クロスヘッド17の位置を検出するための位置センサがこれに限らないことはもちろんであり、電動サーボモータ22に内蔵されたセンサで検出する方式であっても良い。   In the present embodiment, the stroke sensor 24 is arranged as a position sensor for detecting the position of the crosshead 17. However, the position sensor for detecting the position of the crosshead 17 is not limited to this. Of course, a method of detecting by a sensor built in the electric servo motor 22 may be used.
また、型締装置110は、型締力を検出するセンサとしてタイバー21の固定盤側の一端に型締力センサ25を備えており、型締力検出センサ25はタイバー21の伸び量を検出することによって型締力を検出する構成となっている。さらに、射出成形装置100は、型開閉ストロークを検出する型開閉ストロークセンサとして、可動盤位置センンサ26が可動盤13の位置を検出するようにして配されており、可動盤位置センサ26の計測値から金型30の開閉ストロークを検出する。そして、これらの検出器からの検出信号を受け、型締制御部の出力信号によって型開閉の制御が行われる。   Further, the mold clamping device 110 includes a mold clamping force sensor 25 at one end of the tie bar 21 on the fixed platen side as a sensor for detecting the mold clamping force, and the mold clamping force detection sensor 25 detects the extension amount of the tie bar 21. Thus, the mold clamping force is detected. Further, the injection molding apparatus 100 is arranged such that the movable platen position sensor 26 detects the position of the movable platen 13 as a mold opening / closing stroke sensor for detecting the mold opening / closing stroke. The opening / closing stroke of the mold 30 is detected. The detection signals from these detectors are received, and the mold opening / closing is controlled by the output signal of the mold clamping control unit.
前記型締装置110は、異なる厚さの金型30を取付けるための型厚調整機構19を備えている。駆動手段29によりリンクハウジング11に内挿され、且つ、タイバー21に螺合したタイバーナット27を回転駆動することでトグル機構16を前後進できるようになっている。さらに、型厚調整機構19を駆動して型締力を設定することができる。
符号28は、型厚調整機構19によってトグル機構16とともに移動するリンクハウジング11の移動量を検出してダイハイト位置を検出するダイハイト位置センサであり、ダイハイト位置を正確に検出することができる。
The mold clamping device 110 includes a mold thickness adjusting mechanism 19 for attaching the molds 30 having different thicknesses. The toggle mechanism 16 can be moved forward and backward by rotationally driving a tie bar nut 27 that is inserted into the link housing 11 by the driving means 29 and screwed into the tie bar 21. Further, the mold clamping force can be set by driving the mold thickness adjusting mechanism 19.
Reference numeral 28 denotes a die height position sensor that detects the die height position by detecting the amount of movement of the link housing 11 that moves together with the toggle mechanism 16 by the mold thickness adjusting mechanism 19, and can accurately detect the die height position.
本実施形態におけるトグル機構16は、5つのリンク節を有する5節ダブルトグル式で、クロスヘッド17を型開閉方向に動作させることによって可動盤13の移動と型締力を制御する方式としたが、リンク節が4つである4節ダブルトグル式の機構であっても良い。
また、本実施形態においては、図1に示すような電動サーボモータ22をクロスヘッド17の駆動手段としたが、本発明に適用できる本実施の形態に限らず、クロスヘッド17の駆動手段として油圧シリンダなどを本発明に適用しても良い。そして、型締装置110は図示しないマシンベース上に載置された構成となっている。
The toggle mechanism 16 in the present embodiment is a 5-bar double toggle type having 5 link nodes, and has a method of controlling the movement of the movable platen 13 and the mold clamping force by operating the cross head 17 in the mold opening / closing direction. A four-section double toggle mechanism with four link sections may be used.
Further, in the present embodiment, the electric servo motor 22 as shown in FIG. 1 is used as the driving means for the crosshead 17, but the present invention is not limited to the present embodiment applicable to the present invention, and the driving means for the crosshead 17 is hydraulic. A cylinder or the like may be applied to the present invention. The mold clamping device 110 is placed on a machine base (not shown).
次に、本発明の実施形態に用いた射出装置120の構成について説明する。
図1に示す射出装置120は、金型キャビティ33内に1層目の樹脂成形材料を供給する第1射出ユニット41と、2層目の樹脂成形材料を供給する第2射出ユニット42とからなり、それぞれの射出ユニットがバレルとバレルに内装されフライトを有するスクリュと、バレル内に樹脂成形材料を供給するホッパとを備え、スクリュを前後進させるスクリュ移動手段と、スクリュを回転駆動するスクリュ回転駆動手段が設けられている。
そして、第1射出ユニット41と第2射出ユニット42は、樹脂流路を開閉するシャットオフバルブ43,44とを有している。
Next, the configuration of the injection device 120 used in the embodiment of the present invention will be described.
The injection device 120 shown in FIG. 1 includes a first injection unit 41 that supplies a first layer of resin molding material into a mold cavity 33 and a second injection unit 42 that supplies a second layer of resin molding material. , Each injection unit is equipped with a barrel and a screw having a flight, a hopper for supplying a resin molding material into the barrel, a screw moving means for moving the screw back and forth, and a screw rotation drive for rotating the screw Means are provided.
The first injection unit 41 and the second injection unit 42 have shut-off valves 43 and 44 that open and close the resin flow path.
前記第1射出ユニット41及び第2射出ユニット42は、スクリュの回転手段によってスクリュが回転することにより、ホッパからペレット状の樹脂成形材料がバレル内に供給される構成となっており、該供給されたペレット状の樹脂成形材料はバレルに取付けられたヒータによって加熱され、また、スクリュの回転によって混練圧縮作用を受けることによって溶融し、スクリュ前方へ送られる。スクリュ前方へ送られた溶融樹脂は、スクリュ移動手段により先進するスクリュによってバレルの先端に取付けられたシャットオフバルブ43、44を通りノズルを介して金型キャビティ内に射出充填される。   The first injection unit 41 and the second injection unit 42 are configured such that a pellet-shaped resin molding material is supplied from the hopper into the barrel when the screw is rotated by a screw rotating means. The pellet-shaped resin molding material is heated by a heater attached to the barrel, melted by being subjected to a kneading compression action by the rotation of the screw, and sent to the front of the screw. The molten resin sent to the front of the screw is injected and filled into the mold cavity through the nozzles through the shut-off valves 43 and 44 attached to the tip of the barrel by the screw advanced by the screw moving means.
そして、第1射出ユニット41は固定型31の射出成形装置100の軸線方向から、第2射出ユニット42は固定型31の射出成形装置100の軸線と交差方向から金型キャビティ内に溶融樹脂を供給する構成となっている。なお、第1層及び第2層の樹脂成形材料は、ポリエチレン(PE)、ポリプロピレン(PP)、ABS樹脂などの汎用熱可塑性樹脂や、ポリカーボネート(PC)、ポリアセタール(POM)、ポリアミド(ナイロン)などの汎用エンプラなどを用いることができる。また、これらのリサイクル材をサンドイッチ成形の核材として用いることは有用である。
また、本実施形態における射出装置100のスクリュ移動手段及びスクリュ回転手段は電動サーボモータを駆動源としたが、本発明に適用できる実施形態は本実施例に限らず、油圧シリンダと油圧モータを駆動源とした移動及び回転手段であっても良い。
The first injection unit 41 supplies molten resin into the mold cavity from the axial direction of the injection molding apparatus 100 of the fixed mold 31 and the second injection unit 42 supplies the mold cavity from the direction intersecting with the axis of the injection molding apparatus 100 of the fixed mold 31. It is the composition to do. The resin molding materials for the first layer and the second layer are general-purpose thermoplastic resins such as polyethylene (PE), polypropylene (PP), and ABS resin, polycarbonate (PC), polyacetal (POM), polyamide (nylon), etc. General-purpose engineering plastics can be used. It is also useful to use these recycled materials as the core material for sandwich molding.
Moreover, although the screw moving means and the screw rotating means of the injection apparatus 100 in this embodiment are driven by an electric servo motor, the embodiment applicable to the present invention is not limited to this embodiment, and drives a hydraulic cylinder and a hydraulic motor. It may be a moving and rotating means as a source.
そして、本実施の形態に用いた制御装置130は、型締装置110を制御する型締制御部71と型締条件を設定する型締条件設定器、及び射出装置130を制御する射出制御部72と射出条件を設定する射出条件設定器を基本構成としている。   The control device 130 used in the present embodiment includes a mold clamping control unit 71 that controls the mold clamping device 110, a mold clamping condition setting unit that sets the mold clamping conditions, and an injection control unit 72 that controls the injection device 130. And an injection condition setting device for setting injection conditions.
図2に示す型厚調整19は、リンクハウジング11背面の四隅に挿通されたタイバー21に螺合されたタイバーナット27を回転駆動する電動サーボモータを駆動源とする駆動手段29が4本のタイバー21それぞれに設けられた構成となっている。符号22は、トグル機構16を駆動するリンク駆動機構18の駆動手段である電動サーボモータである。
型厚調整機構19により移動するリンクハウジング11の移動量は、前述したダイハイト位置を検出するダイハイト位置センサ28により検出される。本実施形態では、4本のタイバー21にそれぞれ独立してタイバーナット27を駆動する駆動手段を備えて、四軸が同期又は個別に駆動される構成としたが、2本のタイバーを一対として、または4本のタイバー21を一組として一つの駆動手段で駆動する形態であって良い。
The mold thickness adjustment 19 shown in FIG. 2 has four tie bars including a drive means 29 that uses an electric servomotor that drives and rotates a tie bar nut 27 screwed into a tie bar 21 inserted through four corners on the back of the link housing 11. 21 is provided in each. Reference numeral 22 denotes an electric servo motor which is a drive unit of the link drive mechanism 18 that drives the toggle mechanism 16.
The amount of movement of the link housing 11 that is moved by the mold thickness adjusting mechanism 19 is detected by the above-described die height position sensor 28 that detects the die height position. In this embodiment, the four tie bars 21 are each provided with driving means for driving the tie bar nuts 27 independently, and the four axes are driven synchronously or individually. However, the two tie bars are paired, Alternatively, the four tie bars 21 may be driven as a set by one driving means.
以上のように構成された射出成形装置100の作動について説明する。図3は成形動作手順を示すフローチャート、図4は2層目の樹脂成形材料を発泡させる成形動作手順を示すフローチャート、図5は成形工程の概略を説明する工程説明図、図6は2層目の樹脂成形材料を発泡させる成形工程の概略を説明する工程説明図である。   The operation of the injection molding apparatus 100 configured as described above will be described. FIG. 3 is a flowchart showing a molding operation procedure, FIG. 4 is a flowchart showing a molding operation procedure for foaming a second-layer resin molding material, FIG. 5 is a process explanatory diagram for explaining the outline of the molding process, and FIG. It is process explanatory drawing explaining the outline of the molding process which foams the resin molding material of this.
成形動作手順は、図3及び図5で示すように以下の手順により行う。
(a)先に型締条件設定器で設定したクロスヘッド位置設定値(S1)に基づいて型閉動作を行う。ストロークセンサ24の検出信号が設定値(S1)に達した後は設定値(S1)を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構はメカロック状態)。
(b)第1射出ユニット41のシャットオフバルブ43を開いて、1層目の溶融樹脂を金型キャビティ33内に射出充填する。1層目の溶融樹脂が射出充填され保圧が完了した後、シャットオフバルブ43を閉じ、次いで第1層目樹脂の冷却固化状態に応じて設定される所定の時間冷却が行われる。
The molding operation procedure is performed according to the following procedure as shown in FIGS.
(A) A mold closing operation is performed based on the crosshead position setting value (S1) previously set by the mold clamping condition setting device. After the detection signal of the stroke sensor 24 reaches the set value (S1), the electric servo motor 22 is controlled so as to hold the set value (S1) to perform position holding control (the toggle mechanism is in the mechanical lock state).
(B) The shutoff valve 43 of the first injection unit 41 is opened, and the first layer of molten resin is injected and filled into the mold cavity 33. After the first layer of molten resin is injected and filled and the pressure holding is completed, the shutoff valve 43 is closed, and then cooling is performed for a predetermined time set according to the cooling and solidification state of the first layer resin.
(c)第1層目樹脂の冷却が完了したことを検知した後、型締条件設定器で設定したクロスヘッド位置(S2)に基づいて型開動作を行って可動盤13を後退させ型締力を解放する。ストロークセンサ24の検出信号が設定値(S2)に達した後は設定値(S2)を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構は屈曲状態)。
(d)型締力が解放されストロークセンサ24の検出信号が設定値(S2)に達したことを検出した後、型締条件設定器で設定したダイハイト位置設定値(S12)に基づいてダイハイト後退動作を行って可動盤13を後退させ金型キャビティ33の容積を拡大、第1層樹脂表面と可動型キャビティ面との間に2次キャビティ34を形成する。ダイハイト位置センサ28の検出信号が設定値(S12)に達した後は設定値(S12)を保持するように駆動手段29を制御して位置保持制御を行う(トグル機構は屈曲状態)。
(C) After detecting that the cooling of the first layer resin has been completed, the mold opening operation is performed based on the crosshead position (S2) set by the mold clamping condition setting device, and the movable platen 13 is moved backward to clamp the mold. Release power. After the detection signal of the stroke sensor 24 reaches the set value (S2), the electric servo motor 22 is controlled so as to hold the set value (S2) to perform position holding control (the toggle mechanism is in a bent state).
(D) After detecting that the mold clamping force has been released and the detection signal of the stroke sensor 24 has reached the set value (S2), the die height is retracted based on the die height position set value (S12) set by the mold clamping condition setter. By operating, the movable platen 13 is moved backward to enlarge the volume of the mold cavity 33, and a secondary cavity 34 is formed between the first layer resin surface and the movable cavity surface. After the detection signal of the die height position sensor 28 reaches the set value (S12), the drive means 29 is controlled so as to hold the set value (S12) and the position holding control is performed (the toggle mechanism is in the bent state).
(e)所定のダイハイト位置(S12)に達したことを検出した後、型締条件設定器で設定したクロスヘッド位置(S3)に基づいて型閉動作を行って可動盤13を前進させる。ストロークセンサ24の検出信号が設定値(S3)に達した後は設定値(S3)を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構はメカロック状態)。
(f)第2射出ユニット42のシャットオフバルブ44を開いて、2層目の溶融樹脂を2次キャビティ34内に射出充填する。2層目の溶融樹脂が射出充填され保圧が完了した後、シャットオフバルブ44を閉じ、次いで第2層目樹脂の冷却固化状態に応じて設定される所定の時間冷却が行われる。
(E) After detecting that the predetermined die height position (S12) has been reached, the mold closing operation is performed based on the crosshead position (S3) set by the mold clamping condition setting device to advance the movable platen 13. After the detection signal of the stroke sensor 24 reaches the set value (S3), the electric servo motor 22 is controlled so as to hold the set value (S3) to perform position holding control (the toggle mechanism is in the mechanical lock state).
(F) The shutoff valve 44 of the second injection unit 42 is opened, and the second layer of molten resin is injected and filled into the secondary cavity 34. After the second layer of molten resin is injected and filled and the pressure holding is completed, the shutoff valve 44 is closed, and then cooling is performed for a predetermined time set according to the cooling and solidification state of the second layer resin.
(g)第2層目樹脂の冷却が完了したことを検知した後、型締条件設定器で設定した型開位置設定値に基づいて型開動作を行って可動盤13を後退させる。ストロークセンサ24の検出信号が設定値に達した後は型開位置を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構は屈曲状態)。次いで、成形品は金型30から押出され射出成形機外へ取り出される。
(h)型開の完了を検出した後に成形品の押出し動作が行われるとともに、型締条件設定器で設定したダイハイト位置設定値(S11)に基づいてダイハイト前進動作を行って型締条件設定器で設定した型締力を得る位置までトグル機構16を前進させる。ダイハイト位置センサ28の検出信号が設定値(S11)に達した後は、設定値(S11)を保持するように駆動手段29を制御して位置保持制御を行い次成形の開始信号を待機する。
(G) After detecting that the cooling of the second layer resin has been completed, the movable platen 13 is moved backward by performing a mold opening operation based on the mold opening position setting value set by the mold clamping condition setting device. After the detection signal of the stroke sensor 24 reaches the set value, the electric servomotor 22 is controlled so as to hold the mold open position, and position holding control is performed (the toggle mechanism is in a bent state). Next, the molded product is extruded from the mold 30 and taken out of the injection molding machine.
(H) After the completion of mold opening is detected, the extrusion operation of the molded product is performed, and the die height advance operation is performed based on the die height position setting value (S11) set by the mold clamping condition setting device, and the mold clamping condition setting device The toggle mechanism 16 is advanced to a position where the mold clamping force set in step 1 is obtained. After the detection signal of the die height position sensor 28 reaches the set value (S11), the drive means 29 is controlled to hold the set value (S11), position holding control is performed, and a start signal for the next molding is waited.
次に、2層目の樹脂を射出充填後に発泡させる成形動作手順について、図4及び図6により説明する。本手順において、(a)〜(e)までの手順は前述した図3及び図5に示した手順と同一であって、ここでは手順の異なる(f)以降について説明する。
(f)第2射出ユニット42のシャットオフバルブ44を開いて、発泡層となる2層目の溶融樹脂を2次キャビティ34内に射出充填する。2層目の溶融樹脂が射出充填完了された後、シャットオフバルブ44を閉じ、次いで第2層目樹脂の2次キャビティ接触面にスキン層が形成され、該スキン層の形成状態に応じて設定される所定の時間(t1)型締状態を保持する。
(g)第2層目の2次キャビティ接触面にスキン層が形成された後、型締条件設定器で設定したクロスヘッド位置(S4)に基づいて型開動作を行って可動盤13を後退させ2次キャビティ34の容積を拡大する。そして、該拡大されたキャビティ内で2層目樹脂を発泡させる。ストロークセンサ24の検出信号が設定値(S4)に達した後は、所定の冷却時間まで設定値(S4)を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構は屈曲状態)。
Next, a molding operation procedure for foaming the second layer resin after injection filling will be described with reference to FIGS. In this procedure, the procedure from (a) to (e) is the same as the procedure shown in FIG. 3 and FIG. 5 described above.
(F) The shut-off valve 44 of the second injection unit 42 is opened, and a second layer of molten resin to be a foam layer is injected and filled into the secondary cavity 34. After the injection and filling of the second layer of molten resin is completed, the shut-off valve 44 is closed, and then a skin layer is formed on the secondary cavity contact surface of the second layer resin, which is set according to the formation state of the skin layer The mold clamping state is maintained for a predetermined time (t1).
(G) After the skin layer is formed on the secondary cavity contact surface of the second layer, the movable platen 13 is moved backward by performing the mold opening operation based on the crosshead position (S4) set by the mold clamping condition setting device. The volume of the secondary cavity 34 is increased. Then, the second layer resin is foamed in the enlarged cavity. After the detection signal of the stroke sensor 24 reaches the set value (S4), the electric servo motor 22 is controlled so as to hold the set value (S4) until a predetermined cooling time to perform position holding control (the toggle mechanism is Bent state).
(h)第2層の冷却が完了してことを検知した後、型締条件設定器で設定した型開位置設定値に基づいて型開動作を行って可動盤13を後退させる。ストロークセンサ24の検出信号が設定値に達した後は型開位置を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構は屈曲状態)。次いで、成形品は金型30から押出され射出成形機外へ取り出される。
(i)型開の完了を検出した後に成形品の押出し動作が行われるとともに、型締条件設定器で設定したダイハイト位置設定値(S11)に基づいてダイハイト前進動作を行って型締条件設定器で設定した型締力を得る位置までトグル機構16を前進させる。ダイハイト位置センサ28の検出信号が設定値(S11)に達した後は、設定値(S11)を保持するように駆動手段29を制御して位置保持制御を行い次成形の開始信号を待機する。
(H) After detecting that the cooling of the second layer is completed, the mold opening operation is performed based on the mold opening position setting value set by the mold clamping condition setting device, and the movable platen 13 is moved backward. After the detection signal of the stroke sensor 24 reaches the set value, the electric servomotor 22 is controlled so as to hold the mold open position, and position holding control is performed (the toggle mechanism is in a bent state). Next, the molded product is extruded from the mold 30 and taken out of the injection molding machine.
(I) After detecting the completion of mold opening, an extrusion operation of the molded product is performed, and a die height advancement operation is performed based on the die height position setting value (S11) set by the mold clamping condition setting device to set the mold clamping condition setting device. The toggle mechanism 16 is advanced to a position where the mold clamping force set in step 1 is obtained. After the detection signal of the die height position sensor 28 reaches the set value (S11), the drive means 29 is controlled to hold the set value (S11), position holding control is performed, and a start signal for the next molding is waited.
ここで、発泡のための金型キャビティ容積の拡大動作(図6(g))において、可動型32が固定型31に当接(金型タッチ)する直前のクロスヘッド17の移動ストロークに対する可動盤13の移動ストロークは凡そ10対1の比率となる。また、クロスヘッド19の移動速度に対する可動盤13の移動速度も凡そ10対1の比率となる。換言すれば、トグル機構16を備えた型締装置ではクロスヘッド17の位置を制御すれば可動盤13はクロスヘッド位置精度の凡そ10倍程度の精度で制御されることとなり、高精度な型開閉位置制御を行うことが可能である。そして、従来型の金型キャビティ容積の拡大し樹脂を発泡させる射出発泡成形方法及び射出発泡成形装置では成形できなかった成形品であっても、発泡倍率、気泡径、成型品の厚みを高精度に制御でき、表面層が緻密で発泡倍率や気泡径サイズにバラツキが少ない多層射出成形品を得ることができる。
また、2次キャビティを第1層樹脂表面と可動型キャビティ面との間に形成する構成としたが、本発明に適用できる実施形態は本実施例に限らず、第1層樹脂表面と固定型キャビティ面との間に形成する構成であっても良い。
Here, in the expansion operation of the mold cavity volume for foaming (FIG. 6G), the movable plate with respect to the movement stroke of the crosshead 17 immediately before the movable mold 32 comes into contact with the fixed mold 31 (mold touch). The 13 movement strokes have a ratio of about 10: 1. In addition, the moving speed of the movable plate 13 with respect to the moving speed of the crosshead 19 is approximately 10 to 1. In other words, in the mold clamping apparatus provided with the toggle mechanism 16, if the position of the crosshead 17 is controlled, the movable platen 13 is controlled with an accuracy of about 10 times the crosshead position accuracy. Position control can be performed. And even with a molded product that could not be molded by the injection foam molding method and the injection foam molding device that expands the mold cavity volume of the conventional mold and foams the resin, the foaming magnification, the bubble diameter, and the thickness of the molded product are highly accurate. It is possible to obtain a multilayer injection molded product having a dense surface layer and little variation in foaming ratio and bubble size.
Further, the secondary cavity is formed between the surface of the first layer resin and the movable cavity surface, but the embodiment applicable to the present invention is not limited to this example, and the surface of the first layer resin and the fixed mold The structure formed between cavity surfaces may be sufficient.
図7は他の実施形態を示す樹脂の多層射出成形装置の全体構想図、図8は他の実施形態による成形工程の概略を説明する工程説明図、図9は他の実施形態の2層目樹脂成形材料を発泡させる成形工程の概略を説明する工程説明図である。
図7に示す射出成形装置200について、前述した図1に示す射出成形装置100と異なる点について説明する。射出成形装置200の第2射出ユニット52が、第1射出ユニット51と同様に固定盤12の背面に射出成形装置200の軸線方向に射出ノズル56を介して連通して配されて、射出ノズル56に取付けられたシャットオフバルブ55を切替えることによって2種類の溶融樹脂を金型60のキャビティ33及び34に供給するように構成されている。金型60、型締装置110と制御装置230の基本構成はそれぞれ図1に示したものと同じである。
FIG. 7 is an overall conceptual diagram of a multilayer injection molding apparatus for resin showing another embodiment, FIG. 8 is a process explanatory view for explaining the outline of a molding process according to another embodiment, and FIG. 9 is a second layer of another embodiment. It is process explanatory drawing explaining the outline of the molding process which foams a resin molding material.
The difference between the injection molding apparatus 200 shown in FIG. 7 and the injection molding apparatus 100 shown in FIG. 1 will be described. Similar to the first injection unit 51, the second injection unit 52 of the injection molding apparatus 200 is arranged in communication with the back surface of the fixed platen 12 via the injection nozzle 56 in the axial direction of the injection molding apparatus 200. Two types of molten resin are supplied to the cavities 33 and 34 of the mold 60 by switching the shut-off valve 55 attached to the mold 60. The basic configurations of the mold 60, the mold clamping device 110, and the control device 230 are the same as those shown in FIG.
以上のように構成された射出成形装置200の作動について説明する。成形動作手順は、図8に示すように下記の手順により行う。なお、図7の成形動作手順を示すフローチャートを省略した。これは、前述した動作フローに2層目の溶融樹脂をキャビティ内に射出充填したに後に、1層目の樹脂を再充填する工程が追加されているが、この追加部分は図8及び図9に記載された工程説明図で容易に理解できることによる。
(a)先に型締条件設定器で設定したクロスヘッド位置設定値(S1)に基づいて型閉動作を行う。ストロークセンサ24の検出信号が設定値(S1)に達した後は設定値(S1)を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構はメカロック状態)。
(b)第1射出ユニット51のシャットオフバルブ53を開くとともに射出ノズル56内のシャットオフバルブ55を切替え、基材となる1層目の溶融樹脂を金型キャビティ33内に射出充填する。1層目の溶融樹脂が射出充填完了された後、シャットオフバルブ53を閉じるとともに射出ノズル56内のシャットオフバルブ55を2層目の樹脂の射出充填方向に切替え、次いで基材樹脂の冷却固化状態に応じて設定される所定の時間冷却が行われる。
The operation of the injection molding apparatus 200 configured as described above will be described. The molding operation procedure is performed according to the following procedure as shown in FIG. In addition, the flowchart which shows the shaping | molding operation | movement procedure of FIG. 7 was abbreviate | omitted. This is because the step of refilling the first layer of resin after the second layer of molten resin is injected and filled in the cavity is added to the operation flow described above. This is because it can be easily understood from the process explanatory diagram described in the above.
(A) A mold closing operation is performed based on the crosshead position setting value (S1) previously set by the mold clamping condition setting device. After the detection signal of the stroke sensor 24 reaches the set value (S1), the electric servo motor 22 is controlled so as to hold the set value (S1) to perform position holding control (the toggle mechanism is in the mechanical lock state).
(B) The shut-off valve 53 of the first injection unit 51 is opened and the shut-off valve 55 in the injection nozzle 56 is switched to inject and fill the first layer of molten resin as a base material into the mold cavity 33. After the injection and filling of the first layer of molten resin is completed, the shutoff valve 53 is closed and the shutoff valve 55 in the injection nozzle 56 is switched to the injection and filling direction of the second layer of resin, and then the base resin is cooled and solidified. Cooling is performed for a predetermined time set according to the state.
(c)基材樹脂の冷却が完了したことを検知した後、型締条件設定器で設定したクロスヘッド位置(S2)に基づいて型開動作を行って可動盤13を後退させ型締力を解放する。ストロークセンサ24の検出信号が設定値(S2)に達した後は設定値(S2)を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構は屈曲状態)。
(d)型締力が解放されストロークセンサ24の検出信号が設定値(S2)に達したことを検出した後、型締条件設定器で設定したダイハイト位置設定値(S12)に基づいてダイハイト後退動作を行って可動盤13を後退させ金型キャビティ33の容積を拡大、第1層樹脂表面と可動型キャビティ面との間に2次キャビティ34を形成する。ダイハイト位置センサ28の検出信号が設定値(S12)に達した後は設定値(S12)を保持するように駆動手段29を制御して位置保持制御を行う(トグル機構は屈曲状態)。
(C) After detecting that the cooling of the base resin has been completed, the mold opening operation is performed based on the crosshead position (S2) set by the mold clamping condition setting device, and the movable platen 13 is moved backward to apply the mold clamping force. release. After the detection signal of the stroke sensor 24 reaches the set value (S2), the electric servo motor 22 is controlled so as to hold the set value (S2) to perform position holding control (the toggle mechanism is in a bent state).
(D) After detecting that the mold clamping force has been released and the detection signal of the stroke sensor 24 has reached the set value (S2), the die height is retracted based on the die height position set value (S12) set by the mold clamping condition setter. By operating, the movable platen 13 is moved backward to enlarge the volume of the mold cavity 33, and a secondary cavity 34 is formed between the first layer resin surface and the movable cavity surface. After the detection signal of the die height position sensor 28 reaches the set value (S12), the drive means 29 is controlled so as to hold the set value (S12) and the position holding control is performed (the toggle mechanism is in the bent state).
(e)所定のダイハイト位置(S12)に達したことを検出した後、型締条件設定器で設定したクロスヘッド位置(S3)に基づいて型閉動作を行って可動盤13を前進させる。ストロークセンサ24の検出信号が設定値(S3)に達した後は設定値(S3)を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構はメカロック状態)。
(f)第2射出ユニット52のシャットオフバルブ54を開いて、核材となる2層目の溶融樹脂を基材樹脂の内部に射出充填する。2層目の溶融樹脂が射出充填完了された後、シャットオフバルブ54を閉じるとともに射出ノズル56内のシャットオフバルブ55を1層目の樹脂の射出充填方向に切替える。
(g)次いで、核材となる2層目の樹脂が固化する前に、第1射出ユニット51を駆動して1層目の溶融樹脂を適量充填し成形品表面の核材充填の痕跡を除去する。そして、この充填動作によってシャットオフバルブ55からノズル先端までの樹脂流路内の溶融樹脂は1層目の樹脂に置き換えられ、次成形時に1層目樹脂と2層目樹脂とが混ざり合うことがない。核材の冷却固化状態に応じて設定される所定の時間冷却が行われる。
(E) After detecting that the predetermined die height position (S12) has been reached, the mold closing operation is performed based on the crosshead position (S3) set by the mold clamping condition setting device to advance the movable platen 13. After the detection signal of the stroke sensor 24 reaches the set value (S3), the electric servo motor 22 is controlled so as to hold the set value (S3) to perform position holding control (the toggle mechanism is in the mechanical lock state).
(F) The shut-off valve 54 of the second injection unit 52 is opened, and the second layer of molten resin as a core material is injected and filled into the base resin. After the injection and filling of the second layer of molten resin is completed, the shutoff valve 54 is closed and the shutoff valve 55 in the injection nozzle 56 is switched to the injection and filling direction of the first layer of resin.
(G) Next, before the second layer resin as the core material is solidified, the first injection unit 51 is driven to fill an appropriate amount of the first layer molten resin to remove traces of the core material filling on the surface of the molded product. To do. And by this filling operation, the molten resin in the resin flow path from the shut-off valve 55 to the nozzle tip is replaced with the first layer resin, and the first layer resin and the second layer resin may be mixed in the next molding. Absent. Cooling is performed for a predetermined time set according to the cooling and solidification state of the core material.
(h)核材の冷却が完了したことを検知した後、型締条件設定器で設定した型開位置設定値に基づいて型開動作を行って可動盤13を後退させる。ストロークセンサ24の検出信号が設定値に達した後は型開位置を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構は屈曲状態)。次いで、成形品は金型30から押出され射出成形機外へ取り出される。
(i)型開の完了を検出した後に成形品の押出し動作が行われるとともに、型締条件設定器で設定したダイハイト位置設定値(S11)に基づいてダイハイト前進動作を行って型締条件設定器で設定した型締力を得る位置までトグル機構16を前進させる。ダイハイト位置センサ28の検出信号が設定値(S11)に達した後は、設定値(S11)を保持するように駆動手段29を制御して位置保持制御を行い次成形の開始信号を待機する。
(H) After detecting that the cooling of the core material is completed, the mold opening operation is performed based on the mold opening position setting value set by the mold clamping condition setting device, and the movable platen 13 is moved backward. After the detection signal of the stroke sensor 24 reaches the set value, the electric servomotor 22 is controlled so as to hold the mold open position, and position holding control is performed (the toggle mechanism is in a bent state). Next, the molded product is extruded from the mold 30 and taken out of the injection molding machine.
(I) After detecting the completion of mold opening, an extrusion operation of the molded product is performed, and a die height advancement operation is performed based on the die height position setting value (S11) set by the mold clamping condition setting device to set the mold clamping condition setting device. The toggle mechanism 16 is advanced to a position where the mold clamping force set in step 1 is obtained. After the detection signal of the die height position sensor 28 reaches the set value (S11), the drive means 29 is controlled to hold the set value (S11), position holding control is performed, and a start signal for the next molding is waited.
次に、他の実施形態における2層目の樹脂成形材料を発泡させる成形手順を図9に基づいて説明する。本手順において、(a)〜(e)までの手順は前述した図8に記載と同一であり、ここでは、手順の異なる(f)以降について説明する。
(f)第2射出ユニット52のシャットオフバルブ54を開いて、核材となる2層目の発泡剤を含む溶融樹脂を1層目の基材樹脂の内部に射出充填する。2層目の溶融樹脂を射出充填完了の後、シャットオフバルブ54を閉じるとともに射出ノズル56内のシャットオフバルブ55を1層目の樹脂充填方向に切替える。
(g)次いで、2層目の樹脂が発泡また固化する前に、第1射出ユニット51を駆動して1層目の溶融樹脂を適量充填し成形品表面の核材充填の痕跡を除去する。そして、この充填動作によってシャットオフバルブ55からノズル先端までの樹脂流路内の溶融樹脂は1層目の樹脂に置き換えられ、次成形時に1層目樹脂と2層目樹脂とが混ざり合うことがない。核材の気泡核形成状態及び1層目樹脂の冷却固化状態に応じて設定される所定の時間型締力が保持される。
Next, a molding procedure for foaming the second-layer resin molding material in another embodiment will be described with reference to FIG. In this procedure, the procedure from (a) to (e) is the same as that shown in FIG. 8 described above, and here, the procedure (f) and after will be described.
(F) The shut-off valve 54 of the second injection unit 52 is opened, and a molten resin containing a second-layer foaming agent serving as a core material is injected and filled into the first-layer base resin. After the injection filling of the second layer of molten resin is completed, the shutoff valve 54 is closed and the shutoff valve 55 in the injection nozzle 56 is switched to the resin charging direction of the first layer.
(G) Next, before the resin of the second layer is foamed or solidified, the first injection unit 51 is driven to fill with an appropriate amount of the molten resin of the first layer to remove traces of filling of the core material on the surface of the molded product. And by this filling operation, the molten resin in the resin flow path from the shut-off valve 55 to the nozzle tip is replaced with the first layer resin, and the first layer resin and the second layer resin may be mixed in the next molding. Absent. A predetermined time clamping force set according to the bubble nucleus formation state of the core material and the cooling and solidification state of the first layer resin is maintained.
(h)1層目の溶融樹脂が再充填され所定の型締保持時間が経過した後、型締条件設定器で設定したクロスヘッド位置(S4)に基づいて型開動作を行って可動盤13を後退させ2次キャビティの容積を拡大する。そして、拡大されたキャビティ内で2層目樹脂を発泡させる。ストロークセンサ24の検出信号が設定値(S4)に達した後は、所定の冷却時間まで設定値(S4)を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構は屈曲状態)。
(i)発泡層の冷却が完了してことを検知した後、型締条件設定器で設定した型開位置設定値に基づいて型開動作を行って可動盤13を後退させる。ストロークセンサ24の検出信号が設定値に達した後は型開位置を保持するように電動サーボモータ22を制御して位置保持制御を行う(トグル機構は屈曲状態)。次いで、成形品は金型30から押出され射出成形機外へ取り出される。
(j)型開の完了を検出した後に成形品の押出し動作が行われるとともに、型締条件設定器で設定したダイハイト位置設定値(S11)に基づいてダイハイト前進動作を行って型締条件設定器で設定した型締力を得る位置までトグル機構16を前進させる。ダイハイト位置センサ28の検出信号が設定値(S11)に達した後は、設定値(S11)を保持するように駆動手段29を制御して位置保持制御を行い次成形の開始信号を待機する。
(H) After the first layer of molten resin is refilled and a predetermined mold clamping holding time has elapsed, the mold opening operation is performed based on the crosshead position (S4) set by the mold clamping condition setting device, and the movable platen 13 Is retracted to increase the volume of the secondary cavity. Then, the second layer resin is foamed in the enlarged cavity. After the detection signal of the stroke sensor 24 reaches the set value (S4), the electric servo motor 22 is controlled so as to hold the set value (S4) until a predetermined cooling time to perform position holding control (the toggle mechanism is Bent state).
(I) After detecting that the cooling of the foamed layer is completed, the mold opening operation is performed based on the mold opening position setting value set by the mold clamping condition setting device, and the movable platen 13 is moved backward. After the detection signal of the stroke sensor 24 reaches the set value, the electric servomotor 22 is controlled so as to hold the mold open position, and position holding control is performed (the toggle mechanism is in a bent state). Next, the molded product is extruded from the mold 30 and taken out of the injection molding machine.
(J) After the completion of mold opening is detected, the molded product is pushed out, and the die height advancement operation is performed based on the die height position setting value (S11) set by the mold clamping condition setting device to set the mold clamping condition setting device. The toggle mechanism 16 is advanced to a position where the mold clamping force set in step 1 is obtained. After the detection signal of the die height position sensor 28 reaches the set value (S11), the drive means 29 is controlled to hold the set value (S11), position holding control is performed, and a start signal for the next molding is waited.
本発明においては、図5、6、8及び図9の(c)〜(e)に示すように、2次キャビティの形成は型締装置110のトグル機構16を駆動して型締力を解放し(c)、次いで型厚調整機構19を可動盤13がトグル機構16のロッキング状態で所定の金型キャビティ拡大位置(S12)となるまで後退させた後(d)、トグル機構16を駆動してトグル機構16のロッキング状態となるまで可動盤13を前進させて行う(e)こととしたが、例えば、型締力を解放(c)した後、型厚調整機構19の後退動作に同期してトグル機構16を駆動して可動盤13を前進させ、所定の金型キャビティ位置(S12)を検出した際にトグル機構16がロッキング状態となる駆動方法であっても良い。この場合、成形工程の(d)と(e)が同時動作となることから工程時間が短縮される。   In the present invention, as shown in FIGS. 5, 6, 8 and 9 (c) to (e), the secondary cavity is formed by driving the toggle mechanism 16 of the mold clamping device 110 to release the mold clamping force. (C) Next, after the mold thickness adjusting mechanism 19 is retracted until the movable platen 13 is in a locked state of the toggle mechanism 16 until it reaches a predetermined mold cavity enlargement position (S12) (d), the toggle mechanism 16 is driven. The movable platen 13 is moved forward until the toggle mechanism 16 is locked (e). For example, after the mold clamping force is released (c), the mold thickness adjusting mechanism 19 is synchronized with the retreating operation. Alternatively, the toggle mechanism 16 may be driven to advance the movable platen 13 and the toggle mechanism 16 may be locked when a predetermined mold cavity position (S12) is detected. In this case, since the steps (d) and (e) of the molding process are performed simultaneously, the process time is shortened.
以上説明したことから明らかなように、本発明においては、1層目の樹脂成形材料を射出充填した後に、2層目の樹脂成形材料をトグル機構がロッキング状態で型閉じされて形成された2次キャビティ内に射出充填するので、2層目の樹脂充填圧力が可動盤に作用してもトグル機構のクロスヘッドに樹脂の充填力が作用することがない。従って、トグル機構が押し戻されて金型キャビティが更に拡大されることがないので、成形品の厚み精度が維持でき、成形不良の発生がなく所望する多層射出成形品を得ることができる。   As is apparent from the above description, in the present invention, the second layer resin molding material is formed by injection-filling the first layer resin molding material and then closing the mold with the toggle mechanism locked. Since the next cavity is injected and filled, even if the resin filling pressure of the second layer acts on the movable platen, the resin filling force does not act on the crosshead of the toggle mechanism. Therefore, since the toggle mechanism is not pushed back and the mold cavity is not further expanded, the thickness accuracy of the molded product can be maintained, and a desired multilayer injection molded product can be obtained without the occurrence of molding defects.
また、1層目の樹脂成形材料を射出充填した後に、トグル機構がロッキング状態で型閉じされて2次キャビティを形成し、1層目の樹脂成形材料の内部に2層目の樹脂成形材料を射出充填するので、2層目の樹脂充填圧力が可動盤に作用してもトグル機構のクロスヘッドに樹脂の充填力が作用することがない。従って、トグル機構が押し戻されて金型キャビティが更に拡大されることがないので、成形品の厚み精度が維持でき、成形不良の発生がなく所望する多層射出成形品を得ることができる。
そして、冷却完了後の型開工程の開始から次サイクルの型閉開始までの間に、型厚調整機構を駆動してトグル機構を1層目成形の型締力設定位置まで移動させることから、成形サイクルタイムを延長することがない。
Also, after injection-filling the first-layer resin molding material, the toggle mechanism is closed in a locked state to form a secondary cavity, and the second-layer resin molding material is placed inside the first-layer resin molding material. Since injection filling is performed, the resin filling force does not act on the crosshead of the toggle mechanism even if the resin filling pressure of the second layer acts on the movable platen. Therefore, since the toggle mechanism is not pushed back and the mold cavity is not further expanded, the thickness accuracy of the molded product can be maintained, and a desired multilayer injection molded product can be obtained without the occurrence of molding defects.
Since the mold thickness adjustment mechanism is driven and the toggle mechanism is moved to the mold clamping force setting position for the first layer molding between the start of the mold opening process after completion of cooling and the start of mold closing of the next cycle, Does not extend the molding cycle time.
本発明の実施形態において、トグル機構がロッキング状態となる所定のクロスヘッド位置設定値(S1)で1層目の樹脂成形材料を金型キャビティ内に射出充填することとしたが、例えば、クロスヘッド位置設定値をトグル機構が屈曲状態である金型タッチ点からトグル機構がロッキング状態となる所定のクロスヘッド位置設定値(S1)の任意の中間位置に設定する低圧型締状態や、金型タッチ点から所定の隙間を設けて可動型を配した所定のクロスヘッド位置に設定する型開保持状態の方法を適用することができる。
この場合においては、1層目の樹脂成形材料を射出充填の後トグル機構を駆動してクロスヘット位置設置値(S1)とする構成が好ましい。
In the embodiment of the present invention, the resin molding material of the first layer is injected and filled into the mold cavity at a predetermined crosshead position setting value (S1) at which the toggle mechanism is in the locking state. A low pressure mold clamping state in which the position setting value is set to an arbitrary intermediate position of a predetermined crosshead position setting value (S1) in which the toggle mechanism is in a locking state from a mold touch point in which the toggle mechanism is in a bent state, or a mold touch It is possible to apply a mold open holding state method in which a predetermined gap is provided from a point and a movable cross is placed at a predetermined crosshead position.
In this case, a configuration in which the toggle mechanism is driven after the injection molding of the first layer of the resin molding material to obtain the cross head position setting value (S1) is preferable.
さらに、2層目の樹脂成形材料は発泡剤を含む材料を用いるので、発泡層を有する多層射出成形品や内部を発泡させたサンドイッチ成形品を得ることができる。そして、発泡における金型キャビティ容積の拡大は、トグル機構の倍率特性を利用し、金型タッチ点にある型締装置の可動盤を型開方向に移動させた際に検出したクロスヘッド位置と可動盤位置とのデータに基づいて制御する。この方法によれば、所望する発泡倍率、気泡径を有する発泡多層射出成形品を得ることができる。
また、1層目樹脂に発泡剤を含む樹脂成形材料を用い、第1層目を発泡させた多層射出成形品や1層目及び2層目いずれも発泡剤を含む樹脂成形材料を用いて、発泡層と発泡層を積層した多層射出成形品を得ることができる。そして、本発明の実施形態では発泡成形動作を所定の発泡型開位置(S4)まで1段で可動盤を後退させる構成としたが、成形する樹脂材料や発泡剤の種類に応じて多段で可動盤を後退させる構成であっても良い。
Furthermore, since the resin molding material for the second layer uses a material containing a foaming agent, it is possible to obtain a multilayer injection molded product having a foamed layer or a sandwich molded product in which the inside is foamed. The expansion of the mold cavity volume in foaming uses the magnification characteristics of the toggle mechanism, and the crosshead position detected when the movable platen of the mold clamping device at the mold touch point is moved in the mold opening direction. Control based on the data of the board position. According to this method, it is possible to obtain a foamed multilayer injection molded product having a desired foaming ratio and cell diameter.
In addition, using a resin molding material containing a foaming agent in the first layer resin, using a multilayer injection molded product in which the first layer is foamed, and using a resin molding material containing both the first layer and the second layer a foaming agent, A multilayer injection molded product in which a foam layer and a foam layer are laminated can be obtained. In the embodiment of the present invention, the foaming operation is configured such that the movable platen is retracted in one step up to the predetermined foaming mold opening position (S4). However, it is movable in multiple steps according to the type of resin material to be molded and the foaming agent. The structure which reverse | retreats a board may be sufficient.
本発明実施形態による樹脂の多層射出成形装置の全体構想図である。1 is an overall conceptual diagram of a multilayer injection molding apparatus for resin according to an embodiment of the present invention. 型厚調整機構を概念的に示した構想図面である。3 is a conceptual diagram conceptually showing a mold thickness adjusting mechanism. 成形動作手順を示すフローチャートである。It is a flowchart which shows a shaping | molding operation | movement procedure. 2層目の樹脂成形材料を発泡させる成形動作手順を示すフローチャートである。It is a flowchart which shows the shaping | molding operation | movement procedure which foams the resin molding material of the 2nd layer. 成形工程の概略を説明する工程説明図である。It is process explanatory drawing explaining the outline of a formation process. 2層目の樹脂成形材料を発泡させる成形工程の概略を説明する工程説明図である。It is process explanatory drawing explaining the outline of the molding process which foams the resin molding material of the 2nd layer. 他の実施形態を示す樹脂の多層射出成形装置の全体構想図である。It is a whole conceptual diagram of the multilayer injection molding apparatus of resin which shows other embodiment. 他の実施形態による成形工程の概略を説明する工程説明図である。It is process explanatory drawing explaining the outline of the shaping | molding process by other embodiment. 他の実施形態の2層目樹脂成形材料を発泡させる成形工程の概略を説明する工程説明図である。It is process explanatory drawing explaining the outline of the molding process which foams the 2nd layer resin molding material of other embodiment.
符号の説明Explanation of symbols
11 リンクハウジング
12 固定盤
13 可動盤
16 トグル機構
17 クロスヘッド
18 リンク駆動機構
19 型厚調整機構
21 タイバー
22 電動サーボモータ
23 クロスヘッド駆動軸
24 ストロークセンサ
25 型締力センサ
26 可動盤位置センサ
27 タイバーナット
28 ダイハイト位置センサ
29 駆動手段
30、60 金型
31、61 固定型
32、62 可動型
33 金型キャビティ
34 2次キャビティ
41、51 第1射出ユニット
42、52 第2射出ユニット
43、44、53、54、55 シャットオフバルブ
56 射出ノズル
71 型締制御部
72 射出制御部
100、200 射出成形装置
110 型締装置
120、220 射出装置
130、230 制御装置
S1 クロスヘット位置(1層目型締完了設定値)
S2 クロスヘット位置(型締力解放設定値)
S3 クロスヘット位置(2層目型締完了設定値)
S4 クロスヘット位置(発泡型開設定値)
S11 ダイハイト位置(1層目成形設定位置)
S12 ダイハイト位置(2層目成形設定位置)
t1 2層目冷却時間
DESCRIPTION OF SYMBOLS 11 Link housing 12 Fixed board 13 Movable board 16 Toggle mechanism 17 Cross head 18 Link drive mechanism 19 Mold thickness adjustment mechanism 21 Tie bar 22 Electric servo motor 23 Cross head drive shaft 24 Stroke sensor 25 Mold clamping force sensor 26 Movable board position sensor 27 Tie bar Nut 28 Die height position sensor 29 Driving means 30, 60 Mold 31, 61 Fixed mold 32, 62 Movable mold 33 Mold cavity 34 Secondary cavity 41, 51 First injection unit 42, 52 Second injection unit 43, 44, 53 , 54, 55 Shut-off valve 56 Injection nozzle 71 Mold clamping control unit 72 Injection control unit 100, 200 Injection molding device 110 Mold clamping device 120, 220 Injection device 130, 230 Control device S1 Cross head position (1st layer clamping completed) Setting value)
S2 Cross head position (Clamping force release setting value)
S3 Cross head position (2nd layer clamping completion set value)
S4 Cross head position (foaming mold opening setting value)
S11 Die height position (1st layer molding setting position)
S12 Die height position (2nd layer molding setting position)
t1 Second layer cooling time

Claims (8)

  1. 金型キャビティに少なくとも2種類の樹脂成形材料を射出充填する射出装置と、トグル機構を用いて金型の開閉と型締とを行う型締装置とを用いて、多層成形品を得る樹脂の多層射出成形方法であって、
    金型キャビティ内に1層目の樹脂成形材料を射出充填して成形した後に、可動盤を後退させ前記金型キャビティを拡大し第1層目の樹脂成形材料と金型キャビティ面との間に2次キャビティを形成して、該形成した2次キャビティに2層目の樹脂成形材料を射出充填するに際し、
    前記2次キャビティの形成は、型締装置のトグル機構を駆動して型締力を解放し、次いで、前記可動盤がトグル機構のロッキング状態で所定の金型キャビティ拡大位置となるまで型厚調整機構を駆動してトグル機構を後退させた後、前記トグル機構を駆動してトグル機構のロッキング状態まで可動盤を前進させて行うことを特徴とする樹脂の多層射出成形方法。
    Multilayer of resin to obtain a multilayer molded product by using an injection device for injecting and filling at least two types of resin molding materials into a mold cavity and a mold clamping device for opening and closing the mold and clamping using a toggle mechanism An injection molding method,
    After the first layer of the resin molding material is injected and filled into the mold cavity, the movable plate is retracted to enlarge the mold cavity, and between the first layer of the resin molding material and the mold cavity surface. When forming a secondary cavity and injecting and filling the second layer resin molding material into the formed secondary cavity,
    The secondary cavity is formed by driving the toggle mechanism of the mold clamping device to release the mold clamping force, and then adjusting the mold thickness until the movable platen reaches the predetermined mold cavity enlarged position in the locked state of the toggle mechanism. A resin multi-layer injection molding method comprising: driving a mechanism to retract the toggle mechanism and then driving the toggle mechanism to advance the movable platen to a locking state of the toggle mechanism.
  2. 金型キャビティに少なくとも2種類の樹脂成形材料を射出充填する射出装置と、トグル機構を用いて金型の開閉と型締とを行う型締装置とを用いて、多層成形品を得る樹脂の多層射出成形方法であって、
    金型キャビティ内に1層目の樹脂成形材料を射出充填して成形した後に、可動盤を後退させ前記金型キャビティを拡大し第1層目の樹脂成形材料と金型キャビティ面との間に2次キャビティを形成して、第1層目の樹脂成形材料の内部に2層目の樹脂成形材料を射出充填するに際し、
    前記2次キャビティの形成は、型締装置のトグル機構を駆動して型締力を解放し、次いで、前記可動盤がトグル機構のロッキング状態で所定の金型キャビティ拡大位置となるまで型厚調整機構を駆動してトグル機構を後退させた後、前記トグル機構を駆動してトグル機構のロッキング状態まで可動盤を前進させて行うことを特徴とする樹脂の多層射出成形方法。
    Multilayer of resin to obtain a multilayer molded product by using an injection device for injecting and filling at least two types of resin molding materials into a mold cavity and a mold clamping device for opening and closing the mold and clamping using a toggle mechanism An injection molding method,
    After the first layer of the resin molding material is injected and filled into the mold cavity, the movable plate is retracted to enlarge the mold cavity, and between the first layer of the resin molding material and the mold cavity surface. When forming the secondary cavity and injecting and filling the resin molding material of the second layer into the resin molding material of the first layer,
    The secondary cavity is formed by driving the toggle mechanism of the mold clamping device to release the mold clamping force, and then adjusting the mold thickness until the movable platen reaches the predetermined mold cavity enlarged position in the locked state of the toggle mechanism. A resin multi-layer injection molding method comprising: driving a mechanism to retract the toggle mechanism and then driving the toggle mechanism to advance the movable platen to a locking state of the toggle mechanism.
  3. 前記2層目の樹脂成形材料を射出充填した後、前記可動盤が後退して多層成形品を取り出すための型開の開始から次サイクルの型閉開始までの間で、1層目樹脂充填の際の型締力設定位置となるまで前記型厚調整機構を駆動してトグル機構を前進させることを特徴とする請求項1または請求項2に記載の樹脂の多層射出成形方法。   After injection filling the resin molding material of the second layer, the first layer of resin filling is performed between the start of mold opening for taking out the multilayer molded product after the movable plate moves backward and the start of mold closing of the next cycle. 3. The resin multilayer injection molding method according to claim 1, wherein the mold thickness adjusting mechanism is driven until the mold clamping force setting position is reached to advance the toggle mechanism.
  4. 前記1層目及び/又は2層目が物理発泡剤や化学発泡剤などの発泡剤を含んだ樹脂成形材料であって、前記1層目及び/又は2層目の射出充填後にトグル機構を駆動して前記可動盤を所定の発泡位置まで後退させることを特徴とする請求項1乃至請求項3のいずれかに記載の樹脂の多層射出成形方法。   The first layer and / or the second layer is a resin molding material containing a foaming agent such as a physical foaming agent or a chemical foaming agent, and the toggle mechanism is driven after the injection filling of the first layer and / or the second layer. 4. The resin multilayer injection molding method according to claim 1, wherein the movable platen is retracted to a predetermined foaming position.
  5. 金型キャビティに少なくとも2種類の樹脂成形材料を射出充填する射出装置と、トグル機構を用いて金型の開閉と型締とを行う型締装置と、を備え、多層成形品を得る樹脂の多層射出成形装置であって、
    金型キャビティ内に1層目の樹脂成形材料を射出充填して成形した後に、可動盤を後退させ前記金型キャビティを拡大し第1層目の樹脂成形材料と金型キャビティ面との間に2次キャビティを形成して、該形成した2次キャビティに2層目の樹脂成形材料を射出充填するに際し、
    前記2次キャビティの形成は、型締装置のトグル機構を駆動して型締力を解放し、次いで、前記可動盤がトグル機構のロッキング状態で所定の金型キャビティ拡大位置となるまで型厚調整機構を駆動してトグル機構を後退させた後、前記トグル機構を駆動してトグル機構のロッキング状態まで可動盤を前進させるように構成したことを特徴とする樹脂の多層射出成形装置。
    A resin multilayer having an injection device for injecting and filling at least two types of resin molding materials into a mold cavity, and a mold clamping device for opening and closing the mold and clamping using a toggle mechanism. An injection molding device,
    After the first layer of the resin molding material is injected and filled into the mold cavity, the movable plate is retracted to enlarge the mold cavity, and between the first layer of the resin molding material and the mold cavity surface. When forming a secondary cavity and injecting and filling the second layer resin molding material into the formed secondary cavity,
    The secondary cavity is formed by driving the toggle mechanism of the mold clamping device to release the mold clamping force, and then adjusting the mold thickness until the movable platen reaches the predetermined mold cavity enlarged position in the locked state of the toggle mechanism. A resin multilayer injection molding apparatus configured to drive the mechanism to retract the toggle mechanism, and then drive the toggle mechanism to advance the movable platen to the locking state of the toggle mechanism.
  6. 金型キャビティに少なくとも2種類の樹脂成形材料を射出充填する射出装置と、トグル機構を用いて金型の開閉と型締とを行う型締装置と、を備え、多層成形品を得る樹脂の多層射出成形装置であって、
    金型キャビティ内に1層目の樹脂成形材料を射出充填して成形した後に、可動盤を後退させ前記金型キャビティを拡大し第1層目の樹脂成形材料と金型キャビティ面との間に2次キャビティを形成して、第1層目の樹脂成形材料の内部に2層目の樹脂成形材料を射出充填するに際し、
    前記2次キャビティの形成は、型締装置のトグル機構を駆動して型締力を解放し、次いで、前記可動盤がトグル機構のロッキング状態で所定の金型キャビティ拡大位置となるまで型厚調整機構を駆動してトグル機構を後退させた後、前記トグル機構を駆動してトグル機構のロッキング状態まで可動盤を前進させるように構成したことを特徴とする樹脂の多層射出成形装置。
    A resin multilayer having an injection device for injecting and filling at least two types of resin molding materials into a mold cavity, and a mold clamping device for opening and closing the mold and clamping using a toggle mechanism. An injection molding device,
    After the first layer of the resin molding material is injected and filled into the mold cavity, the movable plate is retracted to enlarge the mold cavity, and between the first layer of the resin molding material and the mold cavity surface. When forming the secondary cavity and injecting and filling the resin molding material of the second layer into the resin molding material of the first layer,
    The secondary cavity is formed by driving the toggle mechanism of the mold clamping device to release the mold clamping force, and then adjusting the mold thickness until the movable platen reaches the predetermined mold cavity enlarged position in the locked state of the toggle mechanism. A resin multilayer injection molding apparatus configured to drive the mechanism to retract the toggle mechanism, and then drive the toggle mechanism to advance the movable platen to the locking state of the toggle mechanism.
  7. 前記型厚調整機構は、型締装置のリンクハウジング背面の四隅に挿通して架設されタイバーに螺合するタイバーナットそれぞれに設けた駆動手段により四軸が同期または個別に駆動するように構成したことを特徴とする請求項5または請求項6に記載の樹脂の多層射出成形装置。   The mold thickness adjusting mechanism is configured such that the four axes are driven synchronously or individually by driving means provided in each of the tie bar nuts that are inserted through the four corners of the back surface of the link housing of the mold clamping device and screwed into the tie bars. A multilayer injection molding apparatus for resin according to claim 5 or 6.
  8. 前記1層目及び/又は2層目が物理発泡剤や化学発泡剤などの発泡剤を含んだ樹脂成形材料であって、前記1層目及び/又は2層目の射出充填後にトグル機構を駆動して前記可動盤を所定の発泡位置まで後退させるように構成したことを特徴とする請求項5乃至請求項7のいずれかに記載の樹脂の多層射出成形装置。   The first layer and / or the second layer is a resin molding material containing a foaming agent such as a physical foaming agent or a chemical foaming agent, and the toggle mechanism is driven after the injection filling of the first layer and / or the second layer. 8. The resin multilayer injection molding apparatus according to claim 5, wherein the movable platen is configured to be retracted to a predetermined foaming position.
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JP2011031535A (en) * 2009-08-04 2011-02-17 Ube Machinery Corporation Ltd Foam molding method by laminate molding apparatus
JP2011056774A (en) * 2009-09-09 2011-03-24 Takahashi Seiki Kogyosho:Kk Laminate molding apparatus
JP2012035441A (en) * 2010-08-04 2012-02-23 Japan Steel Works Ltd:The Expansion molding method and toggle type mold clamping device
ITPD20120287A1 (en) * 2012-10-04 2014-04-05 Main Group Technologies S R L Improved equipment for opening and closing presses for injection molding of multi-colored articles in plastic material.
KR101525687B1 (en) * 2013-11-04 2015-06-03 엘에스엠트론 주식회사 Injection Molding Machine and Injection Control Method Thereof

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JP2011031535A (en) * 2009-08-04 2011-02-17 Ube Machinery Corporation Ltd Foam molding method by laminate molding apparatus
JP2011056774A (en) * 2009-09-09 2011-03-24 Takahashi Seiki Kogyosho:Kk Laminate molding apparatus
JP2012035441A (en) * 2010-08-04 2012-02-23 Japan Steel Works Ltd:The Expansion molding method and toggle type mold clamping device
ITPD20120287A1 (en) * 2012-10-04 2014-04-05 Main Group Technologies S R L Improved equipment for opening and closing presses for injection molding of multi-colored articles in plastic material.
KR101525687B1 (en) * 2013-11-04 2015-06-03 엘에스엠트론 주식회사 Injection Molding Machine and Injection Control Method Thereof

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