JP2008229978A - Resin foam molding provided with camber-preventive reinforcing member and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a simple method of manufacturing, through foaming molding, a resin foam molding A which has a wave-like rugged surface on one side of a resin foam plate 1 and a resin sheet 2 composed of a resin material different from that of the resin foam plate 1 and laminated on the rugged surface in an integrated manner and causes no camber after molding. <P>SOLUTION: The method includes laying a preliminarily molded resin sheet 2 on the rugged surface of the lower mold 10 having a wave-like irregularity in the upper surface so as to lie along the rugged surface, arranging a long reinforcing member 3 above the resin sheet 2, setting a side-frame die 20 and a top die 30 so as to surround the lower mold 10 and the long reinforcing member 3 and thus to form a cavity space and filling the cavity space with foaming particles to carry out in-mold foaming molding. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a synthetic resin foam molded product having corrugated irregularities on the surface and used in a box for transporting a glass substrate, for example, and a method for producing the same.

  A glass substrate and a glass panel using the glass substrate are often housed and transported in a special glass substrate transport box in order to prevent breakage during transport. An example is described in Patent Document 1, and the glass substrate transport box is provided with a large number of support grooves made of irregularities on the inner wall of the box in order to support the accommodated glass substrate at a predetermined position. At the bottom of the box, a synthetic resin foam molded product having a number of support grooves formed of corrugated irregularities on the surface is placed.

  The surface of the synthetic resin foam molded article is provided with a resin sheet made of an ultra high molecular weight polyethylene film or the like so that dust or the like is not generated from the surface of the synthetic resin foam plate by contact with the glass substrate. It has a structure. Usually, in this kind of synthetic resin foam board, since the thermal shrinkage rate of a synthetic resin foam board and a resin sheet differs, the curvature toward the one where a shrinkage rate is large tends to arise.

  Patent Document 2 discloses an example of a technique for suppressing warpage that occurs due to a difference in thermal shrinkage in a composite panel in which a resin sheet is laminated on a synthetic resin foam plate. Therein, in a floor heating panel comprising a flat plate made of foamed synthetic resin having a concave groove and a synthetic resin sheet laminated on the flat plate, a slit is provided in the flat plate made of foamed synthetic resin. The flat plate is substantially divided into blocks. Thereby, moderate flexibility is given to the panel, and deformation such as warpage generated in the panel can be easily returned to a flat plate shape.

  Patent Document 3 describes a method for producing a synthetic resin foam composite plate in which a welded wire mesh is embedded in a synthetic resin foam plate. First, a synthetic resin having foaming surplus capacity by foaming expandable particles is described. Mold the foam plate and remove it from the mold. Next, the welding wire mesh is inserted into the mold in a posture supported by a plurality of synthetic resin foam spacers. Then, the synthetic resin foam plate having the above-described foaming surplus capacity is inserted into the mold so that one surface is in contact with the weld metal mesh, and heated after clamping, so that the weld metal mesh is entirely within the synthetic resin foam plate. It is designed to be embedded in the unit.

JP 2005-8194 A JP 2002-371702 A JP-A-9-193272

  The composite panel described in Patent Document 2 was laminated on a flat plate made of foamed synthetic resin by forming a slit in the flat plate made of foamed synthetic resin and dividing the flat plate into substantially block shapes. The warp caused by the difference in heat shrinkage with the synthetic resin sheet can be easily restored. However, a special mold for making a slit in a flat plate made of foamed synthetic resin is required. Further, the flat plate made of foamed synthetic resin is substantially divided into blocks, and the composite panel does not have sufficient rigidity.

  The manufacturing method of the synthetic resin foam composite board described in patent document 3 makes it hard to generate | occur | produce a curvature at the time of cooling after a shaping | molding etc. by embedding and integrating a welding wire mesh in a synthetic resin foam board. However, it is necessary to perform heating and foaming with water vapor or the like in two steps, that is, a step of forming a synthetic resin foam plate having a foaming surplus capacity and a step of embedding and integrating a welded wire mesh therein, and a lot of time is required for production. It requires a lot of work.

  The present invention has been made in view of the circumstances as described above. One surface of the synthetic resin foam plate is a corrugated uneven surface, and the synthetic resin foam plate is different from the synthetic resin foam plate along the uneven surface. A synthetic resin foam molded product in which resin sheets formed of a resin material are integrally laminated, the synthetic resin foam molded product in which warpage or the like does not occur after molding, and the synthetic resin foam molded product It is an object of the present invention to provide a manufacturing method that can be manufactured by a simpler method.

The synthetic resin foam-molded article provided with the warp-preventing reinforcing member according to the present invention is different from the synthetic resin foam plate in such a manner that one surface of the synthetic resin foam plate is a corrugated uneven surface and is along the uneven surface. A resin sheet formed of a synthetic resin material is integrally laminated, and a long reinforcing member is embedded in the longitudinal direction of the synthetic resin foamed plate (Claim 1).
In this synthetic resin foam molded product, a long reinforcing member is embedded in the longitudinal direction, and the warp that tends to occur due to the difference in thermal expansion coefficient between the synthetic resin foam plate and the resin sheet is prevented from the long reinforcing member. It can suppress reliably by a member.

  The manufacturing method according to the present invention for manufacturing a synthetic resin foam-molded article provided with a reinforcing member for preventing warpage of the above form is provided on the uneven surface of the lower mold having an upper surface formed in a corrugated shape. A step of placing a pre-formed resin sheet along the surface, a step of setting a long reinforcing member above the resin sheet, and surrounding the lower mold and the long reinforcing member A step of setting a side frame mold and a top surface mold, a step of filling foamable particles in a cavity space surrounded by the lower mold, the side frame mold and the top surface mold, and performing in-mold foam molding, And a step of removing the lower mold, the side frame mold, and the top mold (claim 2).

  The method for producing a synthetic resin foam molded article according to the present invention uses a molding die that is substantially the same as a conventional mold for producing a synthetic resin foam molded article, and is disposed above a corrugated synthetic resin sheet placed on a lower mold. Only the process of setting a scale-shaped reinforcing member is newly added, and the other processes are the same as the conventional method for manufacturing a synthetic resin foam molded article, and the reinforcing member for preventing warpage is a simplified process. Can be produced.

  In the method for producing a synthetic resin foam molded article according to the present invention, the reinforcing member is provided with support bases at both ends, and at least one of the support bases is placed on the resin sheet. A step of setting a shaped reinforcing member above the resin sheet can be performed (Claim 3). In this method, the resin sheet is pressed by the load of the reinforcing member and the support base, and the resin sheet can be prevented from floating during heating and foaming, and the resin sheet is more closely attached to the synthetic resin foam board. Can do.

  In the method for producing a synthetic resin foam molded article according to the present invention, the support base may be installed on a lower mold (resin sheet), and then a long reinforcing member may be attached thereto. What integrated the scale-shaped reinforcement member may be needed, and you may make it install it on a lower mold | type (resin sheet | seat).

  In the method for producing a synthetic resin foam molded article according to the present invention, it is preferable that the support base is made of a synthetic resin material made of the same resin species as the expandable particles. In this aspect, at the time of heat-foaming molding, the support base is partly melted and integrated with the foamed resin constituting the synthetic resin foamed plate without the boundary portion. Thereby, it can be set as a substantially homogeneous synthetic resin foam molded article.

  In the method for producing a synthetic resin foam molded article according to the present invention, an arbitrary material can be used for the long reinforcing member provided that it has a required strength against bending and does not deteriorate due to heat during molding. However, a hollow metal tube or a square tube such as an aluminum tube, a SUS tube, or an iron tube is particularly preferable because it is lightweight, has good thermal conductivity, and has a stable strength. In addition, resins such as polycarbonate, acrylic and vinyl chloride, and materials such as wood can be used. Considering the filling property of the expandable particles into the cavity space, the circular tube shape is particularly preferable. Further, only one long reinforcing member may be embedded in the longitudinal direction of the synthetic resin foam molded article, and a plurality of long reinforcing members may be disposed when the width in the short direction is large.

  As the expandable particles used in the present invention, those used in the production of conventional synthetic resin foam molded products can be used as they are. The expandable particles are made by impregnating a synthetic resin with a physical foaming agent and are foamed by heating, and include pre-expanded particles. In the production method of the present invention, pre-foamed so-called pre-foamed particles are mainly used. Examples of the synthetic resin constituting the expandable particles include polystyrene, high impact polystyrene, styrene-ethylene copolymer, styrene-modified polyethylene resin, styrene-maleic anhydride copolymer, styrene-acrylonitrile copolymer, and the like. Polystyrene resins, polyethylene resins, polypropylene, polyolefin resins such as ethylene-vinyl acetate copolymer, and polyester resins such as polyethylene terephthalate.

  Examples of the physical blowing agent include aliphatic hydrocarbons such as propane, butane, pentane and hexane; aliphatic cyclized hydrogens such as cyclopentane and cyclobutane; trichlorofluoromethane, dichlorodifluoromethane, dichlorotetrafluoro And halogenated hydrocarbons such as methane, trichlorotrifluoroethane, methyl chloride, methylene chloride, and ethyl chloride. The foam molding conditions may be the same as the conventional one.

  According to the present invention, one surface of the synthetic resin foam plate is a corrugated uneven surface, and a resin sheet formed of a synthetic resin material different from the synthetic resin foam plate along the uneven surface is integrally laminated. It is possible to manufacture a synthetic resin foam-molded article having a formed shape, in which warpage or the like does not occur after molding, by a simpler method.

  DESCRIPTION OF EMBODIMENTS Hereinafter, a synthetic resin foam molded article provided with a warp preventing reinforcing member according to the present invention and a manufacturing method thereof will be described based on embodiments. In the following examples, the synthetic resin foam molded article according to the present invention is a synthetic resin foam molded article for supporting a substrate used for a glass substrate transport box or the like, but the present invention is not limited to this. . FIG. 1 is a perspective view showing an example of a synthetic resin foam molded article provided with a warp preventing reinforcing member of the present embodiment, and FIG. 2 is a cross-sectional view taken along the line aa of FIG.

  In this embodiment, the synthetic resin foam molded product A is formed in a concavo-convex shape on the surface of a rectangular polystyrene synthetic resin foamed plate 1 whose upper surface is a corrugated concavo-convex surface, for example, along the concavo-convex surface. A synthetic resin sheet 2 made of an ultrahigh molecular weight polyethylene film is integrally laminated.

  Inside the synthetic resin foam plate 1, a long aluminum tube 3 is embedded in the longitudinal direction as a reinforcing member. The aluminum tube 3 is a hollow circular tube having substantially the same length as the length of the synthetic resin foam plate 1 in the longitudinal direction, and does not protrude from the synthetic resin foam plate 1. Further, support bases 4A and 4B which will be described later are attached to both ends of the aluminum tube 3. The aluminum tube is light and has high strength and good thermal conductivity, and is suitable as a reinforcing member for a foamed resin molded product.

  Although not shown, the synthetic resin foam molded article A having such a configuration is disposed at the bottom and the lid of the glass substrate transport box having a shape as described in Patent Document 1, for example, and is formed in the groove on the uneven surface. It is used to support the glass substrate by inserting the end of the glass substrate or the like. As described above, the synthetic resin foam molded product A includes the long aluminum tube 3 as a reinforcing member in the synthetic resin foam plate 1, so that the shrinkage ratio between the synthetic resin foam plate 1 and the resin sheet 2 is as follows. Even if the synthetic resin foam molded product A is warped due to the difference, the aluminum tube 3 suppresses the warpage. In addition, the synthetic resin foam molded article A has a large rigidity against bending by the embedded aluminum tube 3, and is attached to the bottom and lid of the glass substrate transport box to stably support the glass substrate and the like, The function of reinforcing the bottom and lid of the glass substrate transport box can also be achieved.

  Next, a method for producing the synthetic resin foam molded article A provided with the above-described warp preventing reinforcing member will be described. FIG. 3 is a cross-sectional view of a mold for molding the synthetic resin foam molded product A. This mold may be the same as the conventional mold for molding the synthetic resin foam molded product, and the inner surface is the same. From the lower mold | type 10 currently formed in the waveform unevenness | corrugation, the side frame type | mold 20 attached on the lower mold | type 10 and forming the side periphery of a shaping | molding die, and the top | upper surface type | mold 30 attached on the side frame type | mold 20 Composed. The inner space formed by the three molds becomes a cavity space.

  Both sides of the lower mold 10 are formed in the flat portion 11, and holes 12 are formed in the flat portion 11. A plurality of protrusions 21 are formed at the lower end of the frame mold 20, and the side frame mold 20 is attached to the lower mold 10 without being displaced by inserting the protrusions 21 into the holes 12 of the lower mold 10. . The top surface mold 30 is formed with a plurality of slits 31 into which steam flows.

  At the time of foam molding, as shown in FIG. 4, the area of the lower mold 10 is the same as the area in the cavity space, and has an irregular shape that conforms to the irregularities formed on the surface of the lower mold 10. A resin sheet 2 made of a high molecular weight polyethylene film is previously formed by vacuum forming or the like. Further, as shown in FIG. 5, support bases 4 made of the same synthetic resin material as the synthetic resin foam plate 1 are attached to both ends of the hollow aluminum tube 3.

  The support base 4 has a width for stably supporting the aluminum tube 3, and a concave portion 4 a is formed in the upper surface of the center thereof. The aluminum tube 3 is sandwiched between the concave portions 4 a and attached to the aluminum tube 3. In the illustrated example, the heights of the both ends 10a and 10b in the cavity space of the lower mold 10 are different, and when the aluminum tube 3 is disposed in the cavity space, the aluminum tube 3 and the lower mold 10 Accordingly, the left and right support bases 4A and 4B have different heights so that they can take a parallel posture.

  FIG. 6 is a view for explaining a method of foam-molding the synthetic resin foam-molded product A using a mold. FIG. 6 (a) shows a state in which the top surface mold 30 is opened, and FIG. Indicates a state in which the top surface mold 30 is attached to the side frame mold 20.

  In a state where the top surface mold 30 of the molding die is opened, the pre-formed corrugated synthetic resin sheet 2 is set according to the corrugated uneven surface of the lower mold 10. Next, the aluminum tube 3 to which the support bases 4A and 4B are attached is placed in the longitudinal direction at the center in the width direction of the lower mold 10 with the support bases 4A and 4B placed on both ends of the corrugated synthetic resin sheet 2. set. Thereafter, the expandable particles 5 are filled into the side frame mold 20, and the top mold 30 is attached to the frame mold 20 to perform clamping. High temperature and high pressure steam is caused to flow into the mold from the slit 31 of the top surface mold 30 by, for example, carrying the clamped mold into the steam chamber. As a result, the expandable particles 5 are foamed and thermally fused to each other, and the synthetic resin foam molded product A is molded.

  In addition, in this example, since the support base 4 is comprised with the synthetic resin material which is the same resin kind as the expandable particle 5, the support base 4 is heat-seal | fused integrally with the expandable particle 5. FIG. In addition, since both ends of the resin sheet 2 are pressed by the support bases 4A and 4B, the end portions of the resin sheet 2 do not float during foam molding of the foamable particles.

  Finally, the top mold 30 and the frame mold 20 are removed from the mold, and the lower mold 10 is further removed, whereby the synthetic resin foam molded article A having the warp preventing reinforcing member according to the present invention is obtained.

The perspective view which shows an example of the synthetic resin foam molded product provided with the reinforcement member for curvature prevention by this invention. Sectional drawing by the bb line of FIG. Sectional drawing which shows an example of the shaping | molding die used for foam-molding the synthetic resin foam molded article provided with the reinforcement member for the curvature prevention by this invention. The perspective view of a resin sheet. The perspective view of the aluminum tube which attached the support stand. FIG. 6A is a view for explaining a method of foam-molding a synthetic resin foam-molded article provided with a warp-preventing reinforcing member according to the present invention. FIG. 6A shows a state in which the top mold is opened, and FIG. b) shows a state in which the top surface mold is attached to the side frame mold.

Explanation of symbols

A ... Synthetic resin foam molded article provided with a reinforcing member for preventing warping, 1 ... Synthetic resin foam plate, 2 ... Resin sheet, 3 ... Aluminum tube (reinforcing member), 4 ... Support base, 4a ... Recess, 5 ... Foam 10 ... Lower mold, 11 ... Flat part, 12 ... Hole, 20 ... Side frame, 21 ... Projection, 30 ... Top face, 31 ... Slit

Claims (5)

  One surface of the synthetic resin foam plate is a corrugated uneven surface, and a resin sheet formed of a synthetic resin material different from the synthetic resin foam plate is integrally laminated along the uneven surface, and the synthetic resin foam A synthetic resin foam molded article provided with a reinforcing member for preventing warping, characterized in that a long reinforcing member is embedded in the inside of the plate in the longitudinal direction. One surface of the synthetic resin foam is a corrugated uneven surface, and a resin sheet formed of a synthetic resin material different from the synthetic resin foam plate is laminated integrally along the uneven surface, and the synthetic resin foam In the interior of the plate is a method for producing a synthetic resin foam molded article provided with a reinforcing member for warpage prevention in which a long reinforcing member is embedded in the longitudinal direction,
Placing a pre-formed resin sheet on the concavo-convex surface of the lower mold, the upper surface of which is formed into wavy concavo-convex,
Setting a long reinforcing member above the resin sheet;
A step of setting the side frame mold and the top mold so as to surround the lower mold and the long reinforcing member;
Filling the foam space in a cavity space surrounded by the lower mold, the side frame mold and the top mold, and performing in-mold foam molding;
Removing the lower mold, the side frame mold and the top mold,
And a method for producing a synthetic resin foam-molded article provided with a reinforcing member for preventing warping.   The reinforcing member having a support at both ends is used, and the long reinforcing member is set above the resin sheet so that at least one of the support is on the resin sheet. The method for producing a synthetic resin foam-molded article provided with the reinforcing member for preventing warpage according to claim 2, wherein a process is performed.   The said support stand is comprised with the synthetic resin material which consists of the same resin seed | species as the said foamable particle, The synthetic resin foam molded article provided with the reinforcement member for curvature prevention of Claim 2 or 3 characterized by the above-mentioned. Production method.   The method for producing a synthetic resin foam-molded article provided with the reinforcing member for preventing warping according to any one of claims 2 to 4, wherein a metal hollow circular tube or square tube is used as the reinforcing member.

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