JP2010036512A - Apparatus and method of producing foamed resin molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an apparatus and method of producing a foamed resin molding in which a skin layer can be formed in a surface of a whole circumference of the foamed resin molding, and mechanical strength of the foamed resin molding can be enhanced. <P>SOLUTION: In the apparatus 1, a skin layer 61 is formed by filling up in a cavity 41 with a molten resin 60 using a first mold 2 provided with a cavity forming recessed part 21 and a second mold 3 provided with a cavity-forming projection part 31, and a foamed layer 62 is formed in an inner side to the skin layer 61 by moving the second mold 3. Between an inner surface 211 formed in a movable direction D parallel to the cavity-forming recessed part 21 and an outer surface 311 formed in the movable direction D parallel to the cavity forming projection part 31, a filling gap 42 for filling up with the molten resin 60 is formed by communicating with the cavity 41A. In the production equipment 1, the second mold 3 is moved in an isolating direction R to the first mold 2 after filling up in the cavity 41A and the filling gap 42 with the molten resin 60. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an apparatus and a method for producing a resin foam molded body by performing so-called core back molding.

  Conventionally, a resin foam molded article having a predetermined expansion ratio can be formed by filling a cavity formed between a fixed mold and a movable mold with a molten resin and retracting the movable mold with respect to the fixed mold. Has been done. For example, in the method for producing a thermoplastic resin foam molded article disclosed in Patent Document 1, a step of injecting an inert gas in advance into a mold having a movable core whose cavity volume is variable, and a molten resin kneaded with a chemical foaming agent Injecting the supercritical fluid into the mold and filling the molten resin into the mold, and retreating the movable core in the direction of increasing the cavity volume when the molten resin is filled in the mold. Foam molded body is molded. Thereby, it is excellent in the surface external appearance quality of a molded object, and a highly uniform foaming cell diameter can be obtained stably.

JP 2007-15231 A

  However, in Patent Document 1, when the molten resin is filled in the cavity, the movable core is retracted in the direction in which the cavity increases. Thereby, it is difficult to form an unfoamed skin layer in which the molten resin is semi-cured on the entire surface of the thermoplastic resin foam molding to be molded, particularly on the side surface in the direction perpendicular to the movable direction of the movable core. Therefore, it is not sufficient for improving the mechanical strength (rigidity) of the thermoplastic resin foam molded article to be molded.

  The present invention has been made in view of such conventional problems, and can form a skin layer on the entire surface of the resin foam molded article, thereby improving the mechanical strength of the resin foam molded article. .

The first invention comprises a first mold part and a second mold part movable relative to the first mold part, and is formed between the second mold part and the first mold part. The cavity is filled with a molten resin obtained by kneading a chemical foaming agent with a thermoplastic resin, and the first mold part and the second mold part are relatively moved in the separation direction in which the volume of the cavity is increased. In an apparatus for producing a resin foam molded body,
The second mold part is provided with a cavity forming convex part arranged in a cavity forming concave part provided in the first mold part,
Between the inner surface formed in parallel to the movable direction of the first mold portion and the second mold portion in the cavity forming concave portion and the outer surface formed in parallel to the movable direction in the cavity forming convex portion. A filling gap for filling the molten resin is formed in communication with the cavity;
The molten resin is filled in the cavity and filled in the filling gap, and then the first mold part and the second mold part are relatively movable in the separation direction. It exists in the manufacturing apparatus of a resin foaming molding (Claim 1).

  The apparatus for producing a resin foam molded article of the present invention is capable of forming a skin layer obtained by curing a molten resin to be filled with almost no foam on the entire surface of the resin foam molded article. Specifically, in the present invention, a filling gap communicating with the cavity is formed between the first mold part and the second mold part, and the skin layer is also formed by the molten resin filled in the filling gap. Can be formed.

In the production apparatus of the present invention, when molding the resin foam molded article, the molten resin is filled into the cavity and filled in the filling gap. At this time, the temperature of the molten resin that is in contact with the bottom surface and the inner surface of the cavity forming concave portion in the first mold portion and the tip surface and the outer surface of the cavity forming convex portion in the second mold portion is normally adjusted to 30 to 100 ° C. Since it is in contact with the molds (the first mold part and the second mold part), the curing starts before the molten resin inside the cavity (inner part). The molten resin is semi-cured to form an unfoamed skin layer not only on the contact surface in the cavity but also on the contact surface in the filling gap.
Here, semi-curing means that the molten resin can no longer form a foam layer, but has cured to such an extent that it can flow as the second mold part moves relative to the first mold part. It means being.

Next, after the skin layer is formed in the cavity and the filling gap, the first mold part and the second mold part are relatively moved in the separation direction. At this time, the outer surface of the cavity forming convex portion slides with respect to the skin layer formed in the filling gap, and the molten resin flows into the inner portion of the skin layer formed in the filling gap.
Then, when the first mold part and the second mold part are relatively moved to a predetermined position and the resin foam molded body is molded, a foamed layer in which the molten resin is foamed is formed inside the resin foam molded body. At the same time, a skin layer in which the molten resin is almost unfoamed and hardened can be formed on the entire surface of the resin foam molded body.

  Therefore, according to the apparatus for producing a resin foam molded article of the present invention, a skin layer can be formed on the entire surface of the resin foam molded article, and the mechanical strength of the resin foam molded article can be improved. .

The second invention uses a first mold part and a second mold part movable relative to the first mold part, and is formed between the second mold part and the first mold part. The cavity is filled with a molten resin obtained by kneading a chemical foaming agent with a thermoplastic resin, and the first mold part and the second mold part are relatively moved in the separation direction in which the volume of the cavity is increased. In the method for producing a resin foam molded article,
The second mold part is provided with a cavity forming convex part disposed in a cavity forming concave part provided in the first mold part,
Between the inner surface formed in parallel to the movable direction of the first mold portion and the second mold portion in the cavity forming concave portion and the outer surface formed in parallel to the movable direction in the cavity forming convex portion. A filling gap for filling the molten resin is formed in communication with the cavity;
Semi-curing the molten resin filled in the cavity and the filling gap to form an unfoamed skin layer,
Next, the first mold part and the second mold part are moved relative to each other in the separation direction to form a foamed layer in which the molten resin is foamed on the inner part with respect to the skin layer, and the resin foam The present invention resides in a method for producing a resin foam molded article, wherein the molded article is produced.

  Also in the present invention, in the same manner as in the first invention, a foamed layer in which the molten resin is foamed is formed inside the resin foam molded body, and the molten resin is formed on the entire surface of the resin foam molded body. Can form a substantially unfoamed and cured skin layer.

  Therefore, according to the method for producing a resin foam molded article of the present invention, a skin layer can be formed on the entire surface of the resin foam molded article, and a resin foam molded article having excellent mechanical strength is produced. Can do.

A preferred embodiment in the first and second inventions described above will be described.
In the first and second inventions, the enlargement ratio of the volume of the cavity by the relative movement of the first mold part and the second mold part can be 1.1 to 2.0 times. This enlargement ratio is the expansion ratio of the resin foam molding.

In the first aspect of the present invention, the apparatus for manufacturing a resin foam molded body performs filling of the molten resin into the entire cavity and the filling gap, and semi-curing the molten resin to form an unfoamed skin layer. After forming, the first mold part and the second mold part are relatively moved in the separation direction, and a foamed layer in which the molten resin is foamed is formed on the inner part with respect to the skin layer. It is preferable that the foam molded body be manufactured.
In this case, after filling the entire cavity and the filling gap with the molten resin, the first mold part and the second mold part are relatively moved in the separation direction, so that the entire circumference of the resin foam molded body is increased. A skin layer can be more stably formed on the surface.

In addition, the entire periphery of the opening tip portion of the mold wall that forms the cavity forming recess in the first mold portion is a closed mold that closes the space between the opening tip portion and the outer peripheral surface of the second mold portion. When the first mold part and the second mold part are relatively movable in the separation direction, the outer peripheral surface of the second mold part is slid with the inner peripheral surface of the closed mold part. It is preferable that the volume of the cavity be increased by maintaining the state where the gap for filling is formed by moving.
In this case, when the second mold part is moved relative to the first mold part by using the closed mold part, the inner peripheral surface of the cavity forming recess in the first mold part and the second mold It is possible to stably maintain the state in which the filling gap is formed between the outer peripheral surface of the cavity forming convex portion in the portion.

Further, when the first mold part and the second mold part are relatively moved in the separation direction, the front end surface of the second mold part and the inner end surface of the closing mold part are matched, It is preferable that the skin layer is formed on the entire surface of the resin foam molded body, and the foam layer is formed on an inner portion of the skin layer.
In this case, the skin layer can be stably formed on the entire surface of the resin foam molded article.

The first mold part is a fixed mold part provided with a resin injection port for filling the molten resin into the cavity, and the second mold part is separated from the first mold part by the distance from the first mold part. Preferably, the movable part is movable in the direction.
In this case, the configuration of the apparatus for manufacturing the resin foam molded body can be further simplified.

  In the first and second aspects of the invention, the cavity has a shape for molding a resin foam molded body having a plate shape that is long in one direction, and the thickness direction of the plate shape is the same as that of the first mold portion and the first shape. Formed in a movable direction with respect to the second mold part, and at least one of the bottom surface of the cavity forming concave part of the first mold part and the tip surface of the cavity forming convex part of the second mold part has the above-mentioned When a long projection is formed along the one direction at the center of the cross section orthogonal to one direction, and the first mold part and the second mold part are relatively movable in the separation direction. A high foam layer in which the molten resin is foamed in an inner portion of the skin layer in the cavity, and a foam ratio lower than that of the high foam layer, and the high foam layer in a portion corresponding to the elongated protrusion. Part of the above skin layer to divide into two Is preferably configured to form a low-foam layer connecting Judges (claims 6, 9).

  In this case, when the second mold part is moved relative to the first mold part, the inner part of the skin layer formed in contact with the surface of the cavity forming concave part and the cavity forming convex part is chemically The molten resin is foamed by utilizing the foaming effect of the foaming agent. At this time, in the foam layer formed in the inner portion of the skin layer, a high foam layer obtained by foaming the molten resin and a low foam layer having a foam rate lower than that of the high foam layer are formed. And a low foaming layer is formed in the state which connects the parts of a skin layer so that a high foaming layer may be divided into two in the part corresponding to an elongate processus | protrusion.

In the molded resin foam molded article, the low foam layer can support the skin layer portions, and the mechanical strength of the resin foam molded article can be improved by forming the low foam layer.
The reason why the low foam layer is formed is that at least one of the bottom surface of the cavity forming concave portion and the tip end surface of the cavity forming convex portion is such that the molten resin is rapidly cooled at the portion where the elongated protrusion is formed. This is considered to be due to the fact that the viscosity of the resin is increased and the molten resin is difficult to foam.

  The cavity has a shape for molding a resin foam molding having a plate shape that is long in one direction, and the thickness direction of the plate shape is directed to the movable direction of the first mold portion and the second mold portion. A plurality of the resin injection ports are formed side by side in the one direction on the bottom surface of the cavity forming recess of the first mold part, and the first mold part and the second mold are formed. When the portion is relatively movable in the separation direction, the inner part of the skin layer in the cavity has a high foam layer in which the molten resin is foamed, a foaming rate lower than the high foam layer, It can also comprise so that the low foam layer which connects the parts of the said skin layer may be formed in the part corresponding to each resin injection port (Claims 7 and 10).

  In this case, when the second mold part is moved relative to the first mold part, the inner part of the skin layer formed in contact with the surface of the cavity forming concave part and the cavity forming convex part is chemically The molten resin is foamed by utilizing the foaming effect of the foaming agent. At this time, in the foam layer formed in the inner portion of the skin layer, a high foam layer obtained by foaming the molten resin and a low foam layer having a foam rate lower than that of the high foam layer are formed. And a low foaming layer is formed in the state which connects the parts of a skin layer in the part corresponding to a some resin injection port.

In the molded resin foam molded article, the low foam layer can support the skin layer portions, and the mechanical strength of the resin foam molded article can be improved by forming the low foam layer.
The reason why the low foam layer is formed is that the periphery of the portion where the plurality of resin injection ports are formed in at least one of the bottom surface of the cavity forming concave portion and the tip end surface of the cavity forming convex portion is compared with other portions. This is because the pressure is high and foaming is difficult.

In the first and second inventions, a plurality of the resin injection ports can be formed along the direction in which the long protrusions are formed at the position where the long protrusions are formed.
In this case, it is possible to make it difficult for the molten resin around the site where the long protrusions are formed to foam, and it is possible to more easily form the low foam layer corresponding to the long protrusions.

Further, when the second mold part is moved relative to the first mold part in the separation direction, the part corresponding to the whole cavity for foam molding the resin foam molded article is moved to move the entire cavity. The volume of can be increased.
In addition to this, the second mold part moves only a part corresponding to a part of the cavity relative to the first mold part, and includes a part including the skin layer and the foam layer, and a skin layer (not yet formed). It is also possible to mold a resin foam molded body in which a portion consisting only of (foamed layer) is bonded.

The content of the chemical foaming agent is appropriately selected according to the type of the chemical foaming agent and the resin used so that a desired foaming ratio can be obtained, but the chemical foaming agent is used with respect to 100 parts by mass of the thermoplastic resin. It is 0.05-5 mass parts, Preferably it is 0.1-4 mass parts, More preferably, it is 0.3-3 mass parts. When the content of the chemical foaming agent is less than 0.05 parts by mass, the content of the chemical foaming agent is small and it is difficult to make the cell diameters of foaming uniform. On the other hand, when the content of the chemical foaming agent exceeds 5 parts by mass, the content of the chemical foaming agent is large, mold contamination due to the residue of the chemical foaming agent occurs, and a foam molded article having an excellent appearance is obtained. Becomes difficult.
As a method of compounding the chemical foaming agent into the molten state plastic resin, the pellets of the thermoplastic resin composition and the foaming agent master batch pellet are dry blended, and then supplied to the molding machine to plasticize the resin in the molding machine. A method of foaming in a mold is preferably used. Moreover, you may use a physical foaming agent together. Specific examples of the physical foaming agent include propane, butane, water, carbon dioxide gas, and the like.

  The thermoplastic resin is not particularly limited, but rubber-reinforced vinyl resins such as ABS resin, AES resin and ASA resin, styrene resins such as AS resin and MAS resin, polycarbonate resin, acrylic resin and vinyl chloride resin. , Polyamide resin (PA), polyester resin, olefin resin, ethylene copolymer and the like. These can be used individually by 1 type and can also be used in combination of 2 or more type. Among these, it is preferable to use a mixture of a polycarbonate resin and a rubber-reinforced vinyl resin.

The molding temperature of the resin foam molding is appropriately selected depending on the blending of the thermoplastic resin and the like, but is usually 220 to 260 ° C. in the present invention. The shape of the resin foam molding is selected according to the purpose, application, etc., and can be plate-shaped (sheet-shaped), cylindrical, semi-cylindrical, rod-shaped, linear, massive, or the like.
The resin foam molded article of the present invention includes civil engineering / architecture related materials such as display boards, interior / exterior materials for vehicles, daily miscellaneous goods such as containers and trays, electrical / electronic parts, sports equipment, walls, floors, machine frames. , Furniture, decorative sheets, partitions, lattices, fences, gutters, sizing boards, interior / exterior materials for homes and offices such as carports, toys, cushioning materials for game machines, reinforcement materials, heat insulating materials, core materials, alternatives It can be used as a plywood or the like.
Furthermore, the resin foam molded article of the present invention can be used as an article that is integrated with another molded product, member, etc. depending on the application, and is applicable to the above application.

Hereinafter, embodiments of the apparatus and method for producing a resin foam molded article of the present invention will be described with reference to the drawings.
Example 1
As shown in FIGS. 1 to 4, the manufacturing apparatus 1 for the resin foam molded body 6 of this example includes a first mold part 2 and a second mold part 3 that is movable relative to the first mold part 2. I have. Then, the manufacturing apparatus 1 fills a cavity 41A formed between the second mold part 3 and the first mold part 2 with a molten resin 60 obtained by kneading a chemical foaming agent with a thermoplastic resin, The mold part 2 and the second mold part 3 are configured to be relatively movable in the separation direction R in which the volume of the cavity 41A is increased.

As shown in FIG. 1, the second mold part 3 is provided with a cavity forming convex part 31 arranged in a cavity forming concave part 21 provided in the first mold part 2. In the first mold part 2 and the second mold part 3, an inner surface 211 formed in the cavity forming recess 21 in parallel with the movable direction D between the first mold part 2 and the second mold part 3, and the cavity forming convex part 31. Between the outer surface 311 formed parallel to the movable direction D, a filling gap 42 for filling the molten resin 60 is formed in communication with the cavity 41A.
The manufacturing apparatus 1 of this example moves the first mold part 2 and the second mold part 3 relatively in the separation direction R after filling the molten resin 60 into the cavity 41A and filling the filling gap 42. It is configured as follows.

Below, it demonstrates in detail with reference to FIGS. 1-4 about the manufacturing apparatus 1 and the manufacturing method of the resin foam molding 6 of this example.
In the manufacturing method of this example, as shown in FIGS. 2 and 3, as a filling process, a molten resin 60 is filled into a cavity 41 </ b> A formed between the second mold part 3 and the first mold part 2. The skin layer 61 is formed on the part of the molten resin 60 that contacts the surface of the cavity 41A, and the volume of the cavity 41A is expanded as shown in FIG. 4 as a movable process in the first mold part 2 and the second mold part 3. A foam layer 62 in which the molten resin 60 is foamed is formed on the inner side of the skin layer 61 by being moved relatively in the separation direction R.

The manufacturing apparatus 1 and the manufacturing method of the resin foam molded body 6 of this example are a method of expanding the volume of the cavity 41A filled with the molten resin 60 while using a chemical foaming agent, and foaming the molten resin 60. The skin layer 61 in which the molten resin 60 is hardened almost without foaming can be effectively formed on the entire surface of the resin foam molded body 6.
In this example, as shown in FIGS. 1 and 4, the resin foam molded body 6 is molded using the manufacturing apparatus 1 including the first mold part 2 and the second mold part 3. The first mold part 2 of this example is a fixed mold part provided with a resin injection port 22 for filling the molten resin 60 in the cavity 41. The second mold part 3 of this example is a movable mold part that is movable in the separation direction R with respect to the first mold part 2.

In addition, the second mold part 3 of this example is larger than the first mold part 2 so that the volume of the cavity 41 formed between the first mold part 2 and the first mold part 2 is enlarged by 1.1 to 1.6 times. It is configured to retreat in the separation direction R. And the expansion ratio of the resin foam molded body 6 to be foam-molded in this example is 1.1 to 2.0 times.
As shown in FIGS. 2 and 3, the manufacturing apparatus 1 of the present example is connected to a resin injection port 22 provided in the first mold part 2, and an injection nozzle 25 for injecting a molten resin 60 into the cavity 41 </ b> A. have. The second mold part 3 of this example is configured to move forward and backward (move in the movable direction D) with respect to the first mold part 2 by a drive source that operates by hydraulic pressure, air pressure, electric power, and the like.

In this example, the first mold part 2 and the second mold part 3 are used to foam a resin foam molded body 6 having a substantially rectangular parallelepiped shape, a rectangular cross section, and a long plate shape in one direction L. To do.
As shown in FIG. 4, the second mold part 3 of this example is separated from the first mold part 2 until the distal end surface 312 of the cavity forming convex part 31 moves to the end part in the movable direction D of the filling gap 42. It is configured to move in the direction R.
When the second mold part 3 is in the original position 301 with respect to the first mold part 2, a filling gap 42 for filling the molten resin 60 is formed in communication with the cavity 41. As shown in FIGS. 1 and 2, when the second mold part 3 is in the original position 301 before moving in the separation direction R, there is a volume between the second mold part 3 and the first mold part 2. As shown in FIG. 4, when the second mold part 3 is in the movable position 302 that is movable in the separation direction R, the second mold part 3 and the first mold are formed. A cavity 41 </ b> B having an enlarged volume is formed between the portion 2.

As shown in FIG. 1, the first mold portion 2 of this example includes a resin injection side surface 212 (a bottom surface of a cavity forming recess for molding the fixed side surface of the resin foam molded body 6) in the cavity 41, and a resin injection side surface. It has a cavity forming recess 21 for forming a side surface 211 (an inner surface 211, a surface on which all the side surfaces of the resin foam molded body 6 are molded) perpendicular to the surface. The second mold part 3 of the present example is orthogonal to the resin receiving side surface 312 of the cavity 41 (the front end surface of the cavity forming convex part that molds the movable side surface of the resin foam molded body 6), and the resin injection side surface. It has a cavity forming convex part 31 for forming a side surface 311 (outer side surface 311) of the entire circumference.
The inner side surface 211 of the cavity forming concave portion 21 of the first mold part 2 and the outer side surface 311 of the cavity forming convex part 31 of the second mold part 3 are formed in parallel to the movable direction D.

Further, as shown in the figure, in the first mold part 2 of the present example, there is an outer periphery of the opening tip part 23 and the second mold part 3 around the entire circumference of the opening tip part 23 of the mold wall part that forms the cavity forming recess 21. The closing type part 5 which closes | closes between the side surfaces 311 is provided.
When the manufacturing apparatus 1 moves the second mold part 3 in the separation direction R with respect to the first mold part 2, the outer surface 311 of the second mold part 3 slides on the inner peripheral surface 51 of the closed mold part 5. By moving, the state where the filling gap 42 is formed is maintained, and the volume of the cavity 41A is increased.

  As shown in FIG. 4, when the manufacturing apparatus 1 moves the second mold part 3 relative to the first mold part 2 in the separation direction R, the manufacturing apparatus 1 closes the distal end surface 312 of the second mold part 3. The inner end face 52 of the mold part 5 is configured to coincide. In the movable step, when the second mold part 3 is moved in the separation direction R with respect to the first mold part 2, the skin layer 61 is formed on the entire surface of the resin foam molded body 6, and the skin A foam layer 62 can be formed on the inner portion of the layer 61.

Depending on the shape of the resin foam molded body 6 to be molded, the second mold part 3 can be moved in the separation direction R until the front end face 312 of the second mold part 3 and the inner end face 52 of the closing mold part 5 coincide. Alternatively, a shape in which the protruding portion of the skin layer 61 protrudes from the resin foam molded body 6 can be formed.
Further, the width of the filling gap 42 in this example can be changed as appropriate, and the thickness of the skin layer 61 formed in the filling gap 42 can be changed as appropriate.

Next, a method for manufacturing the resin foam molded body 6 using the manufacturing apparatus 1 will be described in detail.
In this example, first, as shown in FIGS. 2 and 3, as shown in FIG. 2 and FIG. inject. At this time, the molten resin 60 flows from the cavity 41 </ b> A into the filling gap 42, and the molten resin 60 is filled into the entire cavity 41 and the filling gap 42 in a reduced state. And the part of the molten resin 60 which contacts the bottom surface 212 and the inner side surface 211 of the cavity forming recess 21 of the first mold part 2 and the tip surface 312 and the outer surface 311 of the cavity forming convex part 31 of the second mold part 3 are: The semi-cured skin layer 61 is formed by cooling and hardening earlier than the other molten resin 60 portions (the portions of the molten resin 60 in the cavity 41 (inner portion)). Therefore, the molten resin 60 is semi-cured to form an unfoamed skin layer 61 not only on the contact surface in the cavity 41 but also on the contact surface in the filling gap 42.

Next, as a moving process, as shown in FIG. 4, the second mold part 3 is moved in the separation direction R with respect to the first mold part 2. At this time, the outer surface 311 of the cavity forming convex part 31 of the second mold part 3 slides against the skin layer 61 of the molten resin 60 filled and cured in the filling gap 42, and the skin layer 61 The molten resin 60 flows into the inner portion and foams. Further, on the inner side portion of the skin layer 61 formed on the resin injection side surface 212 of the cavity forming concave portion 21 of the first mold part 2 and the resin receiving side surface 312 of the cavity forming convex part 31 of the second mold part 3. Also, the molten resin 60 flows in and foams.
Thus, the foamed layer 62 in which the molten resin 60 is foamed can be formed inside the resin foam molded body 6, and the skin layer 61 can be formed on the entire surface of the resin foam molded body 6. Therefore, the skin layer 61 can be stably formed on the surface of the entire circumference, and the mechanical strength of the foamed resin foam molded body 6 can be effectively improved.

  Therefore, according to the manufacturing apparatus 1 and the manufacturing method of the resin foam molded body 6 of the present example, the skin layer 61 can be formed on the entire surface of the resin foam molded body 6. Strength can be improved.

As the thermoplastic resin composition of this example, a mixture of an aromatic polycarbonate resin and a rubber-reinforced styrene resin was used.
And in this example, the cell diameter by foaming can be made as uniform as possible by the presence of the aromatic polycarbonate resin having a high viscosity at a predetermined temperature at which resin molding is performed, and the appearance of the resin foam molded body 6 is improved. be able to. Further, the skin layer 61 can be stably formed on the surface of the resin foam molded body 6 due to the presence of the rubber-reinforced styrene resin having a lower viscosity than the aromatic polycarbonate resin at a predetermined temperature at which the resin molding is performed.

(Example 2)
As shown in FIGS. 5 to 7, the manufacturing apparatus 1 and the manufacturing method of the present example provide a low foaming layer 622 having a low foaming rate in the portion of the high foaming layer 621 in the foaming layer 62. It is an example which manufactures the resin foaming molding 6 which improved mechanical strength.
Specifically, the cavity 41 of this example is a shape for molding the resin foam molded body 6 having a plate shape that is long in one direction L, and the thickness direction of the plate shape is the first mold part 2 and the second mold part. 3 toward the movable direction D. The bottom surface 212 of the cavity forming concave portion 21 of the first mold part 2 and the tip surface 312 of the cavity forming convex part 31 of the second mold part 3 of this example are arranged in one direction at the central portion of the cross section orthogonal to the one direction L. A long protrusion 24 is formed along L.

  As shown in FIG. 7, in the manufacturing apparatus 1 of this example, when the second mold part 3 is moved in the separation direction R with respect to the first mold part 2, 41, the low foam layer 622 is formed in a portion corresponding to the elongated protrusion 24, and the high foam layer 621 having a higher foam rate than the low foam layer 622 is formed in the other portion.

  In the manufacturing method of this example, when the second mold part 3 is moved in the separation direction R with respect to the first mold part 2, the skin layer formed in contact with the surfaces of the cavity forming concave part 21 and the cavity forming convex part 31 In the inner portion of 61, the molten resin 60 is foamed by utilizing the foaming effect of the chemical foaming agent. At this time, in the foam layer 62 formed in the inner portion of the skin layer 61, a high foam layer 621 obtained by foaming the molten resin 60 and a low foam layer 622 having a foam rate lower than that of the high foam layer 621 are formed. The And the low foaming layer 622 is formed in the state which connects the parts of the skin layer 61 so that the high foaming layer 621 may be divided into two in the part corresponding to the elongate protrusion 24. FIG.

In the molded resin foam molded body 6, the low foam layer 622 can support the portions of the skin layer 61, and the formation of the low foam layer 622 can improve the mechanical strength of the resin foam molded body 6. .
The reason why the low foam layer 622 is formed is that the cavity 41 in the movable direction D of the portion where the long protrusions 24 are formed on the bottom surface 212 of the cavity forming concave portion 21 and the tip surface 312 of the cavity forming convex portion 31. It is considered that the width (width in the thickness direction) is narrow, the cooling of the molten resin 60 proceeds quickly, and the viscosity of the molten resin 60 increases, so that the molten resin 60 is difficult to foam.

  Further, instead of providing the elongated protrusion 24, a plurality of resin injection ports 22 can be formed on the tip surface 312 of the cavity forming convex portion 31 in the first mold portion 2, as shown in FIG. Thereby, the low foaming layer 622 can also be formed in the state which connects the parts of the skin layer 61 in the part corresponding to the some resin injection port 22. FIG. In this case, the reason why the low foam layer 622 is formed is that the periphery of the portion where the plurality of resin injection ports 22 are formed on the bottom surface 212 of the cavity forming recess 21 and the tip surface 312 of the cavity forming protrusion 31. It is considered that this is because the pressure is higher than other parts and the molten resin 60 is difficult to foam.

Sectional explanatory drawing which shows the manufacturing apparatus which has a 1st type | mold part and a 2nd type | mold part in Example 1. FIG. Sectional explanatory drawing which shows the state which filled the cavity and the clearance gap for filling with the molten resin in the filling process in Example 1. FIG. Cross-sectional explanatory drawing which shows the state which filled the cavity and the clearance gap for filling with molten resin in the filling process in Example 1 from the direction orthogonal to FIG. Sectional explanatory drawing which shows the state which moved the 2nd type | mold part with respect to the 1st type | mold part in the movement process in Example 1, and shape | molded the resin foam molded object in the cavity. Sectional explanatory drawing which shows the state which filled the cavity and the clearance gap for filling in the filling process in Example 2. FIG. Cross-sectional explanatory drawing which shows the state which filled the molten resin in the cavity and the clearance gap for filling in Example 2 in the state seen from the direction orthogonal to FIG. Sectional explanatory drawing which shows the state which moved the 2nd type | mold part with respect to the 1st type | mold part in the movement process in Example 2, and shape | molded the resin foam molded object in the cavity. Sectional explanatory drawing which shows the state which shape | molded the resin foam molding in the cavity in the other manufacturing apparatus in Example 2. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Manufacturing apparatus 2 1st type | mold part 21 Cavity formation recessed part 211 Inner side surface 22 Resin injection port 24 Elongate protrusion 3 2nd type | mold part 31 Cavity formation convex part 311 Outer side surface 41A, B Cavity 42 Filling gap 6 Resin foam molding 60 Molten resin 61 Skin layer 62 Foamed layer D Movable direction R Separation direction

Claims (10)

A first mold part and a second mold part movable relative to the first mold part are provided, and chemical foaming is formed in a cavity formed between the second mold part and the first mold part. Filled with a molten resin obtained by kneading an agent into a thermoplastic resin, the first mold part and the second mold part are relatively moved in the separation direction in which the volume of the cavity is enlarged, In an apparatus for manufacturing
The second mold part is provided with a cavity forming convex part arranged in a cavity forming concave part provided in the first mold part,
Between the inner surface formed in parallel to the movable direction of the first mold portion and the second mold portion in the cavity forming concave portion and the outer surface formed in parallel to the movable direction in the cavity forming convex portion. A filling gap for filling the molten resin is formed in communication with the cavity;
The molten resin is filled in the cavity and filled in the filling gap, and then the first mold part and the second mold part are relatively movable in the separation direction. Production equipment for resin foam moldings.   In Claim 1, after filling the said cavity and the said clearance gap with the said molten resin, semi-hardening this molten resin and forming an unfoamed skin layer, the said 1st type | mold part and the said The second mold part is moved relative to the separation direction, and a foamed layer obtained by foaming the molten resin is formed on the inner part with respect to the skin layer to produce the resin foam molded article. An apparatus for producing a resin foam molded article. 3. The entire periphery of the opening tip of the mold wall that forms the cavity forming recess in the first mold part is closed between the opening tip and the outer surface of the second mold part. An obstructing part is provided,
When the first mold part and the second mold part are relatively movable in the separation direction, the outer peripheral surface of the second mold part slides with the inner peripheral surface of the closed mold part, thereby An apparatus for producing a resin foam molded article, characterized in that a state in which a gap for filling is formed is maintained and the volume of the cavity is increased. In Claim 3, when the said 1st type | mold part and the said 2nd type | mold part are moved relatively in the said separation direction, the front end surface in the said 2nd type | mold part and the inner side end surface in the said closure type | mold part are made to correspond. By
An apparatus for producing a resin foam molded article, wherein the skin layer is formed on the entire surface of the resin foam molded article, and the foam layer is formed on an inner portion of the skin layer. The first mold part according to any one of claims 1 to 4, wherein the first mold part is a fixed mold part provided with a resin inlet for filling the molten resin into the cavity.
The apparatus for producing a resin foam molded article, wherein the second mold part is a movable mold part movable in the separation direction with respect to the first mold part. In any 1 paragraph of Claims 1-5, the above-mentioned cavity is the shape which shape | molds the resin foam molding which has a plate shape long in one direction, Comprising: The said plate-shaped thickness direction is a said 1st type | mold part and the above-mentioned. It is formed toward the movable direction with the second mold part,
At least one of the bottom surface of the cavity forming concave portion of the first mold portion and the front end surface of the cavity forming convex portion of the second mold portion is arranged in the central direction of the cross section orthogonal to the one direction in the one direction. A long protrusion is formed along the
When the first mold part and the second mold part are moved relative to each other in the separation direction, a high foam layer in which the molten resin is foamed in the inner part of the skin layer in the cavity, and the high foam The foaming rate is lower than that of the layer, and the low foaming layer connecting the parts of the skin layer is formed so as to partition the high foaming layer into two at the part corresponding to the long projections, Manufacturing equipment for resin foam moldings. In Claim 5, The said cavity is a shape which shape | molds the resin foam molded object which has a plate shape long in one direction, Comprising: The thickness direction of the said plate shape is movable with the said 1st type | mold part and the said 2nd type | mold part. Is formed in the direction,
A plurality of the resin injection ports are formed side by side in the one direction on the bottom surface of the cavity forming recess of the first mold part,
When the first mold part and the second mold part are moved relative to each other in the separation direction, a high foam layer in which the molten resin is foamed in the inner part of the skin layer in the cavity, and the high foam An apparatus for producing a resin foam molded article, wherein the foaming rate is lower than that of the layer, and the low foam layer connecting the skin layer portions is formed at portions corresponding to the plurality of resin injection ports. . Using a first mold part and a second mold part movable relative to the first mold part, a chemical foam is formed in a cavity formed between the second mold part and the first mold part. Filled with a molten resin obtained by kneading an agent into a thermoplastic resin, the first mold part and the second mold part are relatively moved in the separation direction in which the volume of the cavity is enlarged, In the method of manufacturing
The second mold part is provided with a cavity forming convex part disposed in a cavity forming concave part provided in the first mold part,
Between the inner surface formed in parallel to the movable direction of the first mold portion and the second mold portion in the cavity forming concave portion and the outer surface formed in parallel to the movable direction in the cavity forming convex portion. A filling gap for filling the molten resin is formed in communication with the cavity;
Semi-curing the molten resin filled in the cavity and the filling gap to form an unfoamed skin layer,
Next, the first mold part and the second mold part are moved relative to each other in the separation direction to form a foamed layer in which the molten resin is foamed on the inner part with respect to the skin layer, and the resin foam A method for producing a resin foam molded article, comprising producing a molded article. In Claim 8, The said cavity is a shape which shape | molds the resin foam molded object which has a plate shape long in one direction, Comprising: The thickness direction of the said plate shape is movable with the said 1st type | mold part and the said 2nd type | mold part. Forming towards the direction,
At least one of the bottom surface of the cavity forming concave portion of the first mold portion and the front end surface of the cavity forming convex portion of the second mold portion is arranged in the central direction of the cross section orthogonal to the one direction in the one direction. Along the long projections,
When the first mold part and the second mold part are moved relative to each other in the separation direction, a high foam layer in which the molten resin is foamed in the inner part of the skin layer in the cavity, and the high foam A foamed resin having a lower foaming rate than the layer and forming a low foaming layer connecting the skin layer parts so as to divide the high foaming layer into two parts at the part corresponding to the elongated protrusions Manufacturing method of a molded object. In Claim 8, The said cavity is a shape which shape | molds the resin foam molded object which has a plate shape long in one direction, Comprising: The thickness direction of the said plate shape is movable with the said 1st type | mold part and the said 2nd type | mold part. Forming towards the direction,
On the bottom surface of the cavity forming recess of the first mold part, a plurality of resin injection ports for filling the molten resin into the cavity are formed side by side in the one direction,
When the first mold part and the second mold part are moved relative to each other in the separation direction, a high foam layer in which the molten resin is foamed in the inner part of the skin layer in the cavity, and the high foam A method for producing a resin foam molded article, comprising: forming a low foam layer having a lower foaming rate than a layer and connecting the skin layer portions at portions corresponding to the plurality of resin injection ports.

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