JP2010221535A - Foam molding machine and method for manufacturing mold for foam molding mounted thereon - Google Patents

Foam molding machine and method for manufacturing mold for foam molding mounted thereon Download PDF

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JP2010221535A
JP2010221535A JP2009071568A JP2009071568A JP2010221535A JP 2010221535 A JP2010221535 A JP 2010221535A JP 2009071568 A JP2009071568 A JP 2009071568A JP 2009071568 A JP2009071568 A JP 2009071568A JP 2010221535 A JP2010221535 A JP 2010221535A
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mold
concave
convex
foam molding
molding machine
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JP2009071568A
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Japanese (ja)
Inventor
Yasuhiro Hirano
Kiyotaka Ida
Tatsuya Ida
Tomio Nakajima
Naoyuki Umeda
冨男 中嶋
清孝 井田
達也 井田
保広 平野
直行 梅田
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Daisen Co Ltd
Daisen株式会社
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Abstract

<P>PROBLEM TO BE SOLVED: To further improve energy efficiency such as used steam, simplify mounting/dismounting operation of a mold for foam molding, and reduce the cost of a foam molding machine and the mold for molding. <P>SOLUTION: The foam molding machine is surrounded by a recessed mold member 31 and a recessed side back surface member 33, and a protruded mold member 32 and a protruded side back surface member 34 respectively, and disposed along molded surfaces 31m, 32m of the mold member. A recessed side integrated mold 30A and a protruded side integrated mold 30B which are integrally molded by connecting an outer peripheral part (mold member outer peripheral parts 31a, 32a and back surface member outer peripheral parts 33a, 34a) of each mold member and a back surface member thereof are mounted so as to form independent recessed side individual service chamber 35 and a protruded side individual service chamber 36. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an improvement of a foam molding machine for producing a thermoplastic foamed resin molded article such as polystyrene foam and a method for producing a foam molding die attached thereto.

Conventionally, what is described in patent documents (1), (2), etc. is known as a mold for foam-molding foamed resin molded products such as polystyrene foam.
Referring to FIG. 12, the outer periphery is fixed to the frames 13 and 14, and the concave mold member 11 is disposed on the pair of mold mounting plates 13a disposed opposite to each other, and the convex mold member 12 is disposed on the mold mounting plate 13a. In the same manner as the convex side use chamber 15 which is disposed and forms the molding cavity 1 when the mold is closed, and is surrounded by the frame 13, the back plate 13b, the concave mold member 11, and the mold mounting plate 13a. The frame 14, the back plate 14b, the convex mold member 12, and the concave side use chamber 16 surrounded by the mold mounting plate 14a are formed.

  In the foam molding method using these molds, foam beads are filled into the molding cavity 1 through the filling nozzle 1a, and heated steam is supplied to the convex and concave service chambers 15, 16 through the vents 17a, 18a. Introducing, heating the concave mold member 11 and the convex mold member 12, and also feeding into the molding cavity 1 through the vent holes 11a and 12a, foaming and fusing the foam beads inside, the molded body After forming, cooling water is introduced into the individual service chambers 15 and 16 in place of the heating steam, the foamed molded body in the molding cavity 1 is cooled through the mold member, and then released. It can be taken out as a foamed resin product.

  In the foam molding method using such a mold, the heating steam heats the concavo-convex mold members 11 and 12, and the frames 13 and 14 and the back plate 13b constituting the service chambers 15 and 16 which are structural materials. 14b and the mold mounting plates 13a and 14b are consumed for heating, and similarly, the cooling water is also consumed for cooling them. Since heating and cooling of such a structural material has nothing to do with heating and cooling of the foamed molded product, a large energy loss has occurred.

  In this case, the mold members 11 and 12 are provided with a large number of vent holes 11a and 12a formed of communication holes, and heated steam or the like can be brought into contact with the foam beads filled in the cavity 1. It is considered so. Moreover, although this patent document 1 also discloses a structure in which the vent holes 11a and 12a are omitted, it does not particularly improve the energy efficiency of heating steam or cooling water.

  And in the case of a styrofoam fish box production machine used in a factory, a set of concave and convex molds is provided on a set of mold mounting plates 13a and 14a so that 4 to 6 molded bodies can be obtained in one molding cycle. It is customary that the components are arranged, and in such a case, only a few percent of the input energy is used for heating and cooling the foam beads, and most of them are wasted. Are known.

  Further, when a mold capable of simultaneous molding in such a single molding cycle is used, there is a problem that product quality varies among the respective mold members. The reason for this was thought to be that the supply of utilities such as heating steam and cooling water from one utility chamber was difficult to be performed evenly, and that pressurization and decompression did not work equally as well. There was no reliable means to prevent this.

  In order to cope with such a problem of energy efficiency, a heat insulating coating die disclosed in Patent Document (2) has been proposed. That is, in the above mold apparatus, a highly durable heat insulating coating layer made of silicone resin in which hollow silica particles are dispersed is provided on the inner surface of a mold mounting plate, a frame, a back plate, etc. that form a service chamber, It is intended to reduce heating loss and cooling loss.

  In this case, heat transfer to metal components other than the mold member (mold mounting plate, frame, back plate, etc.) is suppressed, so that a corresponding energy efficiency improvement effect was recognized. However, since the volume of the utility chamber itself does not change from the conventional one, it is necessary to supply a corresponding amount, and the efficiency improvement effect has to be limited to about 20%.

  In the case of this patent document (2), a structure is disclosed in which six molded bodies can be obtained in one molding cycle as a mold for a production machine. Although it is possible to averagely control the molding conditions such as heating and cooling of the plurality of concavo-convex mold members constituting the metal mold, it is not possible to individually control according to the individual concavo-convex mold members, Such variations in quality cannot be suppressed.

In a foam molding machine equipped with such a large number of production molds, the present invention provides a method that can individually control molding conditions such as heating and cooling of a plurality of concave and convex mold members and improve energy efficiency. Has proposed in the patent document (3).
The foam molding mold disclosed in Patent Document (3) is a casing in which a casing is disposed at intervals on the back of concave and convex mold members to form a concave and individual service chamber surrounded by them. This is a mold that can reduce heat loss based on the frame, back plate, etc. of the molding machine.

(1) Japanese Patent Application Laid-Open No. 2000-79931: FIG. 1, FIG. 2, etc. (2) Japanese Patent Application Laid-Open No. 2004-148777: Claims, Examples, FIG. 1, FIG. 4, etc. (3) Japanese Patent Application No. 2008-161884 Application details

  The present invention has been realized in view of the above technical background, and is intended to further improve the technique of Patent Document (3) proposed by the applicant of the present invention. This makes it possible to further improve the process, simplify the mounting and removal work of the foam molding die, reduce the cost of the foam molding machine itself by reducing the size of the power system such as a hydraulic device, and the foam molding die itself The present invention provides a foam molding machine that can reduce the cost and a method for manufacturing a foam molding die to be mounted thereon.

  The above problem is that a molding cavity is formed when a pair of convex mold members and concave mold members arranged so as to be openable and closable are mounted and the convex mold members and concave mold members are closed. A foam molding machine that is filled with a thermoplastic foaming resin raw material, heated and foamed to form a foamed molded body, with a convex mold member and a concave mold member on each back surface The back surface member disposed with a gap can be opened and closed between the convex side integrated die and the concave side integrated die that are integrally connected and formed at the outer peripheral portion of each mold member and the back surface member. This can be solved by the foam molding machine of the present invention, characterized in that the space surrounded by each mold member and its back member is used as each service chamber. .

Furthermore, the foam molding machine of the present invention is preferably embodied in the following forms.
(1) In the service chamber, a convex-side integral mold and a concave-side integral mold in which a reinforcing member is integrated and disposed between the back surface of the convex mold member and / or the concave mold member and each back member. A foam molding machine in the installed form.
(2) A foam molding machine in which the reinforcing member is a partition wall body, and a convex-side integrated mold and a concave-side integrated mold in which a plurality of spaces are provided by separating the utility chamber are mounted.

  (3) A sealing surface that separates the molding cavity formed at the time of mold closing from the outside is provided on the same plane at the opposing portion of the outer peripheral portion that integrally connects the convex mold member and the concave mold member and the respective back members. A foam molding machine in which a convex integral mold and a concave integral mold are provided.

(4) A foam molding machine in which a convex-side integral mold and a concave-side integral mold in which vent holes leading from the respective service chambers to the molding surface are arranged are mounted.
(5) A foam molding machine equipped with a convex-side integral mold and a concave-side integral mold in which utility pipes that allow the molding cavity to connect to the outside through the utility chamber are disposed.

(6) The utility pipe that allows the molding cavity and the outside to be connected through the utility chamber is mounted through the reinforcing member with the convex integral mold and the concave integral mold. Foam molding machine.
(7) A foam molding machine in which a convex integral mold and a concave integral mold in which a heat insulating layer is disposed on the outer surface of the back member are mounted.
(8) A foam molding machine in which the convex-side integral mold and the concave-side integral mold are mounted on a housing-side mounting member of a foam molding machine via a heat insulating material.

  The above-mentioned problem is a method for manufacturing a foam molding die to be mounted on the above-described foam molding machine. 1) Convex-side integration in which a convex mold member and a concave mold member are combined with a back member thereof A model of the same shape as the mold and the concave side integrated mold is formed with a disappearing material, 2) the inside and outside of the model is filled with cast sand, the foundry sand is hardened under reduced pressure, and 3) a predetermined molten aluminum alloy is poured 3), molding sand is removed, 4) a cast product is taken out, 5) a convex integrated die and a concave integrated die are manufactured through machining, and the foam molding die of the present invention is characterized in that Solved by mold manufacturing method.

In the present invention, the term “utility” is used in the following meaning.
The utility is the supply of heated steam and cooling water for heating, fusing, cooling, dehydration, etc. during the process of forming the foam beads, which are raw materials. An operation element such as operation and drain discharge is meant, and the service chamber or service pipe means a chamber or connection pipe for supplying and discharging these operation elements.

  The foam molding machine according to the present invention has a convex-side integral mold and a concave-side integral structure in which a back member is disposed on each of the convex mold member and the concave mold member, and the outer peripheral part is integrally connected and formed. The mold is arranged so that it can be opened and closed, and the space between the mold member and the back member is used as each service chamber, so the mold itself can be made compact and can be attached to and detached from the molding machine. In addition to being simplified and extremely easy, it can also contribute to the cost reduction of the foam molding machine itself by downsizing the power system such as a hydraulic device.

  In addition, the volume of the service chamber can be minimized compared to the conventional case, and members such as frames and back plates, which are not related to the molded product itself, are not heated or cooled during heating and cooling during molding operations. Thus, further improvement in energy efficiency is possible. As a result, it is possible to obtain effects such as reduction in service cost such as use heating steam and cooling water and shortening of molding cycle time.

  In addition, when the utility chamber is divided into a plurality of spaces, each space can be functioned as an independent utility chamber, and more optimal heating / cooling operations are performed on the molding cavity. The effect that the quality of a foaming molding can be controlled for every part is acquired.

According to the method for manufacturing a foam molding mold of the present invention, the foam molding mold of the present invention can be manufactured by a so-called disappearance model casting method, so that the man-hours, material costs, Manufacture is possible with less production time, and significant cost reduction can be expected. Further, according to the present invention, since the volume of the service chamber can be set to a minimum, a mold with higher thermal efficiency can be obtained.
Therefore, the present invention has an extremely great industrial value as a foam molding machine that solves the conventional problems and a method for producing a foam molding die used therefor.

The principal part sectional drawing of the mold for foam molding used for this invention (at the time of mold opening). The principal part sectional drawing of the mold for foam molding used for this invention (at the time of mold closing). The principal part sectional drawing of the foam molding machine of this invention (at the time of mold opening). The principal part sectional drawing of the foam molding machine of this invention (at the time of a mold closing). The principal part sectional drawing which shows the manufacturing processes 1 and 2 of the metal mold | die for foam molding used for this invention. The principal part sectional drawing which similarly shows the manufacturing process 3 of a metal mold | die for foam molding. The principal part sectional drawing which similarly shows the manufacturing process 4 of a metal mold | die for foam molding. The principal part sectional drawing which similarly shows the manufacturing process 5 of a metal mold | die for foam molding. The principal part sectional drawing which similarly shows the mounting state of the metal mold | die for foam molding. The principal part sectional drawing which shows the service piping inside the foam molding machine of this invention. Sectional drawing of the principal part of the metal mold | die for foam molding of the other form used for this invention (at the time of a mold closing). Sectional drawing of the principal part of the conventional mold for foam molding.

Next, the form of the foam molding die characteristically used in the foam molding machine of the present invention will be described with reference to FIGS.
(Mold for foam molding)
The basic structure of the foam molding die in the present invention is a pair of concave mold member 31 and convex mold member 32 having molding surfaces 31m and 32m that are disposed so as to be openable and closable and are in contact with the resulting foam molded body. When the concave mold member 31 and the convex mold member 32 are closed, the molding cavity 1 formed by the molding surfaces 31m and 32m is filled with a foaming resin raw material and heated. It is premised on a foam molding machine that is foamed to form a foam molded body having a three-dimensional shape of the molding cavity 1.

  The foam molding die is provided with concave surfaces having opposing surface shapes that follow the back surface shape of the mold members 31, 32 by providing substantially constant intervals on the back surfaces of the concave mold member 31 and the convex mold member 32. A side back member 33 and a convex back member 34 are disposed. The concave mold member 31 and the convex mold member 32 are substantially plate-shaped three-dimensional structures having molding surfaces 31m and 32m, and the concave back member 33 and the convex back member 34 are also substantially similar. It consists of a plate-like three-dimensional structure.

  And the feature is surrounded by the concave mold member 31 and the concave back member 33 and by the convex mold member 32 and the convex back member 34, respectively, and the molding surface 31m of the mold member , The outer peripheral portion of each mold member and its back member (the outer peripheral portion of the concave mold member) so as to form the independent concave individual role chamber 35 and the convex individual role chamber 36 provided along 32 m. 31a and concave back member outer peripheral portion 33a, and convex mold member outer peripheral portion 32a and convex side rear member outer peripheral portion 34a) are connected integrally to form concave side integrated die 30A and convex side integrated die 30B. It is in the point which constitutes.

In order to integrally form the concave die 30A from the concave die member 31 and the concave back member 33, the concave die member outer peripheral portion 31a and the concave back member 33a are welded to form an integral unit. However, it is most preferable to form both of them simultaneously by a casting method. In the case of the convex-side integral mold 30B, it is preferable to mold the same.
Thus, when the concave side integral mold 30A and the convex side integral mold 30B are closed, as shown in FIG. 2, the molding cavity 1 surrounded by the molding surfaces 31m and 32m in contact with the obtained foamed molded body is formed. It is formed.

(Reinforcing member)
When the reinforcing members 37 and 38 are integrated and disposed between the concave mold member 31 and the back member 33 and between the convex mold member 32 and the back member 34, the respective mold members and the back member are made thin. Material costs can be reduced. The shape of the reinforcing members 37 and 38 may be a columnar shape with a diameter of about 10 to 45 mm, a partition wall shape with a width of about 5 mm to 25 mm, or the like, but the concave side integrated mold 30A and the convex side integrated mold 30B described above. It is preferable to form simultaneously at the time of integral molding.

Furthermore, it is also preferable to use this reinforcing member for the purpose of forming a plurality of spaces by forming the reinforcing member with a partition wall body and partitioning the single service chamber as described above.
Illustrated in FIG. 11, in the concave-side integrated mold 30 </ b> A, a plurality of spaces 71 a to 71 g in which the service chamber is independently partitioned by a plurality of partition walls 71 are provided along the molding cavity 1. In addition, the convex-side integrated mold 30 </ b> B is also provided with spaces 72 a to 72 e that are independently partitioned by the plurality of partition walls 72 along the molding cavity 1.

As described above, when the utility chambers are divided into a plurality of spaces 71a to 71g and 72a to 72e, individual service pipes (not shown) are arranged in the respective spaces, thereby making each independent. It becomes possible to function as a small utility chamber.
Thus, in the structure in which a pair of single use chambers on both sides as shown in FIGS. 1 and 2 cannot be changed depending on the part of the molding cavity 1 by heating / cooling operation, in the present invention, By operating a plurality of small utility chambers individually, it is possible to perform more optimal heating / cooling operation corresponding to the part of the molding cavity 1. Accordingly, there is an effect that the molding operation can be finely controlled for each portion of the obtained foamed molded article, and the optimum quality can be obtained.

(Sealing surface)
At the time of mold closing, the outer peripheral portion that integrally connects the convex mold member 32 and the back member 34 and the outer peripheral portion that integrally connects the concave mold member 31 and the back member 33 face each other. Sealing surfaces 32b and 31b for separating the molding cavity 1 from the outside may be provided on the same plane. Then, by arranging an appropriate sealing packing on the sealing surfaces 32b and 31b, the molding cavity 1 can be reliably separated from the outside. In addition, since the sealing surfaces 32b and 31b are provided on the same plane, there is an advantage that accurate processing can be easily performed at the time of manufacture.

(Insulation treatment)
An appropriate heat insulating layer (not shown) on the outer surface of the back members 34, 33 of the convex-side integrated mold 30B and the concave-side integrated mold 30A, for example, inorganic heat insulation such as coating glass foam particles with a heat-resistant adhesive. When the layer is disposed, heat radiation from the mold is suppressed, and it is difficult to receive thermal influence from the outside, so that there is an advantage that temperature control at the time of foam molding becomes easy.

(Mounting structure of foam molding mold to foam molding machine)
Next, a structure for mounting the foam molding die to the foam molding machine will be described with reference to FIGS. 3 (opened state) and 4 (closed state).
In the illustration of FIG. 3, the concave-side integrated mold 30A and the convex-side integrated mold 30B include a concave mold-side support 45 and a convex mold-side support 46 that extend from the back plates 41 and 42 of the molding machine, bolts, and the like, respectively. Although it is fixed by the mechanical coupling means and arranged at the opposite position, it is not necessarily limited to this form, and the casing structure of the molding machine main body can be applied effectively at the time of closing the mold. It is necessary to be fixed to.
In this case, guide posts 43 and 44 are provided on the upper and lower sides of the molding machine, and have a function of dispersing and reducing the clamping force applied to the concave-side integrated mold 30A and the convex-side integrated mold 30B.

Further, when fixing the concave side integral mold 30A and the convex side integral mold 30B to the concave mold side support 45 and the convex mold side support 46, heat insulating members 45a and 46a made of synthetic resin or the like are interposed. Since the mold side and the support side are thermally cut off and the entire mold is thermally isolated from the molding machine body, there is no adverse external influence on the heat treatment during the molding operation on the mold side. It is preferable because heat loss on the mold side can be suppressed.
Note that one mold is provided with mold displacement prevention cotters 47 and 47 that guide the concave-side integrated mold 30A and the convex-side integrated mold 30B so as not to be displaced when the mold is closed.

(Vent hole and utility piping)
In the present invention, the convex integral mold 30B and the concave integral mold 30A have vent holes (not shown) that lead from the respective service chambers 36, 35 to the molding cavity 1 inner surface (molding surfaces 32m, 31m). A plurality of them can be arranged at an appropriate interval, for example, at a pitch of 20 to 30 mm, and used for supplying and discharging utility such as steam and air. In this embodiment, a conventionally known foam molding method using a vent hole can be employed.

  Furthermore, the present invention can be embodied in a form in which a piping structure that can supply utility directly from the outside to the molding cavity 1 is provided instead of or in combination with the vent hole that is such a vent hole. One example is shown in FIG. 10. The molding cavity service pipe 61 that reaches the molding cavity 1 through the concave side integral mold 30 </ b> A and the molding cavity 1 reaches the molding cavity 1 through the convex side integral mold 30 </ b> B. A forming cavity service pipe 62 is provided.

Then, as shown in FIG. 10, the molding cavity service pipes 61 and 62 are arranged with passages inside the reinforcing members 37 and 38 provided in the service chambers 35 and 36, respectively. Is not limited thereto, and may be directly connected to the molding cavity 1. When the reinforcing members 37 and 38 are used as passages as in the example of FIG. 10, there are advantages such as easy pipe connection processing and no adverse effect on the mechanical strength on the mold side.
When the reinforcing member is used as a service pipe passage, its diameter (width) is 25 mm for pipes for steam, air, etc., for temperature / pressure sensors for molding control, raw material filling machine, extrusion pin, surface pressure In the case of a sensor, 45 mm is preferable.

  The molding cavity service pipes 61 and 62 can be arranged in an appropriate number according to the size and shape of the molding cavity 1 (two examples are shown in FIG. 10), but are usually at least 50 mm. Independent of the service chambers 35 and 36 so as to be able to supply, discharge or supply or discharge cooling water, which is arranged with a pitch and controlled according to the molding conditions in the molding cavity 1. Configured.

Further, as shown in FIG. 10, the service chambers 35 and 36 are provided with service chamber service pipes 63 and 64, and the service chambers 35 and 36 are similarly heated and cooled. It is mounted so that it can be applied while controlling the utility.
The number of these arrangements is not limited to that shown in the figure, and for control purposes, individual service sensors such as individual pressure and temperature are arranged directly in these service chambers or in each service pipe. It is configured so that the utility which is preferably adjusted can be applied.

  Further, as shown in FIG. 10, when the mold is closed, a small third chamber 65 is provided at the sealing portion between the concave-side integral mold 30A and the convex-side integral mold 30B, and a third chamber service pipe 66 is provided there. The structure which connects is also employ | adopted. The function of the third chamber 65 acts to reduce the pressure when filling the foaming raw material and to fill the foaming raw material evenly to the outer peripheral portion of the molding cavity 1.

Next, the advantages of the foam molding machine of the present invention will be summarized.
Conventionally, on the concave mold side, as shown in FIG. 12, the service chamber 15 for heating and cooling the mold member is provided with the concave mold member 11, the frame 13, the mold mounting plate 13a, and the back plate 13b. In the present invention, as shown in FIG. 2, the corresponding service chamber 35 is surrounded by the concave mold member 31 and the concave back member 33. The relationship between the conventional service chamber 16 on the convex mold side and the service chamber 36 of the present invention is the same.

  Thus, the total weight of the outer peripheral members surrounding the service chambers 35 and 36 of the present invention is about 40% of the total weight of the outer peripheral members surrounding the conventional service chambers 15 and 16, and the service chamber volume thereof is also conventional. Since the ratio is reduced to 10% or less, and the weight and volume are reduced, the present invention has an advantage that the amount of heating steam and compressed air or cooling water used per one molding cycle can be reduced by 50% compared to the conventional method. .

  Furthermore, since the convex-side integrated mold 30B and the concave-side integrated mold 30A are used, the mold apparatus itself can be further compared with the mold apparatus described in Patent Document 3 previously proposed by the applicant of the present invention. There is an advantage that the size can be reduced and the time required for the detachment operation to the molding machine can be shortened by at least 50%, which makes it simple and easy.

  Further, as described above, when the concave side integrated mold 30A and the convex side integrated mold 30B are fixed to the concave mold side support 45 and the convex mold side support 46, the axial direction of each support when the mold is closed. Stress can be applied to each mold unit, so the pressure area per mold unit can be reduced by approximately 40%. This makes it possible to reduce the size of power systems such as hydraulic units and reduce the cost of the foam molding machine itself. Can also contribute.

(Method for manufacturing mold for foam molding)
Next, the manufacturing method of the present invention for such a mold for foam molding will be described with reference to FIGS. The present invention includes the following steps. 1) Production and assembly of disappearance model for casting, 2) Filling and hardening of casting sand, 3) Casting of molten metal, 4) Removal of casting sand, 5) Machining of cast product.
Here, the case of the concave-side integral mold 30A will be described as an example, but the case of the convex-side integral mold 30B is exactly the same, and the description thereof is omitted.

1) Production and assembly of vanishing model for casting (see Fig. 5)
Disappearance models 51 and 52 corresponding to the shapes of the concave mold member 31 and the concave back member 33 are prepared (FIG. 5A). In this case, the foamed polystyrene is preferred as the disappearing material. By combining the disappearance models 51 and 52, an assembly disappearance model 50 corresponding to the concave-side integral mold 30A is manufactured as shown in FIG. 5B. In the vanishing model 50, a space 1A corresponding to the concave individual use chamber 35 is disposed. In this case, the disappearance model 52a corresponding to the reinforcing member 37 is also prepared in advance.

2) Filling and hardening casting sand (Fig. 6)
The assembly disappearance model 50 is disposed in the container 55, and the casting sand a is assembled and filled outside and inside the assembly disappearance model 50. Prior to this step, it is preferable to perform a coating process that facilitates release. Moreover, the vibration filling which adds a vibration to the whole container is preferable so that sufficient filling of the casting sand a may be performed.
Next, during or after the filling of the casting sand, the container 55 is sealed, and the inside of the container 55 is depressurized by a vacuum pump to harden the filled casting sand.

3) Injection of molten metal, modeling (Fig. 7)
The molten alloy b of the aluminum alloy is injected into the assembly disappearance model 50, and the disappearance model 50 is decomposed and disappeared by the heat of the hot melt b, and at the same time, the melt b is caused to flow into the generated space, which is a prototype. A concave side integrated mold 30A formed by integrating the concave mold member 31 and the concave back member 33 is formed.

4) Removal of cast product (not shown)
After the shaping, it is cooled, the cast sand is removed, and the cast product is taken out. In this case, the casting sand filled in the service cavity 35 inside the concave-side integral mold 30A can be discharged by opening a discharge port provided at an appropriate position. Thus, the concave-side integrated mold 30A in which the service cavity 35 having the reinforcing member 37 is provided is taken out.

5) Machining of cast products (Fig. 8)
A cast product immediately after casting having a rough surface made of cast sand is finished with a predetermined surface accuracy, and at the same time processed with a suitable grinding device 53 to be processed into a predetermined set size.
The concave side integrated mold 30A manufactured in this way is fixed to the concave mold side support 45 of the foam molding machine as illustrated in FIG.

  As described above, according to the method for manufacturing a foam molding die of the present invention, a more free-form mold can be manufactured from the target foam molding die by a so-called disappearance model casting method. Compared to a mold having a combination structure such as a combination of the above, manufacturing man-hours, material costs, manufacturing time, etc. can be reduced by about 50% or more, and a significant cost reduction can be expected. Furthermore, there is an advantage that the degree of freedom of the mold shape is widened in design, and it is possible to cope with various designs of foam molded products.

Next, it supplements a little based on the foam molding method by the foam molding machine of this invention.
(Uneven mold member)
Since the concave mold member 31 and the convex mold member 32 used in the present invention are filled with a product when the molding pressure is closed and can be reinforced with the reinforcing members 37 and 38, the structure has a large pressure resistance. The strength is not required, and a thin aluminum alloy having a thickness of 5 to 15 mm can be used. As a result, there is an advantage that the heat capacity becomes smaller and the thermal response becomes faster.

(Utility chamber)
As described above, the service chambers 35 and 36 are configured by being surrounded by the convex mold member 31, the convex back member 33, the concave mold member 32, and the concave back member 34. , 34 is required to have a mechanical strength that can withstand the pressure of the heating steam during the molding operation, but in this case as well, it is reinforced by the reinforcing members 37 and 38, so that a relatively thin aluminum alloy having a thickness of 8 to 15 mm is formed. Can be used.

  Further, in the present invention, the service chambers 35 and 36 are configured to have a minimum thickness that is sufficient for the service to circulate so that the service such as heating steam and cooling water is given uniformly throughout. It is better. In addition, when the disappearance model casting method is used as in the present invention, it is also important that the casting sand filled in the portion forming the utility chamber can be smoothly filled and discharged, and the shape design is taken into account in consideration of these. Should be made. In addition, it is preferable that the utility chamber side shapes of the convex-side back member 34 and the concave-side back member 33 have a shape following the utility chamber-side shape of the opposing convex mold member 32 and concave mold member 31.

Next, an outline of a foam molding method using a foam molding machine using the molding die of the present invention will be described.
(Foam molding method)
In the present invention, when the concave mold member 31 and the convex mold member 32 are provided with a vent hole, a well-known molding method is used. That is, after the mold is closed and the molding cavity 1 is formed, foam beads made of a thermoplastic resin are filled into the molding cavity 1 through a filling nozzle (not shown). In this case, if the service chambers 35 and 36 are appropriately depressurized and the inside of the molding cavity 1 is also decompressed through the vent hole, the foamed beads can be operated so as to easily flow into the molding cavity 1.

  Next, heated steam is introduced into the service chambers 35 and 36, and the foamed beads in the molding cavity 1 are heated through the vent holes to be foamed and fused to form a molded body regulated in the cavity shape. Thereafter, cooling water is introduced into the service chambers 35 and 36 to cool the foamed molded body in the molding cavity 1. After cooling and drying, the mold is opened and the molded body is taken out.

Further, in the case of the foam molding method when molding cavity service pipes 61 and 62 independent from the service chamber are arranged (see FIG. 10), the following procedure is performed.
(Foamed beads filling)
Foam beads are filled into the molding cavity 1 through a filling nozzle (not shown). In this case, a molding die having a structure in which a third chamber 65, which is a small space that can be communicated with the molding cavity 1 until just before the mold is closed, is sealed between the molds. Can be preferably used.

  That is, in a state where the third chamber 65 immediately before closing the mold communicates with the molding cavity 1, the foam beads can be caused to flow into the molding cavity 1 by air, and the pressure can be reduced through the attached utility pipe 66. In this case, since the molding cavity 1 is also decompressed, the whole can be quickly filled with a more uniform filling density.

  In the present invention, in the foam bead filling step, while performing such a filling operation, heating steam or hot water is introduced into the individual use chambers 35 and 36 to set the mold members 31 and 32 to a preferable temperature, for example, Preheating can be performed to a temperature just before the foaming and fusing temperature. Thus, it is possible to contribute to shortening of the molding cycle by overlapping the foam bead filling step and the heating step.

(Heating and foaming process)
Heat steam is introduced into the individual service chambers 35, 36, the mold members 31, 32 are heated, and the heat transfer heats the foam beads in contact with the mold members 31, 32. Heating steam is also introduced into the molding cavity 1 from the molding cavity service pipes 61 and 62, and the foam beads in the molding cavity are also heated from the inside. In this case, it is possible to adjust the foaming and fusion state between the skin surface and the inside of the foam molded product, and foam molding while partially adjusting the skin part, for example, by firmly fusing the skin part and foaming the inside to the maximum extent. can do.

(Cooling process)
After the foaming process, the cooling water set to a predetermined temperature is introduced into the individual utility chambers 35, 36, for example, set to the highest temperature (80 ° C in the case of polystyrene resin) within the range where the foam beads are not fused. Then, water is passed, and cooling water is circulated as necessary to cool the foamed molded body in the molding cavity 1 to a temperature at which it can be released.

  In this case, since the cooling water is controlled to a predetermined temperature, the cooling water may be cooled to the highest temperature below the temperature at which the mold can be released. Unnecessary supercooling is not preferable because it hinders the shortening of the molding cycle. In the present invention, compared to the conventional watering method using a cooling nozzle, there is no need to direct maintenance to clogged equipment or uneven cooling. Further, since the cooling water does not directly contact the molded body, there is no problem that the molded body contains water based on the cooling water.

(Decompression cooling process)
When the heating method of supplying heating steam from the molding chamber service pipes 61 and 62 is used, it is inevitable that condensed drain in the molding chamber 1 is generated to some extent, but in this cooling step, the molding chamber service pipe 61 is used. 62 or the third chamber 65, if the pressure is reduced, the drain in the mold can be easily vaporized and removed.

(Release process)
When the mold can be released, both the molds are separated so that the molded body remains on the concave mold member 31 side, and a mold release pin (not shown) is protruded to release the molded body. Thus, a molded body foam-molded into a predetermined shape can be obtained in a dry state. In this case, if the pressure is reduced from the forming chamber service pipe 61 on the concave mold member 31 side, the molded body can be adsorbed on the concave mold member 31 side and easily left.

1: Molding cavity 30A: Concave side integral mold, 30B: Convex side integral mold 31: Concave mold member, 31a: Concave mold member outer periphery, 31b: Sealing surface, 31m: Molding surface 32: Convex mold member 32a: convex mold member outer peripheral part, 32b: sealing surface, 32m: molding surface 33: concave back member, 33a: concave rear member peripheral part 34: convex rear member, 34a: convex rear member peripheral part 35 : Concave side individual use chamber 36: convex side individual use chamber 37, 38: reinforcing member 41, 42: back plate 43, 44: guide post 45: concave mold side support, 45a: heat insulating member 46: convex mold Side support 46a: heat insulating member 47: mold displacement prevention cotter 71: partition wall body, 71a to 71g: space 72: partition wall body, 72a to 72e: space,

Claims (10)

  1.     A pair of convex mold members and concave mold members disposed so as to be openable and closable are mounted, and the molding cavity formed when the convex mold member and the concave mold member are closed is used for thermoplastic foaming. A foam molding machine in which a resin raw material is filled and foamed by heating to form a foamed molded product, and the convex mold member and the concave mold member are arranged at intervals on the back surface thereof. The convex member and the concave integrated die are mounted so that they can be opened and closed, and are integrally connected and formed at the outer periphery of each mold member and the back member. A foam molding machine characterized in that a space surrounded by each mold member and its back member is used as each service chamber.
  2.     In the service chamber, a convex-side integral mold and a concave-side integral mold in which a reinforcing member is integrated and disposed between the back surface of the convex mold member and / or the concave mold member and the respective back members are mounted. Item 2. The foam molding machine according to Item 1.
  3.     The foam molding machine according to claim 2, wherein the reinforcing member is a partition wall body, and is mounted with a convex-side integral mold and a concave-side integral mold in which a plurality of spaces are provided by separating the service chamber.
  4.   A sealing surface that separates the molding cavity formed at the time of closing from the outside is provided on the same plane at the opposing portion of the outer peripheral portion that integrally connects the convex mold member and the concave mold member and the respective back members. The foam molding machine according to claim 1, 2, or 3 equipped with a convex-side integral mold and a concave-side integral mold.
  5.     The foam molding machine according to any one of claims 1 to 4, wherein a convex-side integrated mold and a concave-side integrated mold in which vent holes leading from the respective service chambers to the molding surface are arranged are mounted.
  6.     The convex-side integral mold and the concave-side integral mold in which the utility pipe that allows the molding cavity to connect to the outside through the utility chamber is disposed. Foam molding machine.
  7.     The utility pipe which penetrates the said service chamber and can connect a shaping | molding cavity and the exterior mounted | worn with the convex side integral mold and the concave side integral mold which are arrange | positioned through the said reinforcement member. Foam molding machine.
  8.     The foam molding machine according to any one of claims 1 to 7, wherein a convex-side integral mold and a concave-side integral mold having a heat insulating layer disposed on an outer surface of the back member are mounted.
  9.     The foam molding machine according to claim 1, wherein the convex side integral mold and the concave side integral mold are mounted on a mounting member on a housing side of the foam molding machine via a heat insulating material.
  10. A method for manufacturing a foam molding die to be mounted on the foam molding machine according to any one of claims 1 to 9, wherein 1) a convex mold member, a concave mold member, and a convex member obtained by combining the back surface member. A model having the same shape as the side integrated mold and the concave side integrated mold is formed of a disappearing material, 2) the inside and outside of the model are filled with cast sand, the foundry sand is hardened under reduced pressure, and 3) a predetermined molten aluminum alloy is melted. Injection molding, molding, removing cast sand, 4) taking out a cast product, 5) producing a convex integral mold and a concave integral mold through machining Manufacturing method.


JP2009071568A 2009-03-24 2009-03-24 Foam molding machine and method for manufacturing mold for foam molding mounted thereon Pending JP2010221535A (en)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2436954A2 (en) 2010-09-30 2012-04-04 JATCO Ltd Continuously variable transmission and shift control method thereof
JP2013022792A (en) * 2011-07-19 2013-02-04 Toyota Motor Corp Mold structure and injection molding device
JP2013107301A (en) * 2011-11-22 2013-06-06 Mikio Fukumura Thermoforming device, and forming method

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5514243A (en) * 1978-07-18 1980-01-31 Daisen Kogyo:Kk Foaming mold for thermoplastic synthetic resin
JPS61169229A (en) * 1985-01-22 1986-07-30 Kunio Iida Expansion molding metal mold
JPS61245943A (en) * 1985-04-22 1986-11-01 Honda Motor Co Ltd Production of metallic mold
JP2002187154A (en) * 2000-12-19 2002-07-02 Daisen Kogyo:Kk Mold device for expansion molding
JP2008188857A (en) * 2007-02-05 2008-08-21 Yamasei Seisakusho:Kk Mold for molding foam polystyrene and foam polystyrene molding device
WO2009025013A1 (en) * 2007-08-20 2009-02-26 Daisen Co., Ltd. Steam chamber in resin foam molding machine, resin foam molding machine, and resin foam molding method

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5514243A (en) * 1978-07-18 1980-01-31 Daisen Kogyo:Kk Foaming mold for thermoplastic synthetic resin
JPS61169229A (en) * 1985-01-22 1986-07-30 Kunio Iida Expansion molding metal mold
JPS61245943A (en) * 1985-04-22 1986-11-01 Honda Motor Co Ltd Production of metallic mold
JP2002187154A (en) * 2000-12-19 2002-07-02 Daisen Kogyo:Kk Mold device for expansion molding
JP2008188857A (en) * 2007-02-05 2008-08-21 Yamasei Seisakusho:Kk Mold for molding foam polystyrene and foam polystyrene molding device
WO2009025013A1 (en) * 2007-08-20 2009-02-26 Daisen Co., Ltd. Steam chamber in resin foam molding machine, resin foam molding machine, and resin foam molding method

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2436954A2 (en) 2010-09-30 2012-04-04 JATCO Ltd Continuously variable transmission and shift control method thereof
JP2013022792A (en) * 2011-07-19 2013-02-04 Toyota Motor Corp Mold structure and injection molding device
JP2013107301A (en) * 2011-11-22 2013-06-06 Mikio Fukumura Thermoforming device, and forming method

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