JP2013072480A - Resin molded article containing vacuum heat insulating material and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a resin molded article ensuring high heat insulating property by incorporating a vacuum heat insulating material inside as well as having stable quality.SOLUTION: After a heat insulating material unit is manufactured by covering a vacuum heat insulating material with a heat insulating material, the heat insulating material unit together with an extruded fused resin is sandwiched and molded with split dies.

Description

  The present invention relates to a resin molded article with a vacuum heat insulating material that includes a vacuum heat insulating material and ensures high heat insulating properties, and a method for manufacturing the resin molded product.

  Generally, a vacuum heat insulating material is known as a material having high heat insulating properties. As this vacuum heat insulating material, a core material having a hollow portion is covered with a thin film and then the inside of the film is decompressed.

  As a method for producing a resin molded product including such a vacuum heat insulating material, a method is known in which a vacuum heat insulating material is disposed between two sheet-shaped resins, and is clamped by being sandwiched between split molds (for example, Patent Document 1).

JP 2007-230228 A

  However, as described above, the vacuum heat insulating material is a thin film made of resin, or a multilayer thin film including a thin aluminum layer and a resin layer. For this reason, as in Patent Document 1 described above, when the molten resin sheet is placed on both sides of the vacuum heat insulating material and clamped, depending on conditions such as the temperature and thickness of the molten resin sheet, the heat of the molten resin sheet There was a possibility that the film on the surface of the vacuum heat insulating material would be damaged.

  Since the vacuum heat insulating material secures high heat insulating properties by reducing the pressure inside the film, there is a possibility that air may enter from that portion if the surface film is damaged. In other words, if the surface film is damaged, the internal reduced pressure state cannot be maintained, and the heat insulating property may be deteriorated.

  Further, even when the vacuum heat insulating material is damaged in this way, it is difficult to confirm whether or not the vacuum heat insulating material is damaged because the vacuum heat insulating material is embedded in the resin molded product. . In particular, in the case of mass production, it is extremely difficult to confirm whether or not a part of a resin-molded product to be mass-produced is damaged, and there is a possibility that quality may be deteriorated.

  The present invention has been made in view of such a situation, and a manufacturing method capable of manufacturing a resin molded product of stable quality while ensuring high heat insulation by including a vacuum heat insulating material therein, and its It aims at providing the resin molded product containing a vacuum heat insulating material by a manufacturing method.

In order to achieve such an object, a method for producing a resin molded article with a vacuum heat insulating material according to the present invention includes:
A unit manufacturing process for manufacturing a heat insulating material unit by covering the vacuum heat insulating material with a heat insulating material;
And a molding step of sandwiching and molding the extruded molten resin and the heat insulating material unit with a split mold.

  Moreover, the resin molded product containing a vacuum heat insulating material according to the present invention is manufactured by the manufacturing method according to the present invention described above.

  As described above, according to the present invention, it is possible to manufacture a resin molded product having a stable quality while ensuring high heat insulation by including a vacuum heat insulating material therein.

It is a longitudinal cross-sectional view which shows the thin resin panel 100 as embodiment of this invention. It is an exploded perspective view example of the heat insulating material unit 110. It is a figure which shows the state by which the molten resin sheet was arrange | positioned between the division molds with the shaping | molding apparatus which concerns on embodiment of this invention. It is a figure which shows the state which is making the outer frame of a division mold contact the side surface of a molten resin sheet in the shaping | molding apparatus which concerns on embodiment of this invention. It is a figure which shows the state which is shaping the molten resin sheet in the shaping | molding apparatus which concerns on embodiment of this invention. It is a figure which shows the state which clamped the division mold in the shaping | molding apparatus which concerns on embodiment of this invention. In the molding apparatus which concerns on embodiment of this invention, it is a figure which shows the state which opened the split mold. It is a figure which shows the example of a shape of the thin resin panel 100 provided with the plate-shaped part by this embodiment. It is a figure which shows the example of a shape of the thin resin panel 100 which has a cavity inside by this embodiment. It is a figure which shows the example of a shape of the thin resin panel 100 which has an unevenness | corrugation without a cavity by this embodiment. It is a figure which shows the heat insulating material unit 110 by other embodiment.

  Next, an embodiment in which the resin molded product with a vacuum heat insulating material and the manufacturing method according to the present invention are applied to a thin resin panel will be described in detail with reference to the drawings.

<Example of configuration of thin resin panel 100>
First, a configuration example of a thin resin panel 100 molded according to this embodiment will be described with reference to FIG.

  The thin resin panel 100 according to this embodiment has a vacuum heat insulating material 125 enclosed in a foamed resin lid box 122, and the foamed resin lid box 122 is covered with a skin layer 124. Composed.

  As described above, in the thin resin panel 100 according to the present embodiment, since the vacuum heat insulating material 125 is enclosed in the foamed resin lid box 122, the molten resin sheet is arranged outside the lid box 122 and divided. When molding with a mold to form the skin layer 124, the heat of the molten resin sheet is not directly transmitted to the vacuum heat insulating material 125. For this reason, the thin resin panel 100 with stable quality can be reliably manufactured without damaging the vacuum heat insulating material 125 due to the heat of the molten resin sheet.

  The vacuum heat insulating material 125 is conventionally known, and a core material having a hollow portion is covered with a thin film, and then the inside of the film is decompressed. The core material may be various as long as it has a hollow portion, such as a fibrous material or a powder. The film may be made of various resins, and may be a multilayer film including a thin aluminum layer and a resin layer.

  The foamed resin lid box 122 may be any of various foamed resins as long as it is a pre-molded lid box. For example, a thermoplastic resin such as polyolefin resin, polystyrene, polycarbonate, ABS resin, and a mixture thereof. Furthermore, thermosetting resins such as phenol resin, melamine resin, epoxy resin, and polyurethane can be used.

  The foaming ratio and thickness of each of the lid 122A and the box 122B in the lid box 122 are divided molds by placing a molten resin sheet outside the lid box 122 with the vacuum heat insulating material 125 sealed in the lid box 122. Is determined from the viewpoint of preventing the surface of the vacuum heat insulating material 125 from being damaged by the heat of the molten resin sheet. That is, in accordance with conditions such as the temperature and thickness of the molten resin sheet disposed on the outside of the lidded box 122, it is determined to have a heat insulating property that can reliably protect the surface of the vacuum heat insulating material 125 from the heat of the molten resin sheet. It will be.

  For example, a good result may be obtained by setting the lid 122A and the box 122B to have a thickness of 5 mm and an expansion ratio of 30 times. Depending on conditions such as the temperature and thickness of the molten resin sheet, the lid 122A Any of the boxes 122B may be made thinner, such as 1 mm thick. Further, depending on the expansion ratio and the condition of the molten resin sheet, both the lid 122A and the box 122B may have a thickness of 5 mm or more.

  As the foaming agent, any of physical foaming agents, chemical foaming agents and mixtures thereof may be used. As physical foaming agents, inorganic physical foaming agents such as air, carbon dioxide, nitrogen gas, and water, and organic physical foaming agents such as butane, pentane, hexane, dichloromethane, dichloroethane, and their supercritical fluids are used. be able to.

As the material of the skin layer 124, various known non-foamed resins can be used. For example, polypropylene, engineering plastics, olefin-based resins, and the like can be used.
More specifically, as will be described later, from the viewpoint of manufacturing the thin resin panel 100 by integral molding, the skin layers 124A and 124B are formed by dripping the molten resin sheets P1 and P2 made of thermoplastic resin. Therefore, the molten resin sheets P1 and P2 are preferably made of a resin material having a high melt tension from the viewpoint of preventing a variation in thickness due to drawdown, neck-in, etc. It is preferable to use a resin material with high fluidity in order to improve the transferability and followability.

  More specifically, it is a polyolefin (for example, polypropylene, high density polyethylene) which is a homopolymer or copolymer of an olefin such as ethylene, propylene, butene, isoprene pentene, methyl pentene, etc., and has an MFR (JIS) at 230 ° C. According to K-7210, measured at a test temperature of 230 ° C. and a test load of 2.16 kg) of 3.0 g / 10 min or less, more preferably 0.3 to 1.5 g / 10 min, or acrylonitrile butadiene Amorphous resin such as styrene copolymer, polystyrene, high impact polystyrene (HIPS resin), acrylonitrile / styrene copolymer (AS resin), MFR at 200 ° C. (test temperature 200 according to JIS K-7210) ℃, measured at a test load of 2.16 kg) is 3.0 to 60 g / 10 min More preferably, the melt tension at 30 to 50 g / 10 min and at 230 ° C. (using a melt tension tester manufactured by Toyo Seiki Seisakusho Co., Ltd., preheating temperature 230 ° C., extrusion speed 5.7 mm / min, diameter 2.095 mm, A strand is extruded from an orifice with a length of 8 mm, and the tension when the strand is wound around a roller with a diameter of 50 mm at a winding speed of 100 rpm is 50 mN or more, preferably 120 mN or more.

  In addition, in order to prevent cracking due to impact in the molten resin sheets P1 and P2, it is preferable that a hydrogenated styrene thermoplastic elastomer is added in a range of less than 30 wt%, preferably less than 15 wt%. Specifically, a styrene-ethylene / butylene-styrene block copolymer, a styrene-ethylene / propylene-styrene block copolymer, a hydrogenated styrene-butadiene rubber and a mixture thereof are suitable as the hydrogenated styrene-based thermoplastic elastomer. The styrene content is less than 30 wt%, preferably less than 20 wt%, and the MFR at 230 ° C. (measured at a test temperature of 230 ° C. and a test load of 2.16 kg according to JIS K-7210) is 1.0 to 10 g / 10. Minutes, preferably 5.0 g / 10 min or less and 1.0 g / 10 min or more.

  Furthermore, the molten resin sheets P1 and P2 may contain an additive. Examples of the additive include silica, mica, talc, calcium carbonate, glass fiber, carbon fiber, and other inorganic fillers, plasticizers, and stabilizers. Agents, colorants, antistatic agents, flame retardants, foaming agents and the like. Specifically, silica, mica, glass fiber or the like is added in an amount of 50 wt% or less, preferably 30 to 40 wt%, based on the molding resin.

In this embodiment, the expansion ratio is the density of the thermoplastic resin used in the molding method of this embodiment described later, the skin layer 124 of the thin resin panel 100 obtained by the molding method of this embodiment, and a lid. The value divided by the apparent density of the wall surface of the box 122 was defined as the expansion ratio.
In addition, the tensile fracture elongation is obtained by cutting out the skin layer 124 of the thin resin panel 100 and the wall surface of the box 122 with the lid obtained by the molding method of the present embodiment to be described later, and storing it at −10 ° C. The value obtained by measuring the tensile speed at 50 mm / min as a No. 2 type test piece was taken as the tensile fracture elongation.
In addition, the tensile elastic modulus is cut out from the skin layer 124 of the thin resin panel 100 and the wall surface of the box 122 with the lid obtained by the molding method of the present embodiment described later, and is JIS K-7113 at room temperature (23 ° C.). Accordingly, a value obtained by measuring a tensile speed of 50 mm / min as a No. 2 type test piece was defined as a tensile elastic modulus.

<Example of manufacturing method of thin resin panel 100>
Next, an example of a method for manufacturing the thin plate resin panel 100 of the present embodiment will be described with reference to FIGS. 2-7 is a figure which shows the example of the manufacturing method of the thin resin panel 100 by this embodiment.

In the manufacturing method of the thin resin panel 100 of the present embodiment, first, as shown in FIG. 2, by putting the vacuum heat insulating material 125 in the box 122B in the box 122 with the lid, and closing the opening with the lid 122A, The heat insulating material unit 110 is manufactured by enclosing and integrating the vacuum heat insulating material 125 in the box 122 with the lid.
The lid 122A and the box 122B constituting the lidded box 122 are formed in advance as described below.

The box 122B has a shape in which a space having a thickness that can accommodate the vacuum heat insulating material 125 is provided inside.
It is preferable that the inner side of the lid 122A has a shape appropriately provided with irregularities for fitting with the opening of the box 122B.

  The shape of the lid 122A and the box 122B is not limited to that shown in FIG. 2 as long as the vacuum heat insulating material 125 can be enclosed inside the cover 122 and the entire vacuum heat insulating material 125 can be covered. The shape may be

  The lid 122A and the box 122B are preferably fixed so that the entire vacuum heat insulating material 125 is reliably covered by the box 122 with the lid. As a fixing method between the lid 122A and the box 122B, the lid 122A and the box 122B may be fixed by fitting the irregularities formed in advance, or may be fixed by bonding using various adhesives. Or may be welded by heat, or a combination of these methods. When welding by heat, it is preferable to weld the vicinity of the outer periphery of the box 122 with a lid so that the heat of welding is not transmitted to the vacuum heat insulating material 125.

Further, the vacuum heat insulating material 125 may be bonded to at least one of the lid 122A and the box 122B.
Thus, after bonding the vacuum heat insulating material 125 to the inside of the box 122 with the lid, the lid 122A and the box 122B are fixed by bonding or the like as described above, and the vacuum heat insulating material 125 is enclosed in the box 122 with the lid. Thus, even after molding, the vacuum heat insulating material 125 does not move in the box 122 with a lid, and the thin resin panel 100 having stable strength can be manufactured.

  Further, depending on the strength of the box 122 with the lid, even if the vacuum heat insulating material 125 is sandwiched in the thickness direction by using the repulsive force of the foamed resin constituting the box 122 with the lid, the vacuum heat insulating material 125 is fixed in the thickness direction. Good. Even in this case, the vacuum heat insulating material 125 can be positioned in the lidded box 122 so as not to rattle, and the thin resin panel 100 having stable strength can be manufactured.

  Next, a manufacturing process for molding the heat insulating material unit 110 thus manufactured together with a molten resin sheet using a split mold will be described in detail with reference to FIGS. First, a molding apparatus used for molding will be described below.

  As shown in FIG. 3, the molding device for the thin resin panel 100 includes an extrusion device 12 and a mold clamping device 10 disposed below the extrusion device 12, and a molten resin sheet extruded from the extrusion device 12. P is sent to the mold clamping device 10, and the skin layer 124 is formed by molding the molten resin sheet P made of a thermoplastic resin by the mold clamping device 10. Here, since the apparatus for extruding each of the two molten resin sheets P and sending them to the mold clamping device 10 is the same, only one of them will be described, and the other will be denoted by the same reference numerals and the description thereof will be omitted. To do.

The extruding device 12 is a conventionally known type, and a detailed description thereof is omitted. However, a cylinder 18 provided with a hopper 16, a screw (not shown) provided in the cylinder 18, and a screw are connected to the screw 18. The hydraulic motor 20 includes an accumulator 22 that communicates with the cylinder 18 and a plunger 24 provided in the accumulator 22.
The resin pellets introduced from the hopper 16 are melted and kneaded by rotation of the screw by the hydraulic motor 20 in the cylinder 18, the molten resin is transferred to the accumulator chamber 22 and stored in a certain amount, and driven by the plunger 24. The molten resin is fed toward the T die 28, and the continuous molten resin sheet P is extruded through the extrusion slit 34 at the lower end of the T die 28. The molten resin sheet P pushed out in this way is sent downward while being pinched by a pair of rollers 30 arranged at intervals, and is suspended between the divided molds 32. Thereby, as will be described in detail later, the molten resin sheet P is disposed between the split molds 32 in a state having a uniform thickness in the vertical direction (extrusion direction).

  The extrusion capability of the extrusion device 12 is appropriately selected from the viewpoint of the size of the resin molded product to be molded, the drawdown of the molten resin sheet P, or the prevention of neck-in occurrence. More specifically, from a practical point of view, the extrusion amount of one shot in intermittent extrusion is preferably 1 to 10 kg, and the extrusion rate of the resin from the extrusion slit 34 is several hundred kg / hour or more, more preferably 700 kg / hour or more. Further, from the viewpoint of preventing the draw-down or neck-in of the molten resin sheet P, the extrusion process of the molten resin sheet P is preferably as short as possible and generally depends on the type of resin, MFR value, and melt tension value. The extrusion process should be completed within 40 seconds, more preferably within 10 to 20 seconds. For this reason, the unit area from the extrusion slit 34 of thermoplastic resin and the amount of extrusion per unit time are 50 kg / hour cm 2 or more, more preferably 150 kg / hour cm 2 or more.

  By feeding the molten resin sheet P sandwiched between the pair of rollers 30 downward by the rotation of the pair of rollers 30, the molten resin sheet P can be stretched and thinned, and the extruded molten resin sheet P is extruded. By adjusting the relationship between the speed and the feeding speed of the molten resin sheet P by the pair of rollers 30, it is possible to prevent the occurrence of drawdown or neck-in. For this reason, it is possible to reduce the restrictions on the type of resin, particularly the MFR value and melt tension value, or the extrusion amount per unit time.

  As shown in FIG. 3, the extrusion slit 34 provided in the T die 28 is arranged vertically downward, and the continuous molten resin sheet P extruded from the extrusion slit 34 is vertically lowered in a form that hangs down from the extrusion slit 34 as it is. To be sent to. The extrusion slit 34 can change the thickness of the continuous molten resin sheet P by making the interval variable.

  The pair of rollers 30 are arranged below the extrusion slit 34 so that their respective rotation axes are parallel to each other substantially horizontally, one of which is a rotation drive roller 30A and the other is a rotation drive roller 30B. More specifically, as shown in FIG. 3, the pair of rollers 30 are arranged so as to be line-symmetric with respect to the molten resin sheet P extruded in a form that hangs downward from the extrusion slit 34.

  The diameter of each of the rotation driving roller 30A and the rotation driven roller 30B and the axial length of the roller depend on the extrusion speed of the molten resin sheet P to be molded, the length and width of the sheet in the extrusion direction, and the type of resin. It may be set as appropriate, but as described later, from the viewpoint of smoothly feeding the molten resin sheet P downward by the rotation of the roller with the molten resin sheet P sandwiched between the pair of rollers 30, rotational driving The diameter of the roller 30A is preferably slightly larger than the diameter of the driven roller 30B. The diameter of the roller is preferably in the range of 50 to 300 mm. If the curvature of the roller in contact with the molten resin sheet P is too large or too small, the molten resin sheet P may be wound around the roller. Become.

  On the other hand, the mold clamping device 10 is also a conventionally known type like the extrusion device 12, and detailed description thereof will be omitted, but the two divided molds 32A and 32B and the molds 32A and 32B are melted. And a mold driving device (not shown) that moves between an open position and a closed position in a direction substantially perpendicular to the supply direction of the molten resin sheet P.

  As shown in FIG. 3, the two divided molds 32 </ b> A and 32 </ b> B are arranged with the cavities 116 facing each other, and are arranged so that the bottom surfaces of the cavities 116 face substantially vertically. Concavities and convexities 119 are provided on the surface of each cavity 116 according to the outer shape and surface shape of the molded product molded based on the molten resin sheet P made of thermoplastic resin.

  A pinch-off portion 118 is formed around the cavity 116 in each of the two divided molds 32A and 32B. The pinch-off portion 118 is formed in an annular shape around the cavity 116 and protrudes toward the opposing molds 32A and 32B. As a result, when the two divided molds 32A and 32B are clamped, the two molten resin sheets P1 and P2 are sandwiched between the tip portions of the pinch-off portions 118A and 118B and crushed. In this way, the two molten resin sheets P1 and P2 are welded so that the parting line PL is formed on the periphery of the molded product.

  A mold 33A is slidably fitted on the outer periphery of the mold 32A so as to be slidable in a sealed state, and the mold 33A can be moved relative to the mold 32A by a mold moving device (not shown). . More specifically, the mold frame 33A can contact the side surface of the molten resin sheet P1 disposed between the molds 32A and 32B by projecting toward the mold 32B with respect to the mold 32A. Similarly, a mold 33B is provided for the mold 32B.

  The mold driving device is the same as the conventional one, and the description thereof is omitted. However, the two divided molds 32A and 32B are respectively driven by the mold driving device and are divided into two in the open position. Two continuous molten resin sheets P in a molten state can be placed between the molds 32A and 32B. Further, in the closed position, the pinch-off portions 118A and B of the two divided molds 32A and 32B come into contact with each other, and the annular pinch-off portions 118 come into contact with each other, thereby forming a sealed space in the two divided molds 32A and B. To be. With respect to the movement of the molds 32A and 32B from the open position to the closed position, the closed position, that is, the position where the pinch-off portions 118 abut each other is between the two continuous molten resin sheets P1 and P2. The positions are equidistant from P1 and P2, and the molds 32A and 32B are driven by the mold driving device to move toward the positions.

  In addition, the extrusion apparatus and a pair of roller for one continuous molten resin sheet P1, and the extrusion apparatus and a pair of roller for the other one continuous molten resin sheet P2 are arrange | positioned symmetrically regarding this closed position.

As shown in FIG. 5, a vacuum suction chamber 80 is provided inside the divided mold 32 </ b> A, and the vacuum suction chamber 80 communicates with the surface of the cavity 116 </ b> A via the suction hole 82. By sucking through 82, the molten resin sheet P1 is adsorbed toward the surface of the cavity 116A and shaped into a shape along the outer surface of the cavity 116A.
The split mold 32B has the same configuration, and can be sucked from the vacuum suction chamber 80 inside the split mold 32B through the suction hole 82.

  Next, a manufacturing method of the thin resin panel 100 using the molding apparatus of the present embodiment having the above configuration will be described with reference to FIGS.

First, in the manufacture of the heat insulating material unit 110 described above, the vacuum heat insulating material 125 is enclosed in a box 122 with a lid that is formed in advance as described above. An example of a manufacturing method of the lid 122A and the box 122B constituting the lidded box 122 will be described in detail. For example, a polyolefin resin is supplied to an extruder (not shown) and kneaded while being heated and melted, and then a predetermined amount. The foaming resin is further kneaded in an extruder to obtain a foamed molten resin, and the accumulator (Fig. 1) is maintained while maintaining the foamed molten resin at a resin temperature suitable for foaming and a pressure at which the foamed molten resin does not start foaming. (Not shown). Next, by pressing a ram (not shown) of the accumulator with the gate at the die tip of the extrusion head open, the foamed molten resin is opened to the low pressure region, and the foamed cylindrical parison P is formed. The For example, the cylindrical parison P is placed between a pair of molds, the pair of molds is clamped, and the interior is pressurized from the inside, thereby sequentially forming the lid 122A and the box 122B constituting the lidded box 122. Can continue. The lidded box 122 is formed by such a method.
In addition, the box 122 with a lid | cover may use what was shape | molded by the known manufacturing method using the polystyrene bead.

  On the other hand, as a manufacturing process in which the heat insulating material unit 110 is clamped and molded with a molten resin sheet with a split mold, a predetermined amount of the melt-kneaded thermoplastic resin is stored in the accumulator 22, as shown in FIG. By intermittently extruding the stored thermoplastic resin at a predetermined extrusion amount per unit time from the extrusion slits 34 provided in the die 28, the thermoplastic resin swells and forms a molten sheet downward. It is extruded at a predetermined extrusion speed with a predetermined thickness so as to hang down.

  Next, the pair of rollers 30 is moved to the open state, and the distance between the pair of rollers 30 arranged below the extrusion slit 34 is made wider than the thickness of the molten resin sheet P, thereby the molten resin sheet P extruded downward. So that the lowermost portion is smoothly supplied between the pair of rollers 30. In addition, the timing which expands the space | interval of the rollers 30 from the thickness of the molten resin sheet P may be performed at the time of completion | finish of secondary shaping | molding for every one shot not after an extrusion start.

  Next, the pair of rollers 30 are moved closer to each other and moved to the closed state, the gap between the pair of rollers 30 is narrowed to sandwich the molten resin sheet P, and the thickness of the molten resin sheet P is adjusted by rotating the rollers to be downward. To send.

  Thus, as shown in FIG. 3, the molten resin sheet P formed with a uniform thickness in the extrusion direction is disposed between the divided molds 32 </ b> A and 32 </ b> B disposed below the pair of rollers 30. Accordingly, the molten resin sheet P is positioned at a position that protrudes around the pinch-off portion 118 in the planar direction of the sheet.

The above process is performed for each of the two molten resin sheets P1 and P2, and the molten resin sheet P2 that is the material of the upper surface side skin layer 124A and the molten resin sheet P1 that is the material of the lower surface side skin layer 124B are spaced from each other. Is placed between the split molds 32A and 32B.
In this case, the two molten resin sheets P1 and P2 are arranged between the divided molds 32A and 32B by adjusting the distance between the extrusion slits 34 or the rotation speed of the pair of rollers 30 independently of each other. The thickness at the time can be adjusted.

  Next, as shown in FIG. 4, the outer surface of the molten resin sheet P1 facing the mold 32A is directed toward the molten resin sheet P1 which is the material of the lower surface skin layer 124B with respect to the mold 32A. Move until it hits 117. Similarly, the mold 33B is moved until it contacts the outer surface 117 of the molten resin sheet P2.

  Next, as shown in FIGS. 4 and 5, the first sealed space 84 covered with the cavity 116A of the mold 32A, the inner peripheral surface of the mold 33A, and the outer surface of the molten resin sheet P1 facing the mold 32A. On the other hand, the molten resin sheet P1 is pressed against the cavity 116A by suction from the vacuum suction chamber 80 through the suction hole 82, and the molten resin sheet P1 is shaped into a shape along the uneven surface of the cavity 116A. To do. The molten resin sheet P2 is similarly sucked from the mold 32B and shaped.

  Next, as shown in FIG. 5, the heat insulating material unit 110 manufactured in advance as described above is disposed between the divided molds 32A and 32B, and pressed against the molten resin sheet P1 to be welded. The heat insulating material unit 110 is disposed between the split molds 32 while adsorbing and holding the side surfaces of the heat insulating material unit 110 using, for example, a known adsorbing manipulator, and welded to the molten resin sheet P1, and then adsorbed. The type manipulator may be removed from the heat insulating material unit 110 and retracted from between the split molds 32.

  Next, as shown in FIG. 6, while holding the mold frames 33A and 33B contacting the outer surfaces of the molten resin sheets P1 and P2 in their positions, the molten resin sheets P1 and P2 are sucked and held, respectively. The molds 32A and 32B are moved toward each other until the annular pinch-off portions 118A and B come into contact with each other. In this case, the contact position in the mold clamping direction between the pinch-off portions 118A and 118B is between the two molten resin sheets P1 and P2 that are separated from each other. As shown in FIG. The two molten resin sheets P1 and P2 are welded and fixed to each other at the peripheral edge portions. Further, the lower surface side skin layer 124B and the upper surface side skin layer 124A are welded to the heat insulating material unit 110 in a state where the heat insulating material unit 110 is disposed inside.

  Next, as shown in FIG. 7, the split molds 32A and 32B are opened, the molded thin resin panel 100 is taken out, and the burr portions B outside the pinch-off portions 118A and B are cut and molded. Is completed.

  As described above, each time the molten resin is intermittently extruded in the primary molding, the sheet-like thin resin panel 100 can be molded one after another by repeating the mold clamping process as described above. That is, the thermoplastic resin is intermittently extruded as a molten resin sheet P by primary molding (extrusion molding), and the molten resin sheet P extruded by secondary molding (blow molding or vacuum molding) is molded using a mold. Is possible.

<Effect of this embodiment>
As described above, in the above-described embodiment, the heat insulating material unit 110 in which the vacuum heat insulating material 125 is enclosed in the foamed resin lid box 122 is first manufactured, and the molten resin sheet is formed outside the heat insulating material unit 110. P1 and P2 are arranged and clamped with a split mold to form the skin layer 124. For this reason, even when the skin layer 124 is formed with the molten resin sheets P <b> 1 and P <b> 2, the heat of the molten resin sheet can be prevented from being directly transferred to the vacuum heat insulating material 125.

  The vacuum heat insulating material 125 has a configuration in which a core material is enclosed in a thin film and decompressed as described above. For this reason, when the molten resin sheet is brought into direct contact, the film on the surface is damaged by the heat, and the decompressed state inside the film may not be maintained.

  On the other hand, according to the above-described embodiment, the heat insulating material unit 110 is manufactured first, and then the skin layer 124 is formed by the molten resin sheets P1 and P2. Therefore, the vacuum heat insulating material 125 is damaged by the heat of the molten resin sheet. Therefore, it is possible to reliably manufacture the thin resin panel 100 with stable quality.

  For this reason, the thin resin panel 100 can be manufactured using a conventionally known relatively inexpensive vacuum heat insulating material using a thin film on the surface. For this reason, it is possible to manufacture a resin panel having a sufficient heat insulating property while being a thin plate at a low cost.

  Further, since the surface of the thin resin panel 100 is formed by clamping the molten resin sheets P1 and P2 with the divided molds 32A and 32B, the surface is changed depending on the shape of the cavity 116 of the divided molds 32A and 32B. Various shapes such as irregularities can be easily formed.

  Moreover, since the periphery of the vacuum insulating material 125 inside is covered with the foam, the thin resin panel 100 absorbs the impact even when it receives an impact from the outside. Damage to the material 125 can be prevented. Moreover, by making the surface concavo-convex, for example, attachment to other members is facilitated, and workability can be improved. Moreover, the effect which absorbs the impact from the direction parallel to a thickness direction can be heightened by forming uneven | corrugated shape in the thickness direction of a panel.

<Another shape example of this embodiment>
Next, another shape example of the thin resin panel 100 according to the above-described embodiment will be described with reference to FIGS.

  In the thin resin panel 100 according to the above-described embodiment, the skin layers 124A and B are formed by clamping the molten resin sheets P1 and P2 with the divided molds 32A and 32B. Depending on the shape of the cavity 116 of the molds 32A and 32B, the surface can be easily formed into various shapes such as irregularities.

  Therefore, for example, as shown in FIG. 8, a plate-like portion 124 </ b> C such as a flange portion for connecting to another member may be provided so as to be connected to the skin layers 124 </ b> A and 124 </ b> B. The shape of the plate-like portion 124C can be various shapes by making the cavities 116 of the split molds 32A and 32B corresponding shapes.

  For example, as shown in FIG. 9, it is good also as a shape which provided the cavity between skin layer 124A, B and the heat insulating material unit 110. As shown in FIG.

  In the case of FIG. 9 (a), the cavities 116A, B of the divided molds 32A, 32B are formed in an uneven shape, and the molten resin sheets P1, P2 are formed into the cavities of the divided molds 32A, 32B as described above with reference to FIG. 116A and B are adsorbed, and the molten resin sheets P1 and P2 are shaped into the concavo-convex shape of the cavities 116A and B, and then the heat insulating material unit 110 is placed, clamped, and molded. In this way, the molten resin sheets P1 and P2 can be shaped along the concave and convex shapes of the cavities 116A and B, and then the heat insulating material units 110 having different surface shapes can be welded to form the inside of the convex portion as a cavity.

  The position of the unevenness is not limited to the thickness direction in the plate-like heat insulating material unit 110 as shown in FIG. 9A, but is provided on the side surface portion in the plane direction of the plate-like heat insulating material unit 110. Also good. Also in this case, it can be similarly manufactured by making the cavities 116A and B of the divided molds 32A and 32B have corresponding concavo-convex shapes.

  9B, the skin layer 124 is formed larger than the heat insulating material unit 110 in the plane direction of the plate-shaped heat insulating material unit 110, and the space between the heat insulating material unit 110 and the skin layer 124 is formed. It is a hollow. In this case, the cavities 116A and B of the divided molds 32A and 32B can be similarly manufactured by forming the cavities 116A and B larger than the heat insulating unit 110 in the planar direction of the plate-shaped heat insulating unit 110. .

  By configuring as shown in FIG. 9B, the heat insulating material unit 110 is manufactured in large quantities with the same size as a mass-produced product, and then a slightly larger size is required when manufacturing the thin resin panel 100. Even in this case, it is possible to cope with the design change of the cavities 116A and B of the split molds 32A and 32B. For this reason, the stock loss of the heat insulating material unit 110 manufactured in advance can be reduced, mass production of the heat insulating material unit 110 can be performed, and the thin resin panel 100 can be manufactured at a lower cost.

Further, for example, as shown in FIG. 10, the skin layers 124A and B are formed in an uneven shape, and the surface of the heat insulating unit 110 is formed in a shape corresponding to the unevenness in advance, whereby the skin layers 124A and B are formed in an uneven shape. Although it is a certain shape, it can also be set as the structure which the skin layer 124 was filled without the clearance gap also in the convex part in the heat insulating material unit 110. FIG.
In this case, the cavities 116A and B of the divided molds 32A and 32B are arranged so that the gaps 116A and B of the divided molds 32A and 32B and the surface of the heat insulating material unit 110 arranged at predetermined positions are substantially equidistant. And by manufacturing the heat insulating material unit 110, it can manufacture similarly.

  By configuring as shown in FIG. 10 (b), there is no cavity between the heat insulating unit 110 and the skin layer 124, and the skin layer 124 is filled without any gaps, although the surface has an uneven shape. A thin resin panel 100 having excellent heat insulation can be manufactured.

<Other embodiments>
Next, another embodiment of the present invention will be described with reference to FIG.
In another embodiment, the heat insulating material unit 110 in the above-described embodiment is manufactured by filling a foam filler inside the mold material 126.

  As shown in FIG. 11A, a heat insulating material unit 110 according to another embodiment includes a vacuum heat insulating material 125 similar to that of the above-described embodiment and a foam layer 128 in a mold material 126. Is done.

  As shown in FIG. 11B, a predetermined number of convex portions 127 are provided on the inner bottom surface of the mold material 126, and the convex portions 127 are provided between the vacuum heat insulating material 125 and the inner wall of the mold material 126. The vacuum heat insulating material 125 can be held so that gaps at equal intervals are formed. The number and arrangement of the convex portions 127 are not limited to those shown in FIG. 11B, and may be any number or arrangement as long as the vacuum heat insulating material 125 can be held.

  Moreover, the space | interval between the vacuum heat insulating material 125 and the formwork material 126 inner wall depends on conditions, such as temperature and thickness of the molten resin sheet arrange | positioned outside the heat insulating material unit 110, from the heat | fever of the molten resin sheet. It is determined as appropriate so as to have a heat insulating property that can reliably protect the surface of the vacuum heat insulating material 125.

  Moreover, as long as the mold material 126 has the predetermined shape as described above, it may be a pre-molded resin molded product or may be pre-manufactured from other materials.

  In manufacturing the heat insulating material unit 110, first, the vacuum heat insulating material 125 similar to that of the above-described embodiment is arranged on the convex portion 127 in the mold material 126, and the vacuum heat insulating material 125 in the mold material 126. Fill the gap between the two with foaming filler. As the foam filler, for example, various types having heat insulation properties such as injection-type urethane foam may be used.

  After filling the foam filler in this way, the joints of the upper and lower mold materials 126A and B are welded by heat or bonded with an adhesive.

  After the manufacture of the heat insulating material unit 110, two molten resin sheets are arranged, clamped and molded in the same manner as in the above-described embodiment. Thus, a thin resin panel 100 according to another embodiment can be manufactured.

  The effect similar to embodiment mentioned above can be acquired also by the thin resin panel 100 by other embodiment. Also, various shapes similar to those of the above-described embodiments can be realized by the thin resin panel 100 according to other embodiments.

<About each embodiment>
Each of the above-described embodiments is a preferred embodiment of the present invention, and the present invention is not limited to this, and various modifications can be made based on the technical idea of the present invention.

  For example, the shapes of the cavities 116A and B of the split molds 32A and 32B are not limited to the above-described embodiments, and may be arbitrary shapes.

  Moreover, although each embodiment mentioned above demonstrated the case where a pair of division | segmentation metal mold | die 32A, 32B was used, the division | segmentation number of a division | segmentation mold is not limited to two, It was divided | segmented into arbitrary numbers. Even if a split mold is used, the present invention can be similarly realized.

In each of the above-described embodiments, the two molten resin sheets P1 and P2 are described as being arranged outside the heat insulating material unit 110. However, the number of the molten resin sheets is not limited to two, and may be an arbitrary number. It's okay.
Further, the number of the extrusion devices 12 that extrude the molten resin sheet is not limited to two, and may be any number depending on the shape of the target molded product.

  Moreover, the molten resin sheet is not limited to a single layer, and may be a multilayer structure in which a non-foamed layer is disposed on the outside and a foamed layer is disposed on the inside.

  Moreover, the structure of the extrusion apparatus 12 is not limited to the structure of embodiment mentioned above, As long as the molten resin sheet can be extruded, it may be arbitrary structures.

In the resin molded product according to the present invention, for example, the thin resin panel 100 may be used alone or as an assembly. Moreover, you may use the thin resin panel 100 attached to something panel.
Thus, the resin molded product according to the present invention can be used for various applications that require heat insulation.

P Molten resin sheet PL Parting line 10 Mold clamping device 12 Extrusion device 16 Hopper 18 Cylinder 20 Hydraulic motor 22 Accumulator 24 Plunger 28 T die 30 Roller 32 Split mold 33 Mold frame 34 Extrusion slit 80 Vacuum suction chamber 82 Vacuum suction hole 84A First sealed space 84B Second sealed space 100 Thin resin panel 116 Cavity 118 Pinch-off portion 122 Box with lid 124A, B Skin layer 125 Vacuum heat insulating material 126 Mold frame material 127 Protruding portion 128 Foam layer

Claims (9)

A unit manufacturing process for manufacturing a heat insulating material unit by covering the vacuum heat insulating material with a heat insulating material;
And a molding step of sandwiching and molding the extruded molten resin and the heat insulating material unit with a split mold.   In the said unit manufacturing process, the said heat insulating material unit is manufactured by arrange | positioning the said vacuum heat insulating material inside the foaming molding previously shape | molded, The resin molded product containing a vacuum heat insulating material of Claim 1 characterized by the above-mentioned. Production method. The foamed molded body is a box with a lid,
The method for manufacturing a resin molded article with a vacuum heat insulating material according to claim 2, wherein, in the unit manufacturing step, the heat insulating material unit is manufactured by housing the vacuum heat insulating material in a box with the lid.   In the unit manufacturing process, the heat insulating material unit is manufactured by disposing the vacuum heat insulating material inside a mold material and putting a foaming filler between the mold material and the vacuum heat insulating material. The manufacturing method of the resin molded product containing a vacuum heat insulating material of Claim 1. The heat insulating unit is substantially flat.
5. The molding process according to claim 1, wherein in the molding step, the mold is sandwiched and molded by the split mold so as to provide a hollow portion between the heat insulating material unit and the molten resin. 6. Manufacturing method of resin molded product with vacuum heat insulating material. The heat insulating unit is a shape having irregularities on the surface,
The cavity of the split mold is formed to have an uneven shape corresponding to the unevenness,
5. The molding process according to claim 1, wherein in the molding step, molding is performed by sandwiching the molten resin between the mold and the heat insulating material unit so as to fill the molten resin without a gap. The manufacturing method of the resin molded product containing a vacuum heat insulating material of description.   A resin molded article with a vacuum heat insulating material, which is manufactured by the manufacturing method according to any one of claims 1 to 6. A thermal insulation unit that is covered with foam around the vacuum thermal insulation;
A resin molded article with a vacuum heat insulating material, comprising a skin layer covering the outside of the heat insulating material unit.   9. A resin molded article with a vacuum heat insulating material according to claim 8, wherein a concavo-convex shape is formed on the surface.

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