JP2014208449A - Molding device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molding device in which a foamable resin particle packed in a metal mold can efficiently be heated and foamed by a heating medium over a long period of time.SOLUTION: The molding device A includes one pair of the metal molds 1, 2 with chambers 3, 4 and is used so that the heating medium is supplied to the chambers 3, 4 to heat and foam the foamable resin particle packed in a cavity 5 of the metal mold 1 and then a cooling medium is supplied to the chambers 3, 4 to mold a foam molded article. At least a part of the outside surface or inside surface of a metal member constituting the chambers 3, 4 is covered with a thermal insulation material 8. A linear expansion coefficient of the thermal insulation material 8 is 0.5-5 times of that of a metallic material constituting the chamber.

Description

  The present invention relates to a molding apparatus used for molding a foamed molded article by filling foamed resin particles in a cavity formed between a pair of molds and then foaming the foamed resin particles.

  Conventionally, after foaming resin particles are filled in a mold, a foaming resin particle is foamed by supplying a heating medium to the foaming resin particles, and the foaming resin particles are foamed. It is performed to cool and then form a foam molded product by cooling (in-mold foam molding).

  In the in-mold foam molding, a heating medium for heating the expandable resin particles filled in the mold is supplied into a chamber formed on the back surface of the mold, and enters the cavity of the mold through the chamber. It is supplied to the filled expandable resin particles.

  As described above, since the heating medium is first supplied into the chamber, heat is deprived by contact with the metal member constituting the chamber, and a part of the heating medium supplied into the chamber. However, there is a problem that it does not contribute to the heating of the expandable resin particles filled in the cavity, and the thermal energy of the heating medium is not fully utilized for the foaming of the expandable resin particles.

  Therefore, in Patent Document 1, foamed thermoplastic resin particles are introduced into a molding chamber space constituted by a pair of concave and convex middle molds in a mold, and then a molding chamber is provided from a steam chamber provided at the back of the molding chamber space. Foam molding die used for foam molding to introduce steam into the space, heat the foamed thermoplastic resin particles in the molding chamber space, foam and fuse, cool and then take out from the mold to obtain a molded product of the desired shape A part or all of one or more steam chamber surfaces selected from a frame-side steam chamber surface, a back plate-side steam chamber surface, and a center-plate-side steam chamber surface, which form a steam chamber, are hollow silica particles. There is disclosed a foam molding die coated with a silicone resin containing.

JP 2004-148777 A

  However, in the in-mold foam molding, water vapor is introduced into the steam chamber in order to heat the foamable thermoplastic resin particles, the foamable thermoplastic resin particles in the mold are heated and foamed, and then the foam molding obtained is obtained. Cooling water is introduced into the steam chamber to cool the product. Accordingly, the metal member constituting the vapor chamber and the silicone resin covering at least a part of the vapor chamber are repeatedly expanded and contracted by the heating and cooling described above.

  On the other hand, the silicone resin containing hollow silica particles has a linear expansion coefficient of 10 or more times the linear expansion coefficient of the metal constituting the mold. The degree of expansion and contraction is significantly different from that of the metal member, and this difference causes the silicone resin to easily peel off from the inner surface of the vapor chamber. When the silicone resin is peeled off from the inner surface of the vapor chamber, a gap is formed between the silicone resin and the inner surface of the vapor chamber. Water vapor enters the gap, and the water vapor contacts the metal member constituting the vapor chamber, and There arises a problem that the heat energy is lost to the metal member constituting the steam chamber.

  The present invention provides a gap between the metal member constituting the chamber and the heat insulating material connected to the metal member, regardless of expansion and contraction due to repeated supply of the heating medium and cooling medium supplied into the chamber. Is possible to prevent a part of the heat energy of the heating medium from being taken away, and the foaming resin particles filled in the mold can be efficiently heated and foamed over a long period of time by the heating medium. Providing equipment.

  The molding apparatus of the present invention includes a pair of molds provided with a chamber, supplies a heating medium into the chamber, heats and foams the expandable resin particles filled in the cavity of the mold, and then the chamber. A molding apparatus for molding a foam molded article by supplying a cooling medium therein, wherein the member constituting the chamber includes a metal member, and a heat insulating material is connected to at least a part of the metal member. And the linear expansion coefficient of the said heat insulating material is 0.5-5 times the linear expansion coefficient of the metal material of the said metal member, It is characterized by the above-mentioned.

  In the molding apparatus, at least a part of the surface of the metal member constituting the chamber is covered with a heat insulating material, and the linear expansion coefficient of the heat insulating material is that of the metal material of the metal member constituting the chamber. It is characterized by being 0.5 to 5 times the linear expansion coefficient.

  In the molding apparatus, at least a part of the inner surface of the metal member constituting the chamber is covered with a heat insulating material.

  In the molding apparatus, the member constituting the chamber further includes a heat insulating material, and the linear expansion coefficient of the heat insulating material is 0.5 to 0.5 of the linear expansion coefficient of the metal material of the metal member connected to the heat insulating material. It is characterized by being 5 times. In the molding apparatus, the heat insulating material is a fiber reinforced plastic.

  Since the molding apparatus of the present invention has the above-described configuration, the thermal energy of the heating medium supplied into the chamber is prevented as much as possible from being deprived of other than heating and foaming of the foamable resin particles. The heat energy of the heating medium supplied inside can be efficiently used for heating and foaming of expandable resin particles filled in the mold cavity, saving the heating medium and shortening the supply time of the heating medium. Can do.

  Further, the member constituting the chamber includes a metal member, and a heat insulating material is connected to at least a part of the metal member, and the linear expansion coefficient of the heat insulating material is 0. 0 of the linear expansion coefficient of the metal material of the metal member. 5 to 5 times, and since the difference is small, expansion and contraction between the metal member constituting the chamber and the heat insulating material accompanying the supply of the heating medium and the cooling medium at the time of molding the foamed molded product The difference is small, and there is almost no unexpected gap between the metal member constituting the chamber and the heat insulating material connected thereto. Therefore, it is possible to suppress as much as possible that the heat energy of the heating medium supplied into the chamber is lost due to being taken away by the metal member or leaking out of the chamber through the gap between the metal member and the heat insulating material or through the metal member. The foamable resin particles can be efficiently heated and foamed in addition to the foamable resin particles filled in the cavity of the mold with as little loss of the heat energy of the heating medium as possible.

  In the molding apparatus, at least a part of the surface of the metal member constituting the chamber is covered with a heat insulating material, and the linear expansion coefficient of the heat insulating material is that of the metal material of the metal member constituting the chamber. When the linear expansion coefficient is 0.5 to 5 times, the difference between the linear expansion coefficient of the heat insulating material and the linear expansion coefficient of the metal material of the metal member is small. In addition, the difference in expansion and contraction between the metal member constituting the chamber and the heat insulating material due to the supply of the cooling medium is small, so that the heat insulating material may unexpectedly peel from the surface of the metal member constituting the chamber. The heat insulating material stably coats at least a part of the surface of the metal member constituting the chamber over a long period of time, and the heat energy of the heating medium is put into the mold cavity with as little loss as possible. The expandable resin particles in addition to it being expandable resin particles and Hama efficiently heated may be foamed.

  In the above molding apparatus, when at least a part of the inner surface of the metal member constituting the chamber is covered with a heat insulating material, the heating medium directly contacts the metal member constituting the chamber. Therefore, it is possible to further reduce the heat energy of the heating medium from being taken away by the metal member constituting the chamber, thereby saving the heating medium and further shortening the supply time of the heating medium. Can be planned.

  And in the said shaping | molding apparatus, the member which comprises the chamber contains a heat insulating material further, and the linear expansion coefficient of the said heat insulating material is 0. of the linear expansion coefficient of the metal material of the metal member connected to the said heat insulating material. In the case of 5 to 5 times, since the difference between the linear expansion coefficient of the heat insulating material and the linear expansion coefficient of the metal material of the metal member is small, the heating medium and the cooling medium are supplied during the molding of the foam molded product. In addition, the difference in expansion and contraction between the metal member constituting the chamber and the heat insulating material is small, and an unexpected gap is generated between the heat insulating material and the metal member, or the heat insulating material is cracked. The situation hardly occurs, the heating medium supplied into the chamber is prevented from unexpectedly leaking out of the chamber, and the heat energy of the heating medium is filled in the mold cavity without loss as much as possible. In addition foaming Fat particles efficiently heated may be foamed.

  In addition, since a part of the chamber is made of a heat insulating material, the chamber itself has excellent heat retention, and the use of metal members is reduced to prevent the heat energy of the heating medium from being taken away by the metal members as much as possible. The heat energy of the heating medium supplied into the chamber can be efficiently used for heating and foaming the expandable resin particles filling the cavity of the mold.

  Moreover, in the said shaping | molding apparatus, when a heat insulating material is a fiber reinforced plastic, a chamber can be reinforced and a shaping | molding apparatus can be used stably over a long period of time.

  An example of the molding apparatus A of the present invention will be described with reference to the drawings. As shown in FIG. 1, the forming apparatus A includes a metal female mold 1 having a metal chamber 3 and a metal male mold 2 having a metal chamber 4. The female mold 1 is fixed to the fixed base B, while the male mold 2 is fixed to the moving table C, and the male mold 2 is moved toward and away from the female mold 1 by moving the moving base C. It is arrange | positioned so that a movement in the direction to do is possible.

  Specifically, the female mold 1 has a concave portion, while the male mold 2 has a convex portion. The female and male molds 1 and 2 have the concave portion and the convex portion facing each other. When the male and female molds 1 and 2 are clamped in a state where the convex part of the male mold 2 is inserted into the concave part of the female mold 1, the female mold 1 and the male mold 2 are The cavity 5 is formed between the opposing surfaces of the female mold 1, that is, between the opposing surfaces of the molding wall portion 11 of the female mold 1 and the molding wall portion 21 of the male mold 2. The female mold 1 is integrally provided with an expandable resin particle supply pipe (not shown) for supplying expandable resin particles into the cavity 5 and supplies the expandable resin particles. A filler valve (not shown) is interposed in the pipe, and an extrusion pin (not shown) for releasing the foamed molded product from the female mold 1 is integrally provided.

  The female mold 1 is mounted on a metal mold mounting frame 6, and a metal back plate 61 is mounted on the opening end of the mold mounting frame 6 on the back side of the female mold 1. A space surrounded by the molding wall 11 of the female mold 1, the mold mounting frame 6 and the back plate 61 is formed in the chamber 3.

  Similarly, the male mold 2 is mounted on a metal mold mounting frame 7, and a metal back plate 71 is mounted on the open end of the mold mounting frame 7 on the back side of the male mold 2. A space surrounded by the male mold 2, the mold mounting frame 7 and the back plate 71 is formed in the chamber 4.

  In the present invention, the inner surface of the metal member constituting the chambers 3 and 4 means the surface facing the chambers 3 and 4. The outer surface of the metal member constituting the chambers 3 and 4 means a surface opposite to the chambers 3 and 4.

  Then, the molding walls 11 and 21 forming the cavity 5 in the male and female molds 1 and 2 are connected to each other in the cavity 5 and the chambers 3 and 4, and a heating medium such as water vapor is supplied into the cavity 5. A large number of flow holes 12, 22 are provided through. Note that one end portions of heating medium supply pipes 13 and 23 for supplying a heating medium into the chambers 3 and 4 are connected to and communicated with the chambers 3 and 4.

  Furthermore, the surfaces of the metal members constituting the chambers 3 and 4 provided integrally with the male and female molds 1 and 2, that is, the inner and outer surfaces of the mold mounting frames 6 and 7 and the back plates 61 and 71, or Further, a heat insulating material 8 is integrally provided on at least a part or the entire surface of the surfaces 11a and 21a facing the chambers 3 and 4 of the molding walls 11 and 21 of the male and female molds 1 and 2, respectively. Yes. Although FIG. 1 shows a state in which the inner surfaces of the back plates 61 and 71 of the molding apparatus A are entirely covered with the heat insulating materials 8 and 8, the present invention is not limited to this. Moreover, the heat insulating material 8 should just be fixed to the inner surface or outer surface of the metal member which comprises the chambers 3 and 4 by general purpose fixing means, such as an adhesive agent, a volt | bolt, and a nail.

  The heat insulating material 8 is provided in order to prevent the thermal energy of the heating medium supplied into the chambers 3 and 4 from being taken away by the metal members constituting the chambers 3 and 4 as much as possible.

  Therefore, the heat insulating material 8 should just coat | cover the at least one part or the whole surface of either one or both of the inner surface of the metal member which comprises the chambers 3 and 4, and an outer surface. When the heat insulating material 8 is provided on the inner surfaces of the metal members constituting the chambers 3 and 4, the heat energy of the heating medium supplied into the chambers 3 and 4 is converted into the mold mounting frames 6, 7, It is prevented that the back plates 61 and 71 or the molding wall portions 11 and 21 of the male and female molds 1 and 2 are directly contacted and taken away. When the heat insulating material 8 is provided on the outer surface of the metal member constituting the chambers 3 and 4, the heat energy of the heating medium is dissipated outside through the mold mounting frames 6 and 7 or the back plates 61 and 71. Is suppressed.

  If the heating medium is not in direct contact with the metal members constituting the chambers 3 and 4, the heating medium is more effective in suppressing the heat energy from being taken away by the metal members constituting the chambers 3 and 4. The heat insulating material 8 preferably covers the inner surfaces of the metal members constituting the chambers 3 and 4.

  Further, in order to more effectively suppress the heat medium from being deprived of heat energy by the metal members constituting the chambers 3 and 4, the entire inner surface or outer surface of the metal members constituting the chambers 3 and 4 is used. Is preferably covered with the heat insulating material 8, and the entire inner surface of the metal member constituting the chambers 3 and 4 is preferably covered with the heat insulating material 8.

  On the other hand, when the surfaces 11a and 21a facing the chambers 3 and 4 in the molding walls 11 and 21 forming the cavity 5 in the male and female molds 1 and 2 are covered with the heat insulating material 8, the flow holes 12 and 22 are passed through. The surface facing the chambers 3 and 4 of the molding walls 11 and 21 forming the cavity 5 in the male and female molds 1 and 2 may hinder the supply of the heating medium into the cavity 5. 11a and 21a are preferably not covered with the heat insulating material 8. That is, it is preferable that only the inner surfaces or outer surfaces of the mold mounting frames 6 and 7 or the back plates 61 and 71 are entirely covered with a heat insulating material, and only the inner surfaces of the mold mounting frames 6 and 7 or the back plates 61 and 71 are covered. More preferably, the entire surface is covered with a heat insulating material.

  Further, the linear expansion coefficient of the heat insulating material 8 constitutes the metal members constituting the chambers 3 and 4, that is, the mold mounting frames 6 and 7, the back plates 61 and 71, and the male and female molds 1 and 2. It is limited to 0.5 to 5 times the linear expansion coefficient of the metal material, and the difference in the linear expansion coefficient between the heat insulating material 8 and the metal material of the metal member constituting the chambers 3 and 4 becomes small. It is configured as follows.

The linear expansion coefficient of the heat insulating material 8 refers to a value measured in the following manner. A planar square test piece having a side of 200 mm is cut out from the heat insulating material. The test piece is allowed to stand for 16 hours or more in an environment of a temperature of 23 ° C. and a relative humidity of 50%, and a mark is placed on the inside part of each side of the opposite side of this test piece by 5 mm. Mark. Then, after holding for 24 hours a test piece at -30 ° C., immediately measure the distance L ₁ between the gauge marks of the specimen. After that, after holding the test piece at 80 ° C. for 24 hours, immediately measure the distance L ₂ between the test points of the test piece and calculate the linear expansion coefficient K of the heat insulating material 8 based on the following formula 1. To do.
Thermal expansion coefficient K (/ ° C.) = (L ₂ −L ₁ ) / (L ₁ × 110) ( ₁ )

  Moreover, the metal material of the metal member which comprises the chambers 3 and 4 is also measured in the same way as a heat insulating material. Note that a test piece having a planar square shape with a side of 200 mm and a thickness of 10 mm is prepared as a test piece.

  The heating medium or cooling medium is supplied into the chambers 3 and 4 at the time of in-mold foam molding, and the linear expansion coefficient of the heat insulating material 8 and the metal members constituting the chambers 3 and 4 are repeatedly expanded or contracted. As described above, since the difference in coefficient of linear expansion between the heat insulating material 8 and the metal material of the metal member constituting the chambers 3 and 4 is small, the metal constituting the heat insulating material 8 and the chambers 3 and 4 The difference in the degree of expansion or contraction with the member is small. Therefore, the heat insulating material 8 is not accidentally dropped from the surfaces of the metal members constituting the chambers 3 and 4, and the surface of the metal members constituting the chambers 3 and 4 is kept for a long period of time. Stable coating.

  Although it does not specifically limit as a heat insulating material which has a linear expansion coefficient which is 0.5 to 5 times the linear expansion coefficient of the metal material of the metal member which comprises the chambers 3 and 4, a fiber reinforced plastic is mechanical strength and It is preferable because of excellent heat insulation.

  The fiber reinforced plastic is obtained by impregnating a reinforced fiber with a synthetic resin. Reinforcing fibers that constitute fiber reinforced plastics include glass fibers, carbon fibers, silicon carbide fibers, alumina fibers, Tyranno fibers, basalt fibers, ceramic fibers, and other inorganic fibers; stainless steel fibers, steel fibers, and other metal fibers; aramid Examples thereof include organic fibers such as fibers, polyethylene fibers, and polyparaphenylene benzoxador (PBO) fibers; boron fibers and the like. Reinforcing fibers may be used alone or in combination of two or more. Especially, as a reinforced fiber, carbon fiber, glass fiber, and an aramid fiber are preferable, and carbon fiber is more preferable. These reinforcing fibers have excellent mechanical strength despite being lightweight.

  The reinforcing fiber is preferably used as a reinforcing fiber substrate processed into a desired shape. Examples of the reinforcing fiber base include woven fabrics, knitted fabrics, non-woven fabrics, and face materials formed by binding (sewing) fiber bundles (strands) in which fibers are aligned in one direction. Examples of the weaving method include plain weave, twill weave and satin weave. Examples of the yarn include synthetic resin yarn such as polyamide resin yarn and polyester resin yarn, and stitch yarn such as glass fiber yarn.

  The reinforcing fiber base material may be a single layer of reinforcing fiber base material or may be used as a laminate by laminating a plurality of reinforcing fiber base materials. As a laminate in which a plurality of reinforcing fiber substrates are laminated, (1) a laminate in which only one type of reinforcing fiber substrate is prepared and these reinforcing fiber substrates are laminated, (2) a plurality of types of reinforcement A laminated body in which fiber base materials are prepared and these reinforcing fiber base materials are laminated, and (3) a plurality of face materials obtained by binding (sewing) fiber bundles (strands) in which fibers are aligned in one direction with yarns. A laminate or the like prepared by stacking these face materials so that the fiber directions of the fiber bundles are different from each other and integrating the stitched face materials with a thread is used. Examples of the yarn include synthetic resin yarns such as polyamide resin yarns and polyester resin yarns, and stitch yarns such as glass fiber yarns.

  The fiber reinforced plastic is obtained by impregnating a reinforcing fiber with a thermosetting resin and binding the reinforcing fibers with the thermosetting resin and fixing them together. The thermosetting resin is not particularly limited. For example, epoxy resin, unsaturated polyester resin, phenol resin, melamine resin, polyurethane resin, silicone resin, maleimide resin, vinyl ester resin, cyanate ester resin, and maleimide resin Examples thereof include resins obtained by prepolymerizing cyanate ester resins. A thermosetting resin may be used independently or 2 or more types may be used together. Of these, epoxy resins and vinyl ester resins are preferred.

  The thickness of the fiber reinforced plastic is preferably 1 to 20 mm, and more preferably 2 to 15 mm. A fiber reinforced plastic having a thickness within the above range is excellent in heat insulation and mechanical strength.

Basis weight of the reinforcing fibers of the fiber reinforced plastic is preferably ^{50~4000g / m 2, 100~1000g / m} 2 is more preferable. The fiber reinforced plastic in which the basis weight of the contained reinforcing fiber is within the above range is excellent in heat insulation and mechanical strength.

  The content of the reinforcing fiber contained in the fiber reinforced plastic is preferably 20 to 70% by weight, and more preferably 30 to 60% by weight. A fiber-reinforced plastic having a reinforcing fiber content within the above range is excellent in heat insulation and mechanical strength.

  Next, a procedure for molding a foam molded product using the molding apparatus A will be described. First, a pair of male and female molds 1 and 2 having chambers 3 and 4 are clamped, and a cavity 5 is formed between opposing surfaces of molding wall portions 11 and 21 of the male and female molds 1 and 2 (mold clamping step). ).

  Thereafter, the foamable resin particles are supplied and filled into the cavity 5 through the foamable resin particle supply pipe of the female mold 1 (filling step).

  Here, the expandable resin particles are preferably obtained by pre-expanding synthetic resin particles containing a foaming agent, and conventionally used as the synthetic resin constituting the synthetic resin particles. If it is a thing, it will not specifically limit, For example, polystyrene resin, such as a polystyrene, a high impact polystyrene, a styrene-anhydrous maleate copolymer, a styrene-acrylonitrile copolymer, polyethylene, a polypropylene, ethylene-vinyl acetate copolymer etc. Polyolefin resins, polyester resins such as polyethylene terephthalate, composites of the above synthetic resins, and the like, and polystyrene resins are preferred.

  Examples of the blowing agent include aliphatic chain hydrocarbons such as propane, butane, pentane and hexane, aliphatic cyclic hydrocarbons such as cyclopentane and cyclobutane, trichlorotrifluoromethane, dichlorodifluoromethane, and dichlorotetra. Halogenated hydrocarbons such as fluoromethane, trichlorotrifluoroethane, methyl chloride, methylene chloride, and ethyl chloride are listed, and may be used alone or in combination of two or more.

  Thereafter, the heating medium is supplied and filled in the chambers 3 and 4 of the male and female molds 1 and 2 through the heating medium supply pipes 13 and 23 to heat the molding walls 11 and 21 of the male and female molds 1 and 2, A heating medium is caused to flow into the cavity 5 through the flow holes 12 and 22 of the male and female molds 1 and 2, the foamable resin particles filled in the cavity 5 are heated and foamed, and the foamed particles are integrally heat-sealed. To form a foam-molded product.

  At this time, a part or all of the metal members constituting the chambers 3 and 4 are covered with a heat insulating material, so that the heating medium supplied into the chambers 3 and 4 transfers the thermal energy to the chambers 3 and 4. The foamed resin particles in which the amount of heat taken away by the metal members constituting the resin is small, and thus the heat energy of the heating medium supplied into the chambers 3 and 4 is filled in the cavities 5 of the male and female molds 1 and 2. The foaming can be efficiently performed with a small amount of heating medium.

  Next, after secondary foaming of the expandable resin particles filled in the cavity 5 is completed, cooling water is used as a cooling medium from a cooling pipe (not shown) disposed in the chambers 3 and 4, 2, the male and female molds 1 and 2 are cooled to cool the foamed molded product in the cavity 5, the cavity 5 of the male and female molds 1 and 2 is opened, and the foamed molded product is taken out.

  In a series of in-mold foam molding, by supplying a heating medium and a cooling medium into the chambers 3 and 4, the heat insulating material 8 and the metal members constituting the chambers 3 and 4 are heated or expanded. Since the difference in coefficient of linear expansion is small, it is unpredictable that the heat insulating material 8 falls off the surfaces of the metal members constituting the chambers 3 and 4 due to the difference in the degree of heating or expansion between the two. The situation does not occur, and the heat insulating material 8 continues to stably cover the inner surface or the outer surface of the metal members constituting the chambers 3 and 4 over a long period of time. Therefore, according to the molding apparatus of the present invention, the heating medium This thermal energy can be efficiently used for foam molding of expandable resin particles.

  Although the case where the chambers 3 and 4 of the male and female molds 1 and 2 are made of a metal member has been described in the molding apparatus, the chambers 3 and 4 may be made of a metal member and a heat insulating material. That is, some or all of the members constituting the chambers 3 and 4 may be made of a heat insulating material. In addition, since the thing similar to an above-described heat insulating material can be used for the heat insulating material, the description is abbreviate | omitted. As a method for producing a part or all of the members constituting the chambers 3 and 4 from the heat insulating material, a general-purpose method is used, for example, a hand lay-up method.

  For example, in the molding apparatus A shown in FIG. 1, a part or the whole of the mold mounting frames 6 and 7 or the back plates 61 and 71 may be made of a heat insulating material. By constituting a part or the whole of the mold mounting frames 6 and 7 or the back plates 61 and 71 from a heat insulating material, the heat retaining property of the chambers 3 and 4 can be improved and the amount of metal members used can be reduced. Thus, loss of heat energy of the heating medium through the metal member having high thermal conductivity can be suppressed, and heating of the expandable resin particles filled in the cavity 5 with the heat energy of the heating medium supplied into the chamber can be suppressed. It can be used efficiently for foaming. In the molding apparatus A shown in FIG. 1, the mold mounting frames 6 and 7 and the back plates 61 and 71 are shown as members constituting the chambers 3 and 4, but the mold mounting frames 6 and 7 and the back are shown. Members other than the plates 61 and 71 may be used. When members other than the mold mounting frames 6 and 7 and the back plates 61 and 71 are used as members constituting the chambers 3 and 4, some or all of these members may be made of a heat insulating material. .

  When a part of the members constituting the chambers 3 and 4 is made of a heat insulating material, it is preferable that the portion excluding the outer peripheral edge portion is made of a heat insulating material and the outer peripheral edge portion is made of a metal member. In this way, by configuring the outer peripheral edge portion from the metal member, it is possible to configure the chambers 3 and 4 having higher airtightness and higher heat insulation properties by firmly integrating with other members using bolts or the like. . For example, when a part of the mold mounting frames 6 and 7 or the back plates 61 and 71 is made of a heat insulating material, as shown in FIG. 2, the portions 6a, 7a, 61a or 71a excluding the outer peripheral edge are insulated. The outer peripheral edge 6b, 7b, 61b or 71b can be made of a metal member.

  When some or all of the members constituting the chambers 3 and 4 are made of a heat insulating material, a general-purpose method is used for connection between the heat insulating material and another member (for example, a metal member) connected to the heat insulating material. For example, a connection method using an adhesive, a bolt, or the like can be used, and a connection method using an adhesive is preferable. The adhesive can absorb the difference between expansion and contraction between the heat insulating material and another member (for example, a metal member) connected to the heat insulating material, and firmly integrate the heat insulating material with other members. It is possible to prevent the heat insulating material from being cracked and maintain the heat insulating properties of the chambers 3 and 4 high.

  Further, the linear expansion coefficient of the heat insulating material constituting part or all of the members forming the chambers 3 and 4 is 0. of the linear expansion coefficient of the metal material of the metal member to which the heat insulating material is connected. It is limited to 5 to 5 times, and since the difference between the linear expansion coefficient of the heat insulating material and the linear expansion coefficient of the metal material of the metal member is small, the heating medium and the cooling medium can be supplied during the molding of the foam molded product. In addition, the difference in expansion and contraction between the metal member constituting the chamber and the heat insulating material is small, and the connection portion using a bolt or an adhesive is destroyed, so that the space between the heat insulating material and the metal member is broken. There are almost no unforeseen circumstances such as an unexpected gap or a crack in the heat insulating material. Therefore, the chambers 3 and 4 have excellent hermeticity and heat insulation, and the heating medium supplied into the chambers 3 and 4 does not leak out of the chambers 3 and 4, and the heat energy of the heating medium is reduced. The foamable resin particles can be efficiently heated and foamed in addition to the foamable resin particles filled in the cavity of the mold with almost no loss.

  Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to the examples.

In the following examples and comparative examples, the linear expansion coefficient of the metal material constituting the heat insulating material and the chamber was measured by the following method. The test piece was in the shape of a plane square with a side of 200 mm. In the case of a heat insulating material, the thickness of the test piece was the same as the thickness of each heat insulating material in the examples and comparative examples. In the case of the metal material of the metal member constituting the chamber, the thickness of the test piece was 10 mm. The test piece is allowed to stand for 16 hours or more in an environment of a temperature of 23 ° C. and a relative humidity of 50%, and a mark is placed on the inside part of each side of the opposite side of this test piece by 5 mm. Marked. Next, after holding the test piece for 24 hours at −30 ° C. using an ultra-low temperature and humidity chamber (trade name “PSL-2SP” manufactured by Tabai Espec Co., Ltd.), the distance L ₁ was measured. After that, after holding the test piece at 80 ° C. for 24 hours using an air-cooled thermostatic oven (trade name “DN44” manufactured by Yamato Scientific Co., Ltd.), immediately determine the distance L ₂ between the marks on the test piece. It was measured. The distance between the gauge points was measured to 1/100 mm using a digital caliper (trade name “Digimatic Caliper” manufactured by Mitutoyo Corporation). The linear expansion coefficient was calculated based on the above formula 1 using the distances L ₁ and L ₂ between the measured gauge points.

Example 1

The molding apparatus shown in FIG. 1 was prepared. Three glass chopped strand mats having a basis weight of 380 g / m ² (trade name “MC-380A-100LL” manufactured by Nitto Boseki Co., Ltd.) are laminated, and 50% by volume of microballoons are contained between adjacent glass chopped strand mats. A laminated sheet was produced by interposing a non-woven polyester fiber nonwoven fabric (trade name “Yupica Mat T-3000” manufactured by Nippon Yupica Co., Ltd., basis weight: 135 g / m ² ).

  The entire inner surfaces of the aluminum mold mounting frames 6 and 7 having a thickness of 10 mm and the aluminum back plates 61 and 71 having a thickness of 10 mm in the molding apparatus A were processed to make them rough. After the laminated sheet is entirely disposed on the inner surfaces of the mold mounting frames 6 and 7 and the back plates 61 and 71, a vinyl ester resin (trade name “Lipoxy H-600” manufactured by Showa Denko KK) is applied to the laminated sheet. After the resin is impregnated, the vinyl ester resin is allowed to stand for 24 hours so that the reinforcing fibers constituting the laminated sheet are bonded and fixed together, and the glass chopped strand mat and the polyester fiber nonwoven fabric are bonded. Are laminated and integrated into a fiber reinforced plastic, and the fiber reinforced plastic is used as a heat insulating material by vinyl ester resin to be fixed and integrated on the entire inner surfaces of the mold mounting frames 6 and 7 and the back plates 61 and 71, and the mold mounting frame. 6, 7 and the entire inner surface of the back plates 61 and 71 were covered with fiber reinforced plastic.The thickness of the fiber reinforced plastic was 12 mm. The fiber reinforced plastic was composed of 40% by weight vinyl ester resin, 52% by weight glass chopped strand mat, and 8% by weight microfiber-containing polyester fiber nonwoven fabric. The surfaces 11a and 21a facing the chambers 3 and 4 in the molding walls 11 and 21 forming the cavity 5 in the male and female molds 1 and 2 were not covered with a heat insulating material.

  Table 1 shows the linear expansion coefficients of the male and female molds, the metal mounting frame and the metal material (aluminum) constituting the back plate, and the fiber reinforced plastic.

  A pair of male and female molds 1 and 2 having chambers 3 and 4 of the molding apparatus were clamped, and a cavity 5 was formed between the opposing surfaces of the molding wall portions 11 and 21 of the male and female molds 1 and 2. Next, expandable polystyrene particles (trade name “Eslen beads” manufactured by Sekisui Plastics Co., Ltd.) preliminarily expanded at a bulk magnification of 60 times are supplied and filled into the cavity 5 through the expandable resin particle supply pipe of the female mold 1. did.

  Thereafter, the steam is supplied and filled in the chambers 3 and 4 of the male and female molds 1 and 2 through the heating medium supply pipes 13 and 23 with the steam pressure shown in Table 1 for the heating time shown in Table 1 to fill the male and female gold. Expandable polystyrene particles filled in the cavity 5 by heating the molding walls 11 and 21 of the molds 1 and 2 and flowing water vapor into the cavity 5 through the flow holes 12 and 22 of the male and female molds 1 and 2. Was foamed by heating, and the foamed particles were integrated by heat fusion to form a foam molded product. The total amount of water vapor supplied into the chambers 3 and 4 of the male and female molds 1 and 2 is shown in the column of “Water vapor flow rate” in Table 1.

  Next, after the secondary foaming of the expandable polystyrene particles filled in the cavity 5 is completed, cooling water is used as a cooling medium from a cooling pipe (not shown) disposed in the chambers 3 and 4. Then, the male and female molds 1 and 2 were cooled to cool the foamed molded product in the cavity 5, and the cavity 5 of the male and female molds 1 and 2 was opened to take out the foamed molded product. The above process was defined as one cycle, and 1000 cycles of in-mold foam molding were performed.

(Example 2)
As the laminated sheet, a glass chopped strand mat having a basis weight of 380 g / m ² (trade name “MC-380A-100LL” manufactured by Nitto Boseki Co., Ltd.) was used, and the heating time was set to the time shown in Table 1. Except that, 1000 cycles of in-mold foam molding were performed in the same manner as in Example 1. The fiber reinforced plastic was composed of 40% by weight of vinyl ester resin and 60% by weight of glass chopped strand mat, and the thickness of the fiber reinforced plastic was 2 mm. Table 1 shows the linear expansion coefficient of the fiber-reinforced plastic.

Example 3
Three reinforcing fiber bases (weight per unit: 198 g / m ² , trade name “TORAYCA CO6347” manufactured by Toray Industries, Inc.) made of carbon fiber woven fabric are laminated, and further on the three reinforcing fiber bases laminated, Polyester fiber nonwoven fabric containing 50% by volume of balloon (trade name “Iupikamat T-3000” manufactured by Nippon Yupica Co., Ltd., basis weight: 135 g / m ² ) and a reinforced fiber base material comprising a carbon fiber woven fabric (unit weight: 198 g / m ²⁾ , The product name “Torayca CO6347” manufactured by Toray Industries, Inc.) was alternately laminated three by three in this order to prepare a laminated sheet, and the heating time was set to the time shown in Table 1 in the same manner as in Example 1. 1000 cycles of in-mold foam molding.

  The thickness of the fiber reinforced plastic was 10 mm. The fiber reinforced plastic was composed of 42% by weight of vinyl ester resin, 50% by weight of a reinforcing fiber substrate made of a carbon fiber woven fabric, and 8% by weight of a microballoon-containing polyester fiber nonwoven fabric. Table 1 shows the linear expansion coefficient of the fiber-reinforced plastic.

Example 4
A molding apparatus having a configuration similar to that of the molding apparatus shown in FIG. 1 except that the mold mounting frames 6 and 7, which are entirely made of fiber-reinforced plastic, are used instead of the aluminum mold mounting frames 6 and 7. Prepared.

Mold mounting frames 6 and 7, which are entirely made of fiber reinforced plastic, were manufactured by the hand lay-up method in the following manner. Prepare a plurality of reinforcing fiber base materials (weight per unit: 198 g / m ² , trade name “Torayca CO6347” manufactured by Toray Industries, Inc.) made of carbon fiber woven fabric, and use a plurality of reinforcing fiber base materials as vinyl for these reinforcing fiber base materials. After impregnating an ester resin (trade name “Lipoxy H-600” manufactured by Showa Denko KK) and forming the desired shape by laminating and integrating, the entire vinyl ester resin is cured by allowing it to stand for 24 hours. Produced mold mounting frames 6 and 7 made of fiber reinforced plastic. Table 1 shows the linear expansion coefficient of the fiber reinforced plastic constituting the mold mounting frames 6 and 7.

  The chambers 3 and 4 were configured by connecting and integrating the mold mounting frames 6 and 7 with the male and female molds 1 and 2 and the back plates 61 and 71 using an adhesive.

  1000 cycles of in-mold foam molding was performed in the same manner as in Example 1 except that the molding apparatus configured as described above was used and the heating time was set to the time shown in Table 1.

(Comparative Example 1)
The same as in Example 1 except that the inner surfaces of the aluminum mold mounting frames 6 and 7 and the back plates 61 and 71 were not coated with fiber reinforced plastic, and the water vapor pressure was changed to the water vapor pressure shown in Table 1. 1000 cycles of in-mold foam molding.

(Comparative Example 2)
Instead of covering the entire inner surfaces of the mold mounting frames 6 and 7 and the back plates 61 and 71 with fiber reinforced plastic, the entire inner surfaces of the mold mounting frames 6 and 7 of the male and female molds 1 and 2 and the back plates 61 and 71 are covered. The silicone resin paint was applied, and the entire inner surfaces of the mold mounting frames 6 and 7 and the back plates 61 and 71 were coated with a 2 mm thick silicone resin coating as a heat insulating material, and the heating time was set to the time shown in Table 1. Except that, 1000 cycles of in-mold foam molding were performed in the same manner as in Example 1. The linear expansion coefficient of the silicone resin coating is shown in Table 1.

(Insulation cover)
About Examples 1-3 and the comparative example, the fiber reinforced plastic or silicone resin film after in-mold foam molding of 1000 cycles was visually observed and evaluated based on the following criteria.
○ ・ ・ There were no cracks in the fiber reinforced plastic or silicone resin coating, and there was no peeling from the inner surface of the mold mounting frame or back plate.
× ·· The fiber reinforced plastic or silicone resin film was cracked or peeled off from the inner surface of the mold mounting frame or back plate.
Moreover, about Example 4, the die attachment flame | frame after 1000 cycles in-mold foam molding was observed visually, and it evaluated based on the following reference | standard.
○ ・ ・ There were no cracks in the mold mounting frame connected to the back plate.
× · Cracks occurred in the mold mounting frame connected to the back plate.

  When Examples 1-4 and Comparative Example 1 were compared, the steam flow rate was reduced by about 5-10%, and the reduction effect of the supply amount of the heating medium could be confirmed. When Examples 1, 3, and 4 are compared with Comparative Example 1, Examples 1, 3, and 4 have shorter heating times, and the time for in-mold foam molding can be shortened.

It is the schematic cross section which showed an example of the shaping | molding apparatus of this invention. It is the schematic cross section which showed another example of the shaping | molding apparatus of this invention.

DESCRIPTION OF SYMBOLS 1 Female die 2 Male die 3, 4 Chamber 5 Cavity 8 Heat insulation material A Molding apparatus

Claims (5)

A pair of molds having a chamber is provided. A heating medium is supplied into the chamber to heat and foam the expandable resin particles filled in the mold cavity, and then a cooling medium is supplied into the chamber. A molding apparatus for molding a foam molded article, wherein the member constituting the chamber includes a metal member, and a heat insulating material is connected to at least a part of the metal member, and the wire of the heat insulating material The molding apparatus characterized in that the expansion coefficient is 0.5 to 5 times the linear expansion coefficient of the metal material of the metal member. At least a part of the surface of the metal member constituting the chamber is covered with a heat insulating material, and the linear expansion coefficient of the heat insulating material is 0 of the linear expansion coefficient of the metal material of the metal member constituting the chamber. The molding apparatus according to claim 1, wherein the molding apparatus is 5 to 5 times. The molding apparatus according to claim 2, wherein at least a part of the inner surface of the metal member constituting the chamber is covered with a heat insulating material. The member constituting the chamber further includes a heat insulating material, and the linear expansion coefficient of the heat insulating material is 0.5 to 5 times the linear expansion coefficient of the metal material of the metal member connected to the heat insulating material. The molding apparatus according to claim 1. The molding apparatus according to claim 1, wherein the heat insulating material is a fiber reinforced plastic.

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