JP3860508B2

JP3860508B2 - Method for producing synthetic resin foam and molding die used therefor

Info

Publication number: JP3860508B2
Application number: JP2002177314A
Authority: JP
Inventors: 浩長谷川
Original assignee: Sekisui Kasei Co Ltd
Current assignee: Sekisui Kasei Co Ltd
Priority date: 2002-06-18
Filing date: 2002-06-18
Publication date: 2006-12-20
Anticipated expiration: 2022-06-18
Also published as: JP2004017530A

Description

【０００１】
【発明の属する技術分野】
本発明は、一対の雌雄型の成形壁部間に形成されるキャビティ内で成形された合成樹脂発泡体を均一に冷却することができる合成樹脂発泡体の製造方法及びこれに用いられる成形型に関する。
【０００２】
【従来の技術】
従来から、一対の雌雄型の成形壁部間に形成されたキャビティ内に発泡性樹脂粒子を充填した後、この発泡性樹脂粒子を加熱、発泡させることによって合成樹脂発泡体を製造する方法が広く用いられている。
【０００３】
このような製造方法としては、特公昭６１−１４９３１号公報には、一対の雌雄型の成形壁部間に形成されたキャビティ内に発泡性樹脂粒子を充填して加熱、発泡させた後、雌雄型のチャンバ及び雌型の成形壁部内に蛇行状に配設された一本の冷却管路内に冷却水を供給してキャビティ内の合成樹脂発泡体を冷却させる方法が記載されている。
【０００４】
しかしながら、上記雌型の成形壁部内に蛇行状に配設された冷却管路内を流通する冷却水は、雌型を冷却するにしたがって温度が上昇し、冷却管路の流通終端に近づくにつれて冷却効果が低下してしまい、雌型を均一に冷却することができないといった問題点があった。
【０００５】
【発明が解決しようとする課題】
本発明は、一対の雌雄型の成形壁部間に形成されるキャビティ内で成形された合成樹脂発泡体を均一に冷却することができる合成樹脂発泡体の製造方法及びこれに用いられる成形型を提供する。
【０００６】
【課題を解決する手段】
請求項１に記載の合成樹脂発泡体の製造方法は、一対の雌雄型の成形壁部間にキャビティを形成する型締め工程と、このキャビティ内に発泡性樹脂粒子を充填する充填工程と、上記雌雄型の成形壁部内に形成された加熱管路内に加熱媒体を流通させ、上記発泡性樹脂粒子を加熱、発泡させる加熱発泡工程と、上記キャビティ内の合成樹脂発泡体を冷却する冷却工程と、上記雌雄型を型開きして上記合成樹脂発泡体を取り出す型開き工程とを一連の成形工程とし、この成形工程を繰り返して行う合成樹脂発泡体の製造方法であって、上記冷却工程は、上記雌雄型の成形壁部内に配設された複数本の第一冷却管路内に冷却媒体を同一方向に流通させると共に、上記第一冷却管路と交互に配設された複数本の第二冷却管路内に上記第一冷却管路内の冷却媒体の流通方向と逆方向に冷却媒体を流通させることにより行うことを特徴とする。
【０００７】
そして、請求項２に記載の合成樹脂発泡体の製造方法は、請求項１に記載の合成樹脂発泡体の製造方法であって、冷却工程において、上記雌雄型の冷却管路内に冷却媒体を流通させると共に、上記雌雄型の加熱管路を通じてキャビティ内を真空吸引することを特徴とする請求項１に記載の合成樹脂発泡体の製造方法。
【０００８】
又、請求項３に記載の合成樹脂発泡体の製造方法は、請求項１又は請求項２に記載の合成樹脂発泡体の製造方法であって、加熱発泡工程において、雌雄型の成形壁部内に配設された複数本の第一加熱管路内に加熱媒体を同一方向に流通させると共に、上記第一加熱管路と交互に配設された複数本の第二加熱管路内に上記第一加熱管路内の加熱媒体の流通方向と逆方向に加熱媒体を流通させることにより行うことを特徴とする。
【０００９】
更に、請求項４に記載の合成樹脂発泡体の製造方法は、請求項１乃至請求項３の何れか１項に記載の合成樹脂発泡体の製造方法において、型開き工程の後又は型開き工程の始まり若しくは途上から、次の成形工程の型締め工程に至るまで、雌雄型の冷却管路内に加熱媒体を流通させて、成形壁部を加熱することを特徴とする。
【００１０】
そして、請求項５に記載の成形型は、一対の雌雄型の成形壁部内に、冷却媒体を同一方向に流通させる複数本の第一冷却管路と、この第一冷却管路と交互に配設され且つ上記第一冷却管路内の冷却媒体の流通方向と逆方向に冷却媒体を流通させる複数本の第二冷却管路と、上記雌雄型の成形壁部間に形成されるキャビティに連結、連通し且つ加熱媒体を流通させる加熱管路とを形成していることを特徴とする。
【００１１】
又、請求項６に記載の成形型は、請求項５に記載の成形型において、加熱管路は、加熱媒体を同一方向に流通させる複数本の第一加熱管路と、この第一加熱管路と交互に配設され且つ上記第一加熱管路内の加熱媒体の流通方向と逆方向に加熱媒体を流通させる複数本の第二加熱管路とからなることを特徴とする。
【００１２】
更に、請求項７に記載の成形型は、請求項６に記載の成形型において、互いに隣接する加熱管路間に冷却管路を配設していることを特徴とする。
【００１３】
最後に、請求項８に記載の成形型は、請求項７に記載の成形型において、雌雄型の加熱管路の一部を成形壁部の外面から突出させていると共に、内面が各加熱管路の突出部に接した断熱材によって雌雄型の成形壁部を被覆することによって断熱材の内面と成形壁部との間に空間部を形成していることを特徴とする。
【００１４】
【作用】
本発明の合成樹脂発泡体の製造方法及びこれに用いられる成形型によれば、成形壁部内に配設された複数本の第一冷却管路及び第二冷却管路の夫々に冷却媒体を流通させることによって合成樹脂発泡体の冷却を行ない、従来のように一本の長い冷却管路を蛇行状に配設している場合と異なり、各第一冷却管路及び第二冷却管路の長さを短くして冷却管路内を流通する冷却媒体の冷却効果が大きく低下する前に冷却管路から排出するようにして、冷却管路の流通始端側と流通終端側における冷却媒体の冷却効果に大きな差が生じないようにし、更に、雌雄型の成形壁部内に配設された冷却管路内に冷却媒体を流通させることによってキャビティを形成する雌雄型の成形壁部を集中的に冷却してキャビティ内の合成樹脂発泡体を効率良く冷却している。
【００１５】
しかも、第一冷却管路と第二冷却管路とを交互に配設すると共に、第一冷却管路を流通する冷却媒体の流通方向と、第二冷却管路を流通する冷却媒体の流通方向とが逆方向となるようにしており、第一冷却管路を流通する冷却媒体の流通終端側での冷却効果は、流通始端側での冷却媒体の冷却効果に比して雌雄型を冷却した分だけ相対的に低下しているものの、第一冷却管路の流通終端側に隣接する第二冷却流通管路の流通始端側を流通する冷却媒体が、第一冷却管路の流通終端側を流通する冷却媒体の冷却効果の低下分を補っており、同様に、第二冷却管路の流通終端側を流通する冷却媒体の冷却効果の低下分を、第一冷却管路の流通始端側を流通する冷却媒体が補っており、第一冷却管路と第二冷却管路とは、これら冷却管路内を流通する冷却媒体の冷却効果の低下分を互いに補完し合っている。
【００１６】
従って、本発明の合成樹脂発泡体の製造方法及びこれに用いられる成形型によれば、雌雄型の成形壁部間に形成されたキャビティ内の合成樹脂発泡体を冷却媒体によって効果的に且つ均一に冷却することができる。
【００１７】
【発明の実施の形態】
本発明の合成樹脂発泡体の製造方法に用いられる成形型の一例を図面に基づいて説明する。成形型は、図１に示すように、一対の雌雄金型１、２から構成されてあり、これらの雌雄金型１、２を型締めすると、雌型１の成形壁部1aと雄型２の成形壁部2aとの対向面間によって所定形状のキャビティ３が形成される。
【００１８】
上記雌型１の成形壁部1a内には、図１乃至図３に示すように、この雌型１の成形型面1bに沿って第一加熱管路4Aと第二加熱管路4Bとが複数本、交互に且つ互いに平行に配設されていると共に、隣接する第一加熱管路4Aと第二加熱管路4B間と、次に隣接する第一加熱管路4Aと第二加熱管路4B間とに第一冷却管路5Aと第二冷却管路5Bとが順次、交互に且つ互いに平行に配設されている。
【００１９】
同様に、上記雄型２の成形壁部2a内においても、雄型２の成形型面2bに沿って第一加熱管路4A' と第二加熱管路4B' とが複数本、交互に且つ互いに平行に配設されていると共に、隣接する第一加熱管路4A’と第二加熱管路4B’間と、次に隣接する第一加熱管路4A’と第二加熱管路4B’間とに第一冷却管路5A’と第二冷却管路5B’とが順次、交互に且つ互いに平行に配設されている。
【００２０】
なお、上記第一冷却管路5A、5A' と第二冷却管路5B、5B' とは、隣接する第一加熱管路4A、4A' と第二加熱管路4B、4B' との間に１本だけ順次、配設しておいてもよいが、複数本一組として、順次、交互に配設しておいてもよい。又、上記第一加熱管路4A、4A' と第二加熱管路4B、4B' には、その長さ方向に所定間隔毎に上記キャビティ３に連通した貫通孔が貫設されている。
【００２１】
又、雌雄金型１、２の成形壁部1a、2a内にそれぞれ配設されている上記第一加熱管路4A、4A' と第二加熱管路4B、4B' 及び第一冷却管路5A、5A' と第二冷却管路5B、5B' とは、上下方向に向けて並設しておいてもよいが、図においては左右水平方向に向けて並設されてあり、各管路の両端部を雌雄金型１、２の成形壁部1a、2aの両端面から外方に突出させている。
【００２２】
雌雄金型１、２の外部には、これらの成形壁部1a、2aの両端面に沿って上記各管路に直交する方向に向けて第一加熱媒体供給管6A、6A’と第一加熱媒体排出管6B、6B' 、及び第二加熱媒体供給管7A、7A’と第二加熱媒体排出管7B、7B' が互いに平行に配設されていると共に、同じく第一冷却媒体供給管8A、8A’と第一冷却媒体排出管8B、8B' 、及び第二冷却媒体供給管9A、9A’と第二冷却媒体排出管9B、9B' が互いに平行に配設されている。
【００２３】
詳しくは、雌型１側においては、その成形壁部1aの一端面に沿って第一加熱媒体供給管6Aと第二加熱媒体排出管7B、及び、第一冷却媒体供給管8Aと第二冷却媒体排出管9Bとが配設されていると共に、その成形壁部1aの他端面に沿って第二加熱媒体供給管7Aと第一加熱媒体排出管6B、及び、第二冷却媒体供給管9Aと第一冷却媒体排出管8Bとが配設されてあり、成形壁部1aの一端面から突出している上記第一加熱管路4Aの一端部を第一加熱媒体供給管6Aに、成形壁部1aの他端面から突出しているこれらの第一加熱管路4Aの他端部を第一加熱媒体排出管6Bにそれぞれ長さ方向に一定間隔毎に連結、連通させていると共に、上記第二加熱管路4Bの一端部を第二加熱媒体排出管7Bに、他端部を第二加熱媒体供給管7Aにそれぞれ長さ方向に一定間隔毎に連結、連通させている。
【００２４】
従って、図４及び図５に示したように、第一加熱媒体供給管6Aから各第一加熱管路4A内に一斉に供給されて第一加熱媒体排出管6B側に流出する加熱媒体の流通方向と、第二加熱媒体供給管7Aから各第二加熱管路4B内に一斉に供給されて第二加熱媒体排出管7B側に流出する加熱媒体の流通方向とは互いに逆向きとなるように構成されている。
【００２５】
更に、雌型１の成形壁部1aの一端面から突出している上記第一冷却管路5Aの一端部を第一冷却媒体供給管8Aに、成形壁部1aの他端面から突出している該第一冷却管路5Aの他端部を第一冷却媒体排出管8Bにそれぞれ長さ方向に一定間隔毎に連結、連通させていると共に、上記第二冷却管路5Bの一端部を第二加熱媒体排出管9Bに、他端部を第２冷却媒体供給管9Aにそれぞれ長さ方向に一定間隔毎に連結、連通させている。
【００２６】
従って、図６及び図７に示したように、第一冷却媒体供給管8Aから各第一冷却管路5A内に一斉に供給されて第一冷却媒体排出管8B側に流出する冷却媒体の流通方向と、第二冷却媒体供給管9Aから各第二冷却管路5B内に一斉に供給されて第二冷却媒体排出管9B側に流出する加熱媒体の流通方向とは互いに逆向きとなるように構成されている。
【００２７】
上記第一、第二加熱媒体供給管6A、7Aの長さ方向の中間部には、それぞれ開閉バルブ10、11を有する第一、第二加熱媒体導入管6C、7Cが連結、連通してあり、これらの第一、第二加熱媒体導入管6C、7Cは加熱媒体供給源に連通していると共に、第一、第二加熱媒体排出管6B、7Bの長さ方向の中間部にはそれぞれ開閉バルブ12、13と真空ポンプ14、15を有する第一、第二加熱媒体導出管6D、7Dが連結、連通している。
【００２８】
一方、上記第一、第二冷却媒体供給管8A、9Aの長さ方向の中間部には、冷却媒体供給源と連通している第一、第二冷却媒体導入管8C、9Cがそれぞれ連結、連通していると共にこれらの第一、第二冷却媒体導入管8C、9Cに三方切替弁16、17を介して加熱媒体供給源に連通した第一、第二予備加熱媒体供給管18、19をそれぞれ接続してあり、更に、上記第一、第二冷却媒体排出管8B、9Bの長さ方向の中間部には、開閉バルブ20、21を有する第一、第二冷却媒体導出管8D、9Dがそれぞれ連通している。
【００２９】
同様に、雄型２側においても、その成形壁部2aの一端面に沿って第一加熱媒体供給管6A' と第二加熱媒体排出管7B' 、及び、第一冷却媒体供給管8A' と第二冷却媒体排出管9B' とが配設されていると共に、その成形壁部2aの他端面に沿って第二加熱媒体供給管7A' と第一加熱媒体排出管6B' 、及び、第二冷却媒体供給管9A' と第一冷却媒体排出管8B' とが配設されてあり、成形壁部2aの一端面から突出している上記第一加熱管路4A' の一端部を第一加熱媒体供給管6A' に、成形壁部2aの他端面から突出しているこれらの第一加熱管路4A' の他端部を第一加熱媒体排出管6B' にそれぞれ長さ方向に一定間隔毎に連結、連通させていると共に、上記第二加熱管路4B' の一端部を第二加熱媒体排出管7B' に、他端部を第二加熱媒体供給管7A' にそれぞれ長さ方向に一定間隔毎に連結、連通させている。
【００３０】
従って、図４及び図５に示したように、第一加熱媒体供給管6A' から各第一加熱管路4A' 内に一斉に供給されて第一加熱媒体排出管6B' 側に流出する加熱媒体の流通方向と、第二加熱媒体供給管7A' から各第二加熱管路4B' 内に一斉に供給されて第二加熱媒体排出管7B' 側に流出する加熱媒体の流通方向とは互いに逆向きとなるように構成されている。
【００３１】
更に、雄型２の成形壁部2aの一端面から突出している上記第一冷却管路5A' の一端部を第一冷却媒体供給管8A' に、成形壁部2aの他端面から突出している他端部を第一冷却媒体排出管8B' にそれぞれ長さ方向に一定間隔毎に連結、連通させていると共に、上記第二冷却管路5B' の一端部を第二加熱媒体排出管9B' に、他端部を第２冷却媒体供給管9A' にそれぞれ長さ方向に一定間隔毎に連結、連通させている。
【００３２】
従って、図６及び図７に示したように、第一冷却媒体供給管8A' から各第一冷却管路5A' 内に一斉に供給されて第一冷却媒体排出管8B' 側に流出する冷却媒体の流通方向と、第二冷却媒体供給管9A' から各第二冷却管路5B' 内に一斉に供給されて第二冷却媒体排出管9B' 側に流出する加熱媒体の流通方向とは互いに逆向きとなるように構成されている。
【００３３】
上記第一、第二加熱媒体供給管6A’、7A’の長さ方向の中間部には、それぞれ開閉バルブ10’、11’を有する第一、第二加熱媒体導入管6C’、7C’が連結、連通してあり、これらの第一、第二加熱媒体導入管6C' 、7C' は加熱媒体供給源に連通していると共に、第一、第二加熱媒体排出管6B’、7B’の長さ方向の中間部にはそれぞれ開閉バルブ12’、13’と真空ポンプ14’、15’を有する第一、第二加熱媒体導出管6D’、7D’が連結、連通している。
【００３４】
一方、上記第一、第二冷却媒体供給管8A’、9A’の長さ方向の中間部には、冷却媒体供給源と連通している第一、第二冷却媒体導入管8C’、9C’がそれぞれ連結、連通していると共にこれらの第一、第二冷却媒体導入管8C’、9C’に三方切替弁16’、17’を介して加熱媒体供給源に連通した第一、第二予備加熱媒体供給管18' 、19' をそれぞれ接続してあり、更に、上記第一、第二冷却媒体導出管8B’、9B’の長さ方向の中間部には、開閉バルブ20' 、21' を有する第一、第二冷却媒体導出管8D’、9D’がそれぞれ連通している。
【００３５】
又、これらの雌雄金型１、２における成形壁部1a、2a内に配設している上記第一、第二加熱管路4A、4A' 、4B、4B' の一部は全長に亘って成形壁部1a、2aの外周面から突出させていると共に、成形壁部1a、2aの外周面を断熱材22、22' によってそれぞれ被覆してあり、この断熱材22、22' の内面を成形壁部1a、2aの外周面から突出している第一、第二加熱管路4A、4A' 、4B、4B' の突出端に密接させて断熱材22、22' の内面と成形壁部1a、2aの外周面との間に空間部23、23' をそれぞれ形成している。
【００３６】
次に、上記成形型を用いた合成樹脂発泡体の製造方法について説明する。この合成樹脂発泡体の製造方法は、雌雄型１、２を型締めして雌雄型１、２の成形壁部1a、2aの成形型面1b、2bによってキャビティ３を形成する型閉め工程と、このキャビティ３内に発泡性樹脂粒子を充填する充填工程と、上記発泡性樹脂粒子を発泡させる加熱発泡工程と、上記キャビティ３内の合成樹脂発泡体を冷却する冷却工程と、上記雌雄型１、２を型開きして上記合成樹脂発泡体を取り出す型開き工程とを一連の成形工程とし、この成形工程を繰り返して行なうものである。なお、上記発泡性樹脂粒子とは、ポリスチレン等の熱可塑性樹脂に、プロパン、ブタン、ペンタン等の揮発性発泡剤を含浸させものを必要に応じて予備発泡させてなる発泡可能な粒子である。
【００３７】
具体的には、先の成形工程の型開き工程の後又は型開き工程の始まり若しくは途上から、第一、第二冷却媒体導入管8C、9C、8C' 、9C' をその三方切替弁16、17、16' 、17' を調整して第一、第二予備加熱媒体供給管18、19、18' 、19' 側、即ち、加熱媒体供給源側に開放し、この加熱媒体供給源から予備加熱のための予備加熱媒体を第一、第二予備加熱媒体供給管18、19、18' 、19' 、第一、第二冷却媒体導入管8C、9C、8C' 、9C' 及び第一、第二冷却媒体供給管8A、9A、8A'、9A' を通じて上記雌雄型１、２の第一、第二冷却管路5A、5B、5A' 、5B' 内に予備加熱媒体を流通させて雌雄型１、２の成形壁部1a、2aを予備加熱すると共に、上記雌雄型１、２の第一、第二冷却管路5A、5B、5A' 、5B' から流出された予備加熱媒体は、第一、第二冷却媒体排出管8B、9B、8B' 、9B' 及び第一、第二冷却媒体導出管8D、9D、8D' 、9D' を通じて外部に排出される。
【００３８】
なお、予備加熱媒体の温度は、上記発泡性樹脂粒子が二次発泡を開始しない温度とされ、又、加熱媒体としては、蒸気、熱湯、加熱オイル等の何れであってもよいが、取り扱い性の容易さから蒸気が好ましい。
【００３９】
この時、上記雌型１（雄型２）の複数本の第一冷却管路5A（5A' ）内の予備加熱媒体は全て、同一方向に流通していると共に、上記雌型１（雄型２）の複数本の第二冷却管路5B（5B' ）内の予備加熱媒体は全て、上記第一冷却管路5A（5A'）内の予備加熱媒体の流通方向と逆方向に流通し、互いに隣接する第一冷却管路5A（5A' ）と第二冷却管路5B（5B' ）との間において、一方の冷却管路の流通始端側を流通する予備加熱媒体が、他方の冷却管路の流通終端側を流通する予備加熱媒体の加熱効果の低下を互いに補い合っており、よって、上記雌雄型１、２の成形壁部1a、2aは略均一に予備加熱される。
【００４０】
次に、上記雌雄型１、２を型締めして、雌雄型１、２の成形壁部1a、2aの対向面20、30間にキャビティ３を形成し（型締め工程）、続いて、このキャビティ３内に発泡性樹脂粒子を充填する（充填工程）。
【００４１】
なお、上記キャビティ３への発泡性樹脂粒子の充填工程の開始と同時に、第一、第二冷却媒体導出管8D、9D、8D' 、9D' の開閉バルブ20、21、20' 、21' を閉止して、第一、第二冷却管路5A、5B、5A' 、5B' 内の予備加熱媒体の流通を停止し、雌雄型１、２の成形壁部1a、2aの予備加熱を停止する。
【００４２】
しかる後、上記雌型１の第一、第二加熱媒体導入管6C、7Cをその開閉バルブ10、11を調整して開放すると共に、上記雄型２の第一、第二加熱媒体導出管6D' 、7D' をその開閉バルブ12' 、13' を調整して開放状態を維持する一方、上記雄側第一、第二加熱媒体導入管6C' 、7C' をその開閉バルブ10' 、11' を調整して閉止状態を維持すると共に、上記雌側第一、第二加熱媒体導出管6D、7Dをその開閉バルブ12、13を調整して閉止する。
【００４３】
そして、上記雌型１の第一、第二加熱媒体導入管6C、7C及び第一、第二加熱媒体供給管6A、7Aを通じて上記雌型１の第一、第二加熱管路4A、4B内に加熱媒体を流通させ、この加熱媒体をキャビティ３内に流入させて発泡性樹脂粒子を加熱、発泡させた後、上記雄型２の第一、第二加熱管路4A' 、4B' 内に流入させて、第一、第二加熱媒体排出管6B' 、7B' 及び第一、第二加熱媒体導出管6D' 、7D' を通じて外部に排出する（一方加熱）。
【００４４】
次に、上記雄型２の第一、第二加熱媒体導入管6C' 、7C' をその開閉バルブ10' 、11' を調整して開放すると共に、上記雌型１の第一、第二加熱媒体導出管6D、7Dをその開閉バルブ12、13を調整して開放する一方、上記雌型１の第一、第二加熱媒体導入管6C、7Cをその開閉バルブ10、11を調整して閉止すると共に、上記雄型１の第一、第二加熱媒体導出管6D' 、7D' をその開閉バルブ12' 、13' を調整して閉止する。
【００４５】
そして、上記雄型２の第一、第二加熱媒体導入管6C' 、7C' 及び第一、第二加熱媒体供給管6A' 、7A' を通じて上記雄型２の第一、第二加熱管路4A' 、4B' 内に加熱媒体を流通させ、この加熱媒体をキャビティ３内に流入させて発泡性樹脂粒子を加熱、発泡させた後、上記雌型１の第一、第二加熱管路4A、4B内に流入させて、雌型１の第一、第二加熱媒体排出管6B、7B及び第一、第二加熱媒体導出管6D、7Dを通じて外部に排出する（逆一方加熱）。
【００４６】
更に、上記雌雄型１、２の第一、第二加熱媒体導入管6C、7C、6C' 、7C' の全てをその開閉バルブ10、11、10' 、11' を調整して開放或いは開放状態を維持すると共に、上記雌雄型１、２の第一、第二加熱媒体導出管6D、7D、6D' 、7D' をその開閉バルブ12、13、12' 、13' を調整して閉止或いは閉止状態を維持した上で、加熱媒体供給源から第一、第二加熱媒体導入管6C、7C、6C' 、7C' 、第一、第二加熱媒体供給管6A、7A、6A' 、7A' 及び第一、第二加熱管路4A、4B、4A' 、4B' を通じて加熱媒体をキャビティ３内に供給、充満させて発泡性樹脂粒子を完全に発泡させて合成樹脂発泡体とする（両面加熱）。
【００４７】
上記発泡加熱工程において、上記雌型１（雄型２）の複数本の第一加熱管路4A（4A' ）内の予備加熱媒体は全て、同一方向に流通していると共に、上記雌型１（雄型２）の複数本の第二加熱管路4B（4B' ）内の加熱媒体は全て、上記第一加熱管路4A（4A' ）内の加熱媒体の流通方向と逆方向に流通し、互いに隣接する第一加熱管路4A（4A' ）と第二加熱管路4B（4B' ）との間において、一方の加熱管路の流通始端側を流通する加熱媒体が、他方の加熱管路の流通終端側を流通する加熱媒体の加熱効果の低下を補い合っており、よって、上記雌雄型１、２の成形壁部1a、2aは略均一に加熱され、キャビティ３内の発泡性樹脂粒子は全体的に均一に加熱されて高品質な合成樹脂発泡体を得ることができる。
【００４８】
更に、上記雌雄型１、２の成形壁部1a、2aを、これら成形壁部1a、2a内に配管した第一、第二加熱管路4A、4B、4A' 、4B' 内に流通させた加熱媒体によって集中的に加熱しており、上記雌雄型１、２の成形壁部1a、2aを短時間のうちに効果的に加熱することができる。
【００４９】
しかも、上記雌雄型１、２の第一、第二加熱管路4A、4B、4A' 、4B' は、その一部が全長に亘って雌雄型１、２の外周面から突出した状態となっていると共に、上記雌雄型１、２の外周面全面には断熱材22、22' をその内面が上記第一、第二加熱管路4A、4B、4A' 、4B' の突出端に密着した状態に被覆させており、上記断熱材22、22' の内面とこれに対向する雌雄型１、２の外周面との間には空間部23、23' が形成されている。
【００５０】
従って、上記雌雄型２、３の第一、第二加熱管路4A、4B、4A' 、4B' を流通する加熱媒体によって加熱された第一、第二加熱管路4A、4B、4A' 、4B' の雌雄型１、２の外周面から突出した管壁部が上記空間部23、23' 内の空気を加熱し、この加熱された空気によっても上記第一、第二加熱管路4A、4B、4A' 、4B' 間にある雌雄型１、２の成形壁部1a、2aを加熱することができ、上記雌雄型１、２の成形壁部1a、2aを短時間のうちに均一に加熱することができる。
【００５１】
次に、上記第一、第二冷却媒体導入管8C、9C、8C' 、9C' をその三方切替弁16、17、16' 、17' を調整して冷却媒体供給源側に開放させると共に、上記第一、第二冷却媒体導出管8D、9D、8D' 、9D' をその開閉バルブ20、21、20' 、21' を調整して開放させる一方、上記第一、第二加熱媒体導入管6C、7C、6C' 、7C' をその開閉バルブ10、11、10' 、11' を調整して閉止すると共に、上記第一、第二加熱媒体導出管6D、7D、6D' 、7D' をその開閉バルブ12、13、12' 、13' を調整して開放させる。
【００５２】
しかる後、第一、第二冷却媒体導入管8C、9C、8C' 、9C' 及び第一、第二冷却媒体供給管8A、9A、8A' 、9A' を通じて冷却媒体供給源から冷却媒体を雌雄型１、２の第一、第二冷却管路5A、5B、5A' 、5B' に連続的に供給、流通させて雌雄型１、２の成形壁部1a、2aを集中的に冷却してキャビティ３内の合成樹脂発泡体を効果的に冷却した後、第二冷却管路5A、5B、5A' 、5B' から流出させた冷却媒体は、第一、第二冷却媒体排出管8B、9B、8B' 、9B' 及び第一、第二冷却媒体導出管8D、9D、8D' 、9D' を通じて外部に排出される。なお、冷却媒体としては、雌雄型１、２の成形壁部1a、2aを冷却することができれば、特に限定されず、例えば、水等が挙げられる。
【００５３】
この時、上記雌型１（雄型２）の複数本の第一冷却管路5A（5A' ）内の冷却媒体は全て、同一方向に流通していると共に、上記雌型１（雄型２）の複数本の第二冷却管路5B（5B' ）内の冷却媒体は全て、上記第一冷却管路5A（5A' ）内の冷却媒体の流通方向と逆方向に流通し、互いに隣接する第一冷却管路5A（5A' ）と第二冷却管路5B（5B' ）との間において、一方の冷却管路の流通始端側を流通する冷却媒体が、他方の冷却管路の流通終端側を流通する冷却媒体の冷却効果の低下を互いに補い合っており、よって、上記雌雄型１、２の成形壁部1a、2aは略均一に冷却される。
【００５４】
しかも、第一、第二冷却管路5A、5B、5A' 、5B' 内を流通する冷却媒体は、雌雄型１、２の成形壁部1a、2aの冷却に伴って徐々に冷却効果を低下させていくが、上記雌雄型１、２の第一、第二冷却管路5A、5B、5A' 、5B' は全て、互いに独立した管路から形成され、冷却媒体の冷却効果が大きく低下する前に、冷却媒体を第一、第二冷却管路5A、5B、5A' 、5B' から流出させており、よって、冷却効果の大きな状態の冷却媒体によって雌雄型１、２の成形壁部1a、2aを効率的に冷却して短時間のうちにキャビティ３内の合成樹脂発泡体を冷却することができる。
【００５５】
そして、雌雄型１、２の第一、第二冷却管路5A、5B、5A' 、5B' 内を流通する冷却媒体による雌雄型１、２の成形壁部1a、2aの冷却と同時に、第一、第二加熱媒体導出管6D、7D、6D' 、7D' の真空ポンプ14、15、14' 、15' を作動させて第一、第二加熱管路4A、4B、4A' 、4B' を通じてキャビティ３内を真空吸引して合成樹脂発泡体に付着した水分を気化させ、この気化熱によって合成樹脂発泡体を冷却させる。
【００５６】
このように、上記成形型は、冷却媒体とキャビティ３内の真空吸引とによってキャビティ３内の合成樹脂発泡体を均一に且つ短時間のうちに確実に冷却することができる。
【００５７】
続いて、上記第一、第二加熱媒体導出管6D、7D、6D' 、7D' の真空ポンプ14、15、14' 、15' を停止させる一方、上記雌雄型１、２のキャビティ３内に空気を送り込みつつ上記雌雄型１、２を型開きして合成樹脂発泡体を取り出す（型開き工程）。そして、この雌雄型１、２の型開き工程の後又は型開き工程の始まり若しくは途上から、この型開き工程に続いて行われる次の成形工程の型締め工程に至るまで、第一、第二冷却媒体導入管8C、9C、8C' 、9C' をその三方切替弁16、17、16' 、17' を調整して第一、第二予備加熱媒体供給管18、19、18' 、19' 側、即ち、加熱媒体供給源側に開放し、この加熱媒体供給源から予備加熱のための予備加熱媒体を第一、第二予備加熱媒体供給管18、19、18' 、19' 、第一、第二冷却媒体導入管8C、9C、8C' 、9C' 及び第一、第二冷却媒体供給管8A、9A、8A'、9A' を通じて上記雌雄型１、２の第一、第二冷却管路5A、5B、5A' 、5B' 内に予備加熱媒体を流通させて雌雄型１、２の成形壁部1a、2aを予備加熱すると共に、上記雌雄型１、２の第一、第二冷却管路5A、5B、5A' 、5B' から流出した予備加熱媒体は、第一、第二冷却媒体排出管8B、9B、8B' 、9B' 及び第一、第二冷却媒体導出管8D、9D、8D' 、9D' を通じて外部に排出される。
【００５８】
このように、上記雌雄型１、２の型開き工程の後又は型開き工程の始まり若しくは途上から、この型開き工程に続いて行われる型締め工程に至るまでの間に、上記雌雄型１、２の成形壁部1a、2aに予備加熱媒体を流通させて、上記雌雄型１、２の成形壁部1a、2aを予備加熱していることから、上記加熱発泡工程において、雌雄型１、２の成形壁部1a、2aを所望温度に短時間のうちに確実に加熱することができる。そして、上記一連の成形工程を繰り返して行うことによって、良質な合成樹脂発泡体を連続的に短時間のうちに確実に製造することができる。
【００５９】
【発明の効果】
請求項１に記載の合成樹脂発泡体の製造方法は、一対の雌雄型の成形壁部間にキャビティを形成する型締め工程と、このキャビティ内に発泡性樹脂粒子を充填する充填工程と、上記雌雄型の成形壁部内に形成された加熱管路内に加熱媒体を流通させ、上記発泡性樹脂粒子を加熱、発泡させる加熱発泡工程と、上記キャビティ内の合成樹脂発泡体を冷却する冷却工程と、上記雌雄型を型開きして上記合成樹脂発泡体を取り出す型開き工程とを一連の成形工程とし、この成形工程を繰り返して行う合成樹脂発泡体の製造方法であって、上記冷却工程は、上記雌雄型の成形壁部内に配設された複数本の第一冷却管路内に冷却媒体を同一方向に流通させると共に、上記第一冷却管路と交互に配設された複数本の第二冷却管路内に上記第一冷却管路内の冷却媒体の流通方向と逆方向に冷却媒体を流通させることにより行うことを特徴とするので、互いに隣接する第一冷却管路と第二冷却管路との間において、一方の冷却管路の流通終端側を流通する冷却媒体の冷却効果の低下を、他方の冷却管路の流通始端側を流通する冷却媒体によって補っており、よって、雌雄型の成形壁部を第一、第二冷却管路内を流通する冷却媒体によって集中的に均一にして確実に冷却することができる。
【００６０】
しかも、第一、第二冷却管路は互いに独立した管路に形成し、第一、第二冷却管路内を流通する冷却媒体の冷却効果が大きく低下する前に、第一、第二冷却管路から冷却媒体を排出しており、冷却効果の大きい状態の冷却媒体によって雌雄型の成形壁部を短時間のうちに確実に冷却して、雌雄型間のキャビティ内の合成樹脂発泡体を効果的に冷却することができる。
【００６１】
請求項２に記載の合成樹脂発泡体の製造方法は、請求項１に記載の合成樹脂発泡体の製造方法であって、冷却工程において、上記雌雄型の冷却管路内に冷却媒体を流通させると共に、上記雌雄型の加熱管路を通じてキャビティ内を真空吸引することを特徴とするので、冷却媒体による冷却と真空吸引による冷却とを同時に行ってキャビティ内の合成樹脂発泡体をより短時間のうちに確実に冷却することができる。
【００６２】
請求項３に記載の合成樹脂発泡体の製造方法は、請求項１又は請求項２に記載の合成樹脂発泡体の製造方法であって、加熱発泡工程において、雌雄型の成形壁部内に配設された複数本の第一加熱管路内に加熱媒体を同一方向に流通させると共に、上記第一加熱管路に対して交互に配設された複数本の第二加熱管路内に上記第一加熱管路内の加熱媒体の流通方向と逆方向に加熱媒体を流通させることにより行うことを特徴とするので、互いに隣接する第一加熱管路と第二加熱管路との間において、一方の加熱管路の流通終端側を流通する加熱媒体の加熱効果の低下を、他方の加熱管路の流通始端側を流通する加熱媒体によって補っており、よって、雌雄型の成形壁部を第一、第二加熱管路内を流通する加熱媒体によって均一に且つ確実に加熱して、発泡性樹脂粒子を均一に且つ確実に加熱、発泡させて良質の合成樹脂発泡体を得ることができる。
【００６３】
請求項４に記載の合成樹脂発泡体の製造方法は、請求項１乃至請求項３の何れか１項に記載の合成樹脂発泡体の製造方法において、型開き工程の後又は型開き工程の始まり若しくは途上から、次の成形工程の型締め工程に至るまで、雌雄型の冷却管路内に加熱媒体を流通させて、成形壁部を加熱することを特徴とするので、加熱発泡工程の前に雌雄型の成形壁部を予め加熱し、次に行われる加熱発泡工程において、雌雄型の成形壁部を短時間のうちに所望温度に加熱して、キャビティ内の発泡性樹脂粒子を短時間のうちに完全に発泡させることができる。
【００６４】
請求項５に記載の成形型は、一対の雌雄型の成形壁部内に、冷却媒体を同一方向に流通させる複数本の第一冷却管路と、この第一冷却管路と交互に配設され且つ上記第一冷却管路内の冷却媒体の流通方向と逆方向に冷却媒体を流通させる複数本の第二冷却管路と、上記雌雄型の成形壁部間に形成されるキャビティに連結、連通し且つ加熱媒体を流通させる加熱管路とを形成していることを特徴とするので、互いに隣接する第一冷却管路と第二冷却管路との間において、一方の冷却管路の流通終端側を流通する冷却媒体の冷却効果の低下を、他方の冷却管路の流通始端側を流通する冷却媒体によって補っており、よって、雌雄型の成形壁部を第一、第二冷却管路内を流通する冷却媒体によって集中的に均一にして確実に冷却することができる。
【００６５】
しかも、第一、第二冷却管路は互いに独立した管路に形成し、第一、第二冷却管路内を流通する冷却媒体の冷却効果が大きく低下する前に、第一、第二冷却管路から冷却媒体を排出しており、冷却効果の大きな状態の冷却媒体によって雌雄型の成形壁部を短時間のうちに確実に冷却して、雌雄型間のキャビティ内の合成樹脂発泡体を効果的に冷却することができる。
【００６６】
請求項６に記載の成形型は、請求項５に記載の成形型において、加熱管路は、加熱媒体を同一方向に流通させる複数本の第一加熱管路と、この第一加熱管路と交互に配設され且つ上記第一加熱管路内の加熱媒体の流通方向と逆方向に加熱媒体を流通させる複数本の第二加熱管路とからなることを特徴とするので、互いに隣接する第一加熱管路と第二加熱管路との間において、一方の加熱管路の流通終端側を流通する加熱媒体の加熱効果の低下を、他方の加熱管路の流通始端側を流通する加熱媒体によって補っており、よって、雌雄型の成形壁部を第一、第二加熱管路内を流通する加熱媒体によって均一に且つ確実に加熱して、発泡性樹脂粒子を均一に且つ確実に加熱、発泡させて良質の合成樹脂発泡体を得ることができる。
【００６７】
請求項７に記載の成形型は、請求項６に記載の成形型において、互いに隣接する加熱管路間に冷却管路を配設していることを特徴とするので、加熱発泡工程後における雌雄型の成形壁部の冷却を、加熱媒体によって加熱された状態の加熱管路の両側から効率良く且つ確実に行って雌雄型の成形壁部の冷却を短時間のうちに確実に行うことができる。
【００６８】
請求項８に記載の成形型は、請求項７に記載の成形型において、雌雄型の加熱管路の一部を成形壁部の外面から突出させていると共に、内面が各加熱管路の突出部に接した断熱材によって雌雄型の成形壁部を被覆することによって断熱材の内面と成形壁部との間に空間部を形成していることを特徴とするので、雌雄型の外面から外方に突出した加熱管路の管壁部によって、この管壁部間の空間部にある空気層を加熱し、この加熱された空気層により雌雄型の成形壁部を重複して加熱することができ、従って、雌雄型の成形壁部をより均一に且つ短時間で所望温度に加熱してキャビティ内の発泡性樹脂粒子を均一に且つ確実に加熱、発泡させることができる。
【図面の簡単な説明】
【図１】本発明の成形型を示した縦断面図である。
【図２】本発明の成形型の雌型を示した斜視図である。
【図３】成形型の雌雄型の成形壁部内に配設された第一、第二加熱管路及び第一、第二冷却管路の一部を示した模式図である。
【図４】雌雄型の第一加熱管路の配管状態を示した模式図である。
【図５】雌雄型の第二加熱管路の配管状態を示した模式図である。
【図６】雌雄型の第一冷却管路の配管状態を示した模式図である。
【図７】雌雄型の第二冷却管路の配管状態を示した模式図である。
【符号の説明】
１雌型
1a 成形壁部
２雄型
2a 成形壁部
３キャビティ
4A、4A' 第一加熱管路
4B、4B' 第二加熱管路
5A、5A' 第一冷却管路
5B、5B' 第二冷却管路
6A、6A' 第一加熱媒体供給管
6B、6B' 第一加熱媒体排出管
7A、7A' 第二加熱媒体供給管
7B、7B' 第二加熱媒体排出管
8A、8A' 第一冷却媒体供給管
8B、8B' 第一冷却媒体排出管
9A、9A' 第二冷却媒体供給管
9B、9B' 第二冷却媒体排出管
22、22' 断熱材
23、23' 空間部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a synthetic resin foam capable of uniformly cooling a synthetic resin foam molded in a cavity formed between a pair of male and female mold walls, and a mold used for the same. .
[0002]
[Prior art]
Conventionally, a method for producing a synthetic resin foam by filling foamable resin particles in a cavity formed between a pair of male and female mold walls and then heating and foaming the foamable resin particles has been widely used. It is used.
[0003]
As such a manufacturing method, Japanese Examined Patent Publication No. 61-14931 discloses that a cavity formed between a pair of male and female mold walls is filled with expandable resin particles, heated, foamed, and then male and female. A method of cooling the synthetic resin foam in the cavity by supplying cooling water into one cooling pipe arranged in a meandering manner in the mold chamber and the molding wall of the female mold is described.
[0004]
However, the cooling water flowing through the cooling pipes arranged in a meandering manner in the female forming wall portion rises in temperature as the female mold is cooled, and cools as it approaches the flow end of the cooling pipe. The effect is reduced, and there is a problem that the female mold cannot be cooled uniformly.
[0005]
[Problems to be solved by the invention]
The present invention relates to a method for producing a synthetic resin foam capable of uniformly cooling a synthetic resin foam molded in a cavity formed between a pair of male and female mold walls, and a mold used for the method. provide.
[0006]
[Means for solving the problems]
The method for producing a synthetic resin foam according to claim 1 includes a mold clamping step of forming a cavity between a pair of male and female mold wall portions, a filling step of filling foamable resin particles in the cavity, and A heating foaming process in which a heating medium is circulated in a heating pipe formed in a male and female mold wall, and the foamable resin particles are heated and foamed; and a cooling process in which the synthetic resin foam in the cavity is cooled. , A mold opening step of opening the male and female molds and taking out the synthetic resin foam as a series of molding steps, a synthetic resin foam manufacturing method that repeats this molding step, the cooling step, The cooling medium is circulated in the same direction through a plurality of first cooling pipes arranged in the male and female molding wall portions, and a plurality of second cooling pipes arranged alternately with the first cooling pipes. Inside the first cooling pipe in the cooling pipe And performing by flowing a cooling medium in the flow direction opposite to the direction of the 却媒 body.
[0007]
And the manufacturing method of the synthetic resin foam of Claim 2 is a manufacturing method of the synthetic resin foam of Claim 1, Comprising: In a cooling process, a cooling medium is put in the said male and female type cooling conduit. 2. The method for producing a synthetic resin foam according to claim 1, wherein the inside of the cavity is vacuum-sucked through the male and female heating conduits while being circulated.
[0008]
Moreover, the manufacturing method of the synthetic resin foam of Claim 3 is a manufacturing method of the synthetic resin foam of Claim 1 or Claim 2, Comprising: In a heating foaming process, in the molding wall part of a male and female type | mold. The heating medium is circulated in the same direction in the plurality of first heating pipes arranged, and the first heating pipe is arranged in the plurality of second heating pipes arranged alternately with the first heating pipe. It is characterized in that the heating medium is circulated in the direction opposite to the flow direction of the heating medium in the heating pipe.
[0009]
Furthermore, the manufacturing method of the synthetic resin foam of Claim 4 is a manufacturing method of the synthetic resin foam of any one of Claim 1 thru | or 3, The mold opening process is after a mold opening process. From the beginning or middle of the process to the mold clamping process of the next molding process, a heating medium is circulated in the male and female cooling pipes to heat the molding wall.
[0010]
The molding die according to claim 5 is provided with a plurality of first cooling conduits for circulating the cooling medium in the same direction in the pair of male and female molding wall portions, and alternately arranged with the first cooling conduits. Connected to a plurality of second cooling pipes that are provided and flow the cooling medium in a direction opposite to the flow direction of the cooling medium in the first cooling pipe line, and a cavity formed between the male and female mold walls. And a heating pipe for communicating the heating medium.
[0011]
According to a sixth aspect of the present invention, there is provided the mold according to the fifth aspect, wherein the heating pipe includes a plurality of first heating pipes for circulating the heating medium in the same direction, and the first heating pipe. And a plurality of second heating pipes that are arranged alternately with the passages and allow the heating medium to flow in a direction opposite to the flow direction of the heating medium in the first heating pipe.
[0012]
Further, the molding die according to claim 7 is the molding die according to claim 6, characterized in that cooling pipes are arranged between adjacent heating pipes.
[0013]
Finally, the mold according to claim 8 is the mold according to claim 7, wherein a part of the male and female heating pipes are projected from the outer surface of the molding wall, and the inner surface is each heating pipe. A space portion is formed between the inner surface of the heat insulating material and the molding wall portion by covering the male and female molding wall portions with the heat insulating material in contact with the projecting portion of the road.
[0014]
[Action]
According to the method for producing a synthetic resin foam of the present invention and the molding die used therefor, the cooling medium is circulated through each of the plurality of first cooling pipes and second cooling pipes disposed in the molding wall. Unlike the conventional case where one long cooling pipe is arranged in a meandering manner, the length of each first cooling pipe and the second cooling pipe is reduced. The cooling effect of the cooling medium on the flow start end side and the flow end side of the cooling pipe is such that the cooling effect is reduced before the cooling effect of the cooling medium flowing through the cooling pipe is greatly reduced. In addition, the male and female molding walls forming the cavity are intensively cooled by circulating a cooling medium in the cooling pipes arranged in the male and female molding walls. To efficiently cool the synthetic resin foam in the cavity. That.
[0015]
In addition, the first cooling pipes and the second cooling pipes are alternately arranged, the flow direction of the cooling medium flowing through the first cooling pipe line, and the flow direction of the cooling medium flowing through the second cooling pipe line And the cooling effect on the flow end side of the cooling medium flowing through the first cooling pipe is more cooled than the cooling effect of the cooling medium on the flow start end side. The cooling medium flowing through the flow starting end side of the second cooling flow conduit adjacent to the flow terminating end side of the first cooling pipe passes through the flow terminating end side of the first cooling pipe. Similarly, the decrease in the cooling effect of the circulating cooling medium is compensated. Similarly, the decrease in the cooling effect of the cooling medium flowing in the distribution end side of the second cooling pipeline is set on the distribution start end side of the first cooling pipeline. The circulating cooling medium is supplemented, and the first cooling pipe and the second cooling pipe pass through these cooling pipes. The decreased amount of the cooling effect of the cooling medium are each other and complement each other.
[0016]
Therefore, according to the method for producing a synthetic resin foam of the present invention and the mold used therefor, the synthetic resin foam in the cavity formed between the molding wall portions of the male and female dies can be effectively and uniformly formed by the cooling medium. Can be cooled to.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
An example of a mold used in the method for producing a synthetic resin foam of the present invention will be described with reference to the drawings. As shown in FIG. 1, the mold is composed of a pair of male and female molds 1 and 2. When these male and female molds 1 and 2 are clamped, the molding wall 1 a of the female mold 1 and the male mold 2 are formed. A cavity 3 having a predetermined shape is formed between the opposing surfaces of the molding wall 2a.
[0018]
As shown in FIGS. 1 to 3, the first heating pipe 4 </ b> A and the second heating pipe 4 </ b> B are formed in the female wall 1 a of the female mold 1 along the molding surface 1 b of the female mold 1. Plural, alternately and parallel to each other, between the adjacent first heating pipeline 4A and the second heating pipeline 4B, and next adjacent to the first heating pipeline 4A and the second heating pipeline The first cooling pipes 5A and the second cooling pipes 5B are arranged alternately and in parallel with each other between 4B.
[0019]
Similarly, in the molding wall 2a of the male mold 2, a plurality of first heating pipes 4A 'and second heating pipes 4B' are alternately arranged along the molding die surface 2b of the male mold 2. Arranged in parallel with each other, between the adjacent first heating pipeline 4A 'and the second heating pipeline 4B', and next between the adjacent first heating pipeline 4A 'and the second heating pipeline 4B' In addition, the first cooling pipes 5A ′ and the second cooling pipes 5B ′ are arranged alternately and in parallel with each other.
[0020]
The first cooling pipes 5A and 5A ′ and the second cooling pipes 5B and 5B ′ are disposed between the adjacent first heating pipes 4A and 4A ′ and the second heating pipes 4B and 4B ′. Only one may be arranged sequentially, but a plurality of sets may be arranged alternately one after another. The first heating pipes 4A and 4A 'and the second heating pipes 4B and 4B' are provided with through holes communicating with the cavity 3 at predetermined intervals in the length direction.
[0021]
Also, the first heating pipes 4A, 4A 'and the second heating pipes 4B, 4B' and the first cooling pipe 5A disposed in the molding walls 1a, 2a of the male and female molds 1, 2, respectively. , 5A 'and the second cooling pipes 5B, 5B' may be arranged in parallel in the vertical direction, but in the figure they are arranged in parallel in the horizontal direction, Both end portions are projected outward from both end surfaces of the molding wall portions 1a and 2a of the male and female molds 1 and 2.
[0022]
The first heating medium supply pipes 6A, 6A ′ and the first heating are formed outside the male and female molds 1, 2 in the direction perpendicular to the pipe lines along the both end faces of the molding wall portions 1a, 2a. The medium discharge pipes 6B and 6B ′ and the second heating medium supply pipes 7A and 7A ′ and the second heating medium discharge pipes 7B and 7B ′ are arranged in parallel to each other, and also the first cooling medium supply pipe 8A, 8A ′ and the first cooling medium discharge pipes 8B and 8B ′, the second cooling medium supply pipes 9A and 9A ′, and the second cooling medium discharge pipes 9B and 9B ′ are arranged in parallel to each other.
[0023]
Specifically, on the female mold 1 side, the first heating medium supply pipe 6A and the second heating medium discharge pipe 7B, and the first cooling medium supply pipe 8A and the second cooling are formed along one end surface of the molding wall 1a. The medium discharge pipe 9B is disposed, and the second heating medium supply pipe 7A, the first heating medium discharge pipe 6B, and the second cooling medium supply pipe 9A are arranged along the other end surface of the molding wall 1a. A first cooling medium discharge pipe 8B is disposed, and one end portion of the first heating pipe line 4A protruding from one end face of the molding wall 1a is connected to the first heating medium supply pipe 6A, and the molding wall 1a. The other ends of the first heating pipes 4A protruding from the other end surface of the second heating pipe are connected to and communicated with the first heating medium discharge pipe 6B at regular intervals in the length direction, and the second heating pipe One end of the path 4B is connected to the second heating medium discharge pipe 7B and the other end is connected to the second heating medium supply pipe 7A at regular intervals in the length direction. There.
[0024]
Accordingly, as shown in FIGS. 4 and 5, the circulation of the heating medium that is supplied from the first heating medium supply pipe 6A into the first heating pipe lines 4A all at once and flows out to the first heating medium discharge pipe 6B side. The direction of the heating medium flowing from the second heating medium supply pipe 7A into each second heating pipe line 4B and flowing out to the second heating medium discharge pipe 7B is opposite to each other. It is configured.
[0025]
Further, one end of the first cooling pipe 5A protruding from one end surface of the molding wall 1a of the female mold 1 is connected to the first cooling medium supply pipe 8A, and the first protruding from the other end surface of the molding wall 1a. The other end of one cooling pipe 5A is connected to and communicated with the first cooling medium discharge pipe 8B at regular intervals in the length direction, and one end of the second cooling pipe 5B is connected to the second heating medium. The other end of the discharge pipe 9B is connected to and communicated with the second cooling medium supply pipe 9A at regular intervals in the length direction.
[0026]
Accordingly, as shown in FIGS. 6 and 7, the circulation of the cooling medium that is supplied all at once from the first cooling medium supply pipe 8A into each first cooling pipe line 5A and flows out to the first cooling medium discharge pipe 8B side. And the flow direction of the heating medium that is supplied all at once from the second cooling medium supply pipe 9A into each second cooling pipe line 5B and flows out to the second cooling medium discharge pipe 9B side. It is configured.
[0027]
First and second heating medium introduction pipes 6C and 7C having on-off valves 10 and 11, respectively, are connected to and communicated with intermediate portions in the length direction of the first and second heating medium supply pipes 6A and 7A. The first and second heating medium introduction pipes 6C and 7C communicate with the heating medium supply source, and open and close at the intermediate portions in the length direction of the first and second heating medium discharge pipes 6B and 7B, respectively. First and second heating medium outlet pipes 6D and 7D having valves 12 and 13 and vacuum pumps 14 and 15 are connected and communicated with each other.
[0028]
On the other hand, the first and second cooling medium supply pipes 8A and 9A are connected to first and second cooling medium introduction pipes 8C and 9C, respectively, in communication with the cooling medium supply source, at intermediate portions in the length direction. The first and second preheating medium supply pipes 18 and 19 communicated with the first and second cooling medium introduction pipes 8C and 9C through the three-way switching valves 16 and 17 and the heating medium supply source. Further, the first and second cooling medium outlet pipes 8D and 9D having opening / closing valves 20 and 21 at intermediate portions in the longitudinal direction of the first and second cooling medium discharge pipes 8B and 9B, respectively. Communicate with each other.
[0029]
Similarly, on the male mold 2 side, the first heating medium supply pipe 6A ′, the second heating medium discharge pipe 7B ′, and the first cooling medium supply pipe 8A ′ are arranged along one end surface of the molding wall 2a. The second cooling medium discharge pipe 9B ′ is disposed, and the second heating medium supply pipe 7A ′, the first heating medium discharge pipe 6B ′, and the second heating medium supply pipe 7A ′ are disposed along the other end surface of the molding wall 2a. A cooling medium supply pipe 9A ′ and a first cooling medium discharge pipe 8B ′ are arranged, and one end portion of the first heating pipe line 4A ′ protruding from one end surface of the molding wall portion 2a is connected to the first heating medium. The other end of these first heating pipes 4A 'protruding from the other end face of the molding wall 2a is connected to the supply pipe 6A' at regular intervals in the lengthwise direction to the first heating medium discharge pipe 6B '. The one end of the second heating pipe 4B ′ is connected to the second heating medium discharge pipe 7B ′ and the other end is connected to the second heating medium supply pipe 7A ′ at regular intervals in the length direction. The coupling, are communicated.
[0030]
Therefore, as shown in FIGS. 4 and 5, the heating that is supplied from the first heating medium supply pipe 6A ′ into the first heating pipes 4A ′ and flows out to the first heating medium discharge pipe 6B ′. The flow direction of the medium and the flow direction of the heating medium that is supplied all at once from the second heating medium supply pipe 7A ′ into the second heating pipe lines 4B ′ and flows out to the second heating medium discharge pipe 7B ′ side are mutually It is comprised so that it may become reverse direction.
[0031]
Further, one end portion of the first cooling pipe 5A ′ protruding from one end surface of the molding wall portion 2a of the male mold 2 protrudes from the other end surface of the molding wall portion 2a to the first cooling medium supply pipe 8A ′. The other end is connected to and communicated with the first cooling medium discharge pipe 8B ′ at regular intervals in the lengthwise direction, and one end of the second cooling pipe 5B ′ is connected to the second heating medium discharge pipe 9B ′. The other end is connected to and communicated with the second cooling medium supply pipe 9A ′ at regular intervals in the length direction.
[0032]
Accordingly, as shown in FIG. 6 and FIG. 7, the cooling that is supplied from the first cooling medium supply pipe 8A ′ into the first cooling pipes 5A ′ and flows out to the first cooling medium discharge pipe 8B ′. The flow direction of the medium and the flow direction of the heating medium that is supplied all at once from the second cooling medium supply pipe 9A ′ into each second cooling pipe line 5B ′ and flows out to the second cooling medium discharge pipe 9B ′ side are mutually It is comprised so that it may become reverse direction.
[0033]
First and second heating medium introduction pipes 6C ′ and 7C ′ having opening / closing valves 10 ′ and 11 ′, respectively, are provided at intermediate portions in the length direction of the first and second heating medium supply pipes 6A ′ and 7A ′. These first and second heating medium introduction pipes 6C ′ and 7C ′ communicate with the heating medium supply source and are connected to the first and second heating medium discharge pipes 6B ′ and 7B ′. First and second heating medium outlet pipes 6D ′ and 7D ′ having open / close valves 12 ′ and 13 ′ and vacuum pumps 14 ′ and 15 ′ are connected to and communicated with the intermediate portion in the length direction.
[0034]
On the other hand, the first and second cooling medium supply pipes 8C ′ and 9C ′ communicated with the cooling medium supply source at the intermediate portion in the length direction of the first and second cooling medium supply pipes 8A ′ and 9A ′. Are connected to and communicated with the first and second cooling medium introduction pipes 8C ′ and 9C ′ through the three-way switching valves 16 ′ and 17 ′ and the first and second spares, respectively. Heating medium supply pipes 18 ′ and 19 ′ are connected to each other, and on the intermediate portions in the longitudinal direction of the first and second cooling medium outlet pipes 8B ′ and 9B ′, open / close valves 20 ′ and 21 ′ are connected. The first and second cooling medium outlet pipes 8D ′ and 9D ′ each having are communicated with each other.
[0035]
In addition, a part of the first and second heating pipes 4A, 4A ′, 4B, 4B ′ disposed in the molding walls 1a, 2a of the male and female molds 1, 2 extends over the entire length. The molded wall portions 1a and 2a are projected from the outer peripheral surface, and the outer peripheral surfaces of the molded wall portions 1a and 2a are covered with heat insulating materials 22 and 22 ', respectively, and the inner surfaces of the heat insulating materials 22 and 22' are molded. The inner surfaces of the heat insulating materials 22 and 22 ′ and the molding wall 1a are brought into close contact with the protruding ends of the first and second heating pipes 4A, 4A ′, 4B and 4B ′ protruding from the outer peripheral surfaces of the walls 1a and 2a, Space portions 23 and 23 'are formed between the outer peripheral surface of 2a.
[0036]
Next, the manufacturing method of the synthetic resin foam using the said shaping | molding die is demonstrated. The synthetic resin foam manufacturing method includes a mold closing step in which the male and female molds 1 and 2 are clamped to form the cavity 3 by the molding wall surfaces 1b and 2b of the male and female molds 1 and 2; A filling step of filling the foamable resin particles in the cavity 3, a heating foaming step of foaming the foamable resin particles, a cooling step of cooling the synthetic resin foam in the cavity 3, the male and female molds 1, The mold opening process in which 2 is opened to take out the synthetic resin foam is a series of molding processes, and this molding process is repeated. The expandable resin particles are expandable particles obtained by impregnating a thermoplastic resin such as polystyrene with a volatile foaming agent such as propane, butane, or pentane, and pre-foaming as necessary.
[0037]
Specifically, the first and second cooling medium introduction pipes 8C, 9C, 8C ′, 9C ′ are connected to the three-way switching valve 16, after the mold opening process of the previous molding process or from the beginning or middle of the mold opening process. 17, 16 ', 17' are adjusted and opened to the first and second preliminary heating medium supply pipes 18, 19, 18 ', 19' side, that is, the heating medium supply source side, and the preliminary heating medium supply line is opened from this heating medium supply source. Preheating medium for heating is first, second preheating medium supply pipes 18, 19, 18 ′, 19 ′, first, second cooling medium introduction pipes 8C, 9C, 8C ′, 9C ′ and first, A preheating medium is circulated in the first and second cooling pipes 5A, 5B, 5A 'and 5B' of the male and female molds 1 and 2 through the second cooling medium supply pipes 8A, 9A, 8A 'and 9A'. The preheating medium flowing out from the first and second cooling pipes 5A, 5B, 5A ′ and 5B ′ of the male and female molds 1 and 2 is preheated to the molding walls 1a and 2a of the molds 1 and 2, First and second cooling medium discharge pipes 8B, 9B, 8B ', 9B' and First, the second cooling medium discharge pipe 8D, 9D, 8D ', 9D' is discharged to the outside through.
[0038]
The temperature of the preheating medium is such that the expandable resin particles do not start secondary foaming, and the heating medium may be any of steam, hot water, heating oil, etc. Steam is preferable because of its ease.
[0039]
At this time, all of the preheating media in the plurality of first cooling pipes 5A (5A ') of the female mold 1 (male mold 2) are circulated in the same direction, and the female mold 1 (male mold). 2) all of the preheating medium in the plurality of second cooling pipes 5B (5B ') flow in the direction opposite to the flow direction of the preheating medium in the first cooling pipe 5A (5A'), Between the first cooling pipe 5A (5A ') and the second cooling pipe 5B (5B') adjacent to each other, the preheating medium flowing through the flow start end side of one cooling pipe is the other cooling pipe. This compensates for a decrease in the heating effect of the preheating medium flowing on the flow end side of the path, so that the molding wall portions 1a and 2a of the male and female molds 1 and 2 are preheated substantially uniformly.
[0040]
Next, the male and female molds 1 and 2 are clamped to form a cavity 3 between the opposing surfaces 20 and 30 of the molding wall portions 1a and 2a of the male and female molds 1 and 2 (clamping process). Fill the cavity 3 with expandable resin particles (filling step).
[0041]
The opening and closing valves 20, 21, 20 ', 21' of the first and second cooling medium outlet pipes 8D, 9D, 8D ', 9D' are connected simultaneously with the start of the filling process of the expandable resin particles into the cavity 3. Close and stop the flow of the preheating medium in the first and second cooling pipes 5A, 5B, 5A ′ and 5B ′, and stop the preheating of the molding wall portions 1a and 2a of the male and female molds 1 and 2 .
[0042]
Thereafter, the first and second heating medium introduction pipes 6C and 7C of the female mold 1 are opened by adjusting the opening and closing valves 10 and 11, and the first and second heating medium outlet pipes 6D of the male mold 2 are opened. ', 7D' is adjusted to maintain its open / close valves 12 ', 13', while the male side first and second heating medium introduction pipes 6C ', 7C' are connected to the open / close valves 10 ', 11'. Is adjusted to maintain the closed state, and the female first and second heating medium outlet pipes 6D and 7D are closed by adjusting the opening and closing valves 12 and 13 thereof.
[0043]
Then, in the first and second heating pipes 4A and 4B of the female mold 1 through the first and second heating medium introduction pipes 6C and 7C of the female mold 1 and the first and second heating medium supply pipes 6A and 7A. The heating medium is circulated through the inside, and the heating medium is allowed to flow into the cavity 3 to heat and foam the expandable resin particles, and then into the first and second heating pipes 4A ′ and 4B ′ of the male mold 2. Then, it is discharged to the outside through the first and second heating medium discharge pipes 6B ′ and 7B ′ and the first and second heating medium discharge pipes 6D ′ and 7D ′ (one heating).
[0044]
Next, the first and second heating medium introduction pipes 6C 'and 7C' of the male mold 2 are opened by adjusting the opening and closing valves 10 'and 11', and the first and second heating of the female mold 1 are opened. The medium outlet pipes 6D and 7D are opened by adjusting the opening and closing valves 12 and 13, while the first and second heating medium introduction pipes 6C and 7C of the female mold 1 are closed by adjusting the opening and closing valves 10 and 11. At the same time, the first and second heating medium outlet pipes 6D ′ and 7D ′ of the male mold 1 are closed by adjusting their opening / closing valves 12 ′ and 13 ′.
[0045]
The first and second heating pipes of the male mold 2 are passed through the first and second heating medium introduction pipes 6C ′ and 7C ′ of the male mold 2 and the first and second heating medium supply pipes 6A ′ and 7A ′. A heating medium is circulated in 4A ′ and 4B ′, and this heating medium is caused to flow into the cavity 3 to heat and foam the expandable resin particles, and then the first and second heating lines 4A of the female mold 1 are used. 4B and discharged to the outside through the first and second heating medium discharge pipes 6B and 7B and the first and second heating medium outlet pipes 6D and 7D of the female mold 1 (reverse one-side heating).
[0046]
Further, the first and second heating medium introduction pipes 6C, 7C, 6C ′, 7C ′ of the male and female molds 1, 2 are all opened or opened by adjusting their opening / closing valves 10, 11, 10 ′, 11 ′. And the first and second heating medium outlet pipes 6D, 7D, 6D 'and 7D' of the male and female dies 1 and 2 are closed or closed by adjusting the opening and closing valves 12, 13, 12 'and 13'. While maintaining the state, from the heating medium supply source, the first and second heating medium introduction pipes 6C, 7C, 6C ′, 7C ′, the first and second heating medium supply pipes 6A, 7A, 6A ′, 7A ′ and A heating medium is supplied and filled into the cavity 3 through the first and second heating pipes 4A, 4B, 4A ′ and 4B ′ to completely foam the foamable resin particles to obtain a synthetic resin foam (double-sided heating). .
[0047]
In the foaming heating step, all the preheating media in the plurality of first heating pipes 4A (4A ′) of the female mold 1 (male mold 2) are circulated in the same direction, and the female mold 1 All of the heating media in the plurality of second heating pipes 4B (4B ') of the (male mold 2) flow in the direction opposite to the flow direction of the heating medium in the first heating pipe 4A (4A'). Between the first heating pipe line 4A (4A ') and the second heating pipe line 4B (4B') adjacent to each other, the heating medium flowing through the flow starting end side of one heating pipe line is the other heating pipe This compensates for the decrease in the heating effect of the heating medium flowing on the flow end side of the path. Therefore, the molding wall portions 1a and 2a of the male and female molds 1 and 2 are heated substantially uniformly, and the expandable resin particles in the cavity 3 Can be heated uniformly throughout to obtain a high-quality synthetic resin foam.
[0048]
Further, the molding wall portions 1a and 2a of the male and female molds 1 and 2 were circulated in the first and second heating pipes 4A, 4B, 4A ′ and 4B ′ piped in the molding wall portions 1a and 2a. Heating is intensively performed by the heating medium, and the molding wall portions 1a and 2a of the male and female dies 1 and 2 can be effectively heated within a short time.
[0049]
In addition, the first and second heating pipes 4A, 4B, 4A ′ and 4B ′ of the male and female molds 1 and 2 are partially protruded from the outer peripheral surface of the male and female molds 1 and 2 over the entire length. In addition, heat insulating materials 22 and 22 ′ are adhered to the entire outer peripheral surfaces of the male and female molds 1 and 2 and the inner surfaces thereof are in close contact with the protruding ends of the first and second heating pipes 4A, 4B, 4A ′ and 4B ′. Space portions 23 and 23 ′ are formed between the inner surfaces of the heat insulating materials 22 and 22 ′ and the outer peripheral surfaces of the male and female molds 1 and 2 facing the heat insulating materials 22 and 22 ′.
[0050]
Therefore, the first and second heating pipes 4A, 4B, 4A ′ heated by the heating medium flowing through the first and second heating pipes 4A, 4B, 4A ′, 4B ′ of the male and female molds 2, 3 The tube wall portion protruding from the outer peripheral surface of the male and female molds 1 and 2 of 4B ′ heats the air in the space portions 23, 23 ′, and the first and second heating pipe lines 4A, 4A, The molding wall portions 1a, 2a of the male and female molds 1 and 2 between 4B, 4A 'and 4B' can be heated, and the molding wall portions 1a, 2a of the male and female molds 1, 2 can be made uniform in a short time. Can be heated.
[0051]
Next, the first and second cooling medium introduction pipes 8C, 9C, 8C ′, 9C ′ are adjusted to their three-way switching valves 16, 17, 16 ′, 17 ′ and opened to the cooling medium supply source side, The first and second cooling medium outlet pipes 8D, 9D, 8D ′, 9D ′ are opened by adjusting the opening / closing valves 20, 21, 20 ′, 21 ′, while the first and second heating medium introduction pipes are opened. 6C, 7C, 6C ′, 7C ′ are closed by adjusting their opening / closing valves 10, 11, 10 ′, 11 ′, and the first and second heating medium outlet pipes 6D, 7D, 6D ′, 7D ′ are closed. The opening / closing valves 12, 13, 12 'and 13' are adjusted and opened.
[0052]
Thereafter, the cooling medium is supplied from the cooling medium supply source through the first and second cooling medium introduction pipes 8C, 9C, 8C ′, 9C ′ and the first and second cooling medium supply pipes 8A, 9A, 8A ′, 9A ′. Continuously supply and distribute the first and second cooling pipes 5A, 5B, 5A 'and 5B' of the molds 1 and 2 to cool the molding wall portions 1a and 2a of the male and female molds 1 and 2 intensively. After the synthetic resin foam in the cavity 3 is effectively cooled, the cooling medium discharged from the second cooling pipes 5A, 5B, 5A ′, 5B ′ is the first and second cooling medium discharge pipes 8B, 9B. , 8B ′, 9B ′ and the first and second cooling medium outlet pipes 8D, 9D, 8D ′, 9D ′. The cooling medium is not particularly limited as long as the molding wall portions 1a and 2a of the male and female dies 1 and 2 can be cooled, and examples thereof include water.
[0053]
At this time, all of the cooling medium in the plurality of first cooling pipes 5A (5A ') of the female mold 1 (male mold 2) circulates in the same direction, and the female mold 1 (male mold 2). ) All of the cooling medium in the plurality of second cooling pipes 5B (5B ') flow in the direction opposite to the flow direction of the cooling medium in the first cooling pipe 5A (5A') and are adjacent to each other. Between the first cooling pipe line 5A (5A ') and the second cooling pipe line 5B (5B'), the cooling medium flowing through the flow start end side of one cooling pipe line is the flow end point of the other cooling pipe line This compensates for a decrease in the cooling effect of the cooling medium flowing through the sides, so that the molding wall portions 1a, 2a of the male and female molds 1, 2 are cooled substantially uniformly.
[0054]
In addition, the cooling medium flowing through the first and second cooling pipes 5A, 5B, 5A ′, 5B ′ gradually decreases the cooling effect as the molding walls 1a, 2a of the male and female molds 1, 2 are cooled. However, the first and second cooling pipelines 5A, 5B, 5A 'and 5B' of the male and female dies 1 and 2 are all formed from mutually independent pipelines, and the cooling effect of the cooling medium is greatly reduced. Before, the cooling medium has flowed out from the first and second cooling pipelines 5A, 5B, 5A ′, 5B ′, and therefore, the molding wall portions 1a of the male and female molds 1, 2 are cooled by the cooling medium having a large cooling effect. , 2a can be efficiently cooled to cool the synthetic resin foam in the cavity 3 in a short time.
[0055]
The first and second cooling pipes 5A, 5B, 5A ′, 5B ′ of the male and female molds 1 and 2 are cooled simultaneously with the cooling of the molding wall portions 1a and 2a of the male and female molds 1 and 2a. First, second heating medium outlet pipes 6D, 7D, 6D ′, 7D ′ are operated by operating vacuum pumps 14, 15, 14 ′, 15 ′ and first, second heating pipe lines 4A, 4B, 4A ′, 4B ′ The inside of the cavity 3 is vacuum-sucked to vaporize moisture adhering to the synthetic resin foam, and the synthetic resin foam is cooled by this heat of vaporization.
[0056]
As described above, the molding die can cool the synthetic resin foam in the cavity 3 uniformly and within a short time by the cooling medium and the vacuum suction in the cavity 3.
[0057]
Subsequently, the vacuum pumps 14, 15, 14 ', 15' of the first and second heating medium outlet pipes 6D, 7D, 6D ', 7D' are stopped, while the cavities 3 of the male and female dies 1, 2 are stopped. The male and female molds 1 and 2 are opened while air is fed to take out the synthetic resin foam (mold opening process). Then, after the mold opening process of the male and female dies 1 and 2 or from the beginning or the middle of the mold opening process to the mold clamping process of the next molding process performed following this mold opening process, the first and second The cooling medium introduction pipes 8C, 9C, 8C ′, 9C ′ are adjusted by adjusting the three-way switching valves 16, 17, 16 ′, 17 ′, and the first and second preheating medium supply pipes 18, 19, 18 ′, 19 ′ The preheating medium for preheating from the heating medium supply source to the first, second preheating medium supply pipes 18, 19, 18 ', 19', first The first and second cooling pipes of the male and female molds 1 and 2 through the second cooling medium introduction pipes 8C, 9C, 8C ′ and 9C ′ and the first and second cooling medium supply pipes 8A, 9A, 8A ′ and 9A ′. A preheating medium is circulated in the passages 5A, 5B, 5A ′ and 5B ′ to preheat the molding walls 1a and 2a of the male and female molds 1 and 2, and the first and second cooling of the male and female molds 1 and 2 are performed. From pipelines 5A, 5B, 5A ', 5B' The discharged preheating medium is discharged to the outside through the first and second cooling medium discharge pipes 8B, 9B, 8B ′, 9B ′ and the first and second cooling medium outlet pipes 8D, 9D, 8D ′, 9D ′. .
[0058]
Thus, after the mold opening process of the male and female molds 1 and 2 or from the beginning or middle of the mold opening process to the mold clamping process performed following the mold opening process, the male and female molds 1, In the heating and foaming step, the male and female molds 1 and 2 are preheated by circulating a preheating medium through the molding wall parts 1a and 2a of the two and preheating the molding wall parts 1a and 2a of the male and female molds 1 and 2. The molding wall portions 1a and 2a can be reliably heated to the desired temperature in a short time. By repeating the above-described series of molding steps, a high-quality synthetic resin foam can be continuously and reliably manufactured in a short time.
[0059]
【The invention's effect】
The method for producing a synthetic resin foam according to claim 1 includes a mold clamping step of forming a cavity between a pair of male and female mold wall portions, a filling step of filling foamable resin particles in the cavity, and A heating foaming process in which a heating medium is circulated in a heating pipe formed in a male and female mold wall, and the foamable resin particles are heated and foamed; and a cooling process in which the synthetic resin foam in the cavity is cooled. , A mold opening step of opening the male and female molds and taking out the synthetic resin foam as a series of molding steps, a synthetic resin foam manufacturing method that repeats this molding step, the cooling step, The cooling medium is circulated in the same direction through a plurality of first cooling pipes arranged in the male and female molding wall portions, and a plurality of second cooling pipes arranged alternately with the first cooling pipes. Inside the first cooling pipe in the cooling pipe Since the cooling medium is circulated in the direction opposite to the distribution direction of the rejection medium, the circulation of one cooling line between the first cooling line and the second cooling line adjacent to each other is performed. The decrease in the cooling effect of the cooling medium flowing through the end side is compensated by the cooling medium flowing through the flow starting end side of the other cooling pipe, so that the male and female mold wall portions are the first and second cooling pipes. The cooling medium circulating inside can be intensively made uniform and reliably cooled.
[0060]
In addition, the first and second cooling pipelines are formed as mutually independent pipelines, and before the cooling effect of the cooling medium flowing through the first and second cooling pipelines is greatly reduced, the first and second cooling pipelines are formed. The cooling medium is discharged from the pipeline, and the molding wall of the male and female molds is reliably cooled in a short time by the cooling medium having a large cooling effect, and the synthetic resin foam in the cavity between the male and female molds is cooled. It can be cooled effectively.
[0061]
The method for producing a synthetic resin foam according to claim 2 is the method for producing a synthetic resin foam according to claim 1, wherein a cooling medium is circulated in the male and female cooling pipes in the cooling step. In addition, since the inside of the cavity is vacuum-sucked through the male and female heating pipes, the cooling with the cooling medium and the cooling with the vacuum suction are simultaneously performed, so that the synthetic resin foam in the cavity can be removed in a shorter time. Can be reliably cooled.
[0062]
The method for producing a synthetic resin foam according to claim 3 is the method for producing a synthetic resin foam according to claim 1 or 2, wherein the synthetic resin foam is disposed in the molding wall of the male and female molds in the heating and foaming step. The heating medium is circulated in the same direction in the plurality of first heating pipes, and the first heating pipes are alternately arranged in the plurality of second heating pipes arranged alternately with respect to the first heating pipe. Since the heating medium is circulated in the direction opposite to the flow direction of the heating medium in the heating pipeline, one of the first heating pipeline and the second heating pipeline is adjacent to each other. The decrease in the heating effect of the heating medium flowing through the flow end side of the heating pipe is compensated by the heating medium flowing through the flow start end of the other heating pipe, and thus the male and female mold forming wall portions are first, Heat uniformly and reliably with a heating medium flowing in the second heating pipe. , The expandable resin particles uniformly and reliably heated, it is possible to obtain a good quality synthetic resin foam by foaming.
[0063]
The method for producing a synthetic resin foam according to claim 4 is the method for producing a synthetic resin foam according to any one of claims 1 to 3, wherein after the mold opening step or at the beginning of the mold opening step. Alternatively, from the middle to the mold clamping process of the next molding process, the heating medium is circulated in the male and female cooling pipes to heat the molding wall. The male and female mold walls are pre-heated, and in the next heating and foaming step, the male and female mold walls are heated to a desired temperature within a short period of time, so that the foamable resin particles in the cavity It can be completely foamed.
[0064]
According to a fifth aspect of the present invention, a plurality of first cooling pipes for circulating the cooling medium in the same direction and the first cooling pipes are alternately arranged in the pair of male and female molding walls. And connected to and communicated with a plurality of second cooling pipes for circulating the cooling medium in a direction opposite to the flow direction of the cooling medium in the first cooling pipe, and a cavity formed between the molding wall portions of the male and female molds. And a heating conduit through which the heating medium is circulated, so that the end of circulation of one cooling conduit is between the first cooling conduit and the second cooling conduit that are adjacent to each other. The cooling effect of the cooling medium flowing through the cooling medium is compensated for by the cooling medium flowing through the flow starting end side of the other cooling pipe, so that the male and female mold walls are formed in the first and second cooling pipes. The cooling medium that circulates can be intensively and uniformly cooled.
[0065]
In addition, the first and second cooling pipelines are formed as mutually independent pipelines, and before the cooling effect of the cooling medium flowing through the first and second cooling pipelines is greatly reduced, the first and second cooling pipelines are formed. The cooling medium is discharged from the pipe line, and the molding wall of the male and female molds is reliably cooled in a short time by the cooling medium having a large cooling effect, and the synthetic resin foam in the cavity between the male and female molds is cooled. It can be cooled effectively.
[0066]
The molding die according to claim 6 is the molding die according to claim 5, wherein the heating pipe line includes a plurality of first heating pipe lines for circulating the heating medium in the same direction, and the first heating pipe line. Since it is composed of a plurality of second heating pipes that are alternately arranged and that circulate the heating medium in a direction opposite to the flow direction of the heating medium in the first heating pipe, Between the one heating pipe line and the second heating pipe line, the heating medium flowing through the flow starting end side of the other heating pipe line is reduced in the heating effect of the heating medium flowing through the flow terminal end side of the one heating pipe line. Therefore, the male and female molding walls are uniformly and reliably heated by the heating medium flowing in the first and second heating pipes, and the foamable resin particles are uniformly and reliably heated. A good quality synthetic resin foam can be obtained by foaming.
[0067]
The molding die according to claim 7 is the molding die according to claim 6, characterized in that cooling pipes are disposed between the heating pipes adjacent to each other. Cooling of the molding wall of the mold can be performed efficiently and reliably from both sides of the heating pipeline heated by the heating medium, so that the molding wall of the male and female molds can be reliably cooled in a short time. .
[0068]
The molding die according to claim 8 is the molding die according to claim 7, wherein a part of the male and female heating pipelines are projected from the outer surface of the molding wall portion, and the inner surface is a projection of each heating pipeline. A space is formed between the inner surface of the heat insulating material and the molding wall portion by covering the male and female molding wall portions with the heat insulating material in contact with the portion. The air wall in the space between the tube wall portions is heated by the tube wall portion of the heating pipe line protruding in the direction, and the male and female molding wall portions are heated by overlapping the heated air layer. Therefore, it is possible to heat and foam the foamable resin particles in the cavity uniformly and reliably by heating the molding wall of the male and female molds to a desired temperature more uniformly and in a short time.
[Brief description of the drawings]
FIG. 1 is a longitudinal sectional view showing a molding die of the present invention.
FIG. 2 is a perspective view showing a female die of the molding die of the present invention.
FIG. 3 is a schematic view showing a part of the first and second heating pipes and the first and second cooling pipes disposed in the male and female molding walls of the molding die.
FIG. 4 is a schematic view showing a piping state of a male and female type first heating pipeline.
FIG. 5 is a schematic view showing a piping state of a male and female type second heating pipeline.
FIG. 6 is a schematic view showing a piping state of a male and female first cooling pipe.
FIG. 7 is a schematic view showing a piping state of a male and female second cooling pipe.
[Explanation of symbols]
1 Female
1a Molded wall
2 Male
2a Molded wall
3 cavity
4A, 4A '1st heating pipeline
4B, 4B 'Second heating line
5A, 5A '1st cooling pipeline
5B, 5B 'Second cooling pipeline
6A, 6A '1st heating medium supply pipe
6B, 6B '1st heating medium discharge pipe
7A, 7A 'Second heating medium supply pipe
7B, 7B 'Second heating medium discharge pipe
8A, 8A '1st cooling medium supply pipe
8B, 8B '1st coolant discharge pipe
9A, 9A 'Second coolant supply pipe
9B, 9B 'Second coolant discharge pipe
22, 22 'insulation
23, 23 'space

Claims

A mold clamping step for forming a cavity between a pair of male and female molding wall portions, a filling step for filling the cavity with foamable resin particles, and a heating pipe formed in the molding wall portion of the male and female molds. Circulating a heating medium to heat and foam the foamable resin particles, a cooling process for cooling the synthetic resin foam in the cavity, and opening the male and female molds to open the synthetic resin foam The mold opening process to be taken out is a series of molding processes, and the molding process is repeated to produce a synthetic resin foam, wherein the cooling process includes a plurality of molding walls arranged in the molding wall of the male and female molds. The cooling medium is circulated in the same direction in the first cooling pipe, and the cooling medium in the first cooling pipe is disposed in a plurality of second cooling pipes alternately arranged with the first cooling pipe. The cooling medium is distributed in the direction opposite to the distribution direction of Method for producing a synthetic resin foam, which comprises carrying out the Rukoto.

2. The synthetic resin foam according to claim 1, wherein, in the cooling step, a cooling medium is circulated in the male and female cooling conduits, and the inside of the cavity is vacuumed through the male and female heating conduits. Production method.

In the heating and foaming step, the heating medium is circulated in the same direction through the plurality of first heating pipes arranged in the male and female molding wall portions, and the plurality of the heating mediums arranged alternately with the first heating pipes. The synthesis according to claim 1 or 2, wherein the heating medium is circulated in the second heating line of the book in a direction opposite to the direction of circulation of the heating medium in the first heating line. Manufacturing method of resin foam.

After the mold opening process or from the beginning or the middle of the mold opening process to the mold clamping process of the next molding process, a heating medium is circulated in the male and female cooling pipes to heat the molding wall. The method for producing a synthetic resin foam according to any one of claims 1 to 3, characterized in that:

A plurality of first cooling conduits for allowing the cooling medium to flow in the same direction in the pair of male and female molding wall portions, and cooling in the first cooling conduits, which are alternately arranged with the first cooling conduits A plurality of second cooling pipes for circulating the cooling medium in the direction opposite to the medium flowing direction, and a heating pipe for connecting and communicating with the cavity formed between the male and female molding walls and for circulating the heating medium And forming a mold.

The heating pipe line includes a plurality of first heating pipe lines that allow the heating medium to flow in the same direction, and a flow direction of the heating medium that is alternately arranged with the first heating pipe line and in the first heating pipe line. The mold according to claim 5, comprising a plurality of second heating pipes through which the heating medium flows in the opposite direction.

7. The mold according to claim 6, wherein a cooling pipe is disposed between the heating pipes adjacent to each other.

A part of the male and female heating pipes are protruded from the outer surface of the molding wall, and the inner wall covers the male and female molding walls with a heat insulating material in contact with the protrusion of each heating pipe. The mold according to claim 7, wherein a space is formed between the inner surface of the mold and the molding wall.