JP3878077B2 - Mold for molding foamed resin composite molded body and molding method of foamed resin composite molded body using the same - Google Patents

Mold for molding foamed resin composite molded body and molding method of foamed resin composite molded body using the same Download PDF

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JP3878077B2
JP3878077B2 JP2002206949A JP2002206949A JP3878077B2 JP 3878077 B2 JP3878077 B2 JP 3878077B2 JP 2002206949 A JP2002206949 A JP 2002206949A JP 2002206949 A JP2002206949 A JP 2002206949A JP 3878077 B2 JP3878077 B2 JP 3878077B2
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mold
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foamed resin
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JP2004050422A (en
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田 忠 信 前
野 一 生 浅
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JSP Corp
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【０００１】
【発明の属する技術分野】
本発明は、発泡樹脂を平板にて挟んだ平板層／発泡樹脂層／平板層よりなる発泡樹脂複合成形体を成形するための発泡樹脂複合成形体成形用金型及びそれを用いた発泡樹脂複合成形体の成形方法に関するものである。
【０００２】
【従来の技術】
発泡樹脂成形体を成形する方法については、従来より種々の方法が提案されており、工業的にも各種方法で実施されている。
これら各種方法の中でも、特開平８−９０５８０号公報に記載される方法は、発泡樹脂の上面及び下面を薄厚の金属板により挟んだ複合板を製造するために、縦型式金型の凹型の上面及び下面に金属板を配置して、それら金属板の間に発泡性樹脂粒子を充填した後、一方の側面から水蒸気を供給し、他方の側面から水蒸気を吸引して所定の時間水蒸気を流して加熱させた後、今までの水蒸気供給部を水蒸気吸引部に変更し、水蒸気吸引部を水蒸気供給部に変更して、逆方向から水蒸気を流すことによって加熱発泡成形を行う、上下両面が平坦面をなす発泡樹脂成形体の製造方法が明らかにされている。
しかし、この発泡樹脂成形体の製造方法は、内部に補強材が配置されていると水蒸気が十分に流れ難いことから、特開２０００−２５４９３６号公報には、水蒸気を供給する為のチャンバーを複数の分室に仕切ると共に、チャンバーに成形室に連通する連通孔を多数形成することによって、発泡樹脂粒子を十分に均一に発泡させる方法が提案されている。
また、この特開２０００−２５４９３６号公報の中には、発泡樹脂層を二枚の合板の間に挟み、これら合板と発泡樹脂層とをゴム系接着剤で接着して一体化させた、合板層／ゴム系接着剤層／発泡樹脂層／ゴム系接着剤層／合板層の五層構造から構成される発泡樹脂複合成形体についても明らかにされている。
更に、特開２０００−２６３５７８号公報には、成形室の底面側には複数の通気孔を有する裏面材を配置すると共に、上面側には表面材を配置して、両材料の間に樹脂発泡粒子を投入した後、前記通気孔から水蒸気を供給及び排気して加熱発泡成形することにより合板層／ゴム系接着剤層／発泡樹脂層／ゴム系接着剤層／合板層の五層構造から構成される建築用断熱パネル等として有用な発泡樹脂複合成形体の製造方法が明らかにされている。
【０００３】
【発明が解決しようとする課題】
しかし、これら建築用断熱パネル等として有用な合板層／ゴム系接着剤層／発泡樹脂層／ゴム系接着剤層／合板層の五層構造から構成される発泡樹脂複合成形体は、一般に建築用断熱パネル等として使用されるため、最も小さなものでも９１０ｍｍ×１８２０ｍｍ×８０ｍｍの大きさがあることから、また、これら板状体を発泡成形するためには、上記発泡樹脂複合成形体を成形する成形室の周囲に水蒸気を供給する為のチャンバーが形成されていたり、水蒸気や空気等のユーティリティー供給ラインや排気・排水ラインが付属物として備え付けなければならないことから、加熱発泡成形機としては大型のものとなる。
従って、この様に大型の加熱発泡成形機では、一般に、凹型金型の成形室の上に、上下方向に移動して金型を開閉させることができる様に平板状の蓋状金型を被せて加熱発泡成形する縦型加熱発泡成形機によって製造しているのが普通である。
それ故、これら建築用断熱パネル等の大型の合板層／ゴム系接着剤層／発泡樹脂層／ゴム系接着剤層／合板層の五層構造から構成される発泡樹脂複合成形体を製造する縦型発泡成形機は、設置面積が広くなり、しかも、これら発泡樹脂複合成形体を一枚ずつしか成形することができないために、生産性が低く、製造単価も高価なものとなった。
【０００４】
【課題を解決するための手段】
本発明者は、上記問題点に鑑み鋭意研究を重ねた結果、発泡樹脂層を平板層にて挟んだ発泡樹脂複合成形体を比較的安価に製造するためには、金型を少なくとも金型上面に位置する金型上面分室と、金型下面に位置する金型下面分室と、金型正面に位置する金型正面分室と、金型の左側面・右側面及び背面に位置する金型側面分室とに分割すると共に、上記金型上面分室及び金型下面分室より成形用キャビティー内にスチームを供給して加熱発泡成形した後、金型上面分室を上昇して、金型正面分室を開けば、発泡樹脂複合成形体の平板層を立てた状態で金型正面側より取り出すことができるので、発泡樹脂複合成形体を水平状態で発泡成形する縦型発泡成形機に比較して、設置場所が狭いので生産性が高く、成形用キャビティー内を隔壁により垂直に区切れば複数個の成形体成形室にて、複数個の発泡樹脂複合成形体を同時に生産することが可能であるので、より一層生産性を高めることができるとの知見に基づき本発明を完成するに至ったものである。
【０００５】
すなわち、本発明の発泡樹脂複合成形体成形用金型は、少なくとも２枚の平板の間に発泡性樹脂粒子を充填した後、加熱発泡成形することにより発泡樹脂層を平板層にて挟んだ発泡樹脂複合成形体を成形するための発泡樹脂複合成形体成形用金型において、該金型を、少なくとも金型の上面側に位置する金型上面分室と、金型の正面側に位置する金型正面分室と、金型の下面側及び左面側・右面側・背面側とに位置する金型下面・側面分室とに分割して構成して、これら分室の中心部に上記平板を左右両側端に配置し、これら平板の間に発泡性樹脂粒子を充填して発泡成形するための成形用キャビティーを形成して、上記金型上面分室及び金型下面・側面分室に成形用キャビティーと導通するスチーム供給孔を形成すると共に、該成形用キャビティー内で発泡成形された発泡樹脂複合成形体を取り出す為に上記金型上面分室及び金型正面分室を可動自在に形成したこと、を特徴とするものである。
【０００６】
また、本発明のもう一つの発明である発泡樹脂複合成形体の成形方法は、金型内に少なくとも２枚の平板を配置し、これら平板の間に発泡性樹脂粒子を充填させた後、加熱発泡成形することによって、発泡樹脂層を平板層にて挟んだ発泡樹脂複合成形体を形成する発泡樹脂複合成形体の成形方法において、少なくとも金型の上面側に位置する金型上面分室と、金型の正面側に位置する金型正面分室と、金型の下面側及び左面側・右面側・背面側とに位置する金型下面・側面分室とにより構成された金型を用いると共に、これら分室の中心部に形成された成形用キャビティー内の左右両側端に、少なくとも２枚の平板を配置し、これら平板の間に発泡性樹脂粒子を充填した後、前記成形用キャビティーの上面側及び下面側に配置される金型上面分室及び金型下面・側面分室のスチーム供給孔より、該成形用キャビティー内にスチームを供給して、前記発泡性樹脂粒子を加熱発泡成形することによって、発泡樹脂層を平板層にて挟んだ発泡樹脂複合成形体を形成した後、前記金型の金型上面分室及び金型正面分室を開いて、該成形用キャビティー内で発泡成形された発泡樹脂複合成形体を取り出すこと、を特徴とするものである。
【０００７】
【発明の実施の形態】
[I] 発泡樹脂複合成形体成形用金型
(1) 金型構成部材
本発明の発泡樹脂複合成形体成形用金型１は、図１の正面図及び図２の側面図にて示す様に、少なくとも金型の上面側に位置する金型上面分室２と、金型の正面側に位置する金型正面分室３と、金型の下面側及び左面側・右面側・背面側とに位置する金型下面・側面分室４とに分割された構成部材により形成されており、それら分室２，３，４の中心部分に形成されている成形用キャビティー５内で、図３に示す様な、発泡樹脂層６を平板層７，８にて挟んだ発泡樹脂複合成形体９を発泡成形することができる。
【０００８】
(A) 金型上面分室
本発明の発泡樹脂複合成形体成形用金型１を構成する金型上面分室２は、図１に示す様に、上記金型１の上面側に位置して、内部にスチーム等の加熱媒体を供給して加熱又は保温することができるように、内部が空洞２ａの板状空洞体となっている。
金型上面分室２の成形用キャビティー５側は、発泡樹脂複合成形体９を成形するための金型１の一部となることから、通常は鏡面又はテフロン（登録商標）コーティング仕上げされている。
また、金型上面分室２の成形用キャビティー５側には多数のスチーム供給孔２ｂが穿設されていて、スチーム供給ライン１０ａにて供給されたスチームが金型上面分室２内で均等に分散された後、スチーム供給孔２ｂを通じて成形用キャビティー５内に供給される。
特に、成形用キャビティー５内が隔壁１１によって複数個の成形体成形室１２に分割されている場合には、この金型上面分室２にて各成形体成形室１２内に均等にスチームが供給される様になっている。
【０００９】
また、金型上面分室２より成形用キャビティー５内にスチームが供給される場合には、金型上面分室２にて成形用キャビティー５或いは複数個の成形体成形室１２内へのスチームへの分配が行われるが、後記スチーム供給ライン１０ｂにてスチームが供給される場合には、金型下面・側面分室４にてスチームの分配が行われるために、金型上面分室２は成形用キャビティー５或いは複数個の成形体成形室１２にて不要になったスチームやドレンの抜き出し口として使用されて、排気・排水ライン１３ａを経て系外に排出される。
従って、金型上面分室２は、スチーム供給ライン１０ａと接続してスチームが供給され、排気・排水ライン１３ａ，１３ｂとも接続されて、排気スチームや排出ドレンを系外へ排出する。
また、この金型上面分室２は、成形用キャビティー５内で発泡成形した後に、金型１の成形用キャビティー５内より発泡樹脂複合成形体９を取り出す際に、得られた発泡樹脂複合成形体９の脱型を容易にして取り出し易くするために、油圧アーム等にて金型上面分室２を上下方向に可動自在に形成されている。
更に、この金型上面分室２には、発泡性樹脂粒子供給用充填ガン１４が配備されていて、発泡性樹脂粒子１５や使用済みのポリスチレン発泡樹脂粒子（リサイクル材）を供給することができる様になっている。
また、金型上面分室２の成形用キャビティー５側には平板挿入用溝部２ｃが形成されていることが好ましい。この平板挿入用溝部２ｃを形成することにより、上記発泡性樹脂粒子１５が供給される前でも平板７，８を垂直に維持することができるので、得られた発泡樹脂複合成形体９の平板７，８を常に平行した状態に維持することができる。
【００１０】
(B) 金型正面分室
本発明の発泡樹脂複合成形体成形用金型１を構成する金型正面分室３は、図２に示す様に、上記金型１の正面に位置して、内部にスチーム等の加熱媒体を供給して加熱又は保温することができるように、内部が空洞３ａの板状空洞体となっている。
金型正面分室３の成形用キャビティー５側は、発泡樹脂複合成形体９を成形するための金型１の一部となることから、通常は鏡面又はテフロン（登録商標）コーティング仕上げされている。
また、この金型正面分室３の成形用キャビティー５側に多数のスチーム供給孔３ｂを穿設して、スチーム供給ライン１０ａにて供給されたスチームを金型正面分室３内で均等に分散させた後、スチーム供給孔３ｂを通じて成形用キャビティー５内に供給することもできる。
更に、金型正面分室３の成形用キャビティー５側には平板挿入用溝部３ｃが形成されていることが好ましい。この平板挿入用溝部３ｃを形成することにより、上記発泡性樹脂粒子１５が供給される前でも平板７，８を垂直に維持することができるので、得られた発泡樹脂複合成形体９の平板７，８を常に平行した状態に維持することができる。
この金型正面分室３は、図１１に示す様に、扉状に形成されて、その一部が金型の一部に取り付けられて左右いずれか一方側に開くか、両側に開くか、手前側に傾倒して開くかして、成形用キャビティー５内で発泡成形された発泡樹脂複合成形体９を取り出し自在に形成されている。
この金型正面分室３には、上記金型上面分室２と同様に、スチーム供給ライン１０ａにてスチームを供給するだけでなく、空気供給ライン２２ａ，２２ｂや水供給ライン２３ａ，２３ｂや減圧ライン２４ａ，２４ｂや排気・排水ライン１３ａ，１３ｂと接続して、成形用キャビティー５内に空気や水の供給や、排気や排水を行うこともできる。
【００１１】
(C) 金型下面・側面分室
本発明の発泡樹脂複合成形体成形用金型１を構成する金型下面・側面分室４は、図１及び図２に示す様に、上記金型１の下面側と、左面側と、右面側と、背面側とに位置して、発泡樹脂複合成形体成形用金型１の四面部分を形成するものであるが、内部にスチーム等の加熱媒体を供給して加熱又は保温することができるように、内部が空洞４ａの板状空洞体となっており、これら板状空洞体が４面接続した一方の側壁が開放された升型状に形成したものとなっている。
金型下面・側面分室４の成形用キャビティー５側は、発泡樹脂複合成形体９を成形するための金型１の一部となることから、通常は鏡面又はテフロン（登録商標）コーティング仕上げされている。
また、金型下面・側面分室４の下面側の成形用キャビティー５側には多数のスチーム供給孔４ｂが穿設されていて、スチーム供給ライン１０ｂにて供給されたスチームが金型下面・側面分室４内で均等に分散された後、スチーム供給孔４ｂを通じて成形用キャビティー５内に供給される。
特に、成形用キャビティー５内が隔壁１１によって複数個の成形体成形室１２に分割されている場合には、この金型下面・側面分室４にて各成形体成形室１２内に均等にスチームが供給される様になっている。
【００１２】
また、金型下面・側面分室４より成形用キャビティー５内にスチームが供給される場合には、金型下面・側面分室４にて成形用キャビティー５或いは複数個の成形体成形室１２内へのスチームへの分配が行われるが、前記金型上面分室２より成形用キャビティー５内にスチームが供給される場合には、金型上面分室２にてスチームの分配が行われるために、金型下面・側面分室４では成形用キャビティー５或いは複数個の成形体成形室１２にて不要になったスチームやドレンの抜き出し口として使用されて、排気・排水ライン１３ｂを経て系外に排出される。更に、金型下面・側面分室４の背面側の成形用キャビティー５側に成形品面圧計３９を設置することが好ましく、この成形品面圧計３９の値により、本加熱の終了や放冷時間の終了を制御することができる。
また、金型下面・側面分室４の下面側の成形用キャビティー５側には平板挿入用溝部４ｃが形成されていることが好ましい。この平板挿入用溝部４ｃを形成することにより、上記発泡性樹脂粒子１５が供給される前でも平板７，８を垂直に維持することができるので、得られた発泡樹脂複合成形体９の平板７，８を常に平行した状態に維持することができる。
【００１３】
上記金型下面・側面分室４は、図１及び図２に示す様に、上記金型１の下面側と、左面側と、右面側と、背面側とに位置して、発泡樹脂複合成形体成形用金型１の四面部分を内部が空洞４ａの板状空洞体に形成して、これら板状空洞体が４面接続した一方の側壁が開放された升型状に形成することもできるが、図４及び図５に示す様に、これら金型１の四面部分を、それぞれ金型１の下面側の金型下面分室１６、金型１の左面側の金型左側面分室１７、金型１の右面側の金型右側面分室１８、金型１の背面側の金型背面分室１９の四つに分割して形成したり、或いは、金型左側面分室１７、金型右側面分室１８及び金型背面分室１９の側壁部分を一体としたものと、金型下面分室１６との二つに分割して形成したりすることもできるが、温度制御の観点から上記四つの金型下面分室１６，金型左側面分室１７，金型右側面分室１８，金型背面分室１９とに分割して形成したものが好ましい。
また、これら四つの金型下面分室１６，金型左側面分室１７，金型右側面分室１８，金型背面分室１９を、図４に示す様に、金型左側面細分室１７ａ，１７ｂ，１７ｃ，１７ｄや金型右側面細分室１８ａ，１８ｂ，１８ｃ，１８ｄの如く、更に細分化した細分室として形成することもできる。
【００１４】
(a) 金型下面分室
上記金型下面・側面分室４の中の金型下面分室１６を分割して形成する場合には、図４に示す様に、金型１の下面側の金型下面分室１６は、成形用キャビティー５と接しており、上記金型上面分室２と同様に加熱発泡成形する場合のスチームや空気や水等の通路となるスチーム供給孔１６ｂが穿設されていて、常に加熱や冷却が行われることから、温度制御等の観点にて、他の金型左側面分室１７、金型右側面分室１８及び金型背面分室１９の金型１の側壁部分を形成する部分とは明らかに異なる加熱や冷却の操作が行われるので、これら金型の側壁部分の分室１７，１８，１９とは分割して切り離した方が良い。
金型下面分室１６の成形用キャビティー５側は、発泡樹脂複合成形体９を成形するための金型１の一部となることから、通常は鏡面又はテフロン（登録商標）コーティング仕上げされている。
【００１５】
(b) 金型側面分室
本発明の発泡樹脂複合成形体成形用金型１の側壁部分を構成する金型側面分室１７，１８，１９は、図４及び図５に示す様に、上記金型の左側面・右側面及び背面に位置しており、内部にスチーム等の加熱媒体が通過することにより加熱又は保温することができるように断面コ字状の板状空洞体となっている。
金型側面分室１７，１８，１９は、特に金型の左側面に位置する金型左側面分室１７と、金型の右側面に位置する金型右側面分室１８と、金型の背面に位置する金型背面分室１９とに分割されていることが好ましく、この様に分割することにより、それぞれの分室１７，１８，１９を最適温度に調節することができるので好ましい。
これら金型左側面分室１７及び金型右側面分室１８には、平板７，８が配置されているので、スチーム供給孔が形成されておらず、成形用キャビティー５と連通していないことが好ましい。
しかし、平板７，８に細孔が穿設されている場合には、これら金型左側面分室１７及び金型右側面分室１８にスチーム供給孔を形成することもできる。
けれども、成形用キャビティー５内が隔壁１１により仕切られて成形体成形室１２が形成されている場合には、成形用キャビティー５内の両端の成形体成形室１２と中央部の成形体成形室１２とにスチームの供給量に差が生じてしまうために隔壁１１にも細孔を穿設する必要がある。
【００１６】
金型左側面分室
上記金型左側面分室１７は、成形用キャビティー５内の平板層７，８と接しているので、通常はスチームや空気や水等の通路となる金型上面分室２や金型下面分室１６の様にスチーム供給孔２ｂ，１６ｂが穿設されておらず、スチームや空気や水等の通路とならないので、加熱発泡成形時においては加熱や冷却に直接関与しておらず、金型左側面分室１７は一定した温度に保持されているのが普通である。
【００１７】
金型右側面分室
上記金型右側面分室１８は、上記金型左側面分室１７と同様に、成形用キャビティー５内の平板層７，８と接しているので、通常はスチームや空気や水等の通路となるスチーム供給孔１６ｂが穿設されておらず、スチームや空気や水等の通路とならないので、加熱発泡成形時においては加熱や冷却に直接関与しておらず、金型右側面分室は一定した温度に保持されているのが普通である。
【００１８】
金型背面分室
上記金型背面分室１９は、上記金型左側面分室１７や金型右側面分室１８と異なり、成形用キャビティー５内の発泡樹脂層６と接しているので、通常はスチームや空気や水等の通路となるスチーム供給孔１６ｂを穿設することもできるが、スチームや空気や水等の流れとして良くないので、スチーム供給孔１６ｂを穿設せずに、これらスチームや空気や水等の通路としないで、加熱発泡成形時においては加熱や冷却に直接関与しない様に、金型金型背面分室１９は一定した温度に保持するのが好ましい。
金型背面分室１９の成形用キャビティー５側には、成形品面圧計３９を設置して、この成形品面圧計３９の値により、本加熱の終了や放冷時間の終了を制御することが好ましい。
また、この金型背面分室１９には、成形用キャビティー５内にて発泡成形された発泡樹脂層６を平板層７，８にて挟んだ発泡樹脂複合成形体９を、金型１内より取り出すために、金型の背面側１９より平板層７，８を押圧して取り出すための突出ピン２０が形成されていることが好ましい。
【００１９】
(2) 成形用キャビティー
上記金型１の各金型上面分室２，金型正面分室３，金型下面・側面分室４によって囲まれた中心部に形成された成形用キャビティー５は、発泡樹脂層６を平板層７，８にて挟んだ発泡樹脂複合成形体９を成形するための発泡樹脂複合成形体成形用金型１であり、該金型１の左右両端にはそれぞれ平板層７，８が配置されている。
また、この成形用キャビティー５は、１つの空間であっても良いが、該キャビティー５内に垂直に設けられた隔壁１１により複数個の発泡樹脂複合成形体９を成形することができる成形体成形室１２に分割されていることが好ましい。
【００２０】
(A) 成形体成形室
隔壁１１により分割された成形用キャビティー５は、一般に２〜８個の、特に３〜６個の成形体成形室１２に分割されていることが好ましい。
従って、この様な成形体成形室１２では、１回の加熱発泡成形で複数個の発泡樹脂複合成形体９を同時に成形することができる。
上記隔壁１１により分割された各成形体成形室１２内には、それぞれの成形体成形室１２の左右両端に平板７，８が配置されることとなる。
【００２１】
(B) 隔 壁
上記隔壁１１は、成形用キャビティー５内に、一般に１〜７個、好ましくは２〜５個設けられていることが望ましい。
該隔壁１１は、一般に金型１と同じ材質の金属板が用いられるが、該隔壁１１の金属板には通常は隣接する成形体成形室１２と連通する細孔が穿設されていないが、必要により連通する細孔１１ａを設けることもできる。
【００２２】
(C) 平板挿入用溝部
上記隔壁１１により分割されて形成された各成形体成形室１２の左右両端の金型上面分室２及び金型下面・側面分室４には平板挿入用溝部２ｃ，４ｃが設けられている。
【００２３】
(3) 発泡性樹脂粒子供給用充填ガン
上記発泡樹脂複合成形体成形用金型１の金型上面分室２には、発泡性樹脂粒子供給用充填ガン１４が備えられており、該金型上面分室２には成形用キャビティー５の奥行きが１．８〜１０ｍもあることから、一般に１〜５個、好ましくは２〜３個の発泡性樹脂粒子供給用充填ガン１４が備えられている。
【００２４】
(4) 原料供給ライン（発泡性樹脂粒子供給ライン）
上記発泡性樹脂粒子供給用充填ガン１４には、発泡性樹脂粒子１５を供給する発泡性樹脂粒子供給ライン２１が設けられており、該発泡性樹脂粒子１５の移送には圧縮空気が用いられている。
【００２５】
(5) ユーティリティー供給ライン
上記発泡樹脂複合成形体成形用金型１の金型上面分室２及び金型下面・側面分室４には、金型１によって囲まれた成形用キャビティー５内にスチームや空気や水等が供給されるスチーム供給ライン１０ａ，１０ｂ、空気供給ライン２２ａ，２２ｂ、水供給ライン２３ａ，２３ｂ、減圧ライン２４ａ，２４ｂ等のユーティリティー供給ライン２５ａ，２５ｂが接続されている。
【００２６】
(A) スチーム供給ライン
上記発泡樹脂複合成形体成形用金型１の金型上面分室２及び金型下面・側面分室４には、金型１によって囲まれた成形用キャビティー５内にスチームを供給するスチーム供給ライン１０ａ，１０ｂが設けられている。
【００２７】
(B) 空気供給ライン
上記発泡樹脂複合成形体成形用金型１の金型上面分室２及び金型下面・側面分室４には、金型１によって囲まれた成形用キャビティー５内に空気を供給する空気供給ライン２２ａ，２２ｂが設けられている。
【００２８】
(C) 水供給ライン
上記発泡樹脂複合成形体成形用金型１の金型上面分室２及び金型下面・側面分室４には、金型１によって囲まれた成形用キャビティー５内に水を供給する水供給ライン２３ａ，２３ｂが設けられている。
【００２９】
(D) 減圧ライン
上記発泡樹脂複合成形体成形用金型１の金型上面分室２及び金型下面・側面分室４には、金型１によって囲まれた成形用キャビティー５内の空気を排気したり、減圧して水分を蒸発させるために真空ポンプ等に接続する減圧ライン２４ａ，２４ｂが設けられている。
【００３０】
(6) 排気・排水ライン
上記発泡樹脂複合成形体成形用金型１の金型上面分室２及び金型下面・側面分室４には、金型上面分室２や金型下面・側面分室４に供給されたスチームや空気やスチームが冷却されて凝縮したドレン等を排気及び排水するための排気・排水ライン１３ａ，１３ｂが設けられている。
【００３１】
[II] 発泡樹脂複合成形体の成形方法
(1) 使用金型
発泡樹脂複合成形体９の成形方法において用いられる金型１としては、図１及び図２に示す様な、少なくとも金型の上面に位置する金型上面分室２と、金型の正面側に位置する金型正面分室３と、金型の下面側及び左面側・右面側・背面側とに位置する金型下面・側面分室４とに分割された発泡樹脂複合成形体成形用金型１が用いられる。
【００３２】
(2) 金型の予備加熱工程（金型の清掃）
発泡樹脂複合成形体９を成形するには、先ず、図１に示す様に、上記発泡樹脂複合成形体成形用金型１の扉２６となっている金型正面分室３を閉じて、金型上面分室２を降下させることにより、上記金型１の成形用キャビティー５を閉じる。
そして、金型１の上下に配置された排気・排水ライン１３ａ，１３ｂの排出弁２７ａ，２７ｂを開き、金型１の上下に配置されたスチーム供給ライン１０ａ，１０ｂのスチーム弁２８ａ，２８ｂを開いて金型１及び成形用キャビティー５内を予熱すると共に、金型１内で凝縮して液化した水等からなるドレン水やスチームを排気・排水ライン１３ａ，１３ｂより排出する。
【００３３】
(3) 平板の挿入工程
次に、金型１の扉２６となっている金型正面分室３を開いて、図６に示す様に、金型上面分室２の平板挿入用溝部２ｃ及び金型下面・側面分室４の平板挿入用溝部４ｃに沿って少なくとも２枚の平板７，８を挿入して、成形用キャビティー５内の両側端に平板７，８を配置する。
【００３４】
(4) 金型の閉止工程
上記金型１の扉２６となっている金型正面分室３を閉じて金型１の成形用キャビティー５を閉止する。
【００３５】
(5) 発泡性樹脂粒子の充填工程
そして、図７に示す様に、金型上面分室２の上方に備えられている発泡性樹脂粒子供給用充填ガン１４にて金型１の成形用キャビティー５内に発泡性樹脂粒子１５を供給して、図８に示す様に、前記平板７，８の間に発泡性樹脂粒子５を充填する。
【００３６】
(6) 成形用キャビティーの予熱工程
次に、図８に示す様に、金型１の上下に配置された排気・排水ライン１３ａ，１３ｂの排出弁２７ａ，２７ｂを開いた後、金型１の上下に配置されたスチーム供給ライン１０ａ，１０ｂのスチーム弁２８ａ，２８ｂを約５秒間程度開いて金型１の成形用キャビティー５内にスチームを導入し、金型１内のドレンを上記排気・排水ライン１３ａ，１３ｂより排出すると共に金型１全体を予熱する。
【００３７】
(7) 予備加熱発泡成形
(A) 減 圧
金型１の上下に配置された減圧ライン２４ａ，２４ｂの減圧弁２９ａ，２９ｂを開いて発泡性樹脂粒子１５間の空気を系外に排出して成形用キャビティー５内の圧力を約−４０〜７０ｋＰａ程度にまで減圧にする。
【００３８】
(B) スチームの供給・排気
次いで、金型１の上部に配置されたスチーム供給ライン１０ａのスチーム弁２８ａを開き、金型１の下部に配置された排気・排水ライン１３ｂの排出弁２７ｂを開いて、上部側のスチーム供給ライン１０ａよりスチームを供給し、下部の排気・排水ライン１３ｂの排出弁２７ｂより排出させて、成形用キャビティー５内の発泡性樹脂粒子１５間の空気を系外に排出して、金型１の上部の発泡性樹脂粒子１５間の融着を促進させる。
【００３９】
(C) スチームの供給・排気
次いで、金型１の下部に配置されたスチーム供給ライン１０ｂのスチーム弁２８ｂを開き、金型１の上部の排気・排水ライン１３ａの排出弁２７ａを開いて、金型１の下部に配置されたスチーム供給ライン１０ｂよりスチームを供給して、金型１の上部の排気・排水ライン１３ａより系外に排出して、成形用キャビティー５内の発泡性樹脂粒子１５間の空気を系外に排出して、金型１の上部の発泡性樹脂粒子１５間の融着を促進させる。
【００４０】
(8) 本加熱発泡成形（本発泡成形）
更に、図９に示す様に、金型１の上部及び下部のスチーム弁２８ａ，２８ｂを開いて成形用キャビティー５内にスチームを成形品面圧が本加熱設定面圧になるまでの時間供給して成形用キャビティー５内の発泡性樹脂粒子１５を発泡させて、発泡性樹脂粒子１５を互いに融着させることにより本発泡成形を行う。
【００４１】
(A) 成形条件
本発泡成形における成形条件としては、下記の成形条件下で行われるのが普通である。
成形条件
成形スチーム圧力：一般に２０〜１５０ｋＰａ、好ましくは３０〜１００ｋＰａ
成形温度 ：一般に１００〜１３０℃、好ましくは１１０〜１２０℃
本加熱時間：一般に１〜１８０秒、好ましくは５〜６０秒
設定面圧 ：一般に３０〜１５０ｋＰａ、好ましくは５０〜１００ｋＰａ
【００４２】
(9) 冷 却
(A) 金型の冷却
上記本発泡成形が終了した段階で、金型１の上下部に配置された水供給ライン２３ａ，２３ｂの水弁３０ａ，３０ｂを開き、金型１の上下部に配置された排気・排水ライン１３ａ，１３ｂの排出弁２７ａ，２７ｂを開いて、水を金型１内に供給して金型１及び発泡樹脂複合成形体９を冷却する。
【００４３】
(B) 空気冷却
金型１の上下部に配置された空気供給ライン２２ａ，２２ｂの空気弁３１ａ，３１ｂを開いて、金型１内の水を排出すると共に空気により金型１及び成形された発泡樹脂複合成形体９を冷却する。
【００４４】
(C) 減圧冷却（蒸発潜熱による冷却）
金型１の上下部に配置された減圧ライン２４ａ，２４ｂの減圧弁２９ａ，２９ｂを開き、金型１及び成形された発泡樹脂複合成形体９に付着した水を蒸発させて、その蒸発潜熱を利用して成形された発泡樹脂複合成形体９を成形品面圧が取出設定面圧になるまで冷却する。
【００４５】
(10) 成形品の取り出し
(A) 金型上面分室の上昇
上記発泡樹脂層６を平板層７，８にて挟んだ発泡樹脂複合成形体９を金型１の成形用キャビティー５内から取り出すために、図１０に示す様に、金型上面分室２を上昇させて、金型上面分室２を発泡樹脂複合成形体９より離型する。
【００４６】
(B) 金型正面分室の開扉
次に、図１１に示す様に、前記金型正面分室３を開扉することにより金型１の成形用キャビティー５内を開いて、発泡成形された発泡樹脂複合成形体９を取り出す。
【００４７】
(C) 突出ピンによる平板層の押圧
上記金型１の金型下面・側面分室４の背面側部４ｄに、金型１の背面側より平板層７，８を押圧して、正面側の平板層７，８を金型１より一部突出させて、取り出し易くする為の突出ピン３２が形成されていることが好ましい。
【００４８】
[III] 発泡樹脂複合成形体
(1) 構 造
(A) 層構成
本発明の発泡樹脂複合成形体成形用金型１及びそれを用いた発泡樹脂複合成形体９の成形方法によって得られる発泡樹脂層６を平板層７，８にて挟んだ発泡樹脂複合成形体９は、基本的には、平板層７／発泡樹脂層６／平板層８から構成されるものであるが、より強度な発泡樹脂複合成形体９とするために、これら各層の間に接着剤層３３を設けた平板層７／接着剤層３３／発泡樹脂層６／接着剤層３３／平板層８から構成したものが好ましい。
これら各層の肉厚は、平板層が一般に０．５〜５０ｍｍ、好ましくは２〜２０ｍｍ、特に好ましくは５〜１５ｍｍ、発泡樹脂層が一般に５〜４５０ｍｍ、好ましくは１５〜３５０ｍｍ、特に好ましくは２５〜３００ｍｍ、接着剤層が一般に０．０１〜５ｍｍ、好ましくは０．１〜３ｍｍ、特に好ましくは０．３〜２ｍｍである。
【００４９】
(B) 補 強
上記層構成となるのが基本であるが、機械的な補強を行うためには、図３に示す様に、表裏平板層７，８の間に発泡樹脂層６の一部を材木等の補強材３４に変更して形成することにより、平板層７／補強材３４及び発泡樹脂層６／平板層８したり、平板層７／接着剤層３３／補強材３４及び発泡樹脂層６／接着剤層３３／平板層８からなるものに形成することにより一層優れた発泡樹脂複合成形体９とすることもできる。また、補強材３４’の様に柱状に補強材を配置することもできる。
【００５０】
(2) 原材料
(A) 発泡性樹脂
(a) 発泡樹脂の種類
本発明の発泡樹脂複合成形体成形用金型１及びそれを用いた発泡樹脂複合成形体９の成形方法において用いられる発泡性樹脂としては、ポリスチレン系発泡性樹脂、ポリプロピレン系発泡性樹脂、ポリエチレン系発泡性樹脂等の熱可塑性発泡性樹脂を挙げることができる。
これら熱可塑性発泡性樹脂粒子の中でもポリスチレン発泡性樹脂粒子、スチレン・エチレン共重合体等のスチレン系樹脂発泡体が好ましい。
【００５１】
(b) 粒子径
これら発泡性樹脂粒子の粒子径としては、一般に０．３〜２０ｍｍ、好ましくは０．５〜１５ｍｍのものが使用される。
【００５２】
(c) 発泡性倍率
これら発泡性樹脂粒子の発泡性倍率としては、一般に１５〜１５０倍、好ましくは２０〜１２５倍のものが使用される。
【００５３】
(d) リサイクル材の混合
上記発泡性樹脂粒子の一部に、リサイクルにより回収された使用済みのポリスチレン発泡樹脂粒子（リサイクル材）を混合して使用することもできる。
これらリサイクル材は一般に１〜５０重量％、好ましくは５〜３０重量％の範囲で使用することにより環境的に優しく、経済的にも安価に製造することができる。
【００５４】
(B) 平 板
本発明の発泡樹脂複合成形体成形用金型１及びそれを用いた発泡樹脂複合成形体９の成形方法において用いられる平板７，８としては、普通合板、難燃合板、構造用合板、防災合板等の合板、パーティクルボード、ＩＢ（インシュレーションファイバーボード）、ＭＤＦ（ミディアムデンシティーファイバーボード）、ＨＢ（ハードファイバーボード）等の繊維板等の木製板、銅板、塗装鉄板、亜鉛鍍金鉄板、ステンレス板等の金属板、アクリル系樹脂板、塩化ビニル樹脂板、内装用プラスチック化粧ボード類等の樹脂板、木毛セメント板、木片セメント板等の木質系セメント板、パルプセメント板、繊維強化セメント板、ロックウールシージング板、石膏ボード、シージング石膏ボード、強化石膏ボード、石膏ラスボード、化粧石膏ボード、不燃積層石膏ボード等の石膏ボード板、気泡コンクリート板、素板サイデイング、塗装用サイディング、化粧サイディング等の窯業サイディング、タイル等の無機質板やこれらを積層した積層板を挙げることができる。
これら平板７，８の中でも、普通合板、難燃合板、構造用合板、防災合板等の合板、パーティクルボード、塗装鉄板、石膏ボード等を使用することが好ましく、特に構造用合板を使用することが好ましい。
厚 み
これら平板の厚みは、一般に０．５〜５０ｍｍ、好ましくは２〜２０ｍｍ、特に好ましくは５〜１５ｍｍのものが用いられる。
大きさ
これら平板の大きさは、長さが一般に０．９〜１０ｍ、好ましくは１．８〜８ｍ、好ましくは３〜７．５ｍのもの、幅が一般に０．３〜３ｍ、好ましくは０．４〜２ｍ、好ましくは０．６〜１．８ｍのものが用いられる。
【００５５】
(C) 接着剤
上記接着剤層３３に用いられる接着剤としては、エポキシ系接着剤、ウレタン系接着剤、酢酸ビニル系接着剤、樹脂系溶剤型接着剤、クロロプレン系ゴム型接着剤、ニトリル系ゴム型接着剤、変性ゴムラテックス型接着剤、再生ゴム系型接着剤等の溶剤型接着剤、アクリル系接着剤、酢酸ビニル系接着剤、ＳＢＲ系接着剤、ＥＶＡ系接着剤等の水性分散型接着剤、水性高分子−イソシアネート系型接着剤、ホットメルト系型接着剤等を挙げることができる。
これら接着剤の中でも樹脂系溶剤型接着剤、クロロプレン系ゴム型接着剤、ニトリル系ゴム型接着剤、変性ゴムラテックス型接着剤、再生ゴム系型接着剤等の溶剤型接着剤を使用することが好ましい。
【００５６】
(D) 補強材
発泡樹脂層６の外周に施されるランバー３５としては、一般に材木が使用される。
【００５７】
(3) 用 途
この様な発泡樹脂層６を平板層７，８にて挟んだ発泡樹脂複合成形体９は、その外周部分に材木よりなるランバー３５を釘等で打ち付けて補強することにより一般に７２００ｍｍ×９１０ｍｍのパネル３６として使用されるが、図１２に示す様に、これらパネル３６を接続材３７により２枚繋ぎ合わせて７２００ｍｍ×１８２０ｍｍの大きさの大型パネル３８を形成して屋根材、壁材、床材として使用することもできる。
【００５８】
【実施例】
以下に示す実施例及び比較例によって、本発明を更に具体的に説明する。
[I] 評価方法
(1) 引張強度
得られた発泡樹脂複合成形体の引張強度は、測定用複合パネルを１０ｃｍ×１０ｃｍの大きさのサンプルに切り、該サンプルの表裏平板面に引っ張り用治具をエポキシ系接着剤で接着させた後、該サンプルを水平の状態にして下部側の引っ張り用治具を固定し、上部側の引っ張り用治具を引っ張り上げて、そのサンプルの破断時の強度を測定する。
【００５９】
(2) 断熱性能
得られた発泡樹脂複合成形体の断熱性能は、測定用複合パネルより発泡体部分のみ２０ｃｍ×２０ｃｍ×２．５ｃｍの大きさのサンプルに切り、このサンプルの熱伝導率をＪＩＳ−Ａ １４１２−２熱流計法に準拠して測定した。
【００６０】
[II] 実施例及び比較例
実施例１
(1) 金 型
発泡樹脂複合成形体の成形方法において用いた金型は、図４及び図５に示す様に、金型の正面に位置する金型正面分室と、金型の上面に位置する金型上面分室と、金型の下面に位置する金型下面分室と、金型の左側に位置する金型左側面分室と、金型の右側に位置する金型右側面分室と、金型の背側に位置する金型背面側分室とからなる６面の分室にて分割された金型を用いた。
該金型により囲まれて形成される成形用キャビティーは、垂直に形成された４つの隔壁１１により５つの成形体成形室に分割されている。
これら５つの成形体成形室の左右両側端の平板挿入用溝部に厚さ１０ｍｍ×高さ９１０ｍｍ×長さ７２００ｍｍの合板２枚を１００ｍｍ間隔で挿入した後、金型正面分室側の扉を閉じて、金型上面分室を降下させることにより、金型の成形用キャビティーを閉じて、排気・排水ラインの排出弁を開き、スチーム供給ラインのスチーム弁を約５秒間程度開いて成形用キャビティー内にスチームを導入し、金型１内のドレンを上記排気・排水ラインより排出した。
そして、金型内の５つの成形体成形室内に発泡性樹脂粒子供給用充填ガンよりＢＡＳＦ社製のグラファイト粒子を含有する発泡性ポリスチレン樹脂（商品名「Ｎｅｏｐｏｒ」）を原料として用いてダイセン（株）製発泡ポリスチレン用バッチ式予備発泡機「ＤＹＨ−１０００」を使用して予備発泡した発泡比重１５ｋｇ／ｍ３の予備発泡粒子をそれぞれ９．８ｋｇづつ充填した。
【００６１】
次いで、減圧ラインの減圧弁を開いて成形用キャビティー内の圧力を約−６０ｋＰａ程度にまで減圧して発泡性樹脂粒子間の空気を系外に排出した。
次に、金型上部のスチーム供給ラインのスチーム弁を開き、金型下部の排気・排水ラインの排出弁を開いて、成形体成形室内にスチームを供給して発泡性樹脂粒子間の融着を促進させる。
更に、金型下部のスチーム供給ラインのスチーム弁を開き、金型上部の排気・排水ラインの排出弁を開いて、金型下部のスチーム供給ラインよりスチームを供給して発泡性樹脂粒子間の融着を促進させる。
次いで、金型の上部及び下部のスチーム弁を開いて成形用キャビティー内に５０ｋＰａ、１１１℃のスチームを成形品面圧が８０ｋＰａになるまで成形用キャビティー内の発泡性樹脂粒子を発泡させて、発泡性樹脂粒子を互いに融着させることにより本発泡成形を行う。
【００６２】
そして、本発泡成形が終了した段階で、水供給ラインの水弁を開き、排気・排水ラインの排出弁を開いて、水を金型内に供給して金型及び成形品を冷却する。更に、空気供給ラインの空気弁を開いて、水を排出すると共に空気により金型及び成形品を成形品面圧が０ｋＰａになるまで冷却する。
次いで、減圧ラインの減圧弁を開き、金型及び成形された発泡樹脂複合成形体に付着した水を蒸発させて、その蒸発潜熱を利用して成形された発泡樹脂複合成形体を冷却する。
金型上面分室を上昇させて、金型上面分室を発泡樹脂複合成形体より離型する。
【００６３】
次に、金型正面分室を開扉することにより金型の成形用キャビティー内を開いて、発泡成形された発泡樹脂複合成形体を取り出す。
上記金型背面側分室に形成されている突出ピンにより金型の背面側より平板層を押圧して、正面側の平板層を金型より一部突出させた。
本発明の発泡樹脂複合成形体成形用金型により発泡成形された発泡樹脂複合成形体は、金型の成形用キャビティー内が隔壁により複数個の成形体成形室に垂直方向で分割されているので、成形された発泡樹脂複合成形体も取り出しが容易で、金型の設置面積も少なく、一度の発泡成形で多数の発泡樹脂複合成形体を成形することができる。
【００６４】
実施例２
実施例１において、発泡性樹脂粒子供給用充填ガンにより充填した予備発泡粒子に使用済みのポリスチレン発泡樹脂粒子を３０重量％の割合で含有する予備発泡粒子を使用した以外は実施例１に記載の方法と同様に実施した。
その結果を表１に示す。
【００６５】
実施例３
実施例１において、金型を、図１に示す様な、金型の正面側に位置する金型正面分室と、金型の上面側に位置する金型上面分室と、金型の下面側及び左面側・右面側・背面側とに位置する金型下面・側面分室とからなる３分室にて分割された金型を使用した以外は実施例１に記載の方法と同様に実施した。
その結果を表１に示す。
【００６６】
実施例４
三菱化学フォームプラスティック株式会社製の発泡性ポリスチレン樹脂（商品名「ＪＦＮ２００」）を原料として使用した以外は実施例１と同様に実施した。
その結果を表１に示す。
【００６７】
実施例５
三菱化学フォームプラスティック株式会社製の発泡性ポリスチレン樹脂（商品名「ＪＦＮ２００」）を原料として使用した以外は実施例２と同様に実施した。
その結果を表１に示す。
【００６８】
実施例６
三菱化学フォームプラスティック株式会社製の発泡性ポリスチレン樹脂（商品名「ＪＦＮ２００」）を原料として使用した以外は実施例３と同様に実施した。
その結果を表１に示す。
【００６９】
【表１】

Figure 0003878077
【００７０】
【発明の効果】
このような本発明の発泡樹脂複合成形体成形用金型及びそれを用いた発泡樹脂複合成形体の成形方法は、金型上面分室が上下方向に昇降自在で、金型正面分室が開閉自在に形成された横型式発泡成形用金型で成形されることから、発泡樹脂複合成形体の平板層を立てた状態で金型正面側より出し入れすることができるので、この様な横型式発泡成形用金型は発泡樹脂複合成形体を水平状態で発泡成形して上部から取り出す縦型発泡成形用金型に比較して、設置場所が狭いので生産性が高いし、更に、該金型の成形用キャビティー内を隔壁により垂直方向に区切れば、複数個の成形体成形室にて、複数個の発泡樹脂複合成形体を同時に生産することが可能であるので、より一層生産性を高めることができるとの利点がある。
【図面の簡単な説明】
【図１】図１は、本発明の実施例の発泡樹脂複合成形体成形用金型の断面図である。
【図２】図２は、図２のＡ−Ａ線断面図である。
【図３】図３は、本発明の発泡樹脂複合成形体成形用金型によって発泡成形された発泡樹脂複合成形体の一部切り欠き斜視図である。
【図４】図４は、金型正面分室と、金型上面分室と、金型下面分室と、金型左側面分室と、金型右側面分室と、金型背面側分室とから構成される本発明の実施例において用いた発泡樹脂複合成形体成形用金型の断面図である。
【図５】図５は、図４のＢ−Ｂ線断面図である。
【図６】図６は、図１の金型に平板を配置した状態の断面図である。
【図７】図７は、図６の平板を配置した金型に発泡性樹脂粒子を充填している状態の断面図である。
【図８】図８は、図７の平板を配置し発泡性樹脂粒子を充填した金型の断面図である。
【図９】図９は、図８の平板を配置し発泡性樹脂粒子を充填した金型を加熱発泡成形させた状態の断面図である。
【図１０】図１０は、図９において加熱発泡成形して得られた発泡樹脂複合成形体を取り出すために発泡樹脂複合成形体成形用金型の金型上面分室を上昇させた状態の断面図である。
【図１１】図１１は、発泡成形された発泡樹脂複合成形体を背面に設けられた離型ピンにより押し出した状態の図１０のＣ−Ｃ線断面図である。
【図１２】図１２は、得られた発泡樹脂複合成形体を接続材により２枚繋ぎ合わせた屋根材用の大型パネルの一部切り欠き斜視図である。
【符号の説明】
１ 発泡樹脂複合成形体成形用金型
２ 金型上面分室
２ａ 空洞
２ｂ スチーム供給孔
３ 金型正面分室
３ａ 空洞
３ｂ スチーム供給孔
３ｃ 平板挿入用溝部
４ 金型下面・側面分室
４ａ 空洞
４ｂ スチーム供給孔
４ｃ 平板挿入用溝部
４ｄ 背面側部
５ 成形用キャビティー
６ 発泡樹脂層
７，８ 平板層
９ 発泡樹脂複合成形体
１０ａ，１０ｂ スチーム供給ライン
１１ 隔壁
１１ａ 細孔
１２ 成形体成形室
１３ａ，１３ｂ 排気・排水ライン
１４ 発泡性樹脂粒子供給用充填ガン
１５ 発泡性樹脂粒子
１６ 金型下面分室
１６ｂ スチーム供給孔
１７ 金型左側面分室
１７ａ，１７ｂ，１７ｃ，１７ｄ 金型左側面細分室
１８ 金型右側面分室
１８ａ，１８ｂ，１８ｃ，１８ｄ 金型右側面細分室
１９ 金型背面分室
２０ 突出ピン
２１ 発泡性樹脂粒子供給ライン
２２ａ，２２ｂ 空気供給ライン
２３ａ，２３ｂ 水供給ライン
２４ａ，２４ｂ 減圧ライン
２５ａ，２５ｂ ユーティリティー供給ライン
２６ 扉
２７ａ，２７ｂ 排出弁
２８ａ，２８ｂ スチーム弁
２９ａ，２９ｂ 減圧弁
３０ａ，３０ｂ 水弁
３１ａ，３１ｂ 空気弁
３２ 突出ピン
３３ 接着剤層
３４ 補強材
３４’ 補強材
３５ ランバー
３６ パネル
３７ 接続材
３８ 大型パネル
３９ 成形品面圧計[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a mold for molding a foamed resin composite molded body for molding a foamed resin composite molded body composed of a flat plate layer / foamed resin layer / flat plate layer in which a foamed resin is sandwiched between flat plates, and a foamed resin composite using the same. The present invention relates to a method for forming a molded body.
[0002]
[Prior art]
Various methods have been proposed for molding foamed resin moldings, and various methods have been implemented industrially.
Among these various methods, the method described in Japanese Patent Application Laid-Open No. 8-90580 is a method of manufacturing a composite plate in which the upper surface and the lower surface of a foamed resin are sandwiched between thin metal plates, and the concave upper surface of a vertical mold. And after placing a metal plate on the lower surface and filling expandable resin particles between the metal plates, water vapor is supplied from one side, water vapor is sucked from the other side and water vapor is allowed to flow for a predetermined time and heated. After that, the conventional water vapor supply part is changed to a water vapor suction part, the water vapor suction part is changed to a water vapor supply part, and heat foaming is performed by flowing water vapor in the reverse direction. A method for producing a foamed resin molded body has been clarified.
However, in this method for producing a foamed resin molded article, since it is difficult for water vapor to flow when a reinforcing material is disposed inside, JP 2000-254936 A discloses a plurality of chambers for supplying water vapor. There has been proposed a method of foaming the foamed resin particles sufficiently uniformly by partitioning the chamber into a plurality of chambers and forming a number of communication holes in the chamber communicating with the molding chamber.
Also, in this Japanese Patent Application Laid-Open No. 2000-254936, a plywood layer in which a foamed resin layer is sandwiched between two plywoods, and these plywoods and the foamed resin layers are bonded and integrated with a rubber adhesive. It has also been clarified about a foamed resin composite molded body having a five-layer structure of: / rubber adhesive layer / foamed resin layer / rubber adhesive layer / plywood layer.
Furthermore, in Japanese Patent Laid-Open No. 2000-263578, a back surface material having a plurality of ventilation holes is disposed on the bottom surface side of the molding chamber, and a surface material is disposed on the top surface side, and a resin foam is formed between both materials. After introducing the particles, water vapor is supplied and exhausted from the vent hole and heated and foamed to form a five-layer structure of plywood layer / rubber adhesive layer / foamed resin layer / rubber adhesive layer / plywood layer A method for producing a foamed resin composite molded body useful as a thermal insulation panel for buildings is clarified.
[0003]
[Problems to be solved by the invention]
However, a foamed resin composite molded body composed of a five-layer structure of plywood layer / rubber adhesive layer / foamed resin layer / rubber adhesive layer / plywood layer, which is useful as an insulation panel for buildings, is generally used for construction. Since it is used as a heat insulation panel, etc., even the smallest ones have a size of 910 mm × 1820 mm × 80 mm. Also, in order to foam-mold these plate-shaped bodies, molding to mold the above foamed resin composite molded body A chamber for supplying water vapor is formed around the room, and utility supply lines such as water vapor and air, and exhaust / drain lines must be provided as accessories. It becomes.
Therefore, in such a large-sized heat-foaming molding machine, a flat lid-shaped mold is generally placed on the concave mold molding chamber so that the mold can be opened and closed by moving up and down. In general, it is manufactured by a vertical heating foam molding machine that performs heating foam molding.
Therefore, it is a longitudinal to manufacture a foamed resin composite molded body composed of a five-layer structure of a large plywood layer / rubber adhesive layer / foamed resin layer / rubber adhesive layer / plywood layer, such as a thermal insulation panel for buildings. The mold foam molding machine has a large installation area and can only mold each of these foamed resin composite molded articles one by one, resulting in low productivity and an expensive manufacturing unit price.
[0004]
[Means for Solving the Problems]
As a result of intensive studies in view of the above problems, the present inventor has found that a mold is at least the upper surface of the mold in order to produce a foamed resin composite molded body in which the foamed resin layer is sandwiched between flat plates at a relatively low cost. Mold upper surface compartment located at the mold side, Mold lower surface compartment located at the lower surface of the mold, Mold front compartment located at the front side of the mold, and Mold side surface compartment located at the left side, right side and back side of the mold After supplying steam into the molding cavity from the mold upper surface compartment and the mold lower surface compartment and heating and foaming, the mold upper surface compartment is raised and the mold front compartment is opened. Since the flat plate layer of the foamed resin composite molded body can be taken out from the front side of the mold, the installation place is larger than that of a vertical foam molding machine that foam-molds the foamed resin composite molded body in a horizontal state. Productivity is high because it is narrow, and the inside of the molding cavity is used as a partition wall. If it is divided vertically, it is possible to produce a plurality of foamed resin composite molded bodies at the same time in a plurality of molded body molding chambers. The invention has been completed.
[0005]
That is, the mold for molding a foamed resin composite molded body of the present invention is a foam in which a foamed resin layer is sandwiched between flat plate layers by filling foamable resin particles between at least two flat plates and then subjected to heat foaming. In a mold for molding a foamed resin composite molded body for molding a resin composite molded body, the mold includes at least a mold upper surface compartment located on the upper surface side of the mold and a mold located on the front side of the mold. The front compartment is divided into the mold bottom and side compartments located on the bottom side and the left side, right side, and back side of the mold, and the flat plate is placed on the left and right sides at the center of these compartments. And forming a molding cavity for foam molding by filling expandable resin particles between these flat plates, and is connected to the molding cavity in the mold upper surface compartment and the mold lower surface / side compartment. A steam supply hole is formed and the molding carrier is formed. That the mold top compartment and the mold front compartment to take out the foamed molded foamed resin composite molded article in the tea was movably formed, it is characterized in.
[0006]
Further, in the molding method of the foamed resin composite molded body according to another aspect of the present invention, at least two flat plates are arranged in a mold, and after the foamable resin particles are filled between the flat plates, heating is performed. In a molding method of a foamed resin composite molded body that forms a foamed resin composite molded body in which a foamed resin layer is sandwiched between flat plate layers by foam molding, a mold upper surface compartment positioned at least on the upper surface side of the mold, Use a mold composed of a mold front compartment located on the front side of the mold and a mold lower face / side compartment located on the lower surface side and the left side, right side, and back side of the mold. At least two flat plates are arranged at both left and right ends in the molding cavity formed at the center of the mold, and after filling the foamable resin particles between these flat plates, the upper surface side of the molding cavity and Mold upper surface placed on the lower surface side The foamed resin layer is sandwiched between the flat plate layers by supplying steam into the molding cavity from the steam supply holes in the chamber and the mold lower surface / side surface compartment, and heating and foaming the foamable resin particles. After forming the foamed resin composite molded body, the mold upper surface compartment and the mold front compartment of the mold are opened, and the foamed resin composite molded body foam-molded in the molding cavity is taken out. To do.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
[I] Mold for molding foamed resin composite moldings
(1) Mold components
As shown in the front view of FIG. 1 and the side view of FIG. 2, a mold 1 for molding a foamed resin composite molded body according to the present invention includes a mold upper surface compartment 2 positioned at least on the upper surface side of the mold, and a mold. The mold front compartment 3 is located on the front side of the mold, and the mold is divided into the lower part of the mold and the mold lower face / side compartment 4 located on the left side, right side, and back side. The foamed resin composite molded body in which the foamed resin layer 6 is sandwiched between the flat plate layers 7 and 8 as shown in FIG. 3 in the molding cavity 5 formed in the central portion of the compartments 2, 3, 4. 9 can be foam-molded.
[0008]
(A) Mold top chamber
As shown in FIG. 1, a mold upper surface compartment 2 constituting the mold 1 for molding a foamed resin composite molded body of the present invention is located on the upper surface side of the mold 1 and contains a heating medium such as steam therein. The inside is a plate-like cavity having a cavity 2a so that it can be supplied and heated or kept warm.
Since the molding cavity 5 side of the mold upper surface compartment 2 is a part of the mold 1 for molding the foamed resin composite molded body 9, it is usually mirror-finished or Teflon (registered trademark) coated. .
In addition, a large number of steam supply holes 2b are formed in the mold upper surface compartment 2 on the molding cavity 5 side, and the steam supplied from the steam supply line 10a is evenly distributed in the mold upper surface compartment 2. Then, it is supplied into the molding cavity 5 through the steam supply hole 2b.
In particular, when the inside of the molding cavity 5 is divided into a plurality of molded body molding chambers 12 by the partition walls 11, steam is uniformly supplied into each molded body molding chamber 12 by the mold upper surface compartment 2. It is supposed to be done.
[0009]
Further, when steam is supplied from the mold upper surface compartment 2 into the molding cavity 5, steam into the molding cavity 5 or a plurality of molded body molding chambers 12 is transferred to the mold upper surface compartment 2. However, when steam is supplied from the steam supply line 10b described later, since the steam is distributed in the lower surface / side surface chamber 4 of the mold, the upper surface chamber 2 of the mold has a mold cavity. It is used as an outlet for removing steam or drain which is no longer necessary in the tee 5 or a plurality of molded body forming chambers 12, and is discharged out of the system through an exhaust / drain line 13a.
Accordingly, the mold upper surface compartment 2 is connected to the steam supply line 10a to be supplied with steam, and is also connected to the exhaust / drainage lines 13a and 13b to discharge the exhaust steam and the exhaust drain to the outside of the system.
Further, the mold upper surface compartment 2 is formed by foaming resin composite molding 9 when the foamed resin composite molded body 9 is taken out from the molding cavity 5 of the mold 1 after foam molding in the molding cavity 5. In order to make it easy to remove the molded body 9 from the mold, the mold upper surface compartment 2 is formed to be movable in the vertical direction by a hydraulic arm or the like.
Further, the mold upper surface compartment 2 is provided with a filling gun 14 for supplying expandable resin particles, so that the expandable resin particles 15 and used polystyrene expanded resin particles (recycled material) can be supplied. It has become.
Further, it is preferable that a flat plate insertion groove 2c is formed on the mold upper surface compartment 2 on the molding cavity 5 side. By forming the flat plate insertion groove 2c, the flat plates 7 and 8 can be kept vertical even before the foamable resin particles 15 are supplied. Therefore, the flat plate 7 of the obtained foamed resin composite molded body 9 can be maintained. , 8 can always be kept parallel.
[0010]
(B) Mold front branch
As shown in FIG. 2, a mold front compartment 3 constituting the mold 1 for molding a foamed resin composite molded body of the present invention is located in front of the mold 1 and supplies a heating medium such as steam therein. Then, the inside is a plate-like cavity having a cavity 3a so that it can be heated or kept warm.
Since the molding cavity 5 side of the mold front compartment 3 becomes a part of the mold 1 for molding the foamed resin composite molded body 9, it is usually mirror-finished or coated with Teflon (registered trademark). .
Also, a number of steam supply holes 3b are formed in the mold front compartment 3 on the molding cavity 5 side so that the steam supplied from the steam supply line 10a is evenly distributed in the mold front compartment 3. Then, it can be supplied into the molding cavity 5 through the steam supply hole 3b.
Furthermore, it is preferable that a flat plate insertion groove 3c is formed on the mold cavity 5 side of the mold front compartment 3. By forming the flat plate insertion groove 3c, the flat plates 7 and 8 can be kept vertical even before the foamable resin particles 15 are supplied. Therefore, the flat plate 7 of the obtained foamed resin composite molded body 9 can be maintained. , 8 can always be kept parallel.
As shown in FIG. 11, the mold front compartment 3 is formed in a door shape, and a part of the mold front compartment 3 is attached to a part of the mold and opens on either the left or right side, or opens on both sides. The foamed resin composite molded body 9 that is foam-molded in the molding cavity 5 is formed so that it can be taken out by tilting to the side.
Similar to the mold upper surface compartment 2, not only steam is supplied to the mold front compartment 3 via the steam supply line 10a but also the air supply lines 22a and 22b, the water supply lines 23a and 23b, and the decompression line 24a. , 24b and the exhaust / drainage lines 13a, 13b, and supply of air and water, exhaust and drainage can be performed in the molding cavity 5.
[0011]
(C) Mold bottom / side compartment
As shown in FIGS. 1 and 2, the mold lower surface / side surface compartment 4 constituting the foamed resin composite molded body molding mold 1 of the present invention includes a lower surface side, a left surface side, and a right surface side of the mold 1. And the four sides of the mold 1 for molding a foamed resin composite molded body, which are located on the back side, can be heated or kept warm by supplying a heating medium such as steam to the inside. Further, the inside is a plate-like cavity having a cavity 4a, and these plate-like cavities are formed in a bowl shape in which one side wall connected to four surfaces is opened.
Since the molding cavity 5 side of the mold lower surface / side compartment 4 is a part of the mold 1 for molding the foamed resin composite molded body 9, it is usually mirror-finished or Teflon (registered trademark) coated. ing.
In addition, a large number of steam supply holes 4b are formed on the molding cavity 5 side on the lower surface side of the mold lower surface / side surface compartment 4, and the steam supplied from the steam supply line 10b is formed on the lower surface / side surface of the mold. After being evenly dispersed in the compartment 4, it is supplied into the molding cavity 5 through the steam supply hole 4 b.
In particular, when the inside of the molding cavity 5 is divided into a plurality of molded body molding chambers 12 by the partition walls 11, steam is equally distributed in each molded body molding chamber 12 in the mold lower surface / side surface compartment 4. Is to be supplied.
[0012]
Further, when steam is supplied from the mold lower surface / side compartment 4 into the molding cavity 5, the molding cavity 5 or the plurality of molded body molding chambers 12 are formed in the mold lower face / side compartment 4. However, when the steam is supplied from the mold upper surface compartment 2 into the molding cavity 5, the steam is distributed in the mold upper surface compartment 2. The mold lower surface / side compartment 4 is used as an outlet for removing steam or drain which is no longer needed in the molding cavity 5 or the plurality of molded body molding chambers 12, and is discharged outside the system through an exhaust / drain line 13b. Is done. Further, it is preferable to install a molded product surface pressure gauge 39 on the molding cavity 5 side on the back surface side of the mold lower surface / side surface compartment 4. Can be controlled.
Further, it is preferable that a flat plate insertion groove 4 c is formed on the molding cavity 5 side on the lower surface side of the mold lower surface / side surface compartment 4. By forming the flat plate insertion groove 4c, the flat plates 7 and 8 can be kept vertical even before the foamable resin particles 15 are supplied. Therefore, the flat plate 7 of the obtained foamed resin composite molded body 9 can be maintained. , 8 can always be kept parallel.
[0013]
As shown in FIGS. 1 and 2, the mold lower surface / side surface compartment 4 is located on the lower surface side, the left surface side, the right surface side, and the back surface side of the mold 1, and is a foamed resin composite molded body. Although the four surface portions of the molding die 1 can be formed in a plate-like cavity having a cavity 4a inside, the plate-like cavity can be formed in a saddle shape with one side wall connected to the four surfaces being opened. 4 and 5, the four surface portions of the mold 1 are respectively divided into a mold lower surface compartment 16 on the lower surface side of the mold 1, a mold left side compartment 17 on the left side of the mold 1, and a mold. 1 is divided into four parts, a mold right side compartment 18 on the right side and a mold back side compartment 19 on the back side of the mold 1, or a mold left side compartment 17 and a mold right side compartment 18. It is also possible to divide and form the side wall portion of the mold rear compartment 19 and the mold lower compartment 16 into two parts. The four die underside compartment 16 from your perspective, mold left side compartment 17, the mold right side compartment 18, it is preferable formed by dividing into a mold back compartment 19.
In addition, as shown in FIG. 4, the four mold lower surface compartments 16, the mold left side compartment 17, the mold right side compartment 18, and the mold rear compartment 19 are formed into mold left side subdivision chambers 17a, 17b, 17c. , 17d and the right side subdivision chamber 18a, 18b, 18c, 18d of the mold can be formed as further subdivided subdivision chambers.
[0014]
(a) Mold bottom chamber
When the mold lower surface compartment 16 in the mold lower surface / side surface compartment 4 is divided and formed, as shown in FIG. 4, the mold lower surface compartment 16 on the lower surface side of the mold 1 is provided with a molding cavity. The steam supply hole 16b that is in contact with the tee 5 and serves as a passage for steam, air, water, etc. in the case of heating and foaming in the same manner as the mold upper surface compartment 2 is provided and is always heated and cooled. Therefore, from the viewpoint of temperature control or the like, the heating of the mold left side compartment 17, the mold right side compartment 18, and the mold rear compartment 19 which are clearly different from the portions forming the side wall portions of the mold 1 Since the cooling operation is performed, it is better to divide and separate from the compartments 17, 18, and 19 in the side wall portion of the mold.
Since the molding cavity 5 side of the mold lower surface compartment 16 is a part of the mold 1 for molding the foamed resin composite molded body 9, it is usually mirror-finished or Teflon (registered trademark) coated. .
[0015]
(b) Mold side compartment
As shown in FIGS. 4 and 5, the mold side compartments 17, 18, 19 constituting the side wall portion of the mold 1 for molding a foamed resin composite molded body according to the present invention include the left side surface, the right side surface of the mold, and It is located on the back surface, and is a plate-like hollow body having a U-shaped cross section so that it can be heated or kept warm when a heating medium such as steam passes inside.
The mold side compartments 17, 18, 19 are located in the mold left side compartment 17 located on the left side of the mold, the mold right side compartment 18 located on the right side of the mold, and the back of the mold. It is preferable to be divided into the mold back surface compartment 19 and the division in this manner is preferable because each compartment 17, 18, 19 can be adjusted to the optimum temperature.
Since the flat plates 7 and 8 are disposed in the mold left side compartment 17 and the mold right side compartment 18, the steam supply hole is not formed and the mold cavity 5 is not communicated. preferable.
However, when the flat plates 7 and 8 are provided with pores, steam supply holes can be formed in the mold left side compartment 17 and the mold right side compartment 18.
However, in the case where the molding cavity 5 is partitioned by the partition wall 11 to form the molded body molding chamber 12, the molded body molding chambers 12 at both ends in the molding cavity 5 and the molded body molding at the center portion are formed. Since there is a difference in the amount of steam supplied to the chamber 12, it is necessary to make pores in the partition wall 11.
[0016]
Mold left side compartment
Since the mold left side compartment 17 is in contact with the flat layers 7 and 8 in the molding cavity 5, the mold upper compartment 2 and the mold lower compartment 16 which usually serve as a passage for steam, air, water, etc. Since the steam supply holes 2b and 16b are not drilled as in the above and do not serve as passages for steam, air, water, etc., they are not directly involved in heating and cooling during the heating and foaming process, and the left side of the mold The compartment 17 is normally maintained at a constant temperature.
[0017]
Mold right side compartment
Since the mold right side compartment 18 is in contact with the flat plate layers 7 and 8 in the molding cavity 5, like the mold left side compartment 17, it usually becomes a passage for steam, air, water, or the like. Since the steam supply hole 16b is not drilled and does not serve as a passage for steam, air, water, or the like, it is not directly involved in heating or cooling during heating and foaming molding, and the right side compartment of the mold has a constant temperature. It is normal to be held in.
[0018]
Mold back compartment
Unlike the mold left side compartment 17 and the mold right side compartment 18, the mold back surface compartment 19 is in contact with the foamed resin layer 6 in the molding cavity 5, so that usually steam, air, water, etc. The steam supply hole 16b can be drilled, but the flow of steam, air, water, or the like is not good. Therefore, the steam, air, water, or the like channel is formed without drilling the steam supply hole 16b. However, it is preferable to keep the mold back chamber 19 at a constant temperature so that it is not directly involved in heating and cooling during the heat foaming molding.
A molded product surface pressure gauge 39 is installed on the molding cavity 5 side of the mold back surface compartment 19, and the end of the main heating and the cooling time can be controlled by the value of the molded product surface pressure gauge 39. preferable.
Further, in the mold back surface compartment 19, the foamed resin composite molded body 9 in which the foamed resin layer 6 foamed in the molding cavity 5 is sandwiched between the flat plate layers 7 and 8 is provided from the inside of the mold 1. In order to take out, it is preferable that the protrusion pin 20 for pressing and taking out the flat plate layers 7 and 8 from the back side 19 of the mold is formed.
[0019]
(2) Molding cavity
The molding cavity 5 formed in the center surrounded by the mold upper surface compartment 2, the mold front compartment 3, the mold lower surface / side compartment 4 of the mold 1 includes a foamed resin layer 6 and a flat plate layer 7. , 8 is a mold 1 for molding a foamed resin composite molded body 9 for molding a foamed resin composite molded body 9, and flat plate layers 7, 8 are disposed on the left and right ends of the mold 1, respectively. .
Further, the molding cavity 5 may be a single space, but a molding capable of molding a plurality of foamed resin composite molded bodies 9 by the partition walls 11 provided vertically in the cavity 5. It is preferable that the body forming chamber 12 is divided.
[0020]
(A) Molded body molding chamber
The molding cavity 5 divided by the partition walls 11 is preferably divided into 2 to 8, particularly 3 to 6 molded body molding chambers 12 in general.
Therefore, in such a molded body molding chamber 12, a plurality of foamed resin composite molded bodies 9 can be simultaneously molded by one heating foam molding.
In each molded body molding chamber 12 divided by the partition wall 11, flat plates 7 and 8 are arranged at both left and right ends of each molded body molding chamber 12.
[0021]
(B) Separation wall
In general, 1 to 7 partition walls 11 are preferably provided in the molding cavity 5.
The partition wall 11 is generally made of a metal plate made of the same material as that of the mold 1, but the metal plate of the partition wall 11 is usually not provided with pores communicating with the adjacent molded body forming chamber 12. If necessary, the communicating pores 11a can be provided.
[0022]
(C) Plate insertion groove
Flat plate insertion grooves 2c and 4c are provided in the mold upper surface compartment 2 and the mold lower surface / side surface compartment 4 at both the left and right ends of each molded body molding chamber 12 formed by being divided by the partition wall 11.
[0023]
(3) Filling gun for supplying expandable resin particles
The mold upper surface compartment 2 of the foamed resin composite molded body molding die 1 is provided with a filling gun 14 for supplying foamable resin particles. The mold upper surface compartment 2 has a depth of the molding cavity 5. In general, 1 to 5 and preferably 2 to 3 filling guns 14 for supplying expandable resin particles are provided.
[0024]
(4) Raw material supply line (expandable resin particle supply line)
The foamable resin particle supply filling gun 14 is provided with a foamable resin particle supply line 21 for supplying the foamable resin particles 15, and compressed air is used to transfer the foamable resin particles 15. Yes.
[0025]
(5) Utility supply line
Steam, air, water, or the like is supplied into the mold cavity 5 surrounded by the mold 1 in the mold upper surface compartment 2 and the mold lower surface / side surface compartment 4 of the mold 1 for molding a foamed resin composite molded body. Utility supply lines 25a and 25b such as steam supply lines 10a and 10b, air supply lines 22a and 22b, water supply lines 23a and 23b, and decompression lines 24a and 24b are connected.
[0026]
(A) Steam supply line
A steam supply line 10 a for supplying steam into the molding cavity 5 surrounded by the mold 1 is provided in the mold upper surface compartment 2 and the mold lower surface / side surface compartment 4 of the foamed resin composite molded body molding die 1. , 10b.
[0027]
(B) Air supply line
An air supply line 22 a for supplying air into the molding cavity 5 surrounded by the mold 1 is provided in the mold upper surface compartment 2 and the mold lower surface / side surface compartment 4 of the foamed resin composite molded body molding die 1. , 22b are provided.
[0028]
(C) Water supply line
A water supply line 23a for supplying water into a molding cavity 5 surrounded by the mold 1 is provided in the mold upper surface compartment 2 and the mold lower surface / side surface compartment 4 of the mold 1 for molding a foamed resin composite molded body. , 23b are provided.
[0029]
(D) Decompression line
Air in the molding cavity 5 surrounded by the mold 1 is exhausted or depressurized in the mold upper surface compartment 2 and the mold lower surface / side surface compartment 4 of the mold 1 for molding a foamed resin composite molded body. In order to evaporate the water, decompression lines 24a and 24b connected to a vacuum pump or the like are provided.
[0030]
(6) Exhaust / drainage line
The mold upper surface compartment 2 and the mold lower surface / side surface compartment 4 of the mold 1 for molding a foamed resin composite molded body include steam, air, and steam supplied to the mold upper surface compartment 2 and the mold lower surface / side surface compartment 4. Exhaust / drainage lines 13a and 13b are provided for exhausting and draining the drain and the like that have been cooled and condensed.
[0031]
[II] Molding method of foamed resin composite molded body
(1) Mold used
As the mold 1 used in the molding method of the foamed resin composite molded body 9, as shown in FIGS. 1 and 2, at least the mold upper surface compartment 2 located on the upper surface of the mold and the mold 1 located on the front side of the mold A mold 1 for molding a foamed resin composite molded body is used, which is divided into a mold front compartment 3 and a mold lower face / side compartment 4 located on the lower surface side, left side, right side, and back side of the mold. It is done.
[0032]
(2) Mold preheating process (mold cleaning)
In order to mold the foamed resin composite molded body 9, first, as shown in FIG. 1, the mold front compartment 3 serving as the door 26 of the foamed resin composite molded body molding mold 1 is closed, and the mold is molded. The molding cavity 5 of the mold 1 is closed by lowering the upper surface compartment 2.
Then, the exhaust valves 27a and 27b of the exhaust / drain lines 13a and 13b arranged above and below the mold 1 are opened, and the steam valves 28a and 28b of the steam supply lines 10a and 10b arranged above and below the mold 1 are opened. Then, the mold 1 and the molding cavity 5 are preheated, and drain water and steam composed of water condensed and liquefied in the mold 1 are discharged from the exhaust / drain lines 13a and 13b.
[0033]
(3) Flat plate insertion process
Next, the mold front compartment 3 serving as the door 26 of the mold 1 is opened, and as shown in FIG. 6, the flat plate insertion groove 2c of the mold upper surface compartment 2 and the flat plate of the mold lower surface / side compartment 4 are formed. At least two flat plates 7 and 8 are inserted along the insertion groove 4 c, and the flat plates 7 and 8 are arranged on both side ends in the molding cavity 5.
[0034]
(4) Mold closing process
The mold front compartment 3 serving as the door 26 of the mold 1 is closed, and the molding cavity 5 of the mold 1 is closed.
[0035]
(5) Filling process of expandable resin particles
Then, as shown in FIG. 7, the foamable resin particles 15 are supplied into the molding cavity 5 of the mold 1 by the filling gun 14 for supplying foamable resin particles provided above the mold upper surface compartment 2. Then, as shown in FIG. 8, the foamable resin particles 5 are filled between the flat plates 7 and 8.
[0036]
(6) Preheating process for molding cavity
Next, as shown in FIG. 8, after opening the discharge valves 27a and 27b of the exhaust / drain lines 13a and 13b arranged above and below the mold 1, the steam supply lines 10a arranged above and below the mold 1 are opened. , 10b, the steam valves 28a, 28b are opened for about 5 seconds to introduce steam into the molding cavity 5 of the mold 1, and the drain in the mold 1 is discharged from the exhaust / drain lines 13a, 13b. Preheat the entire mold 1.
[0037]
(7) Preheating foam molding
(A) Pressure reduction
The pressure reducing valves 29a and 29b of the pressure reducing lines 24a and 24b arranged above and below the mold 1 are opened to discharge the air between the expandable resin particles 15 out of the system, so that the pressure in the molding cavity 5 is about −40. The pressure is reduced to about 70 kPa.
[0038]
(B) Steam supply / exhaust
Next, the steam valve 28a of the steam supply line 10a arranged at the upper part of the mold 1 is opened, the discharge valve 27b of the exhaust / drain line 13b arranged at the lower part of the mold 1 is opened, and the steam supply line on the upper side is opened. The steam is supplied from 10a, discharged from the discharge valve 27b of the lower exhaust / drainage line 13b, and the air between the foamable resin particles 15 in the molding cavity 5 is discharged out of the system. The fusion between the upper expandable resin particles 15 is promoted.
[0039]
(C) Steam supply / exhaust
Next, the steam valve 28b of the steam supply line 10b arranged at the lower part of the mold 1 is opened, the discharge valve 27a of the exhaust / drain line 13a at the upper part of the mold 1 is opened, and the lower part of the mold 1 is arranged. Steam is supplied from the steam supply line 10b and discharged out of the system through the exhaust / drain line 13a above the mold 1, and the air between the foamable resin particles 15 in the molding cavity 5 is discharged out of the system. Then, fusion between the expandable resin particles 15 on the upper part of the mold 1 is promoted.
[0040]
(8) Main heating foam molding (main foam molding)
Furthermore, as shown in FIG. 9, the steam valves 28a and 28b on the upper and lower sides of the mold 1 are opened, and steam is supplied into the molding cavity 5 for a period of time until the surface pressure of the molded product reaches the set surface pressure of the heating product. Then, the foamable resin particles 15 in the molding cavity 5 are foamed, and the foamable resin particles 15 are fused together to perform the main foam molding.
[0041]
(A) Molding conditions
As molding conditions in this foam molding, it is common to carry out under the following molding conditions.
Molding condition
Molding steam pressure: generally 20 to 150 kPa, preferably 30 to 100 kPa
Molding temperature: generally 100 to 130 ° C, preferably 110 to 120 ° C
Main heating time: generally 1 to 180 seconds, preferably 5 to 60 seconds
Set surface pressure: generally 30 to 150 kPa, preferably 50 to 100 kPa
[0042]
(9) Cooling
(A) Mold cooling
When the main foam molding is completed, the water valves 30a and 30b of the water supply lines 23a and 23b arranged at the upper and lower parts of the mold 1 are opened, and the exhaust / drainage line 13a arranged at the upper and lower parts of the mold 1 is opened. , 13 b are opened and water is supplied into the mold 1 to cool the mold 1 and the foamed resin composite molded body 9.
[0043]
(B) Air cooling
The air valves 31a and 31b of the air supply lines 22a and 22b arranged at the upper and lower portions of the mold 1 are opened to discharge water in the mold 1 and the mold 1 and the foamed resin composite molded body molded by the air. 9 is cooled.
[0044]
(C) Vacuum cooling (cooling by latent heat of vaporization)
The pressure reducing valves 29a and 29b of the pressure reducing lines 24a and 24b arranged at the upper and lower portions of the mold 1 are opened to evaporate water adhering to the mold 1 and the molded foamed resin composite molded body 9, and the latent heat of evaporation is reduced. The foamed resin composite molded body 9 molded by use is cooled until the molded product surface pressure reaches the take-out set surface pressure.
[0045]
(10) Removing the molded product
(A) Ascent of upper mold compartment
In order to take out the foamed resin composite molded body 9 having the foamed resin layer 6 sandwiched between the flat plate layers 7 and 8 from the molding cavity 5 of the mold 1, as shown in FIG. The mold upper surface compartment 2 is released from the foamed resin composite molded body 9 by being raised.
[0046]
(B) Opening the mold front compartment
Next, as shown in FIG. 11, the mold front cavity 3 is opened to open the molding cavity 5 of the mold 1, and the foamed resin composite molded body 9 is taken out.
[0047]
(C) Flat plate pressing with protruding pins
The flat plate layers 7 and 8 are pressed from the back side of the mold 1 to the back side 4d of the mold lower surface / side compartment 4 of the mold 1 so that the flat plate layers 7 and 8 on the front side are one from the mold 1. It is preferable that a protruding pin 32 is formed so that the protruding portion can be easily taken out.
[0048]
[III] Foamed resin composite molded body
(1) Structure
(A) Layer structure
A foamed resin composite molded body 9 in which a foamed resin layer 6 obtained by a molding method of a foamed resin composite molded body 1 and a foamed resin composite molded body 9 using the same is sandwiched between flat plate layers 7 and 8 of the present invention. Is basically composed of flat plate layer 7 / foamed resin layer 6 / flat plate layer 8, but in order to obtain a stronger foamed resin composite molded body 9, an adhesive layer is interposed between these layers. It is preferable to use the flat plate layer 7 provided with 33 / adhesive layer 33 / foamed resin layer 6 / adhesive layer 33 / flat plate layer 8.
The thickness of each of these layers is generally 0.5 to 50 mm, preferably 2 to 20 mm, particularly preferably 5 to 15 mm, and the foamed resin layer is generally 5 to 450 mm, preferably 15 to 350 mm, particularly preferably 25 to 25 mm. The adhesive layer is generally from 0.01 to 5 mm, preferably from 0.1 to 3 mm, particularly preferably from 0.3 to 2 mm.
[0049]
(B) Reinforcement
Basically, the above layer structure is used. However, in order to perform mechanical reinforcement, a part of the foamed resin layer 6 is reinforced with timber or the like between the front and back flat layers 7 and 8 as shown in FIG. By changing to the material 34, the flat plate layer 7 / the reinforcing material 34 and the foamed resin layer 6 / the flat plate layer 8 or the flat plate layer 7 / the adhesive layer 33 / the reinforcing material 34 and the foamed resin layer 6 / the adhesive agent are formed. The foamed resin composite molded body 9 can be made even better by forming the layer 33 / flat layer 8. Further, the reinforcing material can be arranged in a columnar shape like the reinforcing material 34 '.
[0050]
(2) Raw materials
(A) Expandable resin
(a) Types of foam resin
Examples of the foamable resin used in the molding method of the foamed resin composite molded body mold 1 and the foamed resin composite molded body 9 using the foamed resin composite molded body of the present invention include polystyrene-based foamable resins, polypropylene-based foamable resins, and polyethylene-based resins. Mention may be made of thermoplastic foamable resins such as foamable resins.
Among these thermoplastic foam resin particles, polystyrene foam resin particles and styrene resin foams such as styrene / ethylene copolymers are preferred.
[0051]
(b) Particle size
The particle diameter of these expandable resin particles is generally 0.3 to 20 mm, preferably 0.5 to 15 mm.
[0052]
(c) Foaming ratio
As the expansion ratio of these expandable resin particles, generally 15 to 150 times, preferably 20 to 125 times are used.
[0053]
(d) Mixing of recycled materials
Used polystyrene foamed resin particles (recycled material) collected by recycling may be mixed with a part of the foamable resin particles.
These recycled materials are generally environmentally friendly and can be produced economically by using them in the range of 1 to 50% by weight, preferably 5 to 30% by weight.
[0054]
(B) Flat plate
As the flat plates 7 and 8 used in the molding method 1 of the foamed resin composite molded body and the foamed resin composite molded body 9 using the same according to the present invention, ordinary plywood, flame retardant plywood, structural plywood, disaster prevention plywood Plywood, particle board, IB (insulation fiber board), MDF (medium density fiber board), fiber board such as HB (hard fiber board), copper plate, painted iron plate, galvanized iron plate, stainless steel plate Metal plates such as acrylic resin plates, vinyl chloride resin plates, resin plates such as interior plastic decorative boards, wood cement boards such as wood wool cement boards, wood chip cement boards, pulp cement boards, fiber reinforced cement boards, Rock wool sizing board, gypsum board, sizing gypsum board, reinforced gypsum board, gypsum lath board, makeup gypsum board Noncombustible laminated plasterboard plasterboard plates, gas concrete plates, element plate Saideingu, painting siding, decorative siding etc. Ceramic siding, may be mentioned inorganic board or laminates of these stacked tiles and the like.
Among these flat plates 7 and 8, it is preferable to use ordinary plywood, flame retardant plywood, structural plywood, plywood such as disaster prevention plywood, particle board, painted iron plate, gypsum board, etc., especially structural plywood. preferable.
Thick
The thickness of these flat plates is generally 0.5 to 50 mm, preferably 2 to 20 mm, particularly preferably 5 to 15 mm.
size
These flat plates generally have a length of 0.9 to 10 m, preferably 1.8 to 8 m, preferably 3 to 7.5 m, and a width of generally 0.3 to 3 m, preferably 0.4 to 2 m, preferably 0.6 to 1.8 m is used.
[0055]
(C) Adhesive
Examples of the adhesive used for the adhesive layer 33 include epoxy adhesives, urethane adhesives, vinyl acetate adhesives, resin solvent adhesives, chloroprene rubber adhesives, nitrile rubber adhesives, Solvent adhesives such as modified rubber latex adhesives, recycled rubber adhesives, aqueous adhesives such as acrylic adhesives, vinyl acetate adhesives, SBR adhesives, EVA adhesives, aqueous high adhesives Molecular-isocyanate type adhesives, hot melt type adhesives and the like can be mentioned.
Among these adhesives, solvent type adhesives such as resin solvent type adhesives, chloroprene type rubber type adhesives, nitrile type rubber type adhesives, modified rubber latex type adhesives, recycled rubber type adhesives may be used. preferable.
[0056]
(D) Reinforcing material
Generally, timber is used as the lumbar 35 applied to the outer periphery of the foamed resin layer 6.
[0057]
(3) Application
A foamed resin composite molded body 9 in which such a foamed resin layer 6 is sandwiched between flat plate layers 7 and 8 is generally a panel of 7200 mm × 910 mm by reinforcing a lumbar 35 made of timber with a nail or the like on the outer peripheral portion thereof. As shown in FIG. 12, two panels 36 are connected by a connecting material 37 to form a large panel 38 having a size of 7200 mm × 1820 mm to be used as a roofing material, a wall material, and a flooring material. It can also be used.
[0058]
【Example】
The present invention will be described more specifically with reference to the following examples and comparative examples.
[I] Evaluation method
(1) Tensile strength
Tensile strength of the obtained foamed resin composite molded article was determined by cutting the measurement composite panel into a sample having a size of 10 cm × 10 cm, and attaching a pulling jig to the front and back flat surfaces of the sample with an epoxy adhesive. The sample is placed in a horizontal state, the lower jig is fixed, the upper jig is pulled up, and the strength at break of the sample is measured.
[0059]
(2) Thermal insulation performance
The heat insulating performance of the obtained foamed resin composite molded body was cut into a sample having a size of 20 cm × 20 cm × 2.5 cm from the composite panel for measurement, and the thermal conductivity of this sample was measured according to JIS-A 1412-2. The measurement was performed according to the heat flow meter method.
[0060]
[II] Examples and Comparative Examples
Example 1
(1) Mold
As shown in FIGS. 4 and 5, the mold used in the method of molding the foamed resin composite molded body includes a mold front compartment located in front of the mold, a mold upper compartment located on the upper surface of the mold, and The mold lower surface compartment located on the lower surface of the mold, the mold left side compartment located on the left side of the mold, the mold right side compartment located on the right side of the mold, and the back side of the mold A die divided in a six-sided compartment consisting of a die rear side compartment was used.
A molding cavity surrounded by the mold is divided into five molded body molding chambers by four partition walls 11 formed vertically.
After inserting two plywoods with a thickness of 10 mm x height of 910 mm x length of 7200 mm into the flat plate insertion grooves on the left and right ends of these five molded body molding chambers, close the door on the mold front compartment side. By lowering the mold upper compartment, the mold molding cavity is closed, the exhaust / drain line discharge valve is opened, the steam supply line steam valve is opened for about 5 seconds, and the mold cavity is opened. Steam was introduced into the mold 1, and the drain in the mold 1 was discharged from the exhaust / drainage line.
And using a foaming polystyrene resin (trade name “Neopoor”) containing graphite particles manufactured by BASF from a filling gun for supplying foamable resin particles in five molding chambers in the mold, Daisen Corporation ) Foam specific gravity 15kg / m pre-foamed using a batch pre-foaming machine "DYH-1000" for polystyrene foam39.8 kg of each pre-expanded particle was filled.
[0061]
Next, the pressure reducing valve of the pressure reducing line was opened to reduce the pressure in the molding cavity to about -60 kPa, and the air between the expandable resin particles was discharged out of the system.
Next, open the steam valve in the steam supply line at the top of the mold, open the exhaust valve in the exhaust / drain line at the bottom of the mold, and supply steam into the molding body to fuse the foamable resin particles. Promote.
Furthermore, open the steam valve in the steam supply line at the bottom of the mold, open the exhaust valve in the exhaust / drain line at the top of the mold, and supply steam from the steam supply line at the bottom of the mold to melt the foamed resin particles. Promote wearing.
Next, the upper and lower steam valves of the mold are opened, and 50 kPa and 111 ° C. steam are foamed into the molding cavity to foam the expandable resin particles in the molding cavity until the surface pressure of the molded product reaches 80 kPa. The foam molding is performed by fusing the expandable resin particles to each other.
[0062]
Then, when the foam molding is completed, the water valve of the water supply line is opened, the discharge valve of the exhaust / drain line is opened, and water is supplied into the mold to cool the mold and the molded product. Further, the air valve of the air supply line is opened to discharge water, and the mold and the molded product are cooled by air until the surface pressure of the molded product becomes 0 kPa.
Next, the pressure reducing valve of the pressure reducing line is opened to evaporate water adhering to the mold and the molded foamed resin composite molded body, and the molded foamed resin composite molded body is cooled using the latent heat of vaporization.
The mold upper surface compartment is raised and the mold upper surface compartment is released from the foamed resin composite molded body.
[0063]
Next, the mold front cavity is opened to open the inside of the mold molding cavity, and the foamed resin composite molded article is taken out.
The flat plate layer was pressed from the back side of the mold by the protruding pins formed in the mold back side compartment, and the flat plate layer on the front side was partially protruded from the mold.
The foamed resin composite molded body foam-molded by the foamed resin composite molded body molding die of the present invention is divided into a plurality of molded body molding chambers in the vertical direction by partition walls in the mold molding cavity. Therefore, the molded foamed resin composite molded body can be easily taken out, the installation area of the mold is small, and a large number of foamed resin composite molded bodies can be molded by one foam molding.
[0064]
Example 2
In Example 1, the pre-foamed particles containing 30% by weight of the used polystyrene foam resin particles in the pre-foamed particles filled with the foaming resin particle supply filling gun were used, as described in Example 1. It carried out like the method.
The results are shown in Table 1.
[0065]
Example 3
In Example 1, as shown in FIG. 1, the mold has a mold front compartment located on the front side of the mold, a mold upper compartment located on the upper surface side of the mold, a lower surface side of the mold, and The same procedure as described in Example 1 was performed except that a mold divided in a three-compartment chamber composed of a mold lower surface and a side compartment located on the left side, right side, and rear side was used.
The results are shown in Table 1.
[0066]
Example 4
This was carried out in the same manner as in Example 1 except that an expandable polystyrene resin (trade name “JFN200”) manufactured by Mitsubishi Chemical Foam Plastic Co., Ltd. was used as a raw material.
The results are shown in Table 1.
[0067]
Example 5
The same procedure as in Example 2 was performed except that an expandable polystyrene resin (trade name “JFN200”) manufactured by Mitsubishi Chemical Foam Plastic Co., Ltd. was used as a raw material.
The results are shown in Table 1.
[0068]
Example 6
This was carried out in the same manner as in Example 3 except that an expandable polystyrene resin (trade name “JFN200”) manufactured by Mitsubishi Chemical Foam Plastic Co., Ltd. was used as a raw material.
The results are shown in Table 1.
[0069]
[Table 1]
Figure 0003878077
[0070]
【The invention's effect】
The mold for molding a foamed resin composite molded body according to the present invention and the molding method of the foamed resin composite molded body using the mold are such that the mold upper surface compartment can be raised and lowered in the vertical direction, and the mold front compartment can be opened and closed. Since it is molded with the formed horizontal foam mold, it can be taken in and out from the front side of the mold with the flat plate layer of the foamed resin composite molded body upright, so for such horizontal foam molding Compared with vertical foam molding molds, the mold is foam-molded in a horizontal state and foamed from the top, so the productivity is high and the mold is used for molding the mold. If the inside of the cavity is divided in the vertical direction by the partition walls, it is possible to simultaneously produce a plurality of foamed resin composite molded bodies in a plurality of molded body molding chambers, thereby further improving productivity. There is an advantage that you can.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a mold for molding a foamed resin composite molded body according to an embodiment of the present invention.
FIG. 2 is a cross-sectional view taken along line AA in FIG.
FIG. 3 is a partially cutaway perspective view of a foamed resin composite molded body that is foam-molded by the mold for molding a foamed resin composite molded body of the present invention.
FIG. 4 shows a mold front compartment, a mold top compartment, a mold bottom compartment, a mold left side compartment, a mold right side compartment, and a mold back side compartment. It is sectional drawing of the metal mold | die for foaming resin composite molded object used in the Example of this invention.
5 is a cross-sectional view taken along line BB in FIG. 4. FIG.
6 is a cross-sectional view showing a state in which a flat plate is arranged in the mold shown in FIG. 1. FIG.
7 is a cross-sectional view showing a state in which a mold having the flat plate of FIG. 6 is filled with expandable resin particles.
FIG. 8 is a cross-sectional view of a mold in which the flat plate of FIG. 7 is arranged and filled with expandable resin particles.
9 is a cross-sectional view of a state in which a mold in which the flat plate of FIG. 8 is arranged and filled with expandable resin particles is heated and foam-molded. FIG.
10 is a cross-sectional view of a state in which a mold upper surface compartment of a mold for molding a foamed resin composite molded body is raised in order to take out a foamed resin composite molded body obtained by heating and foam molding in FIG. 9; It is.
11 is a cross-sectional view taken along the line CC of FIG. 10 in a state where the foamed resin composite molded body that has been foam-molded is extruded by a release pin provided on the back surface.
FIG. 12 is a partially cutaway perspective view of a large panel for roofing material in which two obtained foamed resin composite molded bodies are joined together by a connecting material.
[Explanation of symbols]
1 Mold for molding foamed resin composite moldings
2 Mold top compartment
2a cavity
2b Steam supply hole
3 Mold front compartment
3a cavity
3b Steam supply hole
3c Slot for inserting flat plate
4 Mold bottom and side compartments
4a cavity
4b Steam supply hole
4c Slot for inserting flat plate
4d back side
5 Molding cavity
6 Foamed resin layer
7,8 Flat layer
9 Foamed resin composite molded body
10a, 10b Steam supply line
11 Bulkhead
11a pore
12 Molding room
13a, 13b Exhaust / drain line
14 Filling gun for supplying expandable resin particles
15 Expandable resin particles
16 Mold bottom chamber
16b Steam supply hole
17 Mold left side compartment
17a, 17b, 17c, 17d Mold left side subdivision chamber
18 Mold right side compartment
18a, 18b, 18c, 18d Mold right side subdivision chamber
19 Mold back compartment
20 Protruding pin
21 Expandable resin particle supply line
22a, 22b Air supply line
23a, 23b Water supply line
24a, 24b Decompression line
25a, 25b Utility supply line
26 Door
27a, 27b discharge valve
28a, 28b Steam valve
29a, 29b Pressure reducing valve
30a, 30b water valve
31a, 31b Air valve
32 protruding pin
33 Adhesive layer
34 Reinforcing material
34 'reinforcement
35 Lumber
36 panels
37 connection material
38 Large panel
39 Molded surface pressure gauge

Claims (17)

少なくとも２枚の平板の間に発泡性樹脂粒子を充填した後、加熱発泡成形することにより発泡樹脂層を平板層にて挟んだ発泡樹脂複合成形体を成形するための発泡樹脂複合成形体成形用金型において、該金型を、少なくとも金型の上面側に位置する金型上面分室と、金型の正面側に位置する金型正面分室と、金型の下面側及び左面側・右面側・背面側とに位置する金型下面・側面分室とに分割して構成して、これら分室の中心部に上記平板を左右両側端に配置し、これら平板の間に発泡性樹脂粒子を充填して発泡成形するための成形用キャビティーを形成して、上記金型上面分室及び金型下面・側面分室に成形用キャビティーと導通するスチーム供給孔を形成すると共に、該成形用キャビティー内で発泡成形された発泡樹脂複合成形体を取り出す為に上記金型上面分室及び金型正面分室を可動自在に形成したことを特徴とする、発泡樹脂複合成形体成形用金型。For forming a foamed resin composite molded body for molding a foamed resin composite molded body in which a foamed resin layer is sandwiched between flat plate layers by filling foamable resin particles between at least two flat plates and then performing heat foaming. In the mold, the mold includes at least a mold upper surface compartment located on the upper surface side of the mold, a mold front compartment located on the front side of the mold, a lower surface side and a left surface side / right surface side of the mold, It is divided into a mold lower surface and side compartments located on the back side, and the flat plates are arranged at both left and right ends in the center of these compartments, and foamed resin particles are filled between these flat plates. A molding cavity for foam molding is formed, and a steam supply hole is formed in the mold upper surface chamber and the mold lower surface / side surface chamber to communicate with the molding cavity, and foaming is performed in the molding cavity. Take the molded foam resin composite Characterized in that the mold top compartment and the mold front compartment and movably formed in order to, foamed resin composite molded article mold. 成形用キャビティーが、隔壁によって複数個の成形体成形室に分割されている、請求項１に記載の発泡樹脂複合成形体成形用金型。The mold for molding a foamed resin composite molded body according to claim 1, wherein the molding cavity is divided into a plurality of molded body molding chambers by partition walls. 複数個に分割して形成された成形体成形室のそれぞれが、金型上面分室及び金型下面・側面分室とスチーム供給孔によって連通している、請求項２に記載の発泡樹脂複合成形体成形用金型。3. The foamed resin composite molded body molding according to claim 2, wherein each of the molded body molding chambers divided into a plurality of parts communicates with the mold upper surface compartment and the mold lower surface / side surface compartment by a steam supply hole. Mold. 金型の成形用キャビティー内で発泡成形された発泡樹脂複合成形体を取り出す為に、金型の横の金型正面分室が開閉自在に形成されている横型形式の金型である、請求項１〜３のいずれかに記載の発泡樹脂複合成形体成形用金型。A horizontal mold in which a mold front side chamber is formed to be openable and closable in order to take out a foamed resin composite molded body foam-molded in a molding cavity of the mold. A mold for molding a foamed resin composite molded body according to any one of 1 to 3. 金型上面分室が上下方向に可動自在に形成されている、請求項１〜４のいずれかに記載の発泡樹脂複合成形体成形用金型。The mold for molding a foamed resin composite molded body according to any one of claims 1 to 4, wherein the mold upper surface compartment is formed to be movable in the vertical direction. 金型正面分室が金型に扉状に取り付けられていて、左右いずれか一方側に開くか、両側に開くか、上端が手前側に傾倒して開くかして、成形用キャビティー内の発泡樹脂複合成形体を取り出し自在に形成した、請求項１〜５のいずれかに記載の発泡樹脂複合成形体成形用金型。The mold front compartment is attached to the mold in the form of a door, and it opens on either the left or right side, opens on both sides, or the upper end is tilted toward the front side to open the foam in the molding cavity. The mold for molding a foamed resin composite molded body according to any one of claims 1 to 5, wherein the resin composite molded body is formed so as to be freely taken out. 金型上面分室に発泡性樹脂粒子供給用充填ガンが配備されている、請求項１〜６のいずれかに記載の発泡樹脂複合成形体成形用金型。The mold for molding a foamed resin composite molded body according to any one of claims 1 to 6, wherein a filling gun for supplying expandable resin particles is provided in the upper surface compartment of the mold. 金型上面分室及び金型下面・側面分室の成形体成形室側にはそれぞれ平板挿入用溝部が形成されている、請求項１〜７のいずれかに記載の発泡樹脂複合成形体成形用金型。The mold for molding a foamed resin composite molded body according to any one of claims 1 to 7, wherein a flat plate insertion groove is formed on each side of the molded body molding chamber of the mold upper surface compartment and the mold lower surface / side surface compartment. . 金型下面・側面分室が、金型の下面側に位置する金型下面分室と、金型の左側面に位置する金型左側面分室と、金型の右側面に位置する金型右側面分室と、金型の背側面に位置する金型背側面分室とに分割されている、請求項１〜８のいずれかに記載の発泡樹脂複合成形体成形用金型。Mold bottom and side compartments are located on the bottom side of the mold, the mold bottom side compartment located on the left side of the mold, and the mold right side compartment located on the right side of the mold. And a mold for molding a foamed resin composite molded body according to any one of claims 1 to 8, which is divided into a mold back side compartment located on a back side of the mold. 金型左側面分室及び金型右側面分室には、スチーム供給孔が形成されておらず、成形用キャビティーと連通されていない、請求項１〜９のいずれかに記載の発泡樹脂複合成形体成形用金型。The foam resin composite molded body according to any one of claims 1 to 9, wherein a steam supply hole is not formed in the mold left side compartment and the mold right side compartment and is not communicated with a molding cavity. Mold for molding. 金型内に少なくとも２枚の平板を配置し、これら平板の間に発泡性樹脂粒子を充填させた後、加熱発泡成形することによって、発泡樹脂層を平板層にて挟んだ発泡樹脂複合成形体を形成する発泡樹脂複合成形体の成形方法において、少なくとも金型の上面側に位置する金型上面分室と、金型の正面側に位置する金型正面分室と、金型の下面側及び左面側・右面側・背面側とに位置する金型下面・側面分室とにより構成された金型を用いると共に、これら分室の中心部に形成された成形用キャビティー内の左右両側端に、少なくとも２枚の平板を配置し、これら平板の間に発泡性樹脂粒子を充填した後、前記成形用キャビティーの上面側及び下面側に配置される金型上面分室及び金型下面・側面分室のスチーム供給孔より、該成形用キャビティー内にスチームを供給して、前記発泡性樹脂粒子を加熱発泡成形することによって、発泡樹脂層を平板層にて挟んだ発泡樹脂複合成形体を形成した後、前記金型の金型上面分室及び金型正面分室を開いて、該成形用キャビティー内で発泡成形された発泡樹脂複合成形体を取り出すことを特徴とする、発泡樹脂複合成形体の成形方法。A foamed resin composite molded article in which at least two flat plates are arranged in a mold, and foamed resin particles are filled between the flat plates, and then the foamed resin layer is sandwiched between the flat plate layers by heat foaming. In the molding method of the foamed resin composite molded body to form, at least the mold upper surface compartment located on the upper surface side of the mold, the mold front compartment located on the front side of the mold, the lower surface side and the left surface side of the mold・ Use a mold composed of the lower surface of the mold located on the right side and the back side and side compartments, and at least two on the left and right sides of the molding cavity formed in the center of these compartments After the flat plates are placed and filled with expandable resin particles between the flat plates, the mold upper surface compartment and the steam lower surface / side compartment steam supply holes are arranged on the upper surface side and the lower surface side of the molding cavity. And the molding cavity After forming a foamed resin composite molded body in which a foamed resin layer is sandwiched between flat plate layers by supplying steam into the foamed resin particles by heating and foaming, a mold upper surface compartment of the mold and A method for molding a foamed resin composite molded body, comprising: opening a mold front compartment and taking out a foamed resin composite molded body foam-molded in the molding cavity. 成形用キャビティーが、隔壁によって複数個の成形体成形室に分割されており、これら複数個の成形体成形室にて同時に発泡樹脂複合成形体を成形する、請求項１１に記載の発泡樹脂複合成形体の成形方法。12. The foamed resin composite according to claim 11, wherein the molding cavity is divided into a plurality of molded body molding chambers by partition walls, and the foamed resin composite molded body is simultaneously molded in the plurality of molded body molding chambers. Molding method of the molded body. 成形用キャビティー内で発泡成形された発泡樹脂複合成形体の取り出しを、金型上面分室を上昇させることにより金型上面分室を発泡樹脂複合成形体より離型させた後、金型正面分室を開いて発泡樹脂複合成形体を取り出す、請求項１１又は１２に記載の発泡樹脂複合成形体の成形方法。After removing the foam resin composite molded body foam-molded in the molding cavity, the mold upper surface compartment is released from the foam resin composite molded body by raising the mold upper surface compartment, and then the mold front compartment is opened. The molding method of the foamed resin composite molded body according to claim 11 or 12, wherein the foamed resin composite molded body is opened and taken out. 複数個に分割された成形体成形室のそれぞれが、金型上面分室及び金型下面・側面分室のスチーム供給孔により連通されており、金型上面分室又は金型下面分室に供給されたスチームが、金型上面分室又は金型下面分室にて均一に分散されて、各成形体成形室を同時に加熱発泡成形する、請求項１１〜１３のいずれかに記載の発泡樹脂複合成形体の成形方法。Each of the molded body molding chambers divided into a plurality is communicated by the steam supply holes of the mold upper surface compartment and the mold lower surface / side surface compartment, and the steam supplied to the mold upper surface compartment or the mold lower surface compartment is The method for molding a foamed resin composite molded body according to any one of claims 11 to 13, wherein the molding is uniformly dispersed in a mold upper surface compartment or a mold lower surface compartment, and each molding body molding chamber is simultaneously heated and foam-molded. 平板を、金型上面分室及び金型下面分室の成形室側にそれぞれ形成されている平板挿入用溝部に沿って挿入する、請求項１１〜１４のいずれかに記載の発泡樹脂複合成形体の成形方法。The molding of the foamed resin composite molded body according to any one of claims 11 to 14, wherein the flat plate is inserted along a flat plate insertion groove formed on the molding chamber side of the mold upper surface compartment and the mold lower surface compartment, respectively. Method. 発泡性樹脂粒子を金型上面分室に形成された発泡性樹脂粒子供給用充填ガンにて供給する、請求項１１〜１５のいずれかに記載の発泡樹脂複合成形体の成形方法。The method for molding a foamed resin composite molded body according to any one of claims 11 to 15, wherein the foamable resin particles are supplied by a foaming resin particle supply filling gun formed in a mold upper surface compartment. 金型下面・側面分室が、金型の下面側に位置する金型下面分室と、金型の左側面に位置する金型左側面分室と、金型の右側面に位置する金型右側面分室と、金型の背面に位置する金型背面分室とに分割されており、各分室がそれぞれの最適温度に調整されている、請求項１１〜１６のいずれかに記載の発泡樹脂複合成形体の成形方法。Mold bottom and side compartments are located on the bottom side of the mold, the mold bottom side compartment located on the left side of the mold, and the mold right side compartment located on the right side of the mold. The molded resin composite molded body according to any one of claims 11 to 16, wherein each of the compartments is adjusted to an optimum temperature. Molding method.
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