JP4145186B2 - Soap mold - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a soap mold, and more particularly to a mold in which the molded soap is always held in a specific split mold when the mold is opened.
[0002]
[Prior art and problems to be solved by the invention]
The present applicant has previously proposed a method for producing a soap with bubbles excellent in surface finish without causing defects such as surface peeling during demolding (see Patent Document 1). In this method, the molten soap filled in the mold is cooled and solidified until the surface temperature becomes 5 to 30 ° C., and the solidified soap is a temperature 2 to 15 ° C. higher than the surface temperature at the end of cooling. The mold is removed after the temperature is raised to. At that time, a mold having an inner surface roughness Ra of 0.1 to 30 μm is used.
[0003]
According to the above manufacturing method, even foamed soap that is more likely to be deficient than ordinary soap can be successfully demolded. However, when the mold is opened, the solidified soap is not held by the split mold and easily falls. When dropped, the soap is easily damaged, which can contaminate the device. Therefore, it is necessary to securely hold the soap in the split mold. Moreover, even if it does not fall, the split mold that holds the soap when the mold is opened tends to be mixed. As a result, the process of taking out the soap by the take-out device tends to become complicated, and this causes a decrease in productivity.
[0004]
Therefore, it has been proposed to apply a coating having different releasability to the concave part of the split mold so that a difference occurs in the adhesion of soap to the split mold (see Patent Document 2). However, when such a split mold is used, the coating is peeled off as the molding is repeated, and there is no difference in adhesion. Therefore, it is necessary to periodically coat the split mold, which complicates the work and increases the manufacturing cost.
[0005]
[Patent Document 1]
Japanese Patent Laid-Open No. 2002-121599 [Patent Document 2]
Special table 2001-525881
[0006]
Accordingly, an object of the present invention is to provide a mold in which the molded soap is always held in a specific split mold when the mold is opened.
[0007]
[Means for Solving the Problems]
The present invention relates to a soap mold in which a set of split molds are assembled, and a molding cavity is formed therein, and the surface roughness Ra of the recesses forming the cavities in the split mold is set to other values. The object is achieved by providing a soap mold that is larger than the surface roughness Ra of the recesses forming the cavities in each split mold, and the difference in the surface roughness Ra is 0.1 to 30 μm. Achieved.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described below based on preferred embodiments with reference to the drawings. The soap mold shown in FIG. 1 forms a set of two split molds including a first split mold 1A and a second split mold 1B. Each split mold is in the form of a rectangular block made of a rigid body such as a metal, and concave portions 11A and 11B are formed at the central portions thereof. Each of the recesses 11A and 11B has a cavity (not shown) having a shape that matches the shape of the soap to be manufactured when the first split mold 1A and the second split mold 1B are abutted on their parting surfaces PL. Is formed in each split mold. The recesses 11A and 11B have substantially the same shape.
[0009]
In the second split mold 1B, a nozzle insertion hole 2B that penetrates the second split mold 1B in the thickness direction is formed in the outer edge portion of the recess 11B. The diameter of the nozzle insertion hole 2B gradually expands toward the back side of the second split mold 1B. On the other hand, the first split mold 1A is formed with a semi-cylindrical gate 2A formed by recessing a part of the parting surface PL. The gate 2A communicates the end face E of the first split mold 1A and the recess 11A. A piston P that is complementary to the gate 2A is fitted into the gate 2A. The piston P is made of a material such as metal or plastic, and is slidable in the gate 2A. The nozzle insertion hole 2B and the gate 2A reach the cavity from the nozzle insertion hole 2B through the gate 2A when the first split mold 1A and the second split mold 1B are brought into contact with each other at their parting surfaces PL. Each is formed at a position where a communication path is formed. Although not shown, an air vent is provided on the parting surface PL of the second split mold 1B. Moreover, although not shown in figure, the block which comprises the split molds 1A and 1B is provided with the circulating path of the cooling water.
[0010]
The inner surfaces of the recesses 11A and 11B in the split molds 1A and 1B are mirror-finished to form low surface roughness regions. However, in the first split mold 1A, which is one of the split molds, the bottom surface of the recess 11A is roughened after mirror finishing to form a high surface roughness region. That is, in the present embodiment, the surface roughness Ra of the recess 11A in the first split mold 1A is made larger than the surface roughness Ra of the recess 11B in the second split mold 1B. As the rough surface processing, for example, sand blasting is used.
[0011]
Further, the concave portion 11A of the first split mold 1A has a high surface roughness region and a low surface roughness region, while the concave portion 11B of the second split die 1B has only a low surface roughness region. There is. The surface roughness Ra of the low surface roughness region in the recess 11A of the first split mold 1A is approximately the same as the surface roughness Ra of the recess 11B of the second split mold 1B.
[0012]
After the surface roughness Ra of the recess 11A in the first split mold 1A is larger than the surface roughness Ra of the recess 11B in the second split mold 1B, the molten soap is filled into the cavity and cooled and solidified. As a result of the examination by the present inventors, it was found that soap is always held on the second split mold 1B side having a low surface roughness Ra when the mold is opened.
[0013]
As described in Patent Document 1 described above, when the surface roughness Ra of the recess is reduced, soap is held on the split mold side, and conversely, if the surface roughness Ra of the recess is increased, the anchor effect causes that Soap is held on the split mold side. That is, the split mold in which the soap is held varies depending on the surface roughness Ra. As a result of intensive studies by the present inventors, the surface roughness Ra of the recess 11A in the first split mold 1A (that is, the surface roughness Ra of the high surface roughness region) and the recess 11B of the second split mold 1B. It was found that the soap is always held on the second split mold 1B side having the low surface roughness Ra by setting the difference from the surface roughness Ra to 0.1 to 30 μm, preferably 0.2 to 20 μm. .
[0014]
As shown in FIG. 1, the high surface roughness region formed in the recess 11A of the first split mold 1A is located on the bottom surface of the recess 11A. In other words, the high surface roughness region is formed on the bottom surface of the recess 11A, which is a surface substantially parallel to the parting surface PL of the mold. This facilitates the release of the soap from the first split mold 1A, and the soap is more reliably held on the second split mold 1B side. The substantially parallel surface means that the bottom surface of the recess 11A does not need to be a flat surface and may be a curved surface that is a shape unique to soap.
[0015]
In order to hold the soap more securely on the second split mold 1B side, the area of high surface roughness in the recess 11A of the first split mold 1A is 30% or more, particularly 50% of the total area of the recess 11A. It is preferable to occupy the above. Most preferably, the concave portion 11A of the first split mold 1A is a region having a high surface roughness throughout the entire area.
[0016]
Further, in order to hold the soap more securely on the second split mold 1B side, the surface roughness Ra of the high surface roughness region in the recess 11A of the first split mold 1A is 0.2 to 30 μm, In particular, the thickness is preferably 0.4 to 20 μm. On the other hand, the surface roughness Ra of the low surface roughness region of the recess 11A in the first split mold 1A and the surface roughness Ra of the recess 11B in the second split mold 1B are both 0.1 to 30 μm, particularly 0. It is preferable that it is 1-20 micrometers. Note that the surface roughness Ra of the low surface roughness region of the recess 11A in the first split mold 1A and the surface roughness Ra of the recess 11B in the second split mold 1B are not necessarily the same value. . However, considering the manufacturing costs of the split molds 1A and 1B, the split molds 1A and 1B are usually subjected to the same mirror finish, and as a result, the surface roughness Ra of both is described above. As you can see, it is almost the same.
[0017]
Furthermore, in order to hold the soap more reliably on the second split mold 1B side, the surface roughness Ra of the high surface roughness region in the recess 11A of the first split mold 1A, and the second split mold 1B The ratio (the former / the latter) of the recess 11B to the surface roughness Ra is preferably 2 to 300, particularly 4 to 200.
[0018]
The surface roughness Ra is measured according to JIS B0601. As the measuring device, for example, a surface roughness measuring machine SURFCOM590A manufactured by Tokyo Seimitsu Co., Ltd. can be used.
[0019]
Next, a soap manufacturing method using the mold shown in FIG. 1 will be described with reference to FIG. The mold shown in FIG. 1 is used by being attached to the manufacturing apparatus shown in FIG. This manufacturing apparatus includes a mold unit 4A and a molten soap injection device 3A. As shown in FIG. 2A, the mold is attached on the base plate 40 of the mold unit 4A. On the base plate 40, a support plate 41 of the first split mold 1A and a support plate 42 of the second split mold 1B are erected. A cylinder 44 having a piston 43 is attached to the inner surface of the support plate 41. The cylinder 44 is attached so that the piston 43 slides in a direction orthogonal to the support plate 41. The tip of the piston 43 is fixed to the back surface of the first split mold 1A. Accordingly, the first split mold 1A is a movable type that can move in the horizontal direction. The first split mold 1A is fixed with its gate 2A side facing downward. An L-shaped cylinder holding plate 45 is attached to the lower part of the back surface of the first split mold 1A. A cylinder 47 having a piston 46 is attached to the horizontal portion of the cylinder holding plate 45. The cylinder 47 is attached so that the piston 46 slides in the vertical direction. The tip of the piston 46 is connected to a piston P provided in the first split mold 1A.
[0020]
The second split mold 1B is attached to the support plate 42 so that the recess 11B faces the recess 11A of the first split mold 1A and the nozzle insertion hole 2B faces in the horizontal direction. As apparent from FIG. 2A, the second split mold 1B is a fixed mold. A molten soap injection device 3A is attached to the back side of the second split mold 1B. The injection device 3 </ b> A includes a dispensing nozzle 31, a switching valve 32, a cylinder 33, and a piston 34 disposed in the cylinder 33. The dispensing nozzle 31 has a shape that matches the shape of the nozzle insertion hole 2B formed in the second split mold 1B, and is inserted into the nozzle insertion hole 2B. A gate pin 35 is slidably inserted inside the dispensing nozzle 31, and the injection of molten soap from the dispensing nozzle 31 into the cavity is controlled by pushing and pulling out the gate pin 35. The switching valve 32 selectively connects the cylinder 33 to one of a circulation path 36 and a dispensing nozzle 31 that pass through a storage tank (not shown). In the state shown in FIG. 2A, the cylinder 33 and the extraction nozzle 31 are in communication with each other, and the communication between the cylinder 33 and the circulation path 36 is blocked.
[0021]
The manufacturing method of bubble soap using the manufacturing apparatus shown in FIG. 2 will be described. First, the cylinder 44 of the mold unit 4A is operated to push out the piston 43, and the first split mold 1A and the second split mold 1B. And close the mold. In the split mold, water is circulated through the cooling water circulation path described above. Further, the cylinder 47 is operated to retract the piston 46, whereby a part of the piston P connected to the piston 46 is pulled out from the first split mold 1A. On the other hand, in the injection device 3A, the piston 34 is pushed in, and the switching valve 32 is operated under this state to connect the cylinder 33 and the circulation path 36. Then, the piston 34 is pulled out and a predetermined amount of molten soap is fed into the cylinder 33. Molten soap is stored in a storage tank (not shown) and circulates in the circulation path 36 passing through the storage tank. Then, the circulating soap is circulated into the cylinder 33 by the flow path switching by the switching valve 32. By circulating the molten soap, separation of bubbles and liquid components in the molten soap is effectively prevented. As a method for preparing a molten soap containing innumerable bubbles dispersed therein, for example, a method described in the second column, line 15 to column 5, line 1 of Japanese Patent Application Laid-Open No. 11-43699 previously filed by the present applicant. Can be used. Various gases can be used for foaming the molten soap. In particular, by using an inert gas, especially a non-oxidizing inert gas such as nitrogen gas, it is possible to effectively prevent off-flavors, etc. generated by deterioration or oxidative decomposition of the blended components due to heating of the molten soap. Can be prevented.
[0022]
Next, the switching valve 32 is operated to shut off the communication between the cylinder 33 and the circulation path 36 and to connect the cylinder 33 and the dispensing nozzle 31 as shown in FIG. The gate pin 35 is pulled out. Subsequently, the piston 34 is pushed in, and the molten soap 4 in the cylinder 33 is pushed out. Thereby, the molten soap 4 is pressurized and injected into the cavity 11C through the pouring nozzle 31 and the gate 2A (see FIG. 1). By this pressure injection, the molten soap in the cavity 11C is compressed to a predetermined volume.
[0023]
When the pressure injection of the predetermined volume of molten soap is completed, the gate pin 35 is pushed in as shown in FIG. 2B to cut off the communication between the dispensing nozzle 31 and the cavity 11C. Further, the cylinder 47 is operated to push out the piston 46, and the piston P connected to the piston 46 is pushed into the gate 2A (see FIG. 1). Thereby, the molten soap remaining in the gate 2A is injected into the cavity 11C.
[0024]
Next, the mold unit 4A is moved backward (moved to the right in the figure), and the injection device 3A is removed from the second split mold 1B as shown in FIG. 2C, and the molten soap in the cavity 11C is compressed. Allow to cool and solidify. As described above, each of the split molds 1A and 1B is cooled to a predetermined temperature by circulating the cooling water, thereby promoting the cooling and solidification of the molten soap in the cavity 11C. Since the melted soap is pressurized and compressed, shrinkage and sink marks are prevented when it is cooled and solidified.
[0025]
When the molten soap is solidified, as shown in FIG. 2D, the cylinder 44 is operated to retract the piston 43. As a result, the split molds 1A and 1B are opened, and the bubbled soap 5 in the cavity is then taken out by a predetermined gripping means (not shown). In this case, the soap 5 is always held on the second split mold 1B side. Accordingly, the soap 5 can be taken out by the gripping means at all times with respect to the second split mold 1B side, so that the taking out becomes easy and the productivity is improved. Moreover, since the soap does not drop when the mold is opened, the manufacturing apparatus is not contaminated by debris or the like generated from the dropped soap.
[0026]
There is no particular limitation on the time when the mold is opened after cooling and solidifying the molten soap, but the surface part of the soap is solidified at an earlier stage than the mold is opened after the soap is solidified. When the mold is opened in an unsolidified state, the soap is surely held on the second split mold 1B side.
[0027]
The present invention is not limited to the embodiment. For example, in the above-described embodiment, a mold that forms a set of two split molds is used. However, the number of split molds is not limited to this, and depending on the shape of the soap, the mold may be composed of three or more split molds. Also good. In that case, among the plurality of split molds, the surface roughness of at least part of the recesses in one split mold is increased, and the surface roughness of the recesses in the remaining split molds is made lower than that, It is preferable that the surface roughness of the recesses in the remaining split molds is approximately the same.
[0028]
In the embodiment, the high surface roughness region in the concave portion 11A of the first split mold 1A is formed on the bottom surface of the concave portion which is a surface substantially parallel to the parting surface PL. However, the formation location is not limited to this, and may be another region in the recess, for example, a surface substantially perpendicular to the parting surface PL. Furthermore, when forming on the bottom surface of the recess, instead of forming the high surface roughness region over the entire bottom surface, a plurality of high surface roughness regions may be formed discontinuously on the bottom surface.
[0029]
In addition, in the recesses 11A and 11B of the split molds 1A and 1B, for the purpose of reliably holding the soap (second split mold side) and reliably releasing the soap (first split mold side) Suction and blowout slits and small holes may be formed.
[0030]
Moreover, in the said embodiment, although the shaping | molding die of this invention was used for manufacture of the soap with a bubble which is an example of compression molding, the shaping | molding die of this invention can also be used for manufacture of the normal soap which does not contain a bubble. However, the mold of the present invention is particularly suitable for compression molding such as the production of bubble soap having a large sink after cooling.
[0031]
【Example】
Hereinafter, the present invention will be described in more detail with reference to examples. However, the scope of the present invention is not limited to such examples. Unless otherwise specified, “parts” means “parts by weight”.
[0032]
[Example 1]
Using the mold shown in FIG. 1, this was attached to the production apparatus shown in FIG. 2 to produce bubble soap. The recesses of each split mold were mirror-finished to form a low surface roughness region with a surface roughness Ra of 0.463 μm. However, in the first split mold, the bottom surface of the recess was roughened with a sand blaster to form a high surface roughness region with a surface roughness Ra of 18.93 μm. The area of high surface roughness in the first split mold recess accounted for 48% of the total area of the recess.
[0033]
Using the following blending components, a molten soap in which countless bubbles were dispersed and contained was prepared according to the method described in JP-A-11-43699 described above. Nitrogen gas was used for foaming.
Lauric acid Na 30 parts Cocoyl isethionate Na 2 parts Lauroyl lactate Na 5 parts Polyoxyethylene monolaurate 2 parts Lauric acid 5 parts Glycerin 20 parts Sodium chloride 1.5 parts Fragrance 1.5 parts Water 32 parts
Using the prepared molten soap, an aerated soap was produced according to the steps shown in FIGS. The temperature of the molten soap was 64 ° C. Each split mold was cooled with 5 to 15 ° C cooling water. The molten soap was cooled for 1 minute. After cooling, the mold was opened and it was observed which mold was holding the soap. When molding was performed 5 times, it was confirmed that the soap was retained on the second split mold side in all 5 times.
[0035]
[Example 2]
The recesses of each split mold were mirror-finished to form a low surface roughness region with a surface roughness Ra of 0.263 μm. However, in the first split mold, the bottom surface of the recess was roughened with a sand blaster to form a high surface roughness region with a surface roughness Ra of 0.463 μm. Except for this, an aerated soap was produced in the same manner as in Example 1. When molding was performed 5 times, it was confirmed that the soap was retained on the second split mold side in all 5 times.
[0036]
Example 3
The recesses of each split mold were mirror-finished to form a low surface roughness region with a surface roughness Ra of 0.263 μm. However, in the first split mold, the bottom surface of the recess was roughened with a sand blaster to form a high surface roughness region with a surface roughness Ra of 18.93 μm. Except for this, an aerated soap was produced in the same manner as in Example 1. When molding was performed 5 times, it was confirmed that the soap was retained on the second split mold side in all 5 times.
[0037]
[Comparative Example 1]
Aerated soap was produced in the same manner as in Example 1 except that the bottom surface of the first split mold was not roughened with a sand blaster. That is, in this comparative example, the surface roughness Ra of each split mold is the same. When molding was performed 5 times, the number of times the soap was held on the first split mold side was 2 times, the second split mold side was 2 times, and the number of times it was dropped without being held by either split mold was 1 time Met.
[0038]
【The invention's effect】
According to the mold of the present invention, the molded soap is always held in a specific split mold when the mold is opened. Therefore, if the mold of this invention is used, soap can be manufactured stably and with good productivity. The mold of the present invention is particularly suitable for compression molding such as the manufacture of aerated soap.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a soap mold of the present invention.
2 is a schematic view showing a foamed soap manufacturing apparatus including the mold shown in FIG. 1. FIG.
[Explanation of symbols]
1A First split mold 1B Second split mold 11A, 11B Recess

Claims (6)

In a soap mold in which a set of split molds are assembled, and a molding cavity is formed therein, the surface roughness Ra of the recesses forming the cavities in one split mold is determined in each of the other split molds. A soap mold that is larger than the surface roughness Ra of the recesses forming the cavities, and the difference between the surface roughness Ra is 0.1 to 30 μm. The concave portion forming the cavity in one split mold has a high surface roughness region and a low surface roughness region, and the surface roughness Ra in the low surface roughness region is the same in each of the other split molds. 2. The soap mold according to claim 1, wherein the mold has approximately the same surface roughness Ra of the recesses forming the cavity. The soap mold according to claim 2, wherein a surface substantially parallel to the parting surface of the mold is formed in the recess, and the region having the high surface roughness is formed on the surface. The soap mold according to claim 2 or 3, wherein the high surface roughness region in one split mold occupies 30% or more of the total area of the recess. The surface roughness Ra of the high surface roughness region in one split mold is 0.2 to 30 μm, the surface roughness Ra of the low surface roughness region and the surface roughness of the recesses in the other split molds. The soap mold according to any one of claims 2 to 4, wherein Ra is 0.1 to 30 µm. The soap mold according to any one of claims 1 to 5, wherein two split molds form a set, and the recesses in each split mold have substantially the same shape.

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