JP4890280B2 - Method for producing thermoplastic resin molded article - Google Patents
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- JP4890280B2 JP4890280B2 JP2007018993A JP2007018993A JP4890280B2 JP 4890280 B2 JP4890280 B2 JP 4890280B2 JP 2007018993 A JP2007018993 A JP 2007018993A JP 2007018993 A JP2007018993 A JP 2007018993A JP 4890280 B2 JP4890280 B2 JP 4890280B2
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Description
本発明は、熱可塑性樹脂成形品の製造方法に関する。 The present invention relates to a method for producing a thermoplastic resin molded article.
熱可塑性樹脂発泡シートを成形して得られる発泡成形品は、軽量性、リサイクル性、断熱性などに優れることから、自動車部材や建築材料等の種々の用途に用いられている。このような発泡成形品にリブ、ボス、フック等の熱可塑性樹脂からなる非発泡の機能性部材が融着されてなる熱可塑性樹脂成形品もまた、自動車内装用部品等として使用可能である。前記熱可塑性樹脂成形品の製造方法として、以下の工程(1)−(4)を含む方法が知られている(例えば特許文献1参照)。
(1)少なくとも一方に機能性部材の形状の凹部が形成された一対の金型間に、熱可塑性樹脂製発泡シートを供給する工程
(2)金型を閉じて前記熱可塑性樹脂発泡シートを賦形すると同時に、前記凹部の開口部を熱可塑性樹脂製発泡シートで塞ぐ工程
(3)金型を閉じて前記凹部の開口部を熱可塑性樹脂製発泡シートで塞いだ状態で、該凹部に通ずるように金型内に設けられた樹脂通路を通じて溶融状態の熱可塑性樹脂を該凹部に供給し、該熱可塑性樹脂と前記熱可塑性樹脂製発泡シートとを融着一体化して前記熱可塑性樹脂成形品を形成する工程
(4)工程(3)で形成した熱可塑性樹脂成形品を冷却し、金型から取り外す工程
Foam molded articles obtained by molding a thermoplastic resin foam sheet are excellent in light weight, recyclability, heat insulation, and the like, and thus are used in various applications such as automobile members and building materials. A thermoplastic resin molded product in which a non-foamed functional member made of a thermoplastic resin such as a rib, boss, or hook is fused to such a foam molded product can also be used as an automobile interior part or the like. As a method for producing the thermoplastic resin molded article, a method including the following steps (1) to (4) is known (for example, see Patent Document 1).
(1) A step of supplying a thermoplastic resin foam sheet between a pair of molds each having a functional member-shaped recess formed on at least one side. (2) The mold is closed to apply the thermoplastic resin foam sheet. Step of closing the opening of the recess with the thermoplastic resin foam sheet at the same time as forming (3) Closing the mold and closing the opening of the recess with the thermoplastic resin foam sheet so as to pass through the recess The thermoplastic resin in a molten state is supplied to the recess through a resin passage provided in the mold, and the thermoplastic resin and the thermoplastic resin foam sheet are fused and integrated to obtain the thermoplastic resin molded product. Step of forming (4) Step of cooling the thermoplastic resin molded product formed in step (3) and removing it from the mold
しかしながら前記のような方法によって得られる機能性部材を有する熱可塑性樹脂成形品には、図1に示すような機能性部材(1)が設けられた部分に対応する熱可塑性樹脂成形品(2)の表面に部分的なへこみ(ヒケ)(3)が生じることがあった。
本発明は、熱可塑性樹脂発泡シートの一部に機能性部材が融着されてなる熱可塑性樹脂成形品の製造方法において、ヒケのない外観良好な熱可塑性樹脂成形品を製造する方法を提供するものである。
However, the thermoplastic resin molded article having a functional member obtained by the method as described above includes a thermoplastic resin molded article (2) corresponding to a portion provided with the functional member (1) as shown in FIG. A partial dent (sink) (3) may occur on the surface of the film.
The present invention provides a method for producing a thermoplastic resin molded article free from sink marks and having a good appearance in a method for producing a thermoplastic resin molded article in which a functional member is fused to a part of a thermoplastic resin foam sheet. Is.
すなわち本発明の第一の態様は、熱可塑性樹脂発泡シートの一部に機能性部材が融着されてなる熱可塑性樹脂成形品を製造する方法であって、前記機能性部材を賦形するための凹部が成形面に形成された成形型Aと、該成形型Aと対を成す成形型Bとを用いて、下記の工程により熱可塑性樹脂成形品を製造する方法である。
(1)成形型Aと成形型Bとの間に、予め賦形した熱可塑性樹脂発泡シートを供給する工程
(2)成形型Aと成形型Bの金型クリアランスが前記熱可塑性樹脂発泡シートの厚み以下となるまで型締めし、冷却する工程
(3)前記凹部に通ずるように成形型A内に設けられた樹脂通路を通じて、溶融状熱可塑性樹脂を樹脂圧力(P1)で該凹部に供給する工程
(4)凹部に供給する溶融状熱可塑性樹脂の樹脂圧力を、前記樹脂圧力(P1)の2倍以上まで増加させる工程
(5)溶融状熱可塑性樹脂の供給を停止し、型開きして熱可塑性樹脂成形品を取り出す工程
また本発明の第二の態様は、熱可塑性樹脂発泡シートの一部に機能性部材が融着されてなる熱可塑性樹脂成形品を製造する方法であって、前記機能性部材を賦形するための凹部が成形面に形成された成形型Aと、該成形型Aと対を成す成形型Bとを用いて、下記の工程により熱可塑性樹脂成形品を製造する方法である。
(1)成形型Aと成形型Bとの間に、加熱軟化した熱可塑性樹脂発泡シートを供給する工程
(2)成形型Aと成形型Bの金型クリアランスが前記熱可塑性樹脂発泡シートの厚み以下となるまで型締めし、冷却する工程
(3)前記凹部に通ずるように成形型A内に設けられた樹脂通路を通じて、溶融状熱可塑性樹脂を樹脂圧力(P1)で該凹部に供給する工程
(4)凹部に供給する溶融状熱可塑性樹脂の樹脂圧力を、前記樹脂圧力(P1)の2倍以上まで増加させる工程
(5)溶融状熱可塑性樹脂の供給を停止し、型開きして熱可塑性樹脂成形品を取り出す工程
That is, the first aspect of the present invention is a method for producing a thermoplastic resin molded article in which a functional member is fused to a part of a thermoplastic resin foam sheet, for shaping the functional member. This is a method for producing a thermoplastic resin molded article by the following steps using a molding die A having a recess formed on the molding surface and a molding die B paired with the molding die A.
(1) Step of supplying a pre-shaped thermoplastic resin foam sheet between the mold A and the mold B (2) The mold clearance between the mold A and the mold B is that of the thermoplastic resin foam sheet. Clamping and cooling until the thickness is equal to or less than the thickness (3) Supplying the molten thermoplastic resin to the recess with resin pressure (P1) through the resin passage provided in the mold A so as to communicate with the recess. Step (4) Step of increasing the resin pressure of the molten thermoplastic resin to be supplied to the recess to at least twice the resin pressure (P1) (5) Stopping the supply of the molten thermoplastic resin, and opening the mold Step of taking out a thermoplastic resin molded product The second aspect of the present invention is a method for producing a thermoplastic resin molded product in which a functional member is fused to a part of a thermoplastic resin foamed sheet. Concave parts for shaping functional members are formed This is a method for producing a thermoplastic resin molded article by the following steps using a mold A formed on the surface and a mold B paired with the mold A.
(1) Step of supplying a heat-softened thermoplastic resin foam sheet between the mold A and the mold B (2) The mold clearance between the mold A and the mold B is the thickness of the thermoplastic resin foam sheet A step of clamping and cooling until the following conditions are satisfied (3) A step of supplying molten thermoplastic resin to the concave portion with a resin pressure (P1) through a resin passage provided in the molding die A so as to communicate with the concave portion. (4) Step of increasing the resin pressure of the molten thermoplastic resin supplied to the concave portion to at least twice the resin pressure (P1) (5) Stopping the supply of the molten thermoplastic resin, opening the mold and heating The process of taking out the plastic resin molded product
本発明の熱可塑性樹脂発泡シートの一部に機能性部材が融着されてなる熱可塑性樹脂成形品を製造する方法によれば、機能性部材が融着された部分に対応する成形品表面に部分的なへこみ(ヒケ)がなく、外観良好な成形品を得ることができる。 According to the method for producing a thermoplastic resin molded product in which a functional member is fused to a part of the thermoplastic resin foam sheet of the present invention, the surface of the molded product corresponding to the portion to which the functional member is fused is formed. There is no partial dent (sink), and a molded product having a good appearance can be obtained.
本発明では、機能性部材を賦形するための凹部が成形面に形成された成形型Aと、該成形型Aと対を成す成形型Bを用いる。成形型A、Bは、一方が雄型で他方が雌型、両方が雌型、両方が板状成形型等、いずれの組み合わせでもよい。成形型A成形面に設けられる凹部の数や位置、形状は特に限定されるものではなく、発泡シートに賦形する機能性部材の数や位置、形状に応じた凹部が設けられた成形型を用いることができる。成形型の材質は特に限定されるものではないが、通常寸法安定性、耐久性などの観点から金属製であり、コストや軽量性などの面からアルミ製やステンレス製であることが好ましい。また成形型は、ヒーターや熱媒などにより温度調整可能な構造であることが好ましい。発泡シートの変形抑制の観点から、成形型は、熱可塑性樹脂成形品製造時にはその成形面を20〜80℃とすることが好ましく、30〜60℃とすることがさらに好ましい。また成形型は、真空吸引や圧縮空気の供給が可能なものを用いてもよい。 In the present invention, a mold A in which a recess for shaping the functional member is formed on the molding surface and a mold B that forms a pair with the mold A are used. Molding molds A and B may be any combination, such as one is a male mold and the other is a female mold, both are female molds, and both are plate-shaped molds. The number, position, and shape of the recesses provided on the molding die A molding surface are not particularly limited, and a molding die provided with recesses corresponding to the number, position, and shape of the functional member to be formed on the foam sheet. Can be used. The material of the mold is not particularly limited, but is usually made of metal from the viewpoints of dimensional stability and durability, and is preferably made of aluminum or stainless steel in terms of cost and lightness. Moreover, it is preferable that a shaping | molding die is a structure which can adjust temperature with a heater, a heat medium, etc. From the viewpoint of suppressing deformation of the foamed sheet, the molding die preferably has a molding surface of 20 to 80 ° C., more preferably 30 to 60 ° C. during the production of a thermoplastic resin molded product. A mold that can be sucked by vacuum or supplied with compressed air may be used.
成形型A(10)は図2に示すように型内に溶融状熱可塑性樹脂の供給が可能な通路を有しており、該通路の一端はスクリュー式押出機(4)先端のノズル(5)と接続され、もう一端は成形面に形成された凹部(6)と接続されている。樹脂通路と凹部との接続部は、ゲート(7)と呼ばれる。一般的な構造の樹脂通路の場合、ランナー(9)と呼ばれる溝や、スプルー(8)と呼ばれる円筒や円柱状の細管を経て、ゲートから凹部に溶融状熱可塑性樹脂が供給される。通路が長い場合は、溶融状熱可塑性樹脂が冷却固化するのを防止するためにヒーター等の加熱機構を備えていることが好ましい。1つの凹部に設けられるゲートは、1つでも複数でもよい。
成形型Aにより賦形される機能性部材がリブ形状である場合、成形型A(10)の凹部長さ方向に垂直な断面は通常図3の様な形状を有しており、リブ形状を賦形する凹部(6)は開口部リブ厚み(11)、反開口部リブ厚み(12)、リブ高さ(13)などにより特徴づけられる。成形時の離型性に優れることから、通常開口部厚み(11)は反開口部厚み(12)より0.1〜0.5mm程度大きくする。
As shown in FIG. 2, the molding die A (10) has a passage through which molten thermoplastic resin can be supplied, and one end of the passage is at the tip of the screw-type extruder (4) nozzle (5 ) And the other end is connected to a recess (6) formed on the molding surface. A connecting portion between the resin passage and the concave portion is called a gate (7). In the case of a resin passage having a general structure, the molten thermoplastic resin is supplied from the gate to the recess through a groove called a runner (9) and a cylindrical or cylindrical tube called a sprue (8). When the passage is long, it is preferable to provide a heating mechanism such as a heater in order to prevent the molten thermoplastic resin from being cooled and solidified. One or more gates may be provided in one recess.
When the functional member formed by the mold A has a rib shape, the cross section perpendicular to the concave length direction of the mold A (10) usually has a shape as shown in FIG. The shaped recess (6) is characterized by an opening rib thickness (11), an anti-opening rib thickness (12), a rib height (13), and the like. Since it is excellent in the mold release property at the time of shaping | molding, normally opening part thickness (11) is about 0.1-0.5 mm larger than anti-opening part thickness (12).
本発明では、前記したような成形型A、Bを用いる。
本発明の工程(1)は、図4の(1)に示すように、前記した成形型A(10)と成形型B(16)との間に、予め賦形した熱可塑性樹脂発泡シート(14)を供給する工程である。
In the present invention, the molds A and B as described above are used.
As shown in FIG. 4 (1), the step (1) of the present invention comprises a thermoplastic resin foam sheet (shaped in advance) between the mold A (10) and the mold B (16). 14).
本発明で用いる熱可塑性樹脂発泡シートを構成する樹脂としては、エチレン、プロピレン、ブテン、ペンテン、ヘキセン等の炭素原子数が2〜6のオレフィンホモポリマーや、炭素原子数が2〜10のオレフィンから選択される2種類以上のモノマーを共重合して得られるオレフィン共重合体などのオレフィン系樹脂、エチレン−ビニルエステル共重合体、エチレン−(メタ)アクリル酸共重合体、エチレン−(メタ)アクリル酸エステル共重合体、エステル系樹脂、アミド系樹脂、スチレン系樹脂、アクリル系樹脂、アクリロニトリル系樹脂、アイオノマー樹脂などがあげられる。これらの樹脂は単独で使用してもよく、複数の樹脂を併用してもよい。成形性、耐油性、コストなどの観点からオレフィン系樹脂が好ましく用いられ、得られる成形品の剛性、耐熱性などの観点からプロピレン系樹脂が特に好ましく用いられる。 Examples of the resin constituting the thermoplastic resin foam sheet used in the present invention include olefin homopolymers having 2 to 6 carbon atoms such as ethylene, propylene, butene, pentene, hexene, and olefins having 2 to 10 carbon atoms. Olefin resins such as olefin copolymers obtained by copolymerizing two or more selected monomers, ethylene-vinyl ester copolymers, ethylene- (meth) acrylic acid copolymers, ethylene- (meth) acrylic Examples thereof include acid ester copolymers, ester resins, amide resins, styrene resins, acrylic resins, acrylonitrile resins, and ionomer resins. These resins may be used alone or in combination with a plurality of resins. Olefin resins are preferably used from the viewpoints of moldability, oil resistance, cost, etc., and propylene resins are particularly preferably used from the viewpoint of rigidity and heat resistance of the obtained molded product.
プロピレン系樹脂としては、プロピレンホモポリマーや、プロピレン由来のモノマー単位を50モル%以上含むプロピレン系共重合体をあげることができる。共重合体は、ブロック共重合体、ランダム共重合体、グラフト共重合体のいずれでもよい。好ましく用いられるプロピレン系共重合体の例としては、エチレンまたは炭素原子数4〜10のα−オレフィンとプロピレンとの共重合体を挙げることができる。炭素原子数4〜10のα−オレフィンとしては、例えば、1−ブテン、4−メチルペンテン−1、1−ヘキセンおよび1−オクテンが挙げられる。プロピレン系共重合体中のプロピレン以外のモノマー単位の含有量は、エチレンについては15モル%以下、炭素原子数4〜10のα−オレフィンについては30モル%以下であることが好ましい。プロピレン系樹脂は1種類でもよく、2種類以上を混合して用いてもよい。 Examples of the propylene resin include propylene homopolymers and propylene copolymers containing 50 mol% or more of monomer units derived from propylene. The copolymer may be any of a block copolymer, a random copolymer, and a graft copolymer. As an example of the propylene copolymer preferably used, a copolymer of ethylene or an α-olefin having 4 to 10 carbon atoms and propylene can be given. Examples of the α-olefin having 4 to 10 carbon atoms include 1-butene, 4-methylpentene-1, 1-hexene and 1-octene. The content of monomer units other than propylene in the propylene-based copolymer is preferably 15 mol% or less for ethylene and 30 mol% or less for α-olefins having 4 to 10 carbon atoms. One type of propylene resin may be used, or two or more types may be mixed and used.
長鎖分岐プロピレン系樹脂や重量平均分子量が1×105以上の高分子量プロピレン系樹脂を、発泡層を構成する熱可塑性樹脂の50重量%以上用いることにより、微細な気泡を有するプロピレン系樹脂発泡シートを得ることができる。さらにこのようなプロピレン系樹脂の中でも、シートリサイクル時にゲルを生じにくいことから非架橋のプロピレン系樹脂が好ましく使用される。 By using 50% by weight or more of the thermoplastic resin constituting the foam layer of a long-chain branched propylene resin or a high molecular weight propylene resin having a weight average molecular weight of 1 × 10 5 or more, a propylene resin foam having fine bubbles is used. A sheet can be obtained. Further, among such propylene resins, non-crosslinked propylene resins are preferably used because gels are unlikely to occur during sheet recycling.
本発明で用いる熱可塑性樹脂発泡シートを形成するために使用される発泡剤は、いわゆる化学発泡剤および物理発泡剤のいずれでもよく、これらを併用してもよい。上記化学発泡剤としては、例えば分解されて窒素ガスを発生する熱分解型発泡剤(アゾジカルボンアミド、アゾビスイソブチロニトリル、ジニトロソペンタメチレンテトラミン、p−トルエンスルホニルヒドラジド、p,p’−オキシ−ビス(ベンゼンスルホニルヒドラジド)など)、分解されて炭酸ガスを発生する熱分解型無機発泡剤(炭酸水素ナトリウム、炭酸アンモニウム、炭酸水素アンモニウムなど)など公知の熱分解型発泡性化合物が挙げられる。物理発泡剤としては、具体的にはプロパン、ブタン、水、炭酸ガス等があげられる。上記例示の発泡剤のうち、シートが真空成形時の加熱において2次発泡による変形を生じにくいことや、高温条件や、火に対して不活性な物質であることから、水や炭酸ガス等が好適に用いられる。発泡剤の使用量は所望の発泡倍率が得られるように、用いる発泡剤や樹脂の種類に応じて適宜選択されるものであり、通常熱可塑性樹脂100重量に対して発泡剤0.5〜20重量部である。 The foaming agent used for forming the thermoplastic resin foam sheet used in the present invention may be either a so-called chemical foaming agent or a physical foaming agent, or may be used in combination. Examples of the chemical foaming agent include pyrolytic foaming agents that decompose and generate nitrogen gas (azodicarbonamide, azobisisobutyronitrile, dinitrosopentamethylenetetramine, p-toluenesulfonylhydrazide, p, p′- Oxy-bis (benzenesulfonyl hydrazide) and the like, and pyrolytic inorganic foaming agents that decompose to generate carbon dioxide (sodium hydrogen carbonate, ammonium carbonate, ammonium bicarbonate, etc.) . Specific examples of the physical foaming agent include propane, butane, water, carbon dioxide gas, and the like. Among the above-exemplified foaming agents, water, carbon dioxide, and the like are used because the sheet is not easily deformed by secondary foaming during heating during vacuum forming, is a substance that is inert to high temperature conditions, and fire. Preferably used. The amount of the foaming agent used is appropriately selected according to the type of foaming agent and resin used so that a desired foaming ratio can be obtained. Parts by weight.
熱可塑性樹脂発泡シートの製造方法は特に限定するものではないが、フラットダイ(Tダイ)やサーキュラーダイを用いた押出成形により得られたシートが好ましく、サーキュラーダイから溶融した樹脂を発泡させながら押出し、マンドレル等に沿わせて延伸、冷却を行なう方法が特に好ましく用いられる。発泡シートを押出成形により製造する場合には、溶融した樹脂をダイから押出し冷却固化させた後に延伸を行なうこともできる。発泡シートは単層であっても多層であってもよいが、シート製造時の破泡を防止する観点から、非発泡層を両外層に有する多層構成の発泡シートが好ましい。非発泡層を構成する樹脂は、発泡層を構成する樹脂の例として前記したものを使用することができるが、発泡層を構成する樹脂と同種類のものであるものが好ましく、例えば発泡層がプロピレン系樹脂である場合、非発泡層もプロピレン系樹脂で構成されることが好ましい。使用する熱可塑性樹脂発泡シートは特に限定されるものではなく、通常発泡倍率2〜10倍、厚さ1〜10mm程度の発泡シートが用いられる。 The method for producing the thermoplastic resin foam sheet is not particularly limited, but a sheet obtained by extrusion molding using a flat die (T-die) or a circular die is preferable, and extrusion is performed while foaming the molten resin from the circular die. A method of stretching and cooling along a mandrel or the like is particularly preferably used. When the foamed sheet is produced by extrusion molding, the molten resin can be extruded from a die and solidified by cooling and then stretched. The foamed sheet may be a single layer or a multilayer, but from the viewpoint of preventing foam breakage during sheet production, a multilayered foam sheet having non-foamed layers in both outer layers is preferred. As the resin constituting the non-foamed layer, those described above as examples of the resin constituting the foamed layer can be used, but the same type of resin as that constituting the foamed layer is preferable. In the case of a propylene-based resin, the non-foamed layer is also preferably composed of a propylene-based resin. The thermoplastic resin foam sheet to be used is not particularly limited, and a foam sheet having an expansion ratio of 2 to 10 times and a thickness of about 1 to 10 mm is usually used.
本発明で用いる熱可塑性樹脂発泡シートは、表面に表皮層が積層されていてもよい。表皮層の例としては装飾、触感向上、補強、保護などの作用をするものが挙げられ、織布、不織布、編布、シート、フィルム、発泡体、網状物などが挙げられる。これらの材料はオレフィン系樹脂、塩化ビニル系樹脂、スチレン系樹脂などの熱可塑性樹脂、ウレタン系樹脂などの熱硬化性樹脂、シス−1,4−ポリブタジエン、エチレン−プロピレン共重合体などのゴムや熱可塑性エラストマー、綿、麻、竹などのセルロース系繊維などが挙げられる。これら表皮層にはシボなどの凹凸模様、印刷や染色が施されていてもよく、単層構成であっても多層構成であってもよく、ソフト感を付与する為にクッション層を設けた表皮層を用いてもよい。発泡シートと表皮層との積層はドライラミネーション、サンドラミネーション、熱ロール貼合、熱風貼合などにより行なうことができる。 The thermoplastic resin foam sheet used in the present invention may have a skin layer laminated on the surface. Examples of the skin layer include those having functions such as decoration, touch improvement, reinforcement, and protection, and examples thereof include woven fabrics, nonwoven fabrics, knitted fabrics, sheets, films, foams, and nets. These materials include olefin resins, vinyl chloride resins, thermoplastic resins such as styrene resins, thermosetting resins such as urethane resins, rubbers such as cis-1,4-polybutadiene and ethylene-propylene copolymers, Cellulosic fibers such as thermoplastic elastomer, cotton, hemp, bamboo, and the like can be mentioned. These skin layers may be provided with uneven patterns such as wrinkles, printed or dyed, and may have a single layer structure or a multilayer structure, and a skin layer provided with a cushion layer to give a soft feeling. Layers may be used. Lamination of the foam sheet and the skin layer can be performed by dry lamination, sand lamination, hot roll bonding, hot air bonding or the like.
本発明で用いる熱可塑性樹脂発泡シートは、添加剤を含有していてもよい。添加剤としては、充填剤(フィラー)、酸化防止剤、光安定剤、紫外線吸収剤、可塑剤、帯電防止剤、着色剤、剥離剤、流動性付与剤、滑剤などがあげられる。上記充填剤の例としては、具体的にはガラス繊維、カーボン繊維等の無機繊維、タルク、クレー、シリカ、酸化チタン、炭酸カルシウム、硫酸マグネシウム等の無機粒子等があげられる。 The thermoplastic resin foam sheet used in the present invention may contain an additive. Examples of the additive include a filler (filler), an antioxidant, a light stabilizer, an ultraviolet absorber, a plasticizer, an antistatic agent, a colorant, a release agent, a fluidity-imparting agent, and a lubricant. Specific examples of the filler include inorganic fibers such as glass fibers and carbon fibers, inorganic particles such as talc, clay, silica, titanium oxide, calcium carbonate, and magnesium sulfate.
本発明の第一の態様では、前記熱可塑性樹脂発泡シートを予め賦形して用いる。加熱軟化した熱可塑性樹脂発泡シートを賦形する際には、成形型A、Bを用いることができる。また、凹部を有しない以外は成形型Aと同じ形状の成形面を有する成形型を用いてもよい。賦形前に熱可塑性樹脂発泡シートを加熱軟化する方法、あるいは本発明の第二の態様の第二の工程において成形型Aと成形型Bとの間に供給する熱可塑性樹脂発泡シートを加熱軟化する方法としては特に限定されるものではなく、ヒーターや熱風で加熱する方法が挙げられる。加熱軟化時の熱可塑性樹脂発泡シート表面温度は、該発泡シートを構成する熱可塑性樹脂が結晶性樹脂であれば融点以上、非晶性樹脂であれば軟化温度以上とすることが好ましく、プロピレン系樹脂であれば熱電対を接触させて測定した時のシート表面温度が180〜220℃程度とすることが好ましい。 In the first aspect of the present invention, the thermoplastic resin foam sheet is shaped in advance and used. When shaping the heat-softened thermoplastic resin foam sheet, molds A and B can be used. Moreover, you may use the shaping | molding die which has a shaping | molding surface of the same shape as the shaping | molding die A except not having a recessed part. The method of heat-softening the thermoplastic resin foam sheet before shaping, or the heat-softening of the thermoplastic resin foam sheet supplied between the mold A and the mold B in the second step of the second aspect of the present invention The method of performing is not particularly limited, and examples thereof include a method of heating with a heater or hot air. The thermoplastic resin foam sheet surface temperature at the time of heat softening is preferably not less than the melting point if the thermoplastic resin constituting the foam sheet is a crystalline resin, and preferably not less than the softening temperature if it is an amorphous resin. If it is resin, it is preferable that the sheet | seat surface temperature shall be about 180-220 degreeC when it measures by making a thermocouple contact.
以下の工程(2)−(5)は、本発明の第一の態様、第二の態様に共通する工程である。本発明の工程(2)は、図4の(2)に示すように、成形型Aと成形型Bの金型クリアランスが、第一の工程で供給した熱可塑性樹脂発泡シートの厚み以下となるまで型締めし、冷却する工程である。金型クリアランスとは、両成形型の成形面間の距離である。 The following steps (2) to (5) are steps common to the first aspect and the second aspect of the present invention. In the step (2) of the present invention, as shown in FIG. 4 (2), the mold clearance between the mold A and the mold B is equal to or less than the thickness of the thermoplastic resin foam sheet supplied in the first process. This is a process of clamping the mold until it is cooled. Mold clearance is the distance between the molding surfaces of both molds.
本発明の工程(3)は、図4の(3)に示すように、前記凹部に通ずるように成形型A内に設けられた樹脂通路を通じて、溶融状熱可塑性樹脂を樹脂圧力(P1)で該凹部に供給する工程である。凹部に供給した溶融状熱可塑性樹脂が冷却固化されて、機能性部材となる。すなわち該機能性部材は、熱可塑性樹脂からなる。該熱可塑性樹脂としては公知の樹脂を用いることができ、具体的には熱可塑性樹脂発泡シートを構成する樹脂として前記した樹脂を挙げることができる。熱可塑性樹脂発泡シートとの融着性の観点から、機能性部材を形成するために用いる熱可塑性樹脂は、熱可塑性樹脂発泡シートと同種の樹脂であることが好ましい。加熱軟化した熱可塑性樹脂発泡シートを用いる場合、溶融状熱可塑性樹脂を供給する時の発泡シート表面温度は低い方が好ましいが、あまりに低くすると成形サイクルが長くなるため、通常は軟化温度以下であればよく、プロピレン系樹脂であれば100〜50℃であることが好ましい。 In the step (3) of the present invention, as shown in FIG. 4 (3), the molten thermoplastic resin is applied at a resin pressure (P1) through a resin passage provided in the mold A so as to communicate with the recess. It is a process of supplying to this recessed part. The molten thermoplastic resin supplied to the recess is cooled and solidified to form a functional member. That is, the functional member is made of a thermoplastic resin. As the thermoplastic resin, a known resin can be used, and specifically, the resins described above can be used as the resin constituting the thermoplastic resin foam sheet. From the viewpoint of fusibility with the thermoplastic resin foam sheet, the thermoplastic resin used for forming the functional member is preferably the same type of resin as the thermoplastic resin foam sheet. When using a heat-softened thermoplastic resin foam sheet, it is preferable that the surface temperature of the foam sheet when supplying the molten thermoplastic resin is low, but if it is too low, the molding cycle will be long. If it is a propylene-type resin, it is preferable that it is 100-50 degreeC.
本発明では、凹部に通ずるように成形型A内に設けられた樹脂通路を通じて溶融状熱可塑性樹脂を凹部に供給する時の樹脂圧力を制御する。具体的には、樹脂圧力P1で凹部への供給を開始した後、その圧力をP1の2倍以上まで増加させる(工程(4))。 In the present invention, the resin pressure when the molten thermoplastic resin is supplied to the recess through the resin passage provided in the mold A so as to communicate with the recess is controlled. Specifically, after the supply to the concave portion is started at the resin pressure P1, the pressure is increased to at least twice P1 (step (4)).
溶融状熱可塑性樹脂はゲートから凹部に供給される際に圧が開放され、その圧力はゲート付近で最も高くなるそのためゲートの延長線上に位置する発泡シート部分が最も樹脂圧力の影響を受けやすく、変形しやすい。
また溶融状熱可塑性樹脂は凹部を充填した後、その流動末端から冷却固化し、ゲートおよびその延長線上が最後に冷却固化される。したがってゲートの延長線上に位置する発泡シート部分は冷却固化する際の収縮の影響を受けやすく、部分的なへこみ(ヒケ)が生じやすい。本発明のように、凹部に供給する溶融状熱可塑性樹脂の樹脂圧力を制御することにより、ヒケがなく外観良好な熱可塑性樹脂成形品を得ることができる。前記樹脂圧力P1は、0.1〜5MPaであることが好ましい。また工程(4)において溶融状熱可塑性樹脂を供給する際の最高樹脂圧力をP2とするとき、該最高樹脂圧力(P2)は5〜20MPaであることが好ましい。P1およびP2をこのような範囲とすることにより、溶融状熱可塑性樹脂が凹部から漏れにくくすることができる。
樹脂圧力をP1からP2へ増加させる場合には、一段階で昇圧することも可能であるが、数秒かけて徐々に圧力を上昇させたり、段階的に昇圧することが好ましい。
なお本願における樹脂圧力とは、スプルー部で測定される樹脂供給圧力である。
When the molten thermoplastic resin is supplied from the gate to the recess, the pressure is released, and the pressure becomes the highest near the gate, so the foam sheet portion located on the extension line of the gate is most susceptible to the resin pressure, Easy to deform.
The molten thermoplastic resin fills the recesses and then solidifies by cooling from the flow end, and the gate and its extension line are finally cooled and solidified. Therefore, the foamed sheet portion located on the extension line of the gate is easily affected by shrinkage when cooled and solidified, and partial dents (sinks) are likely to occur. By controlling the resin pressure of the molten thermoplastic resin supplied to the recess as in the present invention, a thermoplastic resin molded article having no appearance and good appearance can be obtained. The resin pressure P1 is preferably 0.1 to 5 MPa. Moreover, when the maximum resin pressure at the time of supplying a molten thermoplastic resin in a process (4) is set to P2, it is preferable that this maximum resin pressure (P2) is 5-20 Mpa. By setting P1 and P2 in such a range, the molten thermoplastic resin can be made difficult to leak from the recess.
When the resin pressure is increased from P1 to P2, it is possible to increase the pressure in one step, but it is preferable to gradually increase the pressure over several seconds or increase the pressure stepwise.
In addition, the resin pressure in this application is the resin supply pressure measured by a sprue part.
樹脂圧力をコントロールする方法としては、成形型内の樹脂通路や凹部の形状に合わせて樹脂温度や供給速度を制御して樹脂粘度を変化させる方法が一般的である。発泡シートと溶融状熱可塑性樹脂がいずれもプロピレン系樹脂である場合には、樹脂温度は250〜190℃であることが好ましく、供給速度は0.1〜10g/secであることが好ましい。また溶融樹脂の供給時間は賦形する機能性部材の大きさによるが、0.5〜20sec程度で樹脂の供給が完了するように設定することにより、装置制御が容易で振れが少なく、生産性にも優れるため好ましい。 As a method for controlling the resin pressure, a method in which the resin viscosity is changed by controlling the resin temperature and the supply speed in accordance with the shape of the resin passage and the recess in the mold. When both the foamed sheet and the molten thermoplastic resin are propylene resins, the resin temperature is preferably 250 to 190 ° C., and the supply rate is preferably 0.1 to 10 g / sec. The molten resin supply time depends on the size of the functional member to be shaped, but by setting the resin supply to be completed in about 0.5 to 20 seconds, the apparatus can be controlled easily and there is little fluctuation, and productivity Is also preferable.
本発明の熱可塑性樹脂成形品の製造方法の工程(2)−(4)では、成形型の成形面から真空吸引を行ったり、成形型Bから圧縮空気の供給を行ってもよい。真空吸引や圧縮空気の供給を行うことで熱可塑性樹脂発泡シートを金型に密着させ供給される溶融状熱可塑性樹脂のモレを防止することができる。真空吸引する場合には、成形面と発泡シートとの間の真空度が−0.05〜−0.1MPaとなるようにすることが好ましい。真空度とは、大気圧に対する成形型と発泡シートとの間の圧である。すなわち「真空度が−0.05MPa」とは、大気圧に対する成形型と発泡シートとの間の圧力が0.95MPaであることを示す。大気圧に対する成形型と発泡シートとの間の圧の真空度とは、成形型内の真空吸引用通路において測定される。成形面とシートを介して反対位置にある成形型から圧縮空気の供給を行う場合には、圧縮空気を供給する成形型と発泡シートの間の圧が0.05〜0.7MPaとなるように供給することが好ましい。 In steps (2) to (4) of the method for producing a thermoplastic resin molded article of the present invention, vacuum suction may be performed from the molding surface of the molding die, or compressed air may be supplied from the molding die B. By performing vacuum suction or supply of compressed air, it is possible to prevent the molten thermoplastic resin from being supplied while the thermoplastic resin foam sheet is brought into close contact with the mold. In the case of vacuum suction, the degree of vacuum between the molding surface and the foamed sheet is preferably −0.05 to −0.1 MPa. The degree of vacuum is the pressure between the mold and the foam sheet with respect to atmospheric pressure. That is, “the degree of vacuum is −0.05 MPa” indicates that the pressure between the mold and the foamed sheet with respect to atmospheric pressure is 0.95 MPa. The degree of vacuum of the pressure between the mold and the foamed sheet with respect to atmospheric pressure is measured in a vacuum suction passage in the mold. When the compressed air is supplied from the molding die in the opposite position via the molding surface and the sheet, the pressure between the molding die for supplying the compressed air and the foamed sheet is 0.05 to 0.7 MPa. It is preferable to supply.
所定量の溶融状熱可塑性樹脂を供給した後、供給を停止し、型開きして熱可塑性樹脂成形品を取り出す(工程(5))。得られる熱可塑性樹脂成形品は、成形型凹部に供給された溶融状熱可塑性樹脂が冷却されて形成された機能性部材が、熱可塑性樹脂発泡シートの一部に融着されてなる成形品である。本発明により得られる熱可塑性樹脂成形品における機能性部材とは、熱可塑性樹脂発泡シートから突き出すように形成されたものである。具体的には熱可塑性樹脂成形品を補強する機能を有するリブ、あるいは熱可塑性樹脂成形品を他部材に取り付ける機能を有するボス、クリップ、フックなどの部材である。本発明で得られる熱可塑性樹脂成形品は、機能性部材が融着された面と反対側の面、すなわち成形型Bによって賦形される面が、通常意匠面である。 After supplying a predetermined amount of the molten thermoplastic resin, the supply is stopped, the mold is opened, and the thermoplastic resin molded product is taken out (step (5)). The obtained thermoplastic resin molded product is a molded product in which the functional member formed by cooling the molten thermoplastic resin supplied to the mold recess is fused to a part of the thermoplastic resin foam sheet. is there. The functional member in the thermoplastic resin molded article obtained by the present invention is formed so as to protrude from the thermoplastic resin foam sheet. Specifically, it is a member having a function of reinforcing a thermoplastic resin molded product, or a member such as a boss, clip, or hook having a function of attaching the thermoplastic resin molded product to another member. In the thermoplastic resin molded product obtained in the present invention, the surface opposite to the surface on which the functional member is fused, that is, the surface formed by the molding die B is usually the design surface.
本発明により得られる熱可塑性樹脂成形品は、食品容器などの包装材料や、自動車内装部品、建築材料、家電製品などに使用することができる。自動車内装部品の例としてはドアトリム、天井、トランクサイドなどが挙げることができる。例えば機能性部材としてリブが融着されてなる熱可塑性樹脂成形品を自動車内装部品として用いると、強度に優れたものとなり、機能性部材としてボスやフックが融着されてなる熱可塑性樹脂成形品を用いた場合には、他の自動車構成材料と容易に接続することができる。 The thermoplastic resin molded article obtained by the present invention can be used for packaging materials such as food containers, automobile interior parts, building materials, and home appliances. Examples of automobile interior parts include door trims, ceilings, and trunk sides. For example, if a thermoplastic resin molded product with ribs fused as a functional member is used as an automobile interior part, it will have excellent strength, and a thermoplastic resin molded product with bosses and hooks fused as functional members Can be easily connected to other automobile constituent materials.
以下、本発明を実施例に基づき説明するが、本発明は実施例に何ら限定されるものではない。 EXAMPLES Hereinafter, although this invention is demonstrated based on an Example, this invention is not limited to an Example at all.
実施例および比較例で用いた成形型は、以下のとおりである。
成形型A(10):開口部側リブ厚み厚み3mm、反開口部側リブ厚み2.7mm、高さ5mm、長さ150mmのリブを賦形するための凹部(6)が成形面に成形された成形型。前記凹部は、型内に設けられたスプルー(8)、ランナー(9)などから構成される樹脂通路と8mmφのゲート(7)を介して接続されていた。
成形型B(13):平板状の成形面を有し、真空吸引可能な成形型。
The molds used in the examples and comparative examples are as follows.
Mold A (10): A concave portion (6) for shaping a rib having an opening-side rib thickness of 3 mm, an anti-opening-side rib thickness of 2.7 mm, a height of 5 mm, and a length of 150 mm is formed on the molding surface. Mold. The concave portion was connected to a resin passage composed of a sprue (8), a runner (9) and the like provided in the mold via an 8 mmφ gate (7).
Mold B (13): A mold having a flat molding surface and capable of being vacuumed.
(1)熱可塑性樹脂発泡シートの作製
厚さ0.6mmのオレフィン系熱可塑性エラストマーシートと発泡倍率10倍、厚み2.5mmのポリプロピレン架橋発泡シートからなる積層シート(共和レザー製 商品名ビニラー)と、発泡倍率3倍、厚み3mmのポリプロピレン非架橋発泡シート(住化プラステック製 商品名スミセラー発泡PPシート)とを用いて、原料として用いる発泡積層シートを製造した。
ポリプロピレン非架橋発泡シート表面に熱風供給源より温度250℃、風速15m/secの熱風を照射して表面を溶融させ、溶融させたポリプロピレン非架橋発泡シートが積層シートのポリプロピレン架橋発泡シートと対向するように重ねて、ロール間距離3mm、ロールニップ圧0.05MPaの一対のロール間にライン速度2.5m/minで供給し、厚さ6.1mmの熱可塑性樹脂発泡シートを製造した。
(1) Production of thermoplastic resin foam sheet A laminated sheet (trade name Vinyler made by Kyowa Leather Co., Ltd.) consisting of a 0.6 mm thick olefinic thermoplastic elastomer sheet and a 10 mm foaming ratio and a 2.5 mm thick polypropylene crosslinked foam sheet; A foamed laminated sheet used as a raw material was manufactured using a polypropylene non-crosslinked foamed sheet (product name: Sumiceller foamed PP sheet manufactured by Sumika Plustech) having a foaming ratio of 3 times and a thickness of 3 mm.
The surface of the polypropylene non-crosslinked foamed sheet is irradiated with hot air from a hot air supply source at a temperature of 250 ° C. and a wind speed of 15 m / sec to melt the surface so that the melted polypropylene non-crosslinked foamed sheet faces the polypropylene crosslinked foamed sheet of the laminated sheet. And a line speed of 2.5 m / min was supplied between a pair of rolls having a roll distance of 3 mm and a roll nip pressure of 0.05 MPa, to produce a thermoplastic resin foam sheet having a thickness of 6.1 mm.
[実施例1] [Example 1]
押出機を備えた真空成形機(佐藤鉄工製VAIM0301)のクランプ枠(15)に熱可塑性樹脂発泡シート(14)を固定し、近赤外ヒーターにより熱可塑性樹脂発泡シートのポリプロピレン非架橋発泡シート面が200℃になるように加熱軟化した。加熱軟化した発泡積層シートの厚みは6.3mmであった。加熱軟化した熱可塑性樹脂発泡シート(14)をクランプ枠(15)に固定した状態で、成形型A(10)と成形型B(16)との間に、ポリプロピレン非架橋発泡シート面が成形型A側になるように供給した。成形型B(16)は60℃に温度調整して用いた。
次に成形型A(10)と成形型B(16)を、両成形型の成形面のクリアランスが5.5mmになるように型締めし、成形型B(16)の成形面から−0.09MPaで真空吸引を行い賦形した。その後成形型A(10)と成形型(B)(16)を加圧力200kNで加圧し、プロピレン系樹脂(住友化学製ポリプロピレン、ノーブレンBUE81E6、MFR=80g/10min)を、成形型A(10)内のランナー(9)とスプルー(8)を通じて、樹脂圧力(P1)0.5MPa、射出速度1g/secで成形型凹部に3.4秒間供給し、前記凹部を溶融状熱可塑性樹脂で充填した。さらに最高樹脂圧力(P2)が3.7MPaとなるまで昇圧し、2秒間保持した。その後冷却ファンより送風を行い冷却し、型開きして成形品を取り出した。不要な端部を切断し、図5および図6に示すようなリブ(17)が平板に融着されてなる熱可塑性樹脂成形品(18)を得た。得られた熱可塑性樹脂成形品は、リブが設けられた部分に対応する成形品表面にもへこみ(ヒケ)はなく、外観良好であった。
The thermoplastic resin foam sheet (14) is fixed to a clamp frame (15) of a vacuum forming machine (VAIM0301 manufactured by Sato Tekko Co., Ltd.) equipped with an extruder, and the polypropylene non-crosslinked foam sheet surface of the thermoplastic resin foam sheet by a near infrared heater. Was softened by heating so as to be 200 ° C. The thickness of the heat-softened foamed laminated sheet was 6.3 mm. In a state where the heat-softened thermoplastic resin foam sheet (14) is fixed to the clamp frame (15), a polypropylene non-crosslinked foam sheet surface is formed between the mold A (10) and the mold B (16). It supplied so that it might become the A side. Mold B (16) was used after adjusting the temperature to 60 ° C.
Next, the mold A (10) and the mold B (16) are clamped so that the clearance between the molding surfaces of both molds is 5.5 mm, and −0. It was shaped by vacuum suction at 09 MPa. Thereafter, the mold A (10) and the mold (B) (16) are pressurized at a pressure of 200 kN, and a propylene-based resin (manufactured by Sumitomo Chemical, polypropylene, nobrene BUE81E6, MFR = 80 g / 10 min) is molded into the mold A (10). Through the inner runner (9) and the sprue (8), a resin pressure (P1) of 0.5 MPa and an injection speed of 1 g / sec was supplied to the mold recess for 3.4 seconds, and the recess was filled with a molten thermoplastic resin. . Further, the pressure was increased until the maximum resin pressure (P2) reached 3.7 MPa and held for 2 seconds. Thereafter, air was blown from a cooling fan to cool, and the mold was opened to take out the molded product. Unnecessary end portions were cut to obtain a thermoplastic resin molded product (18) in which ribs (17) as shown in FIGS. 5 and 6 were fused to a flat plate. The obtained thermoplastic resin molded article had good appearance with no dents on the surface of the molded article corresponding to the portion provided with the ribs.
[比較例1]
成形型A(10)内のランナー(9)とスプルー(8)を通じて、樹脂圧力(P1)0.5MPa、射出速度1g/secで成形型凹部に3.4秒間供給した後、昇圧することなく供給を停止し冷却した以外は、実施例1と同様にして成形品を製造した。得られた熱可塑性樹脂成形品は、リブが設けられた部分に対応する成形品表面にへこみ(ヒケ)が見られた。
[Comparative Example 1]
Through the runner (9) and sprue (8) in the mold A (10), the resin pressure (P1) is 0.5 MPa and the injection speed is 1 g / sec. A molded product was produced in the same manner as in Example 1 except that the supply was stopped and the system was cooled. In the obtained thermoplastic resin molded product, dents (sink marks) were observed on the surface of the molded product corresponding to the portion provided with the rib.
1 機能性部材
2 熱可塑性樹脂成形品
3 成形品表面の部分的なへこみ(ヒケ)
4 スクリュー式押出機
5 ノズル
6 凹部
7 ゲート
8 スプルー
9 ランナー
10 成形型A
11 開口部側リブ厚み
12 反開口部側リブ厚み
13 リブ高さ
14 熱可塑性樹脂発泡シート
15 クランプ枠
16 成形型B
17 リブ
18 熱可塑性樹脂成形品
19 リブ長さ
DESCRIPTION OF
4
11 Opening side rib thickness 12 Anti-opening side rib thickness 13 Rib height 14 Thermoplastic resin foam sheet 15 Clamp frame 16 Mold B
17 Rib 18 Thermoplastic resin molded
Claims (3)
(1)成形型Aと成形型Bとの間に、予め賦形した熱可塑性樹脂発泡シートを供給する工程
(2)成形型Aと成形型Bの金型クリアランスが前記熱可塑性樹脂発泡シートの厚み以下となるまで型締めし、冷却する工程
(3)前記凹部に通ずるように成形型A内に設けられた樹脂通路を通じて、溶融状熱可塑性樹脂を樹脂圧力(P1)で該凹部に供給する工程
(4)凹部に供給する溶融状熱可塑性樹脂の樹脂圧力を、前記樹脂圧力(P1)の2倍以上まで増加させる工程
(5)溶融状熱可塑性樹脂の供給を停止し、型開きして熱可塑性樹脂成形品を取り出す工程 A method for producing a thermoplastic resin molded article in which a functional member is fused to a part of a thermoplastic resin foamed sheet, wherein a concave portion for shaping the functional member is formed on a molding surface. A method for producing a thermoplastic resin molded article by the following steps using a mold A and a mold B that forms a pair with the mold A.
(1) Step of supplying a pre-shaped thermoplastic resin foam sheet between the mold A and the mold B (2) The mold clearance between the mold A and the mold B is that of the thermoplastic resin foam sheet. Clamping and cooling until the thickness is equal to or less than the thickness (3) Supplying the molten thermoplastic resin to the recess with resin pressure (P1) through the resin passage provided in the mold A so as to communicate with the recess. Step (4) Step of increasing the resin pressure of the molten thermoplastic resin to be supplied to the recess to at least twice the resin pressure (P1) (5) Stopping the supply of the molten thermoplastic resin, and opening the mold The process of taking out the thermoplastic resin molded product
(1)成形型Aと成形型Bとの間に、加熱軟化した熱可塑性樹脂発泡シートを供給する工程
(2)成形型Aと成形型Bの金型クリアランスが前記熱可塑性樹脂発泡シートの厚み以下となるまで型締めし、冷却する工程
(3)前記凹部に通ずるように成形型A内に設けられた樹脂通路を通じて、溶融状熱可塑性樹脂を樹脂圧力(P1)で該凹部に供給する工程
(4)凹部に供給する溶融状熱可塑性樹脂の樹脂圧力を、前記樹脂圧力(P1)の2倍以上まで増加させる工程
(5)溶融状熱可塑性樹脂の供給を停止し、型開きして熱可塑性樹脂成形品を取り出す工程 A method for producing a thermoplastic resin molded article in which a functional member is fused to a part of a thermoplastic resin foamed sheet, wherein a concave portion for shaping the functional member is formed on a molding surface. A method for producing a thermoplastic resin molded article by the following steps using a mold A and a mold B that forms a pair with the mold A.
(1) Step of supplying a heat-softened thermoplastic resin foam sheet between the mold A and the mold B (2) The mold clearance between the mold A and the mold B is the thickness of the thermoplastic resin foam sheet A step of clamping and cooling until the following conditions are satisfied (3) A step of supplying molten thermoplastic resin to the concave portion with a resin pressure (P1) through a resin passage provided in the molding die A so as to communicate with the concave portion. (4) Step of increasing the resin pressure of the molten thermoplastic resin supplied to the concave portion to at least twice the resin pressure (P1) (5) Stopping the supply of the molten thermoplastic resin, opening the mold and heating The process of taking out the plastic resin molded product
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