JPH0890580A - Method and apparatus for producing foamed resin molded object - Google Patents

Abstract

PURPOSE: To obtain a molded object of which both surfaces are smooth by allowing steam to longitudinally flow to the steam suction part formed to one side surface of a molding chamber from the steam supply part formed to the other side surface of the molding chamber. CONSTITUTION: After a molding chamber 10 is filled with a predetermined amt. of a material 11, saturated steam is supplied into a steam supply chamber 3 from a boiler 5 and, at the same time, a suction pump 6 is operated to reduce the pressure in a steam suction chamber 4 to a predetermined negative pressure. Whereupon, the steam supplied into the steam supply chamber 3 flows in the molding chamber 10 from a large number of steam holes 12 and passes through the steam holes 12 on the side of the steam suction chamber 4 to be rapidly sucked into the steam suction chamber 4 reduced in pressure. At this time, the material 11 in the molding chamber 10 is effectively heated by the flow of high temp. steam and the particles of the material 11 are mutually expanded to be fused. When negative pressure reaches a constant condition, a changeover valve 20 is operated and steam is supplied to the steam suction chamber 4 from the boiler 5 and the steam supply chamber 3 is changed over to the state sucked by the suction pump 6.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for producing a foamed resin molding used for packing heat insulating materials and articles.

[0002]

2. Description of the Related Art FIG. 7 shows an example of a conventional procedure for manufacturing a foamed resin molded body, in which a is a lower mold and b is an upper mold placed on the upper part of the lower mold.

A steam chamber C connected to a steam source such as a boiler (not shown) is formed in each of the lower mold a and the upper mold b. The molding chamber e formed between the recess d in the upper part of the lower mold a and the lower surface of the upper mold b is filled with a granular resin resin material f mixed with a foaming agent. A plurality of small holes h are formed in the partition wall g of a and the lower surface of the upper mold b.

When high-temperature steam is supplied to the upper and lower steam chambers C, it flows into the forming chamber e through the small holes h and heats the material f. Then, the materials f are rapidly expanded and fused to each other. Then, the upper and lower molds are cooled by an appropriate cooling means to obtain a desired foamed resin molded body.

[0005]

As in the conventional method described above, when the upper and lower molds a and b are provided with the small holes h for supplying steam, the material f expands and the internal pressure of the molding chamber e increases. When the temperature rises, part of the material f in a molten state enters the small hole h. In this case, the upper and lower surfaces of the foamed resin molded product after manufacturing become uneven, and in the case of a product requiring a smooth surface, there is a disadvantage that the convex portion must be scraped off after manufacturing.

In particular, when manufacturing a relatively large foamed resin molded body, it is necessary to provide a large number of small holes h to increase the supply amount of steam and prevent the uneven fusion. The work of scraping the convex portion is extremely troublesome.

The present invention has been made to solve the above problems, and by changing the flow direction of steam,
It is an object of the present invention to provide a method and an apparatus for producing a foamed resin molded product, which enables to easily obtain a molded product having smooth surfaces on both sides and high fusion property.

[0008]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention is to fill a hermetically sealed molding chamber with a foamable resin material, and to form a steam supply portion formed on at least one side surface of the molding chamber. To the steam suction section formed on the other side, the steam is allowed to flow in the molding chamber in the longitudinal direction for a predetermined time, and after the predetermined time elapses, the steam supply section up to now is used as the steam suction section and the steam suction section is steamed. It is characterized in that the resin material is switched to the supply part and the steam is allowed to flow for a predetermined time, and this switching step is repeated a predetermined number of times to heat and fuse the resin material.

In this case, the steam supply unit and the steam suction unit are
It is desirable to form the side surfaces around the molding chamber so as to face each other.

Further, it is desirable that the steam supply portion and the steam suction portion are arranged alternately around the molding chamber.

During foaming, it is desirable to simultaneously heat the upper and lower surfaces arranged in the longitudinal direction of the molding chamber by the flow of steam.

The apparatus used for carrying out the above method is such that a molding body having a molding chamber capable of being filled with a resin material and the molding chamber are communicated with each other through a large number of steam holes formed on at least one side surface of the molding body. The steam chamber is provided with a steam chamber provided so as to communicate with each other through a large number of steam holes formed on the other side surface of the mold, and the steam chamber faces the steam chamber. Each steam chamber includes a boiler and a suction pump. And are alternately connected to and.

In this case, it is desirable to provide the second steam chambers at the upper and lower portions of the mold body that sandwich the molding chamber.

Further, it is desirable to provide a cooling means in the second steam chamber.

[0015]

[Function] The steam in the steam supply section flows in the molding chamber in the longitudinal direction toward the steam suction section, and then the flow forces thereof are reversed and repeated, so that the resin material filled in the molding chamber is effectively Since it is heated and melted, unevenness is not formed on the upper and lower surfaces of the molded body after manufacturing, unlike the conventional method in which small holes for steam supply are provided in the thickness direction of the mold, and it is flat. It becomes a face.

[0016]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 and FIG. 2 show a first manufacturing apparatus of the present invention.
1 shows an embodiment, 1 is a lower die having a horizontally long rectangular shape, 2
Is an upper mold placed on the upper part of the lower mold 1.

Steam chambers that can serve as a steam supply chamber 3 and a steam suction chamber 4 are integrally provided on both left and right sides of the lower mold 1. The steam supply chamber 3 is provided in the boiler 5, and the steam suction chamber 4 is also provided.
Are connected to the suction pump 6 via pipes 7,
The steam supply chamber 3 and the steam suction chamber 4 are alternately changed to a steam suction chamber and a steam suction chamber by a predetermined switching operation.

A steam heating chamber 8 is formed in the center of the lower mold 1 between the steam supply chamber 3 and the steam suction chamber 4 and in the upper mold 2.

A predetermined number of steam pipes 2 are provided in each steam heating chamber 8.
1 extends, and a cooling water pipe 9 having a plurality of nozzles 9 a is accommodated in the steam heating chamber 8.

A rectangular space having a small vertical size, which is formed by the recess 1a formed in the central portion of the lower mold 1 and the lower surface of the upper mold 2, constitutes a closed molding chamber 10. A material 11 made of a granular resin resin mixed with a foaming agent is filled in the material 10.

A large number of small-diameter steam holes 12 communicating with the molding chamber 10 are formed on the inner side walls 3a, 4a of the steam supply chamber 3 and the steam suction chamber 4 on the molding chamber 10 side.

Reference numeral 13 denotes a drain pipe with a valve provided in the steam supply chamber 3, the steam suction chamber 4, and the upper and lower steam heating chambers 8.

Next, the procedure for manufacturing a foamed resin molding using a steam device will be described.

First, the molding chamber 10 is filled with a predetermined amount of the material 11, and then the temperature in the steam supply chamber 3 is set to about 12 by the boiler 5.
Saturated steam at 0 ° C. and a pressure of about 2 kg / cm ² is supplied. At the same time, the suction pump 6 is operated to move the vapor suction chamber 4
The internal pressure is reduced to a predetermined negative pressure.

Then, the steam supplied to the steam supply chamber 3 passes through a large number of steam holes 12 as shown in FIG.
Flows into the inside, and is rapidly sucked into the depressurized steam suction chamber 4 through the steam holes 12 on the steam suction chamber 4 side.

Due to the flow of steam at this time, the molding chamber 10
The material 11 therein is effectively heated by the high temperature steam, and the particles of the material 11 expand and fuse together.

When the steam flow is blocked by the mutual fusion of the particles, the pressure in the steam suction chamber 4 gradually starts to decrease. This decrease in pressure is detected by a predetermined sensor (not shown), and when this negative pressure reaches a certain condition, the switching valve 20 operates, supplying steam from the boiler 5 to the steam suction chamber 4 up to then, and Then, the steam supply chamber 3 thus far is switched to a state in which the suction pump 6 is used for suction.

Since the mutual switching is continuously repeated a predetermined number of times, the materials in the molding chamber 10 are uniformly promoted to expand and fuse with each other.

In combination with the above-mentioned supply of steam into the molding chamber 10, as shown in FIG. 1, the steam heating chamber 8 between the lower mold 1 and the upper mold 2 also receives high temperature steam from a plurality of steam pipes 21. Is more effective to heat the molding chamber 10 from above and below.

Then, after a lapse of a certain period of time, the supply of steam is stopped, cooling water is injected into the upper and lower steam heating chambers 8 from the nozzles 9a, and the molding chamber 10 is cooled to a predetermined temperature and then demolded. A desired foamed resin molded product having a plate shape can be obtained.

As described above, when the material 11 is filled in the hermetically sealed forming chamber 10 and the steam is circulated in the longitudinal direction orthogonal to the thickness of the forming chamber 10, the upper and lower surfaces of the formed body are conventionally formed. Unevenness is prevented from being formed, and the upper and lower surfaces are flat surfaces.

Further, the supplied steam is caused to flow rapidly toward the depressurized steam suction chamber 4, and the steam supply chamber and the steam suction chamber are alternately switched within a predetermined time. Even if the resin molded body is relatively large, there is no risk that the temperature of the steam will drop midway or the steam will stagnate, and therefore uneven fusion will occur in the material 11 and a brittle molded body will be formed. There is no such thing.

FIG. 3 shows a second embodiment of the present invention.

This embodiment is a modification of the first embodiment, in which the steam supply chamber 3 and the steam suction chamber 4 are relatively extended to near the middle portion of the long side wall 1b of the lower mold 1. , Which is an increase in their volume.

In this way, the flow rate of the steam increases, the arrival time of the steam to the steam suction chamber 4 is shortened, and the temperature drop of the steam is further reduced.
The fusion property of the material 11 is better than that of the example.

FIG. 4 shows a third embodiment of the present invention, which is the structure of the lower mold 1 when manufacturing a large and long plate-shaped foamed resin molded body.

Around the molding chamber 14 having a vertically long rectangular shape, the vapor supply chamber 15 and the vapor suction chamber 16 are line-symmetrical so that the adjacent chambers and the chambers facing each other in the short side direction are opposite to each other. They are arranged alternately.

That is, in the left half portion, the L-shaped steam supply chamber 15 at the upper and lower corners and the steam suction chamber 16 at the central portion are provided.
Further, an L-shaped vapor suction chamber 16 at the upper and lower corners and a vapor supply chamber 15 at the central portion are formed by partition walls 17 in the right half portion.

The steam is first supplied to the steam supply chamber 15 in the upper part of the figure.
Steam supply chamber 15 in the central part on the right side, steam supply chamber 15 in the lower part
Is supplied to.

That is, while the steam suction chambers 16 arranged every other one are depressurized by a suction pump (not shown), steam is supplied to the steam supply chambers 15 for a certain period of time so that the steam as shown in FIG. The flow is achieved.

The fusion state of the material 11, that is, the timing of switching between the vapor suction chamber and the vapor supply chamber, is such that as the fusion of the material 11 progresses, the voids between the particles of the material 11 are closed and the passage of the vapor. Since the amount decreases, an appropriate detection means such as a flow meter or a pressure gauge capable of detecting any of the flow rate of steam, the internal pressure of the steam supply chamber 15, the vacuum pressure in the steam suction chamber 16, etc. should be used. You can

Even when molding the large-sized and long plate-shaped foamed resin, heating the molding chambers 10 from above and below in the upper and lower steam heating chambers 8 enables more effective molding.

Completion of fusion of the material 11 filled in the lower molding chamber 14 can be detected by the above-mentioned pressure change. At this point, the supply of steam is stopped, and the mold is removed after cooling. A large and long foamed resin molding can be obtained.

As in the third embodiment, the steam supply chamber 15
When the steam suction chambers 16 and the steam suction chambers 16 are alternately arranged in the longitudinal direction and the steam is alternately supplied to the steam supply chambers and the steam suction chambers, the steam flows in a directional manner as shown by arrows in the drawing, and And will not collide with each other and there will be no steam stagnation.

Therefore, even if it is large and long, it is a molded product of stable quality with excellent fusion-bonding property.

FIG. 5 shows a fourth embodiment of the present invention.

This embodiment is a modification of the third embodiment described above, and the side wall portion on the short side on the upper side in the figure, about 2/3 of the side wall portion on the long side on the lower right side, and the lower left side portion. The steam supply chamber 15 is provided in approximately 1/3 of the long side wall portion, the lower short side wall portion is provided, and the upper left long side wall portion is provided with approximately 2/3 of the right side length. The vapor suction chambers 16 are provided point-symmetrically in approximately 1/3 of the side wall portion on the side.

The steam is first supplied to the steam supply chamber 15 in the upper part of the figure.
It is supplied to the lower right steam supply chamber 15 and the lower left steam supply chamber 15.

That is, the steam suction chambers 16 arranged every other space are depressurized by a suction pump (not shown), and steam is supplied to the steam supply chambers 15 for a certain period of time to generate the steam shown in the figure. The flow is achieved.

The fusion state of the material 11, that is, the timing of switching between the vapor suction chamber and the vapor supply chamber, is such that as the fusion of the material 11 progresses, the voids between the particles of the material 11 are closed and the vapor passes. Since the amount decreases, an appropriate detection means such as a flow meter or a pressure gauge capable of detecting any of the flow rate of steam, the internal pressure of the steam supply chamber 15, the vacuum pressure in the steam suction chamber 16, etc. should be used. You can

Even when molding the large and long plate-like foamed resin, heating the molding chambers 10 from above and below in the upper and lower steam heating chambers 8 enables more effective molding.

Also in this embodiment, the steam supply chambers 15 and the steam suction chambers 16 are alternately arranged, and the steam supply chambers 15 and the lower and upper left long sides at the upper and lower right long side walls. Since the steam suction chamber 16 of the side wall on the side is large, the steam has a directivity as shown by an arrow in the drawing and the distribution direction is wide, so that the meltability of the material 11 is enhanced.

The present invention is applicable to the production of a heat-resistant composite plate such as a wall plate in which both surfaces of a foamed resin body are covered with a thin metal plate, in addition to the foamed resin molded body as in each of the above embodiments. Can also be applied.

FIG. 6 shows a molding procedure of the above composite plate. As in FIG. 1, a material 11 and two metal sheets are sandwiched from above and below in a molding chamber 10 formed by upper and lower molds 1 and 2. After inserting the plates 18 and 18, the steam supplied to the steam supply chamber 3 on the left is circulated toward the steam suction chamber 4 on the right, and the steam supply chamber and the steam suction chamber are continued as described above. Switch to each other. At the same time, saturated steam of about 120 ° C. is supplied into the steam chambers (also serving as cooling chambers) 19 formed in the upper and lower molds 1 and 2 to heat both metal plates 18.

Then, similarly to the above, the particles of the material 11 are expanded and fused to each other, and the metal plate 18
Also fused to. After that, the molding chamber 10 is cooled by the cooling water sprayed from the cooling pipe (not shown) and released from the mold to obtain a composite plate in which the metal plates 18 are fixed to both surfaces of the foamed resin molded body.

Although the embodiments of the present invention have been described above with reference to the drawings, the specific configuration is not limited to these embodiments, and even if there are changes and additions within the scope not departing from the gist of the present invention, the present invention is not limited. Included in the invention.

[0058]

According to the present invention, the following effects can be obtained.

(A) Since the steam is circulated in the longitudinal direction of the molding chamber, unevenness is not formed on the upper and lower surfaces of the molding chamber after molding as in the conventional case, and a flat surface is formed.

(B) Since the steam repeats forward and backward flows, the steam rapidly flows without causing a temperature drop or stagnation, so that the fusion property of the material is enhanced.

(C) According to the invention described in claims 2 and 3, a large and long foamed resin molded article can be easily manufactured.

(D) According to the invention described in claim 4, when the molding chamber is heated from above and below with steam or the like, expansion and fusion of the material are promoted.

(E) When the apparatus according to claim 5 is used,
The foamed resin molding can be manufactured very easily.

(F) According to the invention described in claim 6, since the upper and lower surfaces of the foamed resin can be heated by steam in addition to the molding chamber, the steam can be effectively used.

(G) According to the invention described in claim 7, the mold can be forcibly cooled, so that the waiting time until the demolding is shortened and the productivity is enhanced.

[0066]

[Brief description of drawings]

FIG. 1 is a vertical sectional front view showing a first embodiment of an apparatus of the present invention and a manufacturing procedure therefor.

FIG. 2 is a cross-sectional plan view taken along the line XX in FIG.

FIG. 3 is a cross-sectional plan view of the same portion as FIG. 2 showing a second embodiment of the present invention.

FIG. 4 is a sectional plan view showing a third embodiment of the same.

FIG. 5 is a sectional plan view showing a fourth embodiment of the same.

FIG. 6 is a vertical cross-sectional view of a main part showing a procedure for manufacturing a composite plate of a foamed resin and a metal plate.

FIG. 7 is a vertical cross-sectional view showing a manufacturing procedure of a conventional foamed resin molded body.

[Explanation of symbols]

1 Lower mold 1a Recess 1b Side wall 2 Upper mold 3 Steam supply chamber (steam supply part) 3a Side wall 4 Steam suction chamber 4a Side wall 5 Boiler 6 Suction pump 7 Pipe 8 Steam heating chamber (second steam chamber) 9 Cooling water pipe 9a Nozzle 10 forming chamber 11 material 12 steam hole 13 drain pipe 14 forming chamber 15 steam supply chamber (steam supply part) 16 steam suction chamber (steam suction chamber) 17 partition wall 18 metal plate 19 steam chamber 20 switch valve 21 steam pipe

Claims (7)

[Claims] 1. A sealed molding chamber is filled with a foamable resin material, and is directed from a steam supply portion formed on at least one side surface of the molding chamber to a vapor suction portion formed on the other side surface. Then, the steam is allowed to flow in the longitudinal direction in the molding chamber for a predetermined time, and after the predetermined time has passed, the steam supply unit so far is switched to the steam suction unit and the steam suction unit is switched to the steam supply unit to allow the steam to flow for the predetermined time. Is repeated a predetermined number of times to heat-seal the resin material to produce a foamed resin molded body. 2. The method for producing a foamed resin molded product according to claim 1, wherein the steam supply unit and the steam suction unit are formed so as to face each other on the side surface around the molding chamber. 3. The method for producing a foamed resin molded product according to claim 1, wherein steam supply units and steam suction units are arranged alternately around the molding chamber. 4. The apparatus for producing a foamed resin molded article according to claim 1, wherein the upper and lower surfaces arranged in the longitudinal direction of the molding chamber are heated at the same time when foaming is caused by the flow of steam. 5. A mold body having a molding chamber capable of being filled with a resin material, a steam chamber provided so as to communicate with the molding chamber through a large number of steam holes formed on at least one side surface of the mold body, and a mold. The steam chamber is provided so as to communicate with each other through a large number of steam holes formed on the other side surface of the body, and the steam chamber faces the steam chamber. Each steam chamber is alternately connected to the boiler and the suction pump. An apparatus for manufacturing a foamed resin molded body, which is configured as described above. 6. A second member is provided at upper and lower portions of the mold body which sandwich the molding chamber.
The foamed resin molded body manufacturing apparatus according to claim 5, wherein the steam chamber is provided. 7. The apparatus for manufacturing a foamed resin molded article according to claim 6, wherein cooling means is provided in the second steam chamber.