JPH11927A - Molding device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent resin liquid and the like from leaking in a molding passage and obtain a molded article without hindering the running of a device, which is suitable for continuously manufacturing a foamed resin molded body in continuous form. SOLUTION: A desired molding passage 17 is formed by fitting a rectangular top mold 1 into a rectangular groove-like bottom mold 6. At the fitting part between the top and the bottom molds 6 and 7, a gap 18 is cleared. In the molding passage 17, rotatingly driven steel belts 8-11 are arranged. The inner surface sides of the belts are covered with bendable sealing belts 12 and 13 so as to prevent resin liquid and the like from leaking in the molding passage. The edge parts 12a and 13a of the sealing belts 12 and 13 are pinched in the gaps 18 so as to allow to vent through the gaps and make the development of burrs at the clearance except between the edge parts 12a and 13a pinched in the gas impossible. When a resin expands in the molding passage 17, the sealing belts 12 and 13 are pressed by means of its expanding pressure against the steel belts 8-11, resulting in turning with the belts together so as to move a stock to be molded in the molding passage 17.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for forming a desired sectional shape through a material in a molding passage, for example, a resin molded article having a plate-like or long-like shape such as a heat insulating material or a building material. The present invention relates to a molding apparatus suitable for continuous production.

[0002]

2. Description of the Related Art Many proposals have been made for this type of molding apparatus. The basic configuration of this type of apparatus is, for example, as disclosed in Japanese Patent Publication No. 48-30137.
In a molding die forming a rectangular molding passage, four endless belts advancing along the inner wall surface of the molding die are arranged,
A long fiber bundle impregnated with a foam-setting resin liquid or the like is injected from one side of the molding passage as a material to be molded, and a mold is formed by utilizing the volume increase of the resin during foaming while passing through the molding passage. Is given to the material to be molded to continuously obtain a long molded body.

However, in such a configuration, the material to be molded leaks into the molding die from a gap between the endless belts, which appears as burrs on the molded product, or adheres to the surface of the molding cylinder to cause the traveling of the endless belt. There is a problem that this may eventually render the device inoperable.

[0004] Various means have been proposed in order to solve such problems caused by leakage of the material to be molded. For example, in the technology disclosed in JP-A-6-31751, four endless belts are arranged such that one edge thereof is in contact with another endless belt adjacent thereto, and an elastic member or a sheet-like member having a triangular cross section is provided. Elastic members and the like are arranged at the contact portions, and they are deformed by the internal pressure of the molding passage, which is increased by foaming of the resin, to close the gaps at the contact portions, thereby preventing the material to be molded from leaking from these portions. In addition, Japanese Unexamined Patent Publication
According to the technology disclosed in Japanese Patent No. 31752, instead of the above-mentioned elastic member or the like, a thread-like body made of nylon or the like having a circular cross section is continuously supplied to the contact position between the endless belts, and is similarly deformed by the internal pressure of the molding passage. The gap between the contact parts is closed.

However, taking such measures to prevent the generation of burrs has the advantage that the design criteria for the gap between the endless belts can be relaxed, but in order to realize stable operation of the apparatus over a long period of time, it is necessary to use an elastic member or the like. A device for always accurately positioning a thread or the like in a gap between endless belts,
A new problem arises in that a mechanism is required and the device configuration is complicated.

In addition, not only the endless belt but also the elastic member and the thread-like body come into contact with the material to be molded in the molding passage.
These also require good releasability from the material to be molded or the molded product, and whether or not they move with the endless belt, the tensile force applied by the movement of the material to be molded or the cured molded product It must be able to withstand the heat, and on the other hand, it must be able to be deformed flat enough by the internal pressure of the molding passage so as not to affect the shape of the molded product. Must be taken into account, which causes a problem that the amount of usable materials is extremely small.

[0007] As an alternative to these, for example, as disclosed in Japanese Patent Publication No. 57-31981 and Japanese Patent Application Laid-Open No. 9-1682, a single long belt material is formed into a cylindrical shape and placed in a molding die. An apparatus for supplying the same material to be molded into the cylindrical molding passage formed by the belt material and forming the same, for example, JP-A-7-32386 and JP-A-82323
As disclosed in JP-A-49-49, there has been proposed an apparatus for forming a forming passage by bending two long belt members into a semicircle and combining them in a cylindrical shape.

The apparatus disclosed in Japanese Patent Publication No. 57-31981 can solve the above-mentioned drawbacks caused by using an elastic member or the like, but the joint of the belt material is always exposed in the forming passage. Therefore, the leakage of the material to be molded in the molding die, which has been solved by using an elastic member or the like, and a problem caused by the leakage occur.

In view of the above-mentioned conventional problems, the present invention does not prevent burrs from being formed on a molded product, but rather allows burrs to be formed only at a certain position outside a molding die. A simple product that prevents leakage of resin liquid and the like in the passage, can obtain a molded product without hindering the operation of the device, and can easily obtain a molded product of a desired shape by simple post-processing. It is an object of the present invention to provide a molding apparatus having a simple apparatus configuration.

[0010]

According to a first aspect of the present invention, there is provided a molding apparatus in which a material to be molded is introduced into a molding passage having a desired cross-sectional shape to achieve the above object. In a molding apparatus for moving the material to be molded into a molded body having a cross-sectional shape corresponding to the cross-sectional shape of the molding passage while moving in the molding passage, the injection side of the material to be molded, the exit side of the molded body and the molded body A first forming die having a groove shape with at least one surface opened along a moving direction of the raw material and the formed body;
A second molding die for loosely fitting at least a part of the first molding die into the first molding die through the opening on the one surface of the first molding die to form the molding passage; and forming the second molding die in the molding passage. At least one first member movable along the inner surface of the first mold;
A belt-like body, at least one second belt-like body that can be driven to move along the surface of the second molding die facing the molding passage, and with the movement of the first belt-like body. A first driven belt-like body arranged so as to sandwich the first belt-like body between the first mold and the first mold so as to be movable along an inner surface of the first mold; The second belt is sandwiched between the second mold and the second mold so as to be movable along the surface of the second mold facing the molding passage as the belt moves. And a pair of edges of the first driven belt-shaped body and the second driven belt-shaped body, and the second molding die to the first molding die. Characterized in that it is sandwiched between the first and second molding dies at the fitting portion of.

According to a second aspect of the present invention, in order to achieve the above object, the hollow inner shape of the first molding die is a square tube, and the open surface of the hollow inside of the square tube is formed by the first mold. The first belt-shaped body is disposed on each of the surfaces except for the first belt-shaped body, and the first driven belt-shaped body can be bent into a groove shape corresponding to the internal shape of the first mold, and The second driven belt-shaped body can be bent into a groove shape corresponding to the shape of the fitting portion of the second molding die to the first molding die.

According to a third aspect of the present invention, in order to achieve the above object, the first molding die has a rectangular cross section and at least the first belt of the second belt-shaped body. The part to be fitted to the mold has a rectangular cross-sectional shape.
The hollow interior formed by the second mold is a rectangular tube, and the first belt-shaped body is arranged along each of three surfaces except the one open surface of the first mold. The first driven belt-shaped member can be bent into a rectangular groove shape corresponding to the cross-sectional shape of the first forming die, and the second driven belt-shaped member is connected to the first forming die. It is characterized in that it can be bent into a rectangular groove shape corresponding to the shape of the fitting portion of the second molding die.

According to a fourth aspect of the present invention, in order to achieve the above object, the first and second belt-shaped members and the first and second driven belt-shaped members are separately formed into an endless shape. The first and second belt-shaped members are rotated and driven to rotate the first and second driven belt-shaped members together with the first and second belt-shaped members.

According to a fifth aspect of the present invention, in order to achieve the above object, the material to be molded is a resin alone or a fiber assembly which is initially liquid and hardens while expanding in the molding passage. Or a resin obtained by mixing a filler, a short fiber, or the like into the resin, wherein the first and second belt-shaped bodies have a desired mechanical strength, and the first and second belt-like bodies have a desired mechanical strength.
Is characterized in that the driven belt-shaped member has a releasing property from the above-mentioned cured resin and its composite cured body and a sealing property with respect to the above-mentioned resin liquid.

According to a sixth aspect of the present invention, in order to achieve the above object, at least a fold is provided along the moving direction of the first driven belt-like body so that the first molding is performed in the molding passage. It is characterized in that it can be bent according to the sectional shape of the mold.

According to a seventh aspect of the present invention, in order to achieve the above object, at least a portion of the first and second driven belt-like bodies, which forms a surface to be brought into contact with the material to be molded, is made of a fluorine-based resin. Characterized by being impregnated.

[0017]

Embodiments of the present invention will be described below with reference to the drawings. In the embodiment described below, the shape of the molding passage is a rectangular cylindrical shape, and only an example in which the shape of the molded product is a quadrangular prism is described and illustrated, but the present invention is not limited to this. For example, a triangular shape is possible, and a polygonal shape of a pentagon or more may be used. It is only necessary to change the number and arrangement of the belt-shaped members in accordance with the shape of the molding passage. Further, the material to be molded in the present invention is not limited to a resin, and various types of materials can be used.However, even when a resin is used as a material to be molded, a foam-curable resin liquid described and illustrated in the present embodiment, For example, the material is not limited to a phenol resin, a urea resin, a polyurethane resin, or the like, and a resin or the like which is initially liquid and expands and cures in a molding passage may be used as a material. Further, only an example in which a fiber aggregate such as a glass continuous strand mat to which the above-mentioned resin liquid or the like is adhered is used as a material to be molded, but the apparatus according to the present invention uses a single resin liquid or the above-mentioned resin. Various objects such as a mixture of a liquid with a filler and a bundle of long fibers with the liquid resin adhered thereto can be used as a molding target.

FIG. 1 is a perspective view conceptually showing a molding apparatus according to an embodiment of the present invention, FIG. 2 is a side view thereof, and FIG. 3 is a plan view thereof. In the apparatus of the illustrated embodiment, the foaming and curable resin liquid 1 is ejected from a nozzle 2 onto a glass continuous strand mat (hereinafter simply referred to as a glass mat) 3 and adhered thereto. Is a continuous molding of a rectangular elongated molded body 5, mainly comprising a lower die 6 and an upper die 7, which are dies, four endless steel belts 8 to 11, and two similarly endless steel belts. It comprises seal belts 12 and 13, an unloading belt conveyor 14 and a deburring cutter 15 arranged on the output side of the apparatus.

As can be seen from FIG. 4 showing the cross-sectional shape of the lower die 6, the lower die 6 has a rectangular groove 16 which is open on the input side of the material 4 to be molded, the output side of the molded body 5, and the upper surface. Also upper die 7
Has a rectangular cross-sectional shape corresponding to the shape of the groove 16 of the lower die 6. The groove 16 and the upper mold 7 of the lower mold 6 are formed so that a molding passage 17 having a desired shape and dimensions is formed when the steel belts 8 to 11 and the seal belts 12 and 13 are arranged as described later. Similarly, as shown in FIG. 4, the upper die 7 has a width which allows the upper die 7 to be loosely fitted in the groove 16 of the lower die 6 to a predetermined depth so that the gaps 18 and 18 are clear. Various known means may be used for fitting and positioning the upper die 7 to a predetermined depth, and illustration and description thereof will be omitted. The lower mold 6 and the upper mold 7 need only be able to support the steel belts 8 to 11, and it is not necessary to use a so-called mold material as shown in the drawing to make the inner wall surface forming the forming passage 17 flat, and for example, Even if it is a ladder-like or lattice-like thing and there is unevenness or an opening on the inner wall surface facing the forming passage 17, it can be variously adopted as long as the movement of the steel belts 8 to 11 is not hindered. . Although a solid mold is used for the upper mold 7 in the illustrated example, it may of course be a hollow mold.

Four endless steel belts 8 to 1
Reference numeral 1 denotes a dimension of the steel belts 8 and 9 along the substantially entire inner surface of the groove 16 of the lower mold 6, and a steel belt 10
And the steel belt 11 has a dimension along substantially the entire bottom surface of the upper die 7. Each of the side surfaces and the bottom surface described above is wound around the roller 19 in parallel with the roller 19 and along the moving direction of the molding material 4 in the molding passage 17, that is, the longitudinal direction of the lower mold 6 and the upper mold 7. And is rotationally driven by a driving means (not shown) while being in sliding contact with. In the present invention, a belt-shaped body having a required mechanical strength can be appropriately used instead of the steel belt. Further, even if it is not an endless belt, any belt-like body having a required length can be employed. Furthermore, in the present embodiment, the steel belt is wound around the roller and driven to rotate, but the present invention is not limited to this, and it is sufficient that the steel belt or a belt-like body instead of the steel belt can be moved by some means. For example, utilizing the frictional force and adhesive force between the material to be molded 4 or the molded body 5 and the seal belt and the frictional force and the like between the seal belt and the steel belt or an alternative belt-like body,
It is also possible to adopt a configuration in which a steel belt or an alternative belt-like body moves as the material to be molded 4 or the molded body 5 advances in the molding passage 17.

The two seal belts 12, 13 surround the steel belts 10, 11 inside thereof, respectively.
Each of the four rollers 20... Is wound around in parallel with each other.
It is assumed that it only rotates around 1. 1 and 4
As shown in the figure, outside the forming passage 17, it has an original substantially flat shape, and inside the forming passage 17, each has a bent shape,
That is, they are bent into rectangular grooves each opening upward. For this reason, in the illustrated embodiment, both of the seal belts 12 and 13 have a two-layer structure as shown in FIG. Two cuts 23 are formed between the second layer materials 22 located outside in 17. Needless to say, a material having a single-layered structure that can be bent by making a fold or a multilayered structure having three or more layers may be used. Further, the seal belts 12 and 13 are not necessarily endless belts but may be any belt-like body having a required length and structure.

The seal belt 12 is provided with a groove 16 of the lower mold 6.
Steel belts 8 to 1 corresponding to
The width is set so that both edges 12a, 12a are located at least in the gap 18 over the entire surface of the groove 0, and preferably the edge 12a is located at a position equal to or higher than the upper edge of the groove 16.
On the other hand, the seal belt 13 corresponds to the lower part of the upper die 7, and covers the entire surface of the steel belt 11 so that both edges 13 a, 13 a are located at least in the gap 18. The width is set so as to be at a position beyond the edge.

Further, both of the seal belts 12 and 13 are located inside the molding passage 17 and the material 4 to be molded and the molding 5
For the first layer material 21 that comes into contact with the resin, a material having a required liquid sealing property with respect to the foam-curable resin liquid 1 and a required release property with respect to the foamed molded article during molding and the molded article 5 after curing is used. Examples of such a material include a cloth made of polyaramid fiber or glass fiber or a composite cloth thereof impregnated with a fluorine-based resin so as to have releasability and heat resistance. The second layer material 22 located on the outside in the molding passage 17 may be the same as the above material, but in the present invention, the second layer material 22 has a required coefficient of friction with respect to a steel belt or a substitute material thereof, and The material is not limited to a sheet made of the above material and the like as long as it is a material that can rotate in a state pressed against a belt or the like. Material can be appropriately adopted.

It is usual for a molding apparatus of this type to provide a heating means or the like in the lower mold 6 and the upper mold 7 and control the molding process by controlling the temperature, but these means are not shown. I do. Of course, it does not mean that the present invention must have means for controlling such a molding process.

Next, the operation of the present embodiment will be described. In a state where the steel belts 8 to 11 are driven to rotate, the nozzles 2 are initially foamed in a liquid state, such as a polyurethane resin, from the nozzle 2 onto a glass mat 3 drawn from a roll (not shown) of the glass mat while increasing the volume. The foaming-curable resin liquid 1 that is to be cured is ejected to form a material to be molded 4, which is introduced from the entrance of the molding passage 17. Then, the steel belt 10 moving on the bottom surface of the groove 16 near the entrance of the forming passage 17.
The molding material 4 is deposited on the upper seal belt 12, and the weight of the material causes the seal belt 12 to be lightly pressed onto the steel belt 10, and the frictional force between the two causes the seal belt 12 to move with the steel belt 10. ,
Start so-called co-rotation. In the present embodiment, the glass mat 3 forming the material to be molded 4 is not pulled from the exit side of the molding passage 17 by any means, but this may be performed at the start of operation of the apparatus.

In the molding passage 17, the foam-setting resin liquid 1 forming the material to be molded 4 foams while generating heat, and the steel belts 8 to 11 and the seal belt 12 are formed on the inner wall surface of the molding passage 17 due to the volume increase accompanying the foaming. , 13 are, for example, 1-3 kg / cm {2}. Due to this pressure, the seal belts 12 and 13 are strongly pressed against the inner surfaces of the steel belts 8 to 11, respectively, and the forming passage 1 is formed.
The shape of 7 here is the desired shape. In this state, not only the seal belt 12 and the steel belt 10, but also
The seal belt 12 rotates together with the steel belts 8 and 9, and the seal belt 13 rotates together with the steel belt 11. Then, the material to be molded 4 is sequentially and smoothly drawn into the molding passage 17, molded into the shape of the molding passage 17, solidified with the glass mat as a reinforcing material, and formed from the exit of the molding passage 17. Discharged as 5. Since the above operation is performed, the steel belt 8
It is necessary to control so that the moving speeds of No. to No. 11 are equal, but since such control is well known in the related art, the description of the configuration and operation of the control system will be omitted.

As described above, the seal belts 12 and 13 are originally flat sheets when they are outside the molding passage 17, but when they enter the molding passage 17, the edges 12a and 13a are formed.
Overlap each other, enter the gap 18 between the lower mold 6 and the upper mold 7, and bend into a groove along each cut 23.
Of course, the bending deformation of the seal belts 12 and 13 starts before entering the gap 18 as shown in the figure.

A part of the foaming curable resin liquid 1 expanded in the molding passage 17 is sealed before the solidification.
It goes between the edges 12a, 13a of the two, 13 and penetrates between them by the pressure created by the foaming and tries to exit the molding passage 17. Therefore, the discharged molded body 5
Is formed with burrs 5a. However, the burrs 5a can be generated only between the edges 12a and 13a of the seal belts 12 and 13, and are not generated in other portions. It is to be noted that air is evacuated from the molding passage 17 from the edges 12a and 13a of the seal belts 12 and 13 at the same time.

The burrs 5a are scraped off (or cut off) by the deburring cutter 15 while being conveyed on the belt conveyor 14, and formed into a final shape. Since the position at which the burrs 5a occur is constant as described above, the deburring cutter 15 may be as simple as simply pressing a knife-shaped edge against the upper surface of the molded article 5.

[0030]

As described above, the molding apparatus according to the present invention rotates a plurality of belt-shaped members in a molding passage formed by fitting another molding die to be paired with one molding die. A pair of driven belt-like members are provided so as to be drivable and cover the inner surface of the molding passage, and further follow the inside of the molding passage of the belt-like member and co-rotate, so that leakage of resin liquid does not occur in the molding passage. There is an effect that good products can be continuously obtained without hindering the operation of the molding apparatus. In addition, since the edges of these driven belt-shaped members are sandwiched between the fitting portions of the molding die, the portions where burrs may be formed on the molded product are limited between the edges of the driven belt-shaped members sandwiched between the molding dies. This eliminates burrs on the molded product at any point in the molding path, simplifies the design of belt-like bodies that had strict standards for preventing burrs, and reduces the equipment configuration to the same type of conventional molding equipment. Compared to this, there is an effect that the device can be made very simple and inexpensive, and since the process for deburring is simple, the device configuration for the post-process can also be simplified.

[Brief description of the drawings]

FIG. 1 is a perspective view conceptually showing a molding apparatus according to an embodiment of the present invention.

FIG. 2 is a side view of the same.

FIG. 3 is a plan view of the same.

FIG. 4 is an enlarged sectional view showing a configuration of a forming passage.

FIG. 5 is an enlarged sectional view showing the structure of the seal belt.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Foam curable resin liquid 2 Nozzle 3 Glass continuous strand mat (glass mat) 4 Molding material 5 Molded body 5a Burr 6 Lower mold 7 Upper mold 8-11 Steel belt 12,13 Seal belt 12a, 13a Seal belt Edge 14 Belt conveyor 15 Deburring cutter 16 Lower mold groove 17 Molding passage 18 Clearance between lower mold and upper mold 19, 20 Roller 21 First layer material 22 Second layer material 23 Break

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification symbol FI B29L 7:00 31:10 (72) Inventor Yoho Tozaki 1-1-18-1, Sakaemachi Nishiarai, Adachi-ku, Tokyo Nisshin Boseki Co., Ltd. Tokyo in the factory

Claims (7)

[Claims] 1. A molding material having a desired sectional shape is charged into a molding passage having a desired cross-sectional shape. The molded material having a sectional shape corresponding to the sectional shape of the molding passage is moved while moving in the molding passage. A molding apparatus having a groove-shaped first molding die having at least one surface opened along a moving direction of the molding material input side, the molding body discharge side, the molding material, and the molding body moving direction; A second mold for loosely fitting at least a part of the first mold in the first mold through the opening of the one surface of the first mold to define the molding passage;
A molding die, at least one first belt-shaped member movable along the inner surface of the first molding die in the molding passage, and a surface of the second molding die facing the molding passage. At least one second belt-shaped body that can be driven to move along;
A first belt-shaped body is interposed between the first belt and the first mold so as to be movable along the inner surface of the first mold with the movement of the first belt. 1 between the driven belt-like body and the second mold so as to be movable along the surface of the second mold facing the inside of the molding passage as the second belt-like body moves. A second driven belt-shaped body disposed so as to sandwich the second belt-shaped body, and a pair of edges of the first driven belt-shaped body and the second driven belt-shaped body is formed by the second driven belt-shaped body. A molding apparatus characterized in that it is sandwiched between the first and second molding dies at a portion where the second molding die is fitted to the first molding die. 2. The hollow inner shape of the first molding die is a square tube, and the first belt-shaped member is arranged on each surface except for the open surface of the hollow inside of the rectangular tube. The first driven belt-shaped member can be bent into a groove shape corresponding to the internal shape of the first molding die, and the second driven belt-shaped member can be bent into the first molding die. 2. The molding apparatus according to claim 1, wherein said second molding die can be bent into a groove shape corresponding to a shape of a fitting portion of said second molding die. 3. A sectional shape of the first mold is a rectangular groove, and at least a portion of the second belt-like body to be fitted to the first mold has a rectangular sectional shape. The inside of the hollow formed by the first and second molds is a rectangular tube, and the first belt-like body is formed along each of three surfaces of the first mold except for the one open surface. The first driven belt-like body can be bent into a rectangular groove shape corresponding to the cross-sectional shape of the first forming die, and
The driven belt-shaped body of (1) is bendable into a rectangular groove shape corresponding to a shape of a fitting portion of the second molding die to the first molding die. apparatus. 4. The first and second belt-shaped members and the first and second driven belt-shaped members are individually wound around in an endless manner, and the first and second belt-shaped members are rotated. The molding apparatus according to any one of claims 1 to 3, wherein the first and second driven belt-shaped members are driven to rotate together with the first and second belt-shaped members. 5. The resin according to claim 1, wherein the material to be molded is liquid at first, and is formed by attaching the resin to a resin alone or a fiber aggregate which expands and cures in the molding passage, or a filler or a short fiber in the resin. And the like, and the first and second
Has a desired mechanical strength, and the first and second driven belts have a releasing property from the resin cured body and the composite cured body thereof and a sealing property with respect to the resin liquid. The molding apparatus according to any one of claims 1 to 4, wherein: 6. A fold is provided at least along the moving direction of the first driven belt-like body so that it can be bent in the forming passage corresponding to a cross-sectional shape of the first forming die. The molding apparatus according to any one of claims 2 to 5, wherein 7. A method according to claim 1, wherein at least a portion of the first and second driven belt-like bodies, which forms a surface to be brought into contact with the material to be molded, is impregnated with a fluorine-based resin. Any of the molding equipment.