JPS5833107B2 - Manufacturing equipment for synthetic resin foam moldings - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an apparatus for manufacturing a synthetic resin foam molded product having an uneven shape, which is formed by integrally bonding a skin material such as a vehicle interior decorative panel or a door panel.

Molded products, in which a decorative cover or the like is attached to a synthetic resin foam molded product with an uneven surface, are widely used in various fields. Conventionally, the method for manufacturing the above molded products is A skin material is added to the inside of the mold in advance, then a stock solution for foam formation is injected into the mold, and the mold is closed before the stock solution foams and overflows from the mold. In this method, the pressure of the polymerization reaction of the foaming stock solution was used to shape the foam into a certain shape that followed the shape of the mold, and at the same time, the skin material was integrally bonded to the foam layer.

Therefore, the molding apparatus including the mold and the mold moving device needs to have a structure that can withstand the polymerization pressure of the foaming stock solution, resulting in a problem that the equipment becomes large and the equipment cost increases.

Therefore, the synthetic resin foam molding solution is naturally foamed, and a skin material such as a stretchable textile fabric is bonded to the surface.
A method has been developed for integrally manufacturing a foam and a skin material by carrying this material into a mold and press-molding it.

By the way, when using the above method, it is necessary to carry out the process in two steps: the process of combining the foam and the skin material, and the molding process. Therefore, in the case of continuous mass production, polymerization of the foam layer by foaming of the stock solution is still difficult. It is required to efficiently perform the operations of assembling the skin material while the surface is incomplete and has adhesive properties, and then transporting the obtained material into a mold to produce a molded article.

The present invention provides an apparatus for continuously manufacturing the above-mentioned molded product, and includes a first rotary conveyor apparatus for carrying out the steps of injecting a stock solution into a mold and foaming it, and joining a skin material on the foamed layer; a second rotary conveyor device that performs a step of receiving the material obtained by the one-rotation conveyor device into a mold and shaping it into a predetermined shape, and a conveying device that transports the material between both conveyor devices; It is characterized by the fact that it is equipped with.

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

A plurality of formworks 2, 2... are arranged on the upper surface of the rotary table 1 as a first rotary conveyor device for molding the material,
A lining material or release material loading station A sets the lining material or release material 3 in the formwork 2 at a specific position on the periphery along the rotational movement direction; the lining material or release material 3 set in the formwork 2; Above is a stock solution supply station B that injects the foam forming stock solution from the nozzle 4 of the foaming machine.
, a skin material insertion station C that inserts the skin material 5 onto the foam layer a formed in the formwork 2 by foaming the stock solution, and a bonding of the foam layer a formed in the formwork 2 and the skin material 5. A carry-out station D is set up to carry out the finished material to a second conveyor device.

A material conveying device 6 is provided above the center of the rotary table 1, and includes a pressing plate 6A that faces the material unloading station D and transports the material together with the formwork outward.

In addition, a vacuum suction plate 8 connected to a vacuum pump 7 is installed in the skin material insertion station C so that it can be rotated by a swinging arm 9.
This shows an example in which the skin material 5 is attracted to the suction plate 8 and is supplied onto the formwork 2 located at the C station by the swinging movement of the swinging arm 9.

Note that the rotary table 1 is supported in a horizontal position on a rotary shaft 10, and the rotation of a prime mover (motor with brake) 12 is decelerated by a speed reducer 12A through a gear mechanism 11, and its rotational force is transmitted. The rotary table 1 is rotated by a fixed angle at each station by the rotational force of the prime mover 12.

A large number of molds 14, 14, . Eight stations have been set up.

In other words, the E position is the material loading station, the adjacent F position is the mold pressurization and mold clamping station, the area following this to the <G- position is the ripening zone (cure zone), and the L position is the demolding station. It is a station.

Each mold 14 has an upper mold 14A and a lower mold 1 having unevenness on each mold surface.
The upper mold 14A is a combination mold with the lower mold 1.
A spring 15 is held movably up and down by a pair of posts 14C and 14c fixed to N4B, and is externally mounted on N4C.
The mold is urged upward by the pressure, and the mold is kept open at all times.

Further, each mold 14 is provided with a manual or automatic mold clamping clamp 16 for tightening the upper mold 14A and the lower mold 14B.

Further, as shown in FIG. 2, the rotary table 13 is supported horizontally by a rotary shaft 17 provided at its center of rotation, and the rotary shaft 17 is connected to a reducer 19 directly connected to a prime mover (motor with brake) 18. , are interlocked via a gear mechanism 20,
One drive of the prime mover 18 provides rotation feed by a fixed rotation angle for each station.

The mold pressurization and mold clamping station F includes a mold 1.
4, a cylinder device 21 is installed above the transfer line of the mold 13, and a press plate 21A connected to the rond of the cylinder device 21 is provided above the mold 14 so as to be movable up and down. be.

Further, an oven 22 equipped with a heating device is disposed on the conveyance line of the mold 2 over the entire range of the ripening zone G-.

Material loading station E on this rotary table 13
A roller conveyor 23 is installed between the front surface of the rotary table 1 and the material discharge station D of the rotary table 1 to connect the two rotary paper tables 1 and 13.

In Fig. 3, at position A of the rotary table 1, the lining material or release material 3 is set in the formwork 2 whose top is open, and then the rotary table 1 is rotated by a certain angle, and
At this point, a stock solution for molding a synthetic resin foam is injected from the nozzle 4 of the foaming machine, and is foamed on the backing material or mold release material 3 set in the mold 2.

Next, the formwork 2 is moved to position C, the skin material 5 adsorbed to the suction plate 8 by the drive of the pump 7 is moved above the formwork 2 by rotation of the swinging arm 9, and the drive of the pump 7 is stopped. Then, the skin material 5 is set on the foam layer a.

This formwork 2 is further moved to position D, the conveyance device 6 is driven, the formwork 2 formed inside the material is pushed out by the pressing plate 6A, and the material is removed from the formwork 2 on the roller conveyor 23. .

Next, in FIG. 4, the blank removed from the mold 2 is set on the lower mold 14B of the mold 14 at position E.

The rotary table 13 is fed intermittently at the same speed as the rotary table 1.

According to this feeding, the mold 14 is moved to position E.

At position F, the pressurizing cylinder device 21 placed above the mold 14 is driven to push down the suppressing plate 21A, and the upper mold 14A is pressed down against the pressing force of the spring 15, thereby creating a space between the molds 14A and 14B. Press the material with the press.

Next, operate the clamp 16 to remove the upper and lower molds 14A.

Tighten 14B.

The mold 14 is conveyed into the oven 22 from the G position while being clamped by the clamp 16, and the molds H, I, J,
It is aged during this period, and then sent out from the oven 22.

At the L position, the clamp 16 is removed, the upper mold 14A is opened, and the foam molded product M shaped into a predetermined uneven shape is taken out from the upper and lower molds 14A and 14B.

In the above examples, by using the suction plate,
Although the case where the skin material 5 is supplied onto the formwork 2 has been described, the skin material 5 may also be manually supplied into the formwork 2 without using this device.
Of course, it is also possible to feed the material from the rotary table 13 into the mold 14 manually.

Further, it is also possible to configure the mold clamp 16 for the upper mold 14A and the lower mold 14B of the mold 14 to synchronize with the vertical movement of the pressurizing cylinder device 21 to automatically clamp the molds.

Further, without using a clamp, the upper mold 14A is moved along a guide rail (path shown in the figure) arranged on the rotary table 13 in synchronization with the movement feed of the rotary table 13, and the upper mold 14A is moved upward along the guide rail. It is also possible to configure the mold 14A to be clamped and demolded by vertically displacing the mold 14A.

The number of molds set on the rotary table '13 is determined by the time it takes to move the formwork 2 between the two rotary tables 1 and 13.
Assuming that the aging time is 0 seconds and the aging time is 3 minutes, the number of molds in the oven 22 is 6, and the number at the material loading station E is 1.
One mold is placed at the mold, pressurization and mold clamping station F, and one mold is placed at the demolding station L. On the rotary table 1 in the material forming process, one mold is placed at the station A for carrying backing material or mold release material. Type 1 at synthetic resin foam forming stock solution supply station B, type 1 at skin material insertion station C,
A total of 4 types, including 1 type at material unloading station D, is optimal.

The materials and processing conditions used in the present invention are as follows.

(1) Outer material■ When using a stretchable knitted fabric, for example, cotton,
Knitted or woven fabrics made from cotton, nylon, acrylic, polyester, or the like can be used.

■ When using a synthetic resin foam or synthetic resin sheet laminated to a stretchable knitted fabric, for example, foamed polyvinyl chloride, polyethylene, polyurethane, etc., or a urethane-based synthetic resin sheet. There are thin flexible resin films such as film, polyolefin film, butadiene film, or vinyl chloride film.

(2) Backing material or mold release material Used to prevent adhesion between the foamed synthetic resin and the press mold during pressing or to reinforce the molded product. For example, as a backing material, use impregnated woven fabrics, non-woven fabrics, etc. that have been treated to prevent curing. Release materials include release paper, polyethylene film, and the like.

(3) Synthetic resin foam A rigid or semi-rigid foam is used for vehicle interior decoration panels, door panels, etc., and a soft or semi-rigid foam is used for vehicle or furniture cushions.

For example, synthetic resin foams such as polyvinyl chloride, polyethylene, and polyurethane are used, but in the case of cushions, soft or semi-rigid polyurethane with open cells is preferred.

In the case of interior decorative panels for vehicles, rigid or semi-rigid polyurethane is preferred.

(4) Oven temperature: 40° to 220°C (5) Mold Female and male molds, female molds and flat plate molds, or female molds and female molds are also possible.

A small through hole may be made in the design surface of the female mold to improve air release during pressure molding.

(6) Pressure molding time Hard (10 to 60 seconds depending on foam composition) Soft 1 to 10 minutes varies.

(7) Molding pressure o, i ~ 1k19/7 As described above, in the present invention, the foam layer a and the skin material 5 are formed in the formwork 2.
The step of laminating the materials to form a raw material is carried out on the rotary table 1, and then this raw material is transferred into the mold 14 on the rotary table 13 for pressurization, mold clamping and aging,
A molded article M shaped into a predetermined shape is obtained, and by regulating the rotational speed of each rotary table 1.degree. 13, a uniform molded article shaped into a fixed shape can be continuously obtained.

In the present invention, since the stock solution is pressurized and molded in the mold 14 after spontaneously foaming, the polymerization pressure of the foaming stock solution is not applied to the mold 14, and the structure of the mold is simplified and compact equipment is required. This has the effect of automating the work process and efficiently producing synthetic resin foam molded products.

[Brief Description of the Drawings] Figure 1 is a plan view showing an embodiment of the apparatus of the present invention, Figure 2 is a sectional view taken along the line ■-■ in Figure 1, and Figure 3 is an explanatory diagram of the material forming process. , FIG. 4 is an explanatory diagram of the molding process of the molded article within the mold. 1...Rotary table, 2...Formwork, 5
...Skin material, 13...Rotary table,
14A...Top mold, 14B...Bottom mold, A
...Backing material or mold release material delivery station, B...Still solution supply station, C...
・Skin material insertion station, D...Material unloading station, E...Material loading station, F
・・・・・・Mold pressurization and mold clamping station, G
~K...Aging zone, L...Demolding station, M...--Foamed molded product, a...
Foam layer, b...Material.

Claims (1)

[Scope of Claims] 1. While rotating the mold in one direction, a stock solution for forming a foam is sequentially supplied into the mold to cause it to foam naturally, and a skin material is inserted on the upper surface of the foam to form the mold. It is equipped with a first rotary table that molds the molding material within the frame, and a number of molds that receive the materials obtained in the mold frame during the molding process on the first rotary table, and the molds are rotated during rotation and feeding. An apparatus for producing a synthetic resin foam molded product, which is combined with a second rotary table that sequentially performs a pressurizing and mold clamping process, a maturing process, and a demolding process. 2. A station for carrying backing material or release material into the formwork, a station for supplying stock solution for foam formation, a station for inserting skin material, and a station for carrying out material are set along the feed movement direction of the first rotary table, and the second rotary table A patent in which a material loading station, a mold pressurization and clamping station, a maturing zone, and a demolding station are set up in the two rotary tables, and a material conveying device is installed between the material loading station and the material loading station of both rotary tables. An apparatus for producing a synthetic resin foam molded product according to claim 1.