JPS61501502A - Method and apparatus for manufacturing articles from foamed thermoplastic materials - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] Name: Method for manufacturing articles from foamed thermoplastic materials and the present invention The present invention relates to a method and apparatus for manufacturing a product.

The applicant has previously reported, for example, polysulfone, polyether sulfone, polycarbonate We have proposed the production of foamed thermoplastic materials such as carbonate, etc. The polymeric material is immersed in a suitable solvent or partial solvent such as acetone, butanone, and then ignited. Heat the foamed thermoplastic material by placing it in a mold after adding foaming agents, fillers, etc. forming the preceding material; The preceding material is heated and pressurized in the mold, forming the preceding mold ( It is also free to form preliminary formwork.

This preliminary mold is then heated to completion in a mold, for example in an air-circulating furnace or in a fluidized bed. form a product.

Several methods are known for manufacturing articles of laminated (sandinch) construction. Typically , these methods do not require adhesion of other thermoplastic layers, e.g. fiber-reinforced resin plates. This involves the production of a foamed "core" material that is bonded to the core. Such a laminated structure In the usual manufacturing method, the central core and the layers attached to it are molded into side pieces. Then, put all the parts together and put them into another mold to make it into one piece. This issue The aim of the present invention is to provide a method for manufacturing laminated structures, which has advantages compared to known methods. reduces time and forming costs, and requires substantially fewer tools than previously possible. It can be made so that

Furthermore, in the disclosure of the earlier application (UK Patent Specification Letter 2,083°045), the internal structure was A foamed thermoplastic consisting of cells that are qualitatively regularly arranged and of uniform size. A basket for producing plastic materials is described. Depending on the situation, the inside of the thermoplastic finished product may It is preferable for the cell structure to have regular but non-spherical cells lined up. So to speak, sometimes the cells in a foamed thermoplastic article are smaller in size in one direction than in the other two directions. It may be desirable for the two directions to be larger or each to be longer than the third direction. .

Another object of this invention is to obtain a method for achieving such a desired result. .

According to one aspect of the invention, foaming heat is applied in a mold having a first portion and a second portion. Provided is a molding method for manufacturing a plastic material, wherein a third part is provided between the first part and the second part. The material to be molded is transferred between the first part and the third part and between the third part. the second part and then molding the material into at least two separate molded articles. Manufacture.

The third part described above can include multiple parts, and the material to be molded can be They can be placed between adjacent parts to produce more than one article in a single molding operation.

The method further includes the following steps: the first step is to bond two fiber-reinforced thermoplastic layers. <Si, in the second stage, remove the third part and use the mold without the third part. In the third stage, the above two fiber supplements are used instead of the third part. Place the thermoplastic precursor mold in the mold between the strong thermoplastic articles, and the purpose is to composite, laminate It involves molding and making shaped articles.

According to a second aspect of the invention, a molding method for manufacturing an article of foamed thermoplastic material The precursor material or mold is placed in a mold and held under pressure, during which time the mold is Molded articles of foamed thermoplastic material are produced by heating and virtually instantaneous release of pressure. The bubble structure extends in either direction.

According to another aspect of the invention, a mold is provided for use in the above method. There is. The first part is the cavity body, and the second part is the core material or the pushing part. , the third part is interposed between the first part and the second part, and the third part is for replacement of the core part. It is a material. This third part consists of a plurality of members and is a foam article of the same or different shape. is formed to manufacture.゛ According to yet another aspect of the invention, a pressure membrane unit device used in the molding process is provided. and incorporating a body having a membrane of elastomeric material on one side thereof. child The main body has a passage leading to the back side of the membrane, through which hydraulic and/or pneumatic pressure can be applied. It passes through the membrane and is applied to the membrane. This membrane is attached to the above surface of the main body by a gripping plate. Retained, this plate forms part of the cavity body. If there is a spacer, there is a protruding part. The membrane device and the cavity body are both molded. It makes up the type.

What this application proposes here is not only to overcome the wholesaler point recognized in the conventional method. A method for producing molded articles that allows control of the direction and structure of the bubbles in the finished article. It is.

In this proposed method, the material is heated to a predetermined temperature for a predetermined period of time, and During this period, heating (or reaction) generates volatiles/gaseous bodies that are liberated and Other reactions such as bridges, polymerization or complexation also occur. For these elements, ↓“C advanced materials” The heating temperature and duration are mainly determined. Other factors include free volatiles/ This may include the glass transition temperature of the materials used, such as the vapor pressure of the gaseous body. Preliminary materials are directly in a predetermined space that is filled when subjected to pressure (closing pressure) or when the preceding material expands sometimes left behind.

A synthetic layer or a covering layer (skin) can be added to the precursor material, and the skin is a solvent and a skin. / or using a solution or mixture of polymeric materials to create a sticky adhesive coated on both sides with adhesive. I do things. Alternatively, the skins may be manufactured separately and added later in the second stage of the process. It may also be applied.

The temperature applied to the surface of the precursor is important. This temperature should be the same on the opposite side, or it should be different. It shall be assumed that In the latter case, a predetermined temperature difference is applied to the preceding material to create the desired finished product. make the characteristics of

Gradually and periodically (MJ, pressurize, release, pressurize in a predetermined cycle) In addition, the final pressure will be maintained longer. general Generally, pressure is applied evenly, but different pressure ranges are applied to give desired changes in characteristics. You can create one.

The pressure is released by hitting at a predetermined speed to cause the product to expand.

The boundaries of a limited space are left open to a predetermined size, and the required exact shape and shape are Try to get the thickness.

During expansion, bubble size can be controlled in one direction (or substantially one direction) or in two directions. You can adopt general techniques including:

For convenience, a method involving "substantially unidirectional" cell expansion will be briefly described.

In this method, the two main surfaces of the foaming mold as described above are, for example, a metal mold. It is formed from a molded structure.

One or both of the walls can be made of elastic material, which also has a predetermined shape. , a material that assumes a predetermined shape when pressurized may be used.

The preliminary material is placed in the mold described above and pressurized, for example by pneumatic or liquid pressure. advance The material can be heated, for example, by hot air, by a membrane which itself contains a thermally conductive heating element, or by When hydraulic pressure is used, the hydraulic fluid is heated. When using elastic membranes The main reason for this is that the membrane can be stretched to the required strain and still have very little "permanent strain." Also, even if there is any unevenness in the preceding material, it only smooths it out. It must be hard.

The above technology uses a die and an extension to allow the material to expand only in the desired direction. It can also be applied to extrusion molding methods in which die shapes are arranged.

These technologies are used to create molded foams such as air ducts and radomes with complex shapes. Applicable to the manufacturing of products.

A specific example of this invention will be explained based on the attached drawings.

FIG. 1 is a very schematic cross-sectional view of the first mold of the present invention, and FIG. A cross-sectional view of a molded element, FIG. 3, made using a mold similar to that of FIG. An explanatory diagram of the elements of Figure 4 is an explanatory diagram of the use of the mold shown in Figure 1 when making a composite laminated structure; FIG. 5 shows the present invention which specifically forms a foam core with cells having a predetermined structure. A specific example of the type shown in FIG. 6 is a schematic explanatory diagram of the pressure membrane device of the present invention, and FIG. Fig. 8 is a sectional view of a specific example of the part of the present invention; Fig. 9 is an explanatory diagram of an injection molding tool for forming the part shown in FIG. 8; FIG. 10 is an explanatory diagram of a blow molding tool for forming a part as shown in FIG. 1] The figure is an explanatory diagram of the apparatus as shown in Fig. 6, and Figure 12 is an explanatory diagram of the molding technology using the device shown in Figure 11. At 8° Conventionally known molding techniques can be divided into three main groups determined by the mold that is the manufactured part. It can be considered separately.

(i) For flat laminates with a certain thickness Gi) for molded solid laminates of constant or varying thickness; (iii) for constant wall thickness; For laminates with or with varying cores The first category uses the simplest type of pressure mold, which is expensive to make and maintain. It doesn't cost. Generally, the mold is made of two stainless steel face plates and the fastening is done by a chaser on the frame. It consists of a ring. In use, the board or other material to be molded is into the chase ring on one faceplate, then place the other faceplate on top of it. Ku. The molds thus assembled are placed into the platen plate of a press machine and molded. chase ・The ring is thinner than the required thickness of the final sheet material, and excess molding material is chased. "spills out" from the gap between the ring and the top plate. This very simple molding method is a press It relies on the machine's platen plate being precisely flat and hand-hammered.

The second category uses a semi-positive or "positive flush" type. child In this mold, the material is placed in one and a half mold cavities of the mold. Form half of the other mold Molding is performed by pressing the pushing part into the mold cavity. The opposing surfaces of the mold cavity are To make articles of constant thickness, make articles of similar shape and of varying thickness. Make it a different shape. The mold cavity contains a considerable amount of molding material before pressurization. Therefore, multiple films (layers) of thermoplastic material within the mold can be accepted. (in between the impregnated fiber layers of the fcl'i polymer material) Suitable for bulky "film stacking" methods. Close the mold and place a bath between the two halves of the mold. If there is excess molding material, it will overflow and cause a "pinch flare". Go to the falling part of "Shush". Small molds are heated with a heated press platen and then cooled. by natural cooling or cooling means such as cooling passages in the press platen. in a large mold have built-in heating and cooling equipment.

In the third category, semi-positive cored Contains the type of "Sh". These molds are made of It is similar to the semi-positive type described above.

Various types of presses are used to press the mold.

For example, there are downward pressurization, upward pressurization, tilt type presses, and transmission type presses. Press machine is hydraulic This type of device is generally well known, so there is no further explanation. Does not require clarity.

The following description describes a method using a mold, which is unknown in the prior art, as described above. Talk about the manufacturing method.

FIG. 1 shows a mold embodying the present invention, and below, [Replaceable core mold J] (5ubstitue Core Mold). This kind of mold "Multi-Plate J (Multi-Plate) Pressure mold (However, it is used in injection molding. Term multi-impression mold should not be confused with ) may also be called.

The mold shown in FIG. 1 includes a first mold part, a second mold part, and a replacement core material. The first mold part 10 is a mold It is a cavity body whose surface matches the shape of the outer surface of the first part 12 to be molded. It is formed in parallel. The second mold part 14 is a core mold, and its surface is the second part to be molded. It is formed to match the shape of the inner surface of the component 16. The replacement stone 18 is the element part 12 and 16, and has a shape on the inner surface of the outer element 12 and the inner element 16, respectively. It is formed by matching the shape. The first mold part 10 is located on a fixed press plate 22 It is placed on the back plate 20 of the cavity body. The second mold part 14 of the core mold body is an upper plate. 24, which in turn supports a movable press platen 28. It supports the material 26.

The outer edges of the cavity body 10, the replacement core 18 and the core mold body 14 are connected to the elements 12 as shown. and 16, respectively, "core material σ [extracting hooks"] 30 and 32 were created. There is.

A ring-shaped body 34 serving as a backing is provided as shown. Other parts of the mold ( (ejector pins, striker plates, cooling/heating means, fixtures, etc.) are of known shape. , and are not shown for brevity.

In order to form the two elements 12 and 14 in one molding process, material is placed on the surface of the cavity body 10. If you place the replacement core material 18 in the fixed position, Fix it. The material forming element 16 is placed on the exposed surface of replacement core 18 to a predetermined thickness. Make it. The core body 14 is then placed in place and fixed if necessary. Position the upper plate 24 When the mold is finished, the movable platen is lowered and supported on top of the mold. Money The mold is heated (by an internal heater (not shown)) and the pressure is maintained by a press machine. . When enough time has elapsed, turn off the heater and let the mold cool (or let it cool). Meanwhile, the pressure is maintained. After cooling, the platen 28 is removed and the mold is opened. Next, the main point For example, using a protruding bottle (not shown) to remove the blanks 12 and 16 (along with the replacement core material 18) Take it out.

The core body 14 may be permanently attached to the upper movable press platen. Kya The bitty body and ejection device may also be permanently attached to the fixed base of the press, and if If the cavity body needs to be retractable, for example to facilitate the loading of material, a fixture can be used. You can also attach it by placing it on it.

FIG. 2 illustrates the elements produced by the mold of FIG.

The mold shown in Figure 1 allows for the simultaneous production of two elements (elements 12 and 16). This results in significant processing and cooling time savings compared to known molding techniques. It can be understood. Formation surface shapes of cavity body 10, core body 14, and replacement 1 core material 18 By changing I see that it is possible. In addition, by preparing multiple replacement core materials, it is possible to It is also understood that more than two elements can be manufactured simultaneously, as shown in Figure 3D. Ru.

Elements made with a mold similar to the first one are the foam core rA in combination with the preceding mold. A composite structure of J sandwich laminates can be manufactured.

In such technology, a precursor mold for the core is manufactured using the mold shown in Figure 1. If the final product requires special characteristics, it can be manufactured using a mold as described below. It will be done.

The same mold can then be used to form the final laminated composite structure.

Manufacturing a precursor mold using the mold of FIG. 1 requires some modifications to the mold.

That is, the ejector is changed.

The process below should look like this: A crepe tip mold is placed into the cavity body 10, and the core mold body 14 is positioned. warm Raise the degree. The amount needed to release the movable platen and create a foam core of uniform thickness. only to retreat. After that, the temperature of the mold is further raised to reach the foaming temperature and foaming is completed. maintain that temperature for a sufficient period of time.

Next, the mold is allowed to cool down (or cooled down), and then the press platen 28 is raised. Open the mold and take out the foam core.

Figure 4 shows a composite laminated structure using the mold shown in Figure 1 and the core made by the above method. It is an explanatory view used for manufacturing a body. Replacement core material 18 is replaced with foam core material 40 It can be seen that it is. The method for forming this complex is substantially explained with reference to FIG. It's the same as what I did. First, the template 12 of Gai Liu's skin is positioned. Foam core material 4 0 into the mold. Position the inner skin template 16 and position the core mold body 14. Place it. The molding process is then continued in the same way as described above to produce the composite structure. Ru.

A separate method for forming the foam core material will be explained based on Fig. 5. It is possible to produce foams with specific properties.

This type of mold is for the production of specific foams and has evolved from its crepe predecessor. It is suitable for increasing the width, width and thickness of the finished foam.

In the mold shown in FIG. 5, a clamping frame 60 is positioned between opposing plates 62 and 64.

Plate 62 is attached to a stationary platen 66 of the press, and plate 64, when in use, It supports the movable platen 68 of the press. A free pressure plate 70 is installed as shown. I'm being kicked. The fixing plate 72 connects the opposing plate 64 to the extension 74 of the clamping frame as shown. It's set. A projecting pin 76 and a coil spring stop 78 are provided.

When the protruding plate 80 and the rod material 82 operate, the free plate 70 and the foam core material are lifted out of the mold. to complete the molding process.

During the work, place the leading mold of the crepe into the clamping frame 60 between the facing plates 62 and 64. and close the press. Heat platens 66 and 68 and apply pressure for a minimum of 5 minutes. Ru. When the press is suddenly opened, the crepe expands past the clamping ring 60. Rin The inner wall surface of the cage 60 is finished at an angle of 25 degrees, for example, to provide resistance to the expanding foam. Minimize resistance.

This molding technique gives the expanded foam constraint and dimensional stability and consistency) during expansion. The surface of the foam minimizes resistance to movement.

This method describes other methods of forming composite articles using a single semi-positive pressure mold. Here, it can be used in a method called "equilibrium molding."

This method uses a pneumatic/hydraulic press as an auxiliary pressure membrane device.

In this method, skins 12 and 16 are manufactured as described above. At this time, the first The core body 14 of the mold shown is replaced by a membrane device as shown schematically in FIG. No. The apparatus of FIG. It is supplied to the next vacant room 104. The second seal elastic membrane 108 is installed as shown. It is.

The pipe 102 is connected to a reservoir 110 of hydraulic fluid, which includes a pump 112, a pressure gauge 114, and an air reservoir. 116, shutoff valve 118, check valve 120, pressure regulator 122 and relief valve 124 A conduit containing the pipe is formed as shown in the figure.

The skin elements 12 and 16 are placed within the cavity body 10 and the pressure membrane device is placed in the mounting position. (See Figure 7). Then from the supply 0138 in the loading ring 140 the hollow The spherical powder is injected to fill the cavity 130. Due to the operation of pump 112, Apply slight pressure to stretch the membrane and create a semi-rigid core. pressure cover 142 To install, close the press and position it in the molding position.

Apply full pressure to the "pressure membrane" to pressurize the hollow sphere powder and sinter it inside the outer skin 12 let

Next, the pressure from the pressure membrane device is released and the press is opened.

To build a composite structure in this way, the skins for the inner and outer parts are based on Figure 1. The product is prepared as described above and then processed as follows.

The inner surface of skin element 12 and the outer surface of skin element 16 are coated with acetone and a polymeric material. Apply with a concentrated solution of This ensures a good bond between these skins and the foam core material. This creates a concentrated contact surface of polymer with a good adhesion pool. Molded core drawer hook 30 and 32 are removed from elements 12 and 16.

Elements 12 and 16 are replaced in the mold with a replacement core 18.

Close the mold and heat to about 150°C to evaporate the acetone from the coating and dry. Love Once the material has dried, open the mold and remove both elements.

The pressure membrane device is replaced with the core body 14. Remove the loading ring 140 and remove the skin element. Put 12 and 16 into the mold.

The mold is partially closed and heated to 325°C to 350°C. Then, close the mold completely and cool it. to dismiss.

It is possible to manufacture complex structures such as the parts shown in Figure 8 using the above-mentioned technology. Understand the properties of certain thermoplastic materials on the outer surface and the central core of laminates and foams. It is possible to create products with mechanical advantages such as

The part shown in FIG. 8 has a core 160 of expanded foam or pressure-molded laminate; Formed according to any method described above, the outer skin 162 may be injection molded. has been completed.

The manufacture of this part was accomplished as follows, first building the core using the technique described above. Ru. The core body 160 is then used as an insert in an injection mold, and the injection molding process Complete it as a part.

FIG. 9 shows a core 160 placed in parts 164, 165 and 166 of an injection mold. 1, into which the injected polymeric material is introduced from an injector 168.

FIG. 10 shows foam extruder 17 in extruder 174 into extruded outer skin 172. Demonstrates how to make complex shapes by blow molding a core 160 from scratch. are doing. In Figure 10, (8) shows both the molding tool before the core 160 is blown, and (■) the molding tool after the core 160 is blown. It shows.

This special technology combines the use of a "blow molding machine" and a "foam extruder".

First, the external surface 172 of the part is extruded into the empty "half hole" of the mold. Next, this mold “ Close the "half-break" (pinch the extruded skin) and apply it to the nozzle of the foam extrusion tool 170. Activate the extrusion tool. Expanding foam from the extrusion tool 170 causes the skin 172 to form on the mold surface. to create a part filled with the required foam.

Research conducted by the applicant indicates that the most effective molding of foamed articles of thermoplastic materials requires It was found that the first crepe needed to be evenly pressurized during heating/foaming. child For this reason, this study of flat-impact pressure molding using the pneumatic/hydraulic membrane device described above. Consider the proposal favorable. See Figures 11 and 12 for equipment using this technique. and explain.

FIG. 11 is a diagram schematically illustrating a hydraulic pressurized mold device including a cavity body 200. The surface of the cavity body can be shaped to obtain the desired shape of the article to be manufactured. be.

This cavity body receives a pressure membrane device 202 that is supplied with pressure fluid via a conduit 204. It will be done. The apparatus 202 includes a hydraulic heating chamber 206 within which electrical heating elements 208 There is.

Chamber 206 is connected to the back of membrane 210 by tube 212 . Membrane 2] 0 is the device 2020 is attached to the main body by an annular plate 214. Capity body 200 is provided with a spacer/protruding ring 216 as shown in the figure, and when in use, 214 is listed. This ring 216 includes an air vent plug 218. Canada A passage 220 serving as a passage for heat and/or cooling fluid is formed between the cavity body 200 and the device 2. It is provided on both of the main body 202 of 02.

The pipe line 204 is connected to a pressure liquid tank 226 via a check valve 222 and a pump 224. Ru. A branch pipe 228 is led to a cooling water tank 234 via a shutoff valve 230 and a withdrawal valve 232. The heated pressure liquid in this tank is cooled, and then (via the isolation valve 236) is released into the tank. 226. Relief valve 238 bypasses extraction valve 232 as shown are doing. A pressure gauge 240 is provided r6 as shown.

In this proposal, a relatively small mold can be an independent unit (with an appropriate fixing mechanism). The large mold is placed in an appropriate press machine for molding.

Molding using the apparatus of FIGS. 11 and 12 is carried out as follows; The device 202 is heated to below the operating temperature (eg 200°C) and the membrane 21 is heated for a sufficient period of time. 0 and pressure fluid at operating temperature. The cavity body 200 is heated to about 130°C. . Place the leading edge of the crepe made by any suitable method into the cavity body j, and place it into the mold. Close and tighten.

The fluid pressure is 14 (200 psi) (1,38 meganewtons/-), and the air vent is closed. 218 and heat the entire mold to 200°C.

When the mold reaches operating temperature, close the air vent valve and release the hydraulic pressure. The foam expands and the first Push membrane 210 back against the body of device 202 as shown in FIG. Then cool the mold. Cool (remove from cooling ring).

Due to this special form of mold, the above technology can produce regularly deformed bubbles. It turns out that it is suitable for obtaining a foam with a structure.

Although the above is supposed to be operated using hydraulic pressure, the membrane device may also be operated using pneumatic pressure. I can understand that.

It turns out that this hydraulic/pneumatic pressurized membrane device can also be used in "normal" molding techniques. Ru. Furthermore, if this membrane device is heated to one temperature and the cavity body is heated to another temperature, By molding the foamed material with a temperature difference on both sides of its cross section, the characteristics of the material can be It is understood that it is also possible to change gender.

In order to manufacture high-quality molded products, the manufacturing molds should be made of high-quality, for example, mold-grade tool steel. construction, dimensional stability and reliability at the required processing temperatures. It is essential. The surface of the mold is preferably smooth and, for example, plated with chrome. Mold The cavity must be finished to the correct dimensions to ensure good quality molding. There is.

Before any molding, apply a suitable mold release agent (e.g. polytetrafluoroethylene). It is desirable to create a permanent mold release film by baking it onto the surface of the molding tool. This is mold release It is obtained by spraying the agent onto the entire surface of the mold and the molding tool and heating it at an appropriate temperature for 3 hours.

During the molding process, the material inside the mold may scrape and remove a small portion of the release film. There is. Therefore, in order to maintain good mold release characteristics, the mold must be released on the mold surface during the molding process. It is best to apply a fresh coat of agent.

FIG, 2゜ Fl (3, 3A, FIG, 3B.

FIG.! ,.

FIG, 7° Submission of translation of written amendment (Article 184-7, Paragraph 1 of the Patent Act) November 13, 1985 Mr. Michibe Uga, Commissioner of the Patent Office 1. Display of patent application PCT/GB85100107 2. Name of the invention Method and apparatus for manufacturing articles from expanded thermoplastic materials 31. ! patent applicant Address: United Kingdom, OEX 85 TF, Oxford Share , Witney, Crowley Road, New Mill (no place) Name Yu Ichi, Earl, Smith (Technical Developments) Limited 4, Representative 〒100 5. Date of submission of amendment: October 21, 1985 6. Catalog of Appendix II The scope of the claims 1. A composition for producing a foamed thermoplastic material in a mold having a first part and a second part. A molding method, including the step of interposing a third part between the first part and the second part, The material to be molded is placed between the first part and the third part and between the third part and the second part, and then A method of forming at least two separate molded articles.

'2. ．． The method according to claim 1, wherein the third part is a frame made of a plurality of members. , the material to be molded is placed between adjacent parts of the above parts, and in a single molding operation. A molding method for manufacturing two or more articles.

3. By the method according to claim 2, two fiber-reinforced thermoplastic layers are attached to the outermost sides. Comb, remove the third part and heat using the mold without the third part. Thirdly, in place of the third part, the two fiber-reinforced heat Place a thermoplastic precursor in the mold between the plastic articles and create a composite, laminate article. A molding method that includes a step of molding and manufacturing.

4. According to claim 1 or 2, the third part is made of foamed thermoplastic material. The above-mentioned molding method is a molding method for manufacturing a composite laminate structure.

5. Place the preceding material or the preceding mold into the mold and hold it under pressure, during which time the mold is Molded articles of foamed thermoplastic material are produced by heating and virtually instantaneous release of pressure. fabricated to produce a foamed thermoplastic article in which the structure of the vacuoles is distorted. Type method.

61M is a type used in the method of any one of items 1 to 4 of the range, , a first portion which is a cavity body; and 1. Second part which is T5 body or perforation part and a third part interposed between the first and second parts, the third part being Mold that is the replacement core part.

7. A mold as set forth in claim 6, wherein the third portion is made of a plurality of members. A mold.

8. A type as claimed in claim 6 or 7, in which the third part or The surface of the member may be shaped to produce foam articles of the same or different shapes. The mold that has been made.

9. For use in the molding method set forth in any one of claims 1 to 6. pressure membrane device having a membrane of elastomeric material on one side thereof. The main body has a passage leading to the back side of the membrane, and has a hydraulic and/or or a membrane unit device through which air pressure is applied to the membrane.

10. A membrane device as claimed in claim 9, wherein the membrane is attached to the surface of the main body by a gripping plate. This plate is held in place by spacers or projecting ribs that form part of the cavity plate. The membrane device is designed to cooperate with the mating surface of the cavity body. Membrane unit device that makes up the mold.

11. A molding method as set forth in claim 5, comprising a molding method as set forth in claim 1O. A molding method that uses a mold.

1z Any one of claims 1 to 5, 10, and 11 A method of molding a foamable aromatic polymer material.

13. A foamed thermoplastic article produced according to claim 12.

14. Any one of claims 1 to 5, 1D, and 11 An article having a core of thermoplastic material manufactured by The outer skin is provided by injection molding, and the thermoplastic material is molded during the injection molding process. An article used as a core.

15. A molding method according to the claims above and substantially as herein described. .

16. A mold substantially as herein described with reference to the accompanying drawings.

international search report 1m□ae,,,lsa,'c'LzoGB 85100107violet-denmMl@ PaImuwl’clln+PN&per/Gn85100107ANN■To THE INTERNATIONAj, SEA only CHREP○RT 0NPat ant docu+nent Publication Patent fam ily Publication in 5earch date me+nbar(s) dateπaport

Claims (18)

[Claims] 1. A composition for producing a foamed thermoplastic material in a mold having a first part and a second part. A molding method, including the step of interposing a third part between the first part and the second part, The material to be molded is placed between the first part and the third part and between the third part and the second part, and then A method of forming at least two separate molded articles. 2. In the method according to claim 1, the third portion is composed of a plurality of members; The material to be molded is placed between adjacent parts of the above-mentioned parts, so that two or more parts can be molded in a single molding operation. A molding method used to produce the above article. 3. By the method according to claim 2, first two fiber-reinforced thermoplastic layers are applied. The third part is removed and the mold without the third part is used to make a thermoplastic. A plastic precedent mold is made, and thirdly, the above two fiber-reinforced thermoplastic parts are added in place of the third part. Place the thermoplastic precursor in the mold between the plastic articles and form a composite, laminate article. A molding method that includes the steps of shaping and manufacturing. 4. The method according to claim 1 or 2, wherein the third part is a foamed thermoplastic material. The above-mentioned molding method is a molding method for manufacturing a composite laminated structure. 5. The precursor material or mold is placed in the mold and held under pressure, during which time the mold is A molded article of foamed thermoplastic material is produced by heating and releasing pressure substantially instantaneously. Molding to produce a foamed thermoplastic article in which the structure of the air cells is deformed Method. 6. A mold used in the method according to any one of claims 1 to 4, , a first part which is a cavity body, and a second part which is a core body or a perforation part, a third part interposed between the first and second parts, the third part being replaceable; The mold is the core material. 7. The mold as claimed in claim 6, wherein the third portion is made of a plurality of members. mold. 8. A type as claimed in claim 6 or 7, wherein the third part or The surface of the member may be shaped to produce foam articles of the same or different shapes. The mold that is being made. 9. A pressure membrane device used in the molding process, on one side of which is coated with elastomer material. incorporating a main body having a membrane, the main body having a passage leading to the back side of the membrane; membrane unit through which hydraulic and/or pneumatic pressure is applied to the membrane Device. 10. In the membrane device as claimed in claim 9, the membrane is attached to the surface of the main body by a gripping plate. This plate is held together by spacers or projecting ribs that form part of the cavity plate. The membrane device and the cavity body are Membrane unit device that makes up the mold. 11. A molding method as set forth in claim 5, comprising a molding method as set forth in claim 9. A molding method that uses a membrane unit device as part of the mold. 12. A molding method as set forth in claim 5, comprising a molding method as set forth in claim 10. A molding method that uses a mold. 13. Any one of claims 1 to 5, 11, and 12 A method of molding a foamable aromatic polymer material. 14. A foamed thermoplastic article made according to claim 13. 15. Any one of claims 1 to 5, 11, and 12 An article having a core of a thermoplastic material manufactured by The outer skin is provided by injection molding, and the thermoplastic core article is provided with an outer skin by injection molding. Items used as a body. 16. An extruded external skin of synthetic resin or reinforced synthetic resin material and An article having a core formed by blow molding a thermoplastic material therein. 17. A molding method according to the claims above and substantially as herein described. . 18. A mold substantially as herein described with reference to the accompanying drawings.