KR20150081684A - Molding method for foamed resin, and foamed panel produced by using the same - Google Patents

Abstract

A method for forming a foamed resin is provided. The method for forming a foamed resin according to one embodiment of the present invention comprises: a step of arranging a reinforcement unit for reinforcing a strength of a molded body in a mold space of a mold unit wherein the mold space for a molded body is provided by a plurality of molds capable of moving with respect to each other such that a foamed resin is provided and a molded body is formed; a step of filling the mold space by a foamed resin supply unit supplying a foamed resin to the mold space wherein the foamed resin supply unit is connected to the mold unit; a step of heating a foamed resin by a steam supply unit supplying steam to the mold space and then replacing the air between foamed resins with steam; a step of a cooling unit, which is connected to the mold unit, cooling a molded body molded in the mold space; and a step of separating a molded body embedded with the reinforcement unit from the mold space by separating the molds.

Description

TECHNICAL FIELD [0001] The present invention relates to a foam resin molding method and a foamed resin panel manufactured using the same,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed resin molding method and a foamed resin panel manufactured using the foamed resin mold. More specifically, the present invention relates to a foamed resin molded article which can be foamed by injecting foamed resin particles into a mold together with air, And a foamed resin panel manufactured using the same.

In general, foaming resins are easy to shape, light in weight, able to absorb impact, and are mainly used as packaging materials for food materials and electronic products. The foaming resin is injected into a mold having a molding space of a package shape, and is made into a desired molded article.

Fig. 9 shows a foamed resin molding apparatus capable of producing a molded article using a foamed resin. This foamed resin molding apparatus is concretely a fixed side die plate 1 to which a back plate 3 and a frame 5 are coupled.

In the frame 5, a recessed die is attached through the center plate 71. [ The back plate 3, the frame 5, the center plate 71, and the concave die 7 together constitute the steam chamber 9.

A raw material-filling machine 11 and an ejector pin 12 are installed in the back plate 3 from the rear side thereof to the steam chamber 9. A cooling water inlet portion 13 and a steam inlet portion 15 are provided on the frame 5 and a cooling water pipe 17 is connected to the cooling water inlet portion 13.

The back plate 4 and the frame 6 are coupled to the movable die plate 2. A protruded die 8 is coupled to the frame 6 through a central plate 81. [ The back plate 4, the frame 5, the center plate 81, and the convex die 8 constitute the steam chamber 10 together.

The frame 6 is provided with a cooling water inlet portion 14 and a steam inlet portion 16 and a cooling water pipe 18 is connected to the cooling water inlet portion 14. The concave die 7 and the convex die 8 are aligned in a single unit to form a cavity 19.

In order to form a molded body by the conventional foamed resin molding apparatus as described above, the raw material composed of the foamed resin is first injected into the cavity 19 by using the raw material filling apparatus 11.

Next, the steam is introduced into the steam chamber 9 from the steam inlet portions 15 and 16 and the steam is supplied through the steam hole (not shown) drilled in the concave die 7 and the convex die 8 Into the cavity (19). The raw material heated by the steam is foamed and formed into a desired molded article. At this time, the dies 7, 8 and the frames 5, 6 are heated to a high temperature of about 120 占 폚.

Thereafter, the cooling water is supplied from the cooling water inlet portions 13 and 14 through the cooling water pipes 17 and 18. Cooling water is sprayed on the back surface of the concave die 7 and the convex die 8 through the nozzles 21 and 22 to cool the formed body 20 in the cavity 19. [ At this time, the dies 7, 8 and the frames 5, 6 are cooled to a low temperature of about 40 占 폚. After the cooling is completed, the concave die 7 and the convex die 8 are separated and opened, and then the molded body 20 is pushed out by using the ejector pin 12.

The foamed resin molding method using the conventional foamed resin molding apparatus can produce a molded article that can withstand a relatively light article such as agricultural and marine products and electronic products or withstand a small external impact, It was not sufficient to produce a molded body capable of withstanding the weight.

Korean Patent Application No. 10-2010-0044679

SUMMARY OF THE INVENTION Accordingly, the present invention has been made in view of the above problems, and it is an object of the present invention to provide a foamed resin molding method capable of producing a foamed resin molded article that can withstand a heavy weight than a conventional foamed resin molding apparatus and a foamed resin panel manufactured using the same.

According to one aspect of the present invention, the strength of the molded body is reinforced in the molding space of the mold unit in which the molding space of the foamed resin is provided by a plurality of dies that are relatively moved so that the foamed resin is supplied to form the molded body Disposing a reinforcement unit; Supplying the foamed resin to the molding space by the foamed resin supply unit connected to the mold unit to fill the molding space; Supplying steam to the molding space by a steam supply unit coupled to the mold unit, heating the foam resin, and replacing the air between the foam resin with steam; Cooling the formed body to be formed in the forming space by a cooling unit connected to the mold unit; And separating the plurality of molds and separating the molded body in which the reinforcing unit is embedded from the molding space.

The reinforcing unit includes: a reinforcing member embedded in the forming body to reinforce the forming body; And a spacing member provided on the reinforcing member to dispose the reinforcing member away from the mold.

The reinforcing member may be arranged in a zigzag or net shape.

Wherein at least one of the plurality of dies is provided with a nozzle for increasing a flow rate of the vapor so that the vapor is injected into the molding space, And a steam injection unit provided with a slit capable of shutting off the outflow of the steam.

Wherein the steam injection unit comprises: a steam nozzle block connected to the steam supply unit, wherein the steam nozzle block is provided with the nozzle; And a slit panel member coupled to the steam nozzle block, wherein the slit panel member is provided with slits connected to the nozzle.

According to still another aspect of the present invention, there can be provided a foamed resin panel manufactured using the above-described foamed resin molding method.

According to the present invention, there is provided a foamed resin molding method capable of producing a foamed resin molded article which can withstand a heavy weight than a conventional foamed resin molding method by insert-molding a reinforcing unit capable of reinforcing strength inside the foamed resin molded article, and A foamed resin panel can be produced.

1 is a cross-sectional view of a foamed resin molding apparatus according to an embodiment of the present invention.
2 is a perspective view of the stationary mold of FIG.
3 is a schematic cross-sectional view of the forming part of the stationary mold and the movable mold of FIG.
4 is a plan view showing a slit arrangement with respect to the forming portion of Fig.
FIG. 5 is a diagram showing a state of supplying steam to the mold unit of FIG. 1. FIG.
6 is a cooling state view of the mold unit of FIG.
7 is a state in which the molded body is separated from the mold unit shown in Fig.
Fig. 8 is a perspective view of the molded body of Fig. 7;
Fig. 9 is a cross-sectional view of a molding apparatus for a conventional foamed resin.

In order to fully understand the present invention, operational advantages of the present invention, and objects achieved by the practice of the present invention, reference should be made to the accompanying drawings and the accompanying drawings which illustrate preferred embodiments of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Like reference symbols in the drawings denote like elements.

Fig. 1 is a cross-sectional view of a foamed resin molding apparatus according to an embodiment of the present invention, Fig. 2 is a perspective view of the stationary mold of Fig. 1, and Fig. 3 is a schematic sectional view of a molding part of the stationary mold and the movable mold of Fig. Fig. 4 is a plan view showing a slit arrangement with respect to the forming unit of Fig. 3, Fig. 5 is a view of supplying steam to the mold unit of Fig. 1, Fig. 6 is a cooling state of the mold unit of Fig. 7 is a state in which the molded body is separated from the mold unit in Fig. 1, and Fig. 8 is a perspective view of the molded body in Fig.

As shown in FIGS. 1 and 5 to 7, a method for molding a foamed resin according to an embodiment of the present invention is a method for molding a foamed resin (f) The reinforcing unit 120 for reinforcing the strength of the molded body m is disposed in the molding space 112 of the mold unit 100 in which the molding space 112 of the foamed resin f is provided by the mold 101 of the mold 101 And supplying the foamed resin f to the molding space 112 by the foamed resin supply unit 140 connected to the mold unit 100 to fill the molding space 112; Supplying steam to the molding space 112 by a steam supply unit 150 coupled to the mold unit 100 to heat the foaming resin f and replacing the air between the foaming resins with steam, Cooling the molded body m to be molded in the molding space 112 by the cooling unit 160 that is provided in the molding space 112, And a step of separating the reinforcing unit 120 is a shaped body (m) implied from the forming space 112. The

According to the method for forming a foamed resin according to an embodiment of the present invention, since the reinforcing unit 120 capable of reinforcing strength to the inside of the formed body m made of the foamed resin can be insert-molded, It is possible to produce a molded article (m) capable of withstanding a weight greater than the method.

The foaming resin molding method according to one embodiment of the present invention described above is carried out in a foaming resin molding apparatus to be described later.

1 to 3, a foamed resin molding apparatus according to an embodiment of the present invention includes a plurality of molds 105 (a) to 105 A mold unit 100 provided with a molding space 112 for the foaming resin f by means of the molding space 112 and provided so that steam can be supplied into the molding space 112; A vapor supply unit 150 coupled to the mold unit 100 to supply the vapor to the molding space 112, and a mold supply unit 150 connected to the mold unit 100. [ And a cooling unit 160 disposed in the mold unit 100 to cool the molded body m to be molded in the space 112. [

The reinforcing unit 120 may be disposed on at least one of the plurality of dies 105 to reinforce the molded body m. That is, the molded body m may have the reinforcing unit 120 built in the molding space 112 at the time of molding. At this time, the reinforcing unit 120 is disposed in the molding space 112 before the foaming resin f is supplied to the molding space 112.

The reinforcing unit 120 according to the present embodiment includes a reinforcing member 121 which is embedded in the formed body m and reinforces the formed body m and a reinforcing member 121 which is provided on the reinforcing member 121, And a spacing member 122 arranged to be spaced apart from the spacer 107. These reinforcing members 121 may be arranged in a zigzag or net shape.

Since the reinforcing member 121 according to the present embodiment is supported by the spacing member 122 and is located in the middle of the molding space 112, the reinforcing member 121 is not exposed and is not exposed at the time of molding the molded body m, 122 may be disposed above and below the formed body m from the reinforcing member 121 to expose the upper end and the lower end.

At this time, the molded body m is made of a panel-shaped foamed resin panel as described later, so that the strength against bending and twisting is reinforced by the reinforcing member 121. Such a molded body m can be cut and used as a piece, since the reinforcing member 121 can be arranged evenly or zigzag, although it is not shown as a net or as described above.

As described above, the panel-shaped molded body m made only of the foamed resin (f) has a limited use because of its strength limit as compared with the advantage of being light in weight. However, the molded body (m) in which the reinforcing unit (120) The strength can be reinforced for bending and torsion and can be used sufficiently for applications that can support a table or a relatively heavy object.

The molded body m according to the present embodiment assumes mainly a panel shape, and the reinforcing unit 120 is arranged corresponding to almost all areas of the molded body m, so that the molded body m has a reinforced structure.

The reinforcing unit 120 can be used as long as it is a linear structure composed of a metal having a rigid structure, a non-metal material, or a composite material of a non-metal. Further, the foaming resin (f) is assumed to be beads of granules or particles formed by foaming the resin.

That is, the foaming resin (f) is a granule or a particle-shaped bead formed by foaming the resin. As the foaming resin (f), expanded polypropylene (EPP) can be used. EPP is a foam of white polypropylene which is generally white, has a closed cell structure, is lightweight, has a high impact resistance against external impact, is excellent in chemical resistance and heat resistance, and specifically, It can be realized as a product having various densities and compressive strengths.

1 to 7, the foamed resin f in relation to the fixed mold 107 and the movable mold 108 constituting the vapor nozzle block 103 and the slit panel member 105 according to the present embodiment, The main components of the foamed resin molding apparatus capable of molding the foamed resin are described in detail.

 1, 3, and 4, at least one of the plurality of dies 101 according to the present embodiment includes a nozzle 104 for increasing the flow rate of the vapor so that the vapor is injected into the molding space 112, And a steam injection unit 102 connected to the nozzle 104 and capable of spraying steam and provided with a slit 106 capable of blocking the outflow of the foaming resin f from the molding space 112 .

According to the steam injection unit 102 according to the present embodiment, the steam supplied to the steam supply unit 150 is firstly accelerated by the nozzle 104 and flows into the slit 106. The steam can be secondarily accelerated to be strongly injected into the molding space 112 from the slit 106 provided narrower than the nozzle 104, and the air between the foaming resins can be smoothly replaced with steam.

The steam injection unit 102 according to this embodiment includes a steam nozzle block 103 connected to the steam supply unit 150 and provided with a nozzle 104, And a slit panel member 105 provided with a slit 106 connected to the slit panel member 104.

At this time, not only can the vapor nozzle block 103 support the thin plate-shaped slit panel member 105 which is substantially in contact with the foaming resin f to receive the internal pressure so that the molding space 112 is maintained, (104) may be formed to provide high-pressure accelerated vapor to the slit panel member (105) side.

In addition, the slit panel member 105 can be configured such that the fine slits 106 are arranged in a mesh-like manner as described below so that the steam is evenly supplied into the molding space 112, It is possible to provide a processable thickness. That is, the nozzle 104 and the slit 106 may have a mesh or a lattice-like projection shape with respect to a plane. The slit 106 of the slit panel member 105 can be formed by micro laser processing.

That is, the steam nozzle block 103 and the slit panel member 105 can constitute the stationary mold 107 and the movable mold 108 as described later. Although not shown on the outside of the steam nozzle block 103, a base mold may be disposed to support the steam nozzle block 103.

Next, the mold unit 100 according to the present embodiment will be described with reference to FIG. The plurality of dies 105 of the mold unit 100 are fixed on the ground and include a stationary mold 107 in which the above-described reinforcing unit 120 is disposed, A mold 108 may be included.

The stationary mold 107 and the movable mold 108 are formed with a molding space 112 in which a nozzle 106 through which steam passes and a slit 111 are provided, And a steam chamber part 115 provided with an inlet and an outlet of steam for supplying steam to the steam space. The forming part 111 of the stationary mold 107 and the movable mold 108 according to the present embodiment may be formed of molds appropriately arranged according to the shape of the molding m.

The molding portion 111 of the movable mold 108 is pressed against the molding die 111 of the stationary mold 107 while the molding portion 111 of the stationary mold 107 and the molding portion 111 of the movable mold 108 are disposed opposite to each other. The molding space 112 of the formed body m is formed in the molding part 111 by being moved toward the side of the mold part 111 and merged with the molded parts 111. The foamed resin f Is filled to produce a molded body m.

The steam introduced into the steam chamber part 115 flows through the nozzle 104 and the slit 106 which can be arranged in a lattice form as described above The foamed resin f is heated and further expanded by flowing the air between the foaming resins to the outside of the molding part 111 while flowing into the molding part 111, And is firmly compressed and joined by mutual fusion while being expanded. Thus, the clearance between the foamed resin (f) is removed, and the strength of the molded article (m) produced from the foamed resin (f) can be improved.

The reinforcing unit 120 may be disposed in the forming part 111 of the stationary mold 107 before the foaming resin f is filled in the forming part 111. [

1, the foamed resin supply unit 140 capable of filling the foamed resin (f) into the molded part 111 of the stationary mold 107 and the movable mold 108 according to the present embodiment, A foam resin supply pipe 141 connected to the vapor chamber part 115 of the stationary mold 107 and connected to the forming part 111 and having venturi 142 disposed in the flow path of the foaming resin f, The storage container 145 of the foamed resin f connected to the foamed resin supply pipe 141 so that the resin f passes through the venturi 142 and the foamed resin f formed by the foamed resin f, And a compressor 146 that provides pressurized air to the venturi 142 to flow into the venturi 112.

In this foamed resin supply unit 140, the air pressurized by the compressor 146 is supplied to the foamed resin supply pipe 141 and passes through the venturi 142. At this time, in principle, the venturi 142 generates a vacuum pressure due to the pressure drop from the inlet side of the venturi 142 to the outlet side. By this vacuum pressure, the foaming resin (f) The resin (f) may flow into the forming part 111 together with the air passing through the venturi 142.

The venturi 142 may be provided with venturi holes 147 through which the pressurized air flows downstream to increase the flow rate of the foaming resin f passing through the venturi 142.

A flow path is provided between the foamed resin supply pipe 141 and the venturi 142 so that pressurized air flows from the compressor 146 and flows into the venturi hole 147. The pressurized air is supplied to the venturi hole 147 And flows through the venturi 142 to press the foaming resin f in the form of granules whose flow velocity has been lowered to increase the flow rate toward the forming part 111 side.

1 and 5, the steam supply unit 150 according to the present embodiment is connected to the inlet and outlet sides of the steam chamber part 115 of each of the stationary mold 107 and the movable mold 108 And a steam valve 152 for selectively opening and closing the steam pipe 151 and the steam pipe 151 connected to the steam chamber part 115 of the stationary mold 107 and the movable mold 108. [

The steam supply unit 150 is connected to the stationary mold 107 and the movable mold 108 so as to supply steam to the steam supply pipe 150. A steam valve 152 is installed in the steam pipe 151.

For example, the steam valve 152 may be opened such that steam passes through the stationary mold 107 and the movable mold 108, respectively. When the steam outflow side opening and closing valve 165 of the movable mold 108 is closed, the steam introduced into the movable mold 108 can be discharged to the outflow side of the stationary mold 107 side through the molding part 111, The opposite vapor flow is also possible.

At this time, the stationary mold 107 and the movable mold 108 can be heated to a high temperature of about 120 캜 by the steam. Some of the steam may flow into the molding space 112 formed by the combination of the stationary mold 107 and the movable mold 108 to directly heat the foam resin f.

That is, the steam can flow into the molding part 111 through the fixed mold 107 and the slits 106 of the movable mold 108 to heat and expand the charged foam resin f, The foaming resin (f) is bonded by heating and pressing, and the contact surfaces are mutually fused to each other in a rigid structure. That is, the surface of the foamed resin (f) is melted by the steam, the inner foaming agent expands and the air between the foaming resin (f) is removed, and at the same time, the foaming resin (f)

The foamed resin f foamed and joined in the molding part 111 is formed as a molded product m in the molding part 111. [ After the molded part 111 heated by the steam is cooled, the molded part m is separated from the fixed part 107 by the ejector unit 170, which will be described later, after the movable part 108 is separated from the molded part 111, Lt; / RTI >

That is, when the molding of the foamed resin (f) is completed, the pressure of the foamed foam in the molding space 112 is lowered to prevent further deformation by the foaming agent remaining in the foamed resin (f) A cooling process for cooling the heat exchanger 108 is performed.

This cooling is performed by a direct cooling method in which cooling water is directly injected into each of the stationary mold 107 and the movable mold 108 through the cooling unit 160 as described later or a direct cooling method in which the pressure in the molding part 111 The indirect cooling method can be considered.

1 and 6, the cooling unit 160 according to the present embodiment for cooling the forming part 111 of the stationary mold 107 and the movable mold 108 is built in the steam chamber part 115 A plurality of cooling water supply pipes 163 connected to the cooling water pipe 161 and an opening and closing valve 165 selectively opening and closing the plurality of cooling water supply pipes 163, .

That is, since the cooling water pipe 161 according to the present embodiment is connected to the plurality of cooling water supply pipes 163, the cooling water supplied through the cooling water supply pipe 163 can be selectively used according to the opening and closing of the opening and closing valve 165.

The cooling water finally cools the molded body m. The steam between the foaming resins f can further shrink the gap that may exist between the foaming resins f to the condensation phenomenon, so that the foaming resin f ) Can have a dense and improved structure.

1 and 7, the above-described foamed resin molding machine according to the present embodiment is arranged so as to be able to move up and down on a stationary mold 107. When the movable mold 108 is separated from the stationary mold 107, And an ejector unit 170 for ejecting the molded body m from the ejector unit 112.

The ejector unit 170 is lifted from the bottom surface of the molding part 111 to move the molded article m in the molding part 111 The rotor 111 can be detached from the forming part 111 of the stationary mold 107. [

A foamed resin panel corresponding to the molded article m having the reinforcing unit 120 as shown in Fig. 8 can be provided by the foamed resin molding method using the above-described foamed resin molding apparatus.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Accordingly, such modifications or variations are intended to fall within the scope of the appended claims.

f: foaming resin m: molded article 100: mold unit
101: a plurality of dies 102: a steam injection unit
103: Steam nozzle block 104: Nozzle
105: Slit panel member 106: Slit
107: stationary mold 108: movable mold
111: forming part 112: forming space
115: steam chamber part 120: reinforcing unit
121: reinforcing member 122: spacing member
140: foaming resin supply unit 141: foaming resin supply pipe
142: Venturi 145: Storage container
146: Compressor 147: Venturi Hall
150: steam supply unit 151: steam piping
152: Steam valve 160: Cooling unit
161: cooling water pipe 163: cooling water supply pipe
165: opening / closing valve 170: ejector unit

Claims (6)

Disposing a reinforcing unit for reinforcing the strength of the molded body in the molding space of the mold unit in which the molding space of the foamed resin is provided by a plurality of molds which are relatively moved so that the foamed resin is supplied to form a molded body;
Supplying the foamed resin to the molding space by the foamed resin supply unit connected to the mold unit to fill the molding space;
Supplying steam to the molding space by a steam supply unit coupled to the mold unit, heating the foam resin, and replacing the air between the foam resin with steam;
Cooling the formed body to be formed in the forming space by a cooling unit connected to the mold unit; And
And separating the plurality of dies to separate the molded body having the reinforcing unit from the molding space. The method according to claim 1,
Wherein the reinforcing unit comprises:
A reinforcing member embedded in the formed body to reinforce the formed body; And
And a spacing member provided on the reinforcing member for spacing the reinforcing member away from the mold. 3. The method of claim 2,
Wherein the reinforcing members are arranged in a zigzag or net shape. 3. The method of claim 2,
Wherein at least one of the plurality of dies is provided with a nozzle for increasing a flow rate of the vapor so that the vapor is injected into the molding space, And a steam injection unit provided with a slit that can block the outflow of the foamed resin. The method of claim 3,
The steam injection unit includes:
A steam nozzle block connected to the steam supply unit, wherein the steam nozzle block is provided with the nozzle; And
And a slit panel member coupled to the steam nozzle block, wherein the slit panel member is provided with a slit connected to the nozzle. A foamed resin panel produced using the foamed resin molding method according to any one of claims 1 to 5.

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