JP2004009650A - Molding method for foam resin molded body - Google Patents

Molding method for foam resin molded body Download PDF

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Publication number
JP2004009650A
JP2004009650A JP2002169018A JP2002169018A JP2004009650A JP 2004009650 A JP2004009650 A JP 2004009650A JP 2002169018 A JP2002169018 A JP 2002169018A JP 2002169018 A JP2002169018 A JP 2002169018A JP 2004009650 A JP2004009650 A JP 2004009650A
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mold
foamed resin
pressure
resin material
cavity
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JP2002169018A
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JP4007548B2 (en
Inventor
Masahiko Hara
原　正彦
Tatsufumi Ono
大野　樹史
Hiroyuki Aizawa
相澤　洋行
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Kasai Kogyo Co Ltd
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Kasai Kogyo Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a molding method for a foam resin molded body which can prevent appearance defects such as silver streaks by suppressing the foaming reaction at the time of injection of a foam resin material and which enhances the moldability of the foam resin molded body with eliminated foaming nonuniformity. <P>SOLUTION: When the cavity mold 30 is lowered to the bottom dead center to conduct the mold clamping, the pressure gas is filled into the product cavity C from the pressure gas tank 61, and the resin pressure and the inmold pressure at the time of injection of the foam resin material M are controlled almost equally. By raising the cavity mold 30 by the resin pressure and ejecting the pressure gas out of the mold from the circumference, the foam resin material M is charged into the product cavity C, and the primary pressurization is performed without causing the foaming reaction. Then, by compulsively holding up the cavity mold 30 to ensure the foaming space S, the foaming reaction not entailing the foaming nonuniformity is carried out to mold the foam resin molded body which is free of thickness unevenness. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
この発明は、モールドプレス成形工法、射出成形工法を利用した発泡樹脂成形体の成形方法に係り、特に、製品キャビティ内に発泡樹脂材料を射出充填する際、製品キャビティの内圧を樹脂圧とほぼ同程度に調整することで発泡樹脂材料の発泡反応を抑え、シルバーストリーク等の外観不良をなくすことにより、外観性能に優れた発泡樹脂成形体を成形できる発泡樹脂成形体の成形方法に関する。
【０００２】
【従来の技術】
図１０は、射出成形工法を利用した発泡樹脂成形体の成形方法における従来例を示す。この方法に用いる射出成形金型１は、固定側金型２、可動側金型３、及び固定側金型２と連接する射出成形機４とから構成され、可動側金型３は、プレスラム３ａに接続し、固定側金型２に対して進退動作を行なう。
【０００３】
そして、図１０（ａ）に示すように、プレスラム３ａの駆動により、可動側金型３が固定側金型２に近接して、固定側金型２と可動側金型３が型締めされる。そして、この型締めにより、初期スペースのキャビティＣ１が形成され、射出成形機４から発泡樹脂材料Ｍが固定側金型２に設けたスプル、ランナ（共に図示せず）等の通路を通じて初期スペースのキャビティＣ１内に射出される。
【０００４】
次いで、図１０（ｂ）に示すように、可動側金型３がプレスラム３ａの動作により固定側金型２に対して後退して、最終製品形状となる製品キャビティＣ２を形成し、同時に発泡樹脂材料Ｍが発泡反応を行ない、図１０（ｃ）に示すように、製品キャビティＣ２の形状に対応して、発泡樹脂成形体Ｐが成形される。
【０００５】
【発明が解決しようとする課題】
このように、従来の発泡樹脂成形体Ｐは、射出工程、発泡工程を経て成形されるものの、図１０（ａ）に示す射出工程において、射出直後から発泡反応が開始されるため、製品表面にシルバーストリーク等の外観不良が生じ易く、発泡樹脂成形体Ｐの製品歩留まりを低下させる大きな要因となっている。
【０００６】
この発明は、このような事情に鑑みてなされたもので、車両用アームレストや内装部品のコアとして最適な発泡樹脂成形体を成形する発泡樹脂成形体の成形方法であって、発泡樹脂材料の成形型内への射出工程で発泡反応が行なわれず、製品表面にシルバーストリーク等の外観不良が発生するのを確実に抑えることができ、製品歩留まりを向上させることができる発泡樹脂成形体の成形方法を提供することを目的とする。
【０００７】
【課題を解決するための手段】
上記目的を達成するために、この出願の請求項１に記載の発明は、第一型と、第二型との間に画成される製品キャビティ内に発泡樹脂材料を射出充填することにより、所要形状に成形される発泡樹脂成形体の成形方法において、第一型をシリンダにより所定位置まで移動させるとともに、第一型、第二型のいずれか一方側に内装された高圧ガスタンクから製品キャビティ内に高圧ガスを注入して、発泡樹脂材料の射出前状態の製品キャビティの内圧を樹脂圧とほぼ同等の圧空状態に維持する高圧ガスの注入工程と、圧空状態の製品キャビティ内に発泡樹脂材料を射出充填し、このときの樹脂圧で第一型を型開方向に移動させるとともに、製品キャビティ内の高圧ガスを型外に排出する発泡樹脂材料の射出工程と、発泡樹脂材料の樹脂圧と製品キャビティの内圧のバランスにより、第一型の型開方向への移動が停止した状態で一次加圧を施す発泡樹脂材料の一次加圧工程と、一次加圧工程後、第一型を強制的に所定ストローク型開方向に移動させて、発泡スペースを確保して発泡樹脂材料を所望厚みに発泡成形する発泡樹脂材料の発泡成形工程と、からなることを特徴とする。
【０００８】
ここで、第一型は、シリンダの駆動により、型締位置と型開位置との間で所定ストローク移動するとともに、第二型は連接する射出成形機から発泡樹脂材料を製品キャビティ内に供給するために、マニホールド、ゲート等の樹脂通路が設けられている。
【０００９】
例えば、モールドプレス成形工法では、第一型は、シリンダ駆動されるキャビティ型であり、また、第二型は、射出成形機に接続されるコア型を指す。一方、射出成形工法では、第一型は、シリンダ駆動されるコア型であり、第二型は、射出成形機に接続されるキャビティ型を指す。
【００１０】
また、高圧ガスタンクは、製品キャビティ内に高圧ガスをタイミングよく供給できるように、制御バルブを備えており、制御バルブの開放動作により、高圧ガスタンクから高圧ガス注入口を通して製品キャビティ内に高圧ガスが注入される。この高圧ガスタンクに高圧ガスを供給するための高圧ガス供給管、及び高圧ガス発生器が型外に設けられている。尚、高圧ガスタンクは、キャビティ型、あるいはコア型のいずれか一方側に設けることができる。
【００１１】
更に、発泡樹脂材料の製品キャビティ内への射出時には、発泡樹脂材料の樹脂圧と型内圧力をほぼ同程度、約８０ｋｇ／ｃｍ２に設定することが望ましい。そして、発泡樹脂材料の樹脂圧により、第一型が型開方向に移動するとともに、製品外周及び入れ子、あるいはエジェクタピン周りに設定された高圧ガス逃げ通路を通して高圧ガスが外部に排出されることにより、製品キャビティの内圧が適正に調整される。
【００１２】
発泡樹脂材料としては、ポリプロピレン（以下、ＰＰという）樹脂に重炭酸ナトリウムを混入したものが使用できる。
【００１３】
そして、請求項１に記載の発明によれば、発泡性樹脂を製品キャビティ内に射出充填する前にキャビティ内は高圧ガスタンクから高圧ガスが注入された圧空状態である。従って、製品キャビティ内に発泡樹脂材料を射出充填する際、樹脂射出時には樹脂圧と型内圧はほぼ均等である。そして、第一型が樹脂圧により型開方向に移動するとともに、キャビティ外周から高圧ガスが型外に排出されるため、型内圧が低下し、樹脂がキャビティ内に拡がる。このように、発泡樹脂材料の射出時には、樹脂圧と型内圧とがほぼ等しいため、発泡反応が行なわれることがなく、シルバーストリーク等の成形不良を回避できる。
【００１４】
この出願の請求項２に記載の発明は、第一型と第二型の双方のパーティング面における製品外周部に沿って、外周シール部材が設けられており、製品キャビティ内への高圧ガスの注入工程において、外周シール部材間のシール性により製品キャビティの圧空状態が維持され、かつ発泡樹脂材料を製品キャビティ内に射出充填する発泡樹脂材料の射出工程において、樹脂圧による第一型の型開方向への移動に伴ない、この外周シール部材間から高圧ガスが型外に排出されることを特徴とする。
【００１５】
ここで、第一型及び第二型のパーティング面の製品キャビティ外周に設けられる外周シール部材としては、発泡ウレタン、シリコーンゴム等が使用できる。
【００１６】
この出願の請求項３に記載の発明は、第二型に設けられている入れ子、あるいはエジェクタピンにより、発泡樹脂材料の射出工程において、製品キャビティ内の高圧ガスが入れ子、またはエジェクタピン周りから型外に排出されることを特徴とする。
【００１７】
そして、請求項２，３記載の発明によれば、高圧ガスを製品キャビティ内に注入して、型内圧を精度良く維持し、しかも、発泡樹脂材料を製品キャビティ内に射出充填する際は、高圧ガスを型外に逃がす作用をする外周シール部材が第一型及び第二型の製品外周部に設けられているため、これら簡易シール構造により、型費コストを低減化でき、一般金型への対応が可能となる。
【００１８】
【発明の実施の形態】
以下、本発明に係る発泡樹脂成形体の成形方法の好適な実施形態について、添付図面を参照しながら詳細に説明する。
【００１９】
図１，図２は本発明方法を適用して成形した発泡樹脂成形体を一部に採用した自動車用ドアトリムの正面図並びに断面図、図３は本発明に係る発泡樹脂成形体の成形方法に使用する成形装置の概略構成を示す側面図、図４は同成形装置の成形工程における成形金型のタイムチャート図、図５乃至図９は発泡樹脂成形体の成形方法における各工程を示す説明図である。
【００２０】
図１，図２に示す自動車用ドアトリム１０は、上下に２分割されたドアトリムアッパー１１と、ドアトリムロア１２との上下２分割体から構成されている。上記ドアトリムアッパー１１は、樹脂製基材１３の表面の一部に中接シート１４が貼付され、ドアトリムロア１２には、ドアポケット用開口１５、フロント側にスピーカグリル１６が設けられている。
【００２１】
ドアトリムアッパー１１の樹脂製基材１３は、ＰＰ樹脂のモールドプレス成形体、あるいは射出成形体からなり、樹脂製基材１３の成形時にクロス、不織布等の中接シート１４が一体化されている。
【００２２】
また、ドアトリムロア１２は、ＰＰ樹脂に発泡剤（重炭酸ナトリウム）を混入した発泡樹脂材料をモールドプレス成形、射出成形により所要形状に成形されている。
【００２３】
ところで、本発明は、発泡樹脂成形体の成形方法に係り、ドアトリム１０におけるドアトリムロア１２のような発泡樹脂成形体の成形に好適であり、ドアトリムロア１２を発泡成形する際、外観品質性能を高めることができる。
【００２４】
上記ドアトリムロア１２の成形に使用する成形装置２０の構成について、図３を基に説明する。この図３に示す成形装置２０は、射出成形工法を利用したものであるが、モールドプレス成形工法に準用することもできる。
【００２５】
成形装置２０は、相互に型締め、型開き可能なキャビティ型３０並びにコア型４０と、コア型４０に連接され、発泡樹脂材料を供給する射出成形機５０と、キャビティ内を圧空状態に維持して発泡樹脂成形体の外観性能を良好に維持できる高圧ガス供給機構６０とから大略構成されている。
【００２６】
更に詳しくは、キャビティ型３０は、昇降シリンダ３１の駆動により、所定ストローク上下動作することができ、後述するが、図４に示すタイムチャート図から明らかなように、下死点まで降下した後、樹脂圧により上方に押し上げられ、一旦停止して一次加圧を行なった後、再度上昇して発泡スペースを確保し、発泡反応完了時、型開きされるという一連の動作を行なう。
【００２７】
また、このキャビティ型３０のコア型４０に対するパーティング面におけるキャビティ外周に沿って発泡ウレタン、シリコーンゴム等の外周シール部材３２が接着止め、あるいは機械止めされている。尚、本実施形態では、発泡ウレタンが使用されている。
【００２８】
一方、コア型４０は、連接する射出成形機５０から発泡樹脂材料を製品キャビティＣ内に供給できるように、マニホールド４１、ゲート４２が設けられており、高圧ガスを型外に排出する入れ子構造の高圧ガス逃げ通路４３が設けられている。
【００２９】
そして、キャビティ型３０と同様にキャビティ型３０に対するパーティング面におけるキャビティ外周に沿って外周シール部材４４が接着、あるいは機械止めされており、この外周シール部材４４の材質は、キャビティ型３０の外周シール部材３２と同様、発泡ウレタンを使用する。
【００３０】
次いで、高圧ガス供給機構６０の構成としては、本実施形態ではキャビティ型３０に高圧ガスタンク６１が内装され、この高圧ガスタンク６１から高圧ガスを製品キャビティＣ内に必要に応じて供給できるように高圧ガス注入口６２が設けられており、制御バルブ６３により高圧ガスの供給及び停止のタイミングが制御される。
【００３１】
更に、この高圧ガスタンク６１に高圧ガスを供給するために、高圧ガス供給管６４が高圧ガス発生器６５に接続しており、高圧ガス供給管６４には開閉バルブ６６が設けられている。
【００３２】
そして、この高圧ガス供給機構６０においては、図４に示すタイムチャート図から明らかなように、キャビティ型３０が下死点まで到達するまで高圧ガスが製品キャビティＣ内に注入され、発泡樹脂材料Ｍの射出を開始したときには高圧ガスのキャビティＣ内への注入は停止するように制御される。
【００３３】
次いで、図４のタイムチャート図及び図５乃至図９に示す工程図を基にプレス上型であるキャビティ型３０と高圧ガス供給機構６０の動作タイミングについて説明する。
【００３４】
すなわち、図５に示すように、成形開始時、昇降シリンダ３１の駆動によりキャビティ型３０が下降を始めるが、その際、高圧ガス供給機構６０が作動している。すなわち、高圧ガスタンク６１と製品キャビティＣとを連通させる高圧ガス注入口６２は、制御バルブ６３が開放状態に制御されることで、高圧ガスタンク６１から高圧ガス注入口６２を経て製品キャビティＣ内に高圧ガスが注入される。
【００３５】
従って、製品キャビティＣ内の型内圧力は、キャビティ型３０が下死点に到達するまで急激に上昇することになる。例えば、本実施形態では、８０ｋｇ／ｃｍ２程度まで上昇している。
【００３６】
そして、キャビティ型３０が下死点まで到達したとき、高圧ガス供給機構６０における制御バルブ６３が閉鎖され、高圧ガスの製品キャビティＣ内への供給は停止し、同時に射出成形機５０からマニホールド４１、ゲート４２を通じて製品キャビティＣ内に発泡樹脂材料Ｍが射出充填される。
【００３７】
図６は、キャビティ型３０が下死点に到達した状態を示しており、この状態においてはキャビティ型３０及びコア型４０のパーティング面におけるキャビティ外周に設けられている外周シール部材３２、４４が圧縮状態で当接しており、外周シール部材３２，４４を通じて製品キャビティＣ内の高圧ガスが外部に排出されることがなく、良好なシール機能が達成されている。
【００３８】
次に、図６に示すキャビティ型３０の下死点状態から、発泡樹脂材料Ｍが製品キャビティＣ内に射出充填されれば、図７に示すように、高圧ガス供給機構６０により製品キャビティＣ内に予め注入されている高圧ガスのガス圧は、上述した通り、発泡樹脂材料Ｍの射出充填当初８０ｋｇ／ｃｍ２であり、また、発泡樹脂材料Ｍの樹脂圧が８０ｋｇ／ｃｍ２であるとともに、キャビティ型３０のプレス加圧が低圧であるため、高圧ガスのガス圧と発泡樹脂材料Ｍの樹脂圧により、キャビティ型３０が上方に押し上げられ、キャビティの内圧が適正に調整される。
【００３９】
そして、図８に示すように、この状態で一次加圧が行なわれ、この一次加圧の際には、発泡反応が行なわれないため、製品表面にシルバーストリーク等の外観不良が生じることがない。
【００４０】
このように、キャビティ型３０が上昇して、製品キャビティＣのスペースが広くなるとともに、高圧ガスは外周シール部材３２、４４を通じて一部が型外に排出されることで、キャビティの内圧が低下し、発泡樹脂材料Ｍが製品キャビティＣ内にゆきわたり易くなる。
【００４１】
このとき、高圧ガス外部逃げ通路４３を通じて高圧ガスを外部に逃がすようにしても良く、この高圧ガス外部逃げ通路４３は、図示はしないがエジェクタピンを利用することもできる。
【００４２】
そして、一次加圧工程が完了すれば、図４のタイムチャート図、及び図９に示すように、キャビティ型３０が所定ストローク上昇し、これに伴ない製品キャビティＣに新たな発泡スペースＳが確保されて一次加圧成形された発泡樹脂体Ｍ１内部の発泡反応が行なわれ、図９に示す最終的な製品板厚に対応する発泡成形が行なわれる。
【００４３】
このように、本発明に係る発泡樹脂成形体の成形方法によれば、発泡樹脂材料Ｍを製品キャビティＣに射出する際には、高圧ガスタンク６１から高圧ガスが製品キャビティＣ内に予め注入され、型内圧力が上昇しているため、発泡樹脂材料Ｍの発泡反応が有効に抑えられる。
【００４４】
更に、発泡樹脂材料Ｍを製品キャビティＣ内に射出を行なう際、製品キャビティＣ内の内圧は発泡樹脂材料Ｍの樹脂圧とほぼ同等であるとともに、射出を継続するに連れてキャビティ型３０が上昇するとともに、外周シール部材３２、４４等を通じて高圧ガスが外部に排出されることで、発泡反応を誘起させることなく、円滑に一次加圧成形が行なえ、その後、キャビティ型３０を強制的に上昇させて発泡スペースＳを確保した状態で発泡樹脂体Ｍ１の発泡反応を行なわせれば、シルバーストリーク等の外観不良が生じることがなく、かつ発泡ムラのない均一な発泡反応を誘起させることができるため、成形精度に優れた発泡樹脂成形体を成形でき、製品歩留まりが大幅に向上するという有利さがある。
【００４５】
そして、本発明方法に使用する成形装置２０については、キャビティ型３０とコア型４０に画成される製品キャビティＣの型内圧力を調整する機構として、キャビティ型３０及びコア型４０のパーティング面における製品キャビティ外周に沿って発泡ウレタン、シリコーンゴム等の外周シール部材３２、４４を用いた簡易シール構造を採用したため、金型構造が廉価でコストアップを招来することなく実施できるという利点がある。
【００４６】
また、高圧ガスは、乾燥エア、不活性ガス等が使用でき、高圧ガスタンク６１は、キャビティ型３０に替えて、コア型４０に内装することもできる。
【００４７】
【発明の効果】
以上説明した通り、本発明に係る発泡樹脂成形体の成形方法は、第一型及び第二型のいずれかに設けた高圧ガスタンクから製品キャビティ内に高圧ガスを注入して、発泡樹脂材料を製品キャビティ内に射出充填する前に製品キャビティの内圧を上昇させ、発泡樹脂材料の樹脂圧とほぼ同程度になるように制御する。そして、樹脂圧により第一型を型開方向に移動させ、かつ外周から高圧ガスを型外に排出させることでキャビティの内圧を制御して一次加圧を行ない、その後、第一型を強制的に移動させて発泡スペースを確保して発泡成形を行なうという発泡成形工程を採用したから、シルバーストリーク等の外観不良が生じることがなく、製品外観を良好に維持できるとともに、射出充填後の発泡成形工程においてもキャビティの内圧を常に一定に維持することができることから、発泡ムラのない発泡反応が期待でき、厚みバラツキのない成形性能に優れた発泡樹脂成形体を成形できるという効果を有する。
【図面の簡単な説明】
【図１】本発明方法で成形する発泡樹脂成形体を一部適用した自動車用ドアトリムを示す正面図である。
【図２】図１に示す自動車用ドアトリムの構成を示す断面図である。
【図３】本発明に係る発泡樹脂成形体の成形方法に使用する成形装置の概略構成を示す説明図ある。
【図４】本発明に係る発泡樹脂成形体の成形方法におけるキャビティ型のプレスストローク、製品キャビティの内圧の変化、並びに高圧ガス発生機構の動作をそれぞれ示すタイムチャート図である。
【図５】本発明に係る発泡樹脂成形体の成形方法における高圧ガスのキャビティ内への注入工程を示す説明図である。
【図６】本発明に係る発泡樹脂成形体の成形方法におけるキャビティ型の下降状態を示す説明図である。
【図７】本発明に係る発泡樹脂成形体の成形方法における発泡樹脂材料の射出工程での製品キャビティ内を示す説明図である。
【図８】本発明に係る発泡樹脂成形体の成形方法における一次加圧時の状態を示す説明図である。
【図９】本発明に係る発泡樹脂成形体の成形方法における発泡成形工程を示す説明図である。
【図１０】従来の発泡樹脂成形体の成形方法を示す説明図である。
【符号の説明】
１０　自動車用ドアトリム
１１　ドアトリムアッパー
１２　ドアトリムロア
２０　成形装置
３０　キャビティ型
３１　昇降シリンダ
３２　外周シール部材
４０　コア型
４１　マニホールド
４２　ゲート
４３　高圧ガス逃げ通路
４４　外周シール部材
５０　射出成形機
６０　高圧ガス供給機構
６１　高圧ガスタンク
６２　高圧ガス注入口
６３　制御バルブ
６４　高圧ガス供給管
６５　高圧ガス発生器
６６　開閉バルブ
Ｃ　製品キャビティ
Ｍ　発泡樹脂材料[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a molding method of a foamed resin molded body using a mold press molding method and an injection molding method, and particularly, when injection molding a foamed resin material into a product cavity, the internal pressure of the product cavity is substantially equal to the resin pressure. The present invention relates to a method for molding a foamed resin molded article capable of molding a foamed resin article having excellent appearance performance by suppressing the foaming reaction of a foamed resin material by adjusting the degree of foaming, and eliminating appearance defects such as silver streaks.
[0002]
[Prior art]
FIG. 10 shows a conventional example of a method for molding a foamed resin molded article using an injection molding method. The injection mold 1 used in this method includes a fixed mold 2, a movable mold 3, and an injection molding machine 4 connected to the fixed mold 2, and the movable mold 3 includes a press ram 3a. To perform an advancing / retreating operation with respect to the fixed mold 2.
[0003]
Then, as shown in FIG. 10A, by driving the press ram 3a, the movable mold 3 approaches the fixed mold 2 and the fixed mold 2 and the movable mold 3 are clamped. . By this mold clamping, a cavity C1 in the initial space is formed, and the foamed resin material M is supplied from the injection molding machine 4 through a passage such as a sprue or a runner (both not shown) provided in the fixed mold 2 so as to form the initial space. It is injected into the cavity C1.
[0004]
Next, as shown in FIG. 10B, the movable mold 3 is retracted with respect to the fixed mold 2 by the operation of the press ram 3a to form a product cavity C2 having a final product shape. The material M undergoes a foaming reaction, and as shown in FIG. 10 (c), a foamed resin molded body P is formed corresponding to the shape of the product cavity C2.
[0005]
[Problems to be solved by the invention]
As described above, the conventional foamed resin molded article P is molded through the injection step and the foaming step. However, in the injection step shown in FIG. Appearance defects such as silver streaks are likely to occur, which is a major factor in lowering the product yield of the foamed resin molded product P.
[0006]
The present invention has been made in view of such circumstances, and is a method of molding a foamed resin molded article for molding an optimal foamed resin molded article as a core of a vehicle armrest or an interior component, and comprises a method of molding a foamed resin material. A foaming reaction is not performed in the injection step into the mold, and it is possible to reliably suppress appearance defects such as silver streaks from occurring on the product surface and to improve a product yield. The purpose is to provide.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, the invention according to claim 1 of the present application is to provide an injection-filling of a foamed resin material into a product cavity defined between a first mold and a second mold. In the method of molding a foamed resin molded article having a required shape, a first mold is moved to a predetermined position by a cylinder, and a first mold and a high-pressure gas tank provided on one side of the second mold are used to form a product cavity. A high-pressure gas into the product cavity before injection of the foamed resin material to maintain the internal pressure of the product cavity in a compressed air state substantially equal to the resin pressure, and a foamed resin material in the product cavity in the compressed air state. Injecting filling, moving the first mold in the mold opening direction with the resin pressure at this time, and discharging the high pressure gas in the product cavity to the outside of the mold, the injection process of the foamed resin material, the resin pressure of the foamed resin material and the product Due to the balance of the internal pressure of the cavity, the primary pressing step of the foamed resin material for applying the primary pressing while the movement of the first die in the mold opening direction is stopped, and the first pressing forcibly after the primary pressing step A foaming resin material foaming step of foaming the foamed resin material to a desired thickness by moving the foamed resin material to a desired thickness while moving the foamed resin material in a predetermined stroke mold opening direction.
[0008]
Here, the first mold moves a predetermined stroke between the mold clamping position and the mold opening position by driving the cylinder, and the second mold supplies the foamed resin material from the connected injection molding machine into the product cavity. For this purpose, a resin passage such as a manifold or a gate is provided.
[0009]
For example, in a mold press molding method, the first mold is a cavity mold driven by a cylinder, and the second mold is a core mold connected to an injection molding machine. On the other hand, in the injection molding method, the first mold is a core mold driven by a cylinder, and the second mold is a cavity mold connected to an injection molding machine.
[0010]
The high-pressure gas tank is equipped with a control valve so that high-pressure gas can be supplied into the product cavity in a timely manner. When the control valve is opened, high-pressure gas is injected into the product cavity from the high-pressure gas tank through the high-pressure gas inlet. Is done. A high-pressure gas supply pipe for supplying high-pressure gas to the high-pressure gas tank and a high-pressure gas generator are provided outside the mold. The high-pressure gas tank can be provided on either the cavity type or the core type.
[0011]
Further, when the foamed resin material is injected into the product cavity, it is desirable that the resin pressure of the foamed resin material and the in-mold pressure are set to approximately the same level, that is, about 80 kg / cm 2 . Then, by the resin pressure of the foamed resin material, the first mold moves in the mold opening direction, and the high pressure gas is discharged to the outside through the high pressure gas escape passage set around the product outer periphery and the nest, or around the ejector pin. The internal pressure of the product cavity is properly adjusted.
[0012]
As the foamed resin material, a material obtained by mixing sodium bicarbonate with polypropylene (hereinafter, referred to as PP) resin can be used.
[0013]
According to the first aspect of the present invention, before the foamable resin is injected and filled into the product cavity, the inside of the cavity is in a compressed air state in which high-pressure gas is injected from a high-pressure gas tank. Therefore, when the foamed resin material is injected and filled in the product cavity, the resin pressure and the mold inner pressure are substantially equal at the time of resin injection. Then, the first mold moves in the mold opening direction due to the resin pressure, and the high-pressure gas is discharged from the outer periphery of the cavity to the outside of the mold, so that the internal pressure of the mold decreases and the resin spreads in the cavity. As described above, at the time of injection of the foamed resin material, the resin pressure and the mold internal pressure are substantially equal to each other, so that a foaming reaction does not take place and molding defects such as silver streaks can be avoided.
[0014]
The invention according to claim 2 of this application is characterized in that an outer peripheral sealing member is provided along the outer peripheral portion of the product on the parting surfaces of both the first mold and the second mold, and the high-pressure gas is introduced into the product cavity. In the injection step, the compressed air state of the product cavity is maintained by the sealing property between the outer peripheral seal members, and in the injection step of the foamed resin material for injecting and filling the foamed resin material into the product cavity, the mold opening of the first mold by resin pressure is performed. Along with the movement in the direction, the high-pressure gas is discharged out of the mold from between the outer peripheral seal members.
[0015]
Here, urethane foam, silicone rubber, or the like can be used as the outer peripheral sealing member provided on the outer periphery of the product cavity on the parting surfaces of the first mold and the second mold.
[0016]
The invention according to claim 3 of the present application is characterized in that, in the injection step of the foamed resin material, high-pressure gas in the product cavity is nested or ejected from around the ejector pin by the nest or ejector pin provided in the second mold. It is characterized by being discharged outside.
[0017]
According to the second and third aspects of the present invention, a high-pressure gas is injected into the product cavity to maintain the mold internal pressure with high accuracy. Since the outer peripheral sealing member that functions to release gas to the outside of the mold is provided on the outer peripheral portion of the first mold and the second mold, these simple sealing structures can reduce mold cost and reduce the cost for general molds. Response is possible.
[0018]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, preferred embodiments of a method for molding a foamed resin molded article according to the present invention will be described in detail with reference to the accompanying drawings.
[0019]
1 and 2 are a front view and a cross-sectional view of an automobile door trim partially adopting a foamed resin molded article formed by applying the method of the present invention. FIG. 3 shows a method of molding a foamed resin molded article according to the present invention. FIG. 4 is a side view showing a schematic configuration of a molding apparatus to be used, FIG. 4 is a time chart of a molding die in a molding step of the molding apparatus, and FIGS. 5 to 9 are explanatory views showing respective steps in a molding method of a foamed resin molded article. It is.
[0020]
The vehicle door trim 10 shown in FIGS. 1 and 2 is composed of a vertically divided door trim upper 11 and a vertically divided door trim lower 12. The door trim upper 11 has an insulated sheet 14 attached to a part of the surface of a resin base material 13. The door trim lower 12 has a door pocket opening 15 and a speaker grill 16 on the front side.
[0021]
The resin base material 13 of the door trim upper 11 is made of a PP resin mold-pressed or injection-molded body, and an intermediate sheet 14 such as a cloth or a nonwoven fabric is integrated when the resin base material 13 is formed.
[0022]
The door trim lower 12 is formed into a required shape by mold press molding and injection molding of a foamed resin material obtained by mixing a foaming agent (sodium bicarbonate) with a PP resin.
[0023]
By the way, the present invention relates to a method for molding a foamed resin molded article, which is suitable for molding a foamed resin molded article such as a door trim lower 12 in a door trim 10, and improves appearance quality performance when foaming the door trim lower 12. be able to.
[0024]
The configuration of the molding apparatus 20 used for molding the door trim lower 12 will be described with reference to FIG. The molding apparatus 20 shown in FIG. 3 uses an injection molding method, but can be applied to a mold press molding method.
[0025]
The molding apparatus 20 includes a cavity mold 30 and a core mold 40 which can be closed and opened with each other, an injection molding machine 50 connected to the core mold 40 and supplying a foamed resin material, and a pressurized state in the cavity. And a high-pressure gas supply mechanism 60 capable of maintaining good appearance performance of the foamed resin molded article.
[0026]
More specifically, the cavity mold 30 can move up and down by a predetermined stroke by driving the lifting cylinder 31. As will be described later, as apparent from the time chart shown in FIG. The resin is pushed upward by the resin pressure, temporarily stopped, subjected to primary pressurization, then raised again to secure a foaming space, and when the foaming reaction is completed, a series of operations of opening the mold are performed.
[0027]
Further, an outer peripheral sealing member 32 of urethane foam, silicone rubber, or the like is fixed by adhesion or mechanical fixing along the outer periphery of the cavity on the parting surface of the cavity mold 30 with respect to the core mold 40. In this embodiment, urethane foam is used.
[0028]
On the other hand, the core mold 40 is provided with a manifold 41 and a gate 42 so that a foamed resin material can be supplied into the product cavity C from the connected injection molding machine 50, and has a nested structure for discharging high-pressure gas out of the mold. A high-pressure gas escape passage 43 is provided.
[0029]
An outer peripheral seal member 44 is adhered or mechanically stopped along the outer periphery of the cavity on the parting surface with respect to the cavity mold 30 as in the case of the cavity mold 30. Like the member 32, urethane foam is used.
[0030]
Next, as the configuration of the high-pressure gas supply mechanism 60, in the present embodiment, a high-pressure gas tank 61 is provided in the cavity mold 30, and the high-pressure gas is supplied from the high-pressure gas tank 61 to the product cavity C as necessary. An injection port 62 is provided, and the control valve 63 controls the supply and stop timing of the high-pressure gas.
[0031]
Further, in order to supply high-pressure gas to the high-pressure gas tank 61, a high-pressure gas supply pipe 64 is connected to a high-pressure gas generator 65, and the high-pressure gas supply pipe 64 is provided with an opening / closing valve 66.
[0032]
In the high-pressure gas supply mechanism 60, as is clear from the time chart shown in FIG. 4, high-pressure gas is injected into the product cavity C until the cavity mold 30 reaches the bottom dead center, and the foamed resin material M Is started so that injection of the high-pressure gas into the cavity C is stopped.
[0033]
Next, the operation timing of the cavity mold 30 which is the upper press mold and the high-pressure gas supply mechanism 60 will be described based on the time chart of FIG. 4 and the process charts shown in FIGS.
[0034]
That is, as shown in FIG. 5, at the start of molding, the cavity mold 30 starts descending by driving the elevating cylinder 31. At this time, the high-pressure gas supply mechanism 60 is operating. That is, the high-pressure gas inlet 62 for communicating the high-pressure gas tank 61 with the product cavity C has a high pressure from the high-pressure gas tank 61 to the product cavity C via the high-pressure gas inlet 62 by controlling the control valve 63 to be opened. Gas is injected.
[0035]
Therefore, the in-mold pressure in the product cavity C rapidly increases until the cavity mold 30 reaches the bottom dead center. For example, in the present embodiment, it has increased to about 80 kg / cm 2 .
[0036]
Then, when the cavity mold 30 reaches the bottom dead center, the control valve 63 in the high-pressure gas supply mechanism 60 is closed, and the supply of the high-pressure gas into the product cavity C is stopped, and at the same time, the manifold 41, The foam resin material M is injected and filled into the product cavity C through the gate 42.
[0037]
FIG. 6 shows a state where the cavity mold 30 has reached the bottom dead center. In this state, the outer peripheral sealing members 32 and 44 provided on the outer periphery of the cavity on the parting surfaces of the cavity mold 30 and the core mold 40 are shown. Since it is in contact with the compressed state, the high pressure gas in the product cavity C is not discharged to the outside through the outer peripheral seal members 32 and 44, and a good sealing function is achieved.
[0038]
Next, from the bottom dead center state of the cavity mold 30 shown in FIG. 6, if the foamed resin material M is injected and filled into the product cavity C, as shown in FIG. As described above, the gas pressure of the high-pressure gas previously injected into the foam resin is 80 kg / cm 2 at the beginning of the injection filling of the foamed resin material M, and the resin pressure of the foamed resin material M is 80 kg / cm 2 , Since the press pressure of the cavity mold 30 is low, the cavity mold 30 is pushed upward by the gas pressure of the high-pressure gas and the resin pressure of the foamed resin material M, and the internal pressure of the cavity is appropriately adjusted.
[0039]
Then, as shown in FIG. 8, primary pressurization is performed in this state, and at the time of the primary pressurization, no foaming reaction occurs, so that appearance defects such as silver streaks do not occur on the product surface. .
[0040]
As described above, the cavity mold 30 is raised, the space of the product cavity C is widened, and a part of the high-pressure gas is discharged out of the mold through the outer peripheral sealing members 32 and 44, so that the internal pressure of the cavity is reduced. Thus, the foamed resin material M easily spreads in the product cavity C.
[0041]
At this time, the high-pressure gas may be made to escape to the outside through the high-pressure gas outside escape passage 43. The high-pressure gas outside escape passage 43 may use an ejector pin (not shown).
[0042]
When the primary pressurizing step is completed, as shown in the time chart of FIG. 4 and FIG. 9, the cavity mold 30 rises by a predetermined stroke, and a new foaming space S is secured in the product cavity C accordingly. Then, a foaming reaction is performed inside the foamed resin body M1 subjected to the primary pressure molding, and foaming molding corresponding to the final product sheet thickness shown in FIG. 9 is performed.
[0043]
As described above, according to the method for molding a foamed resin molded article according to the present invention, when the foamed resin material M is injected into the product cavity C, the high-pressure gas is previously injected into the product cavity C from the high-pressure gas tank 61, Since the pressure in the mold is increased, the foaming reaction of the foamed resin material M is effectively suppressed.
[0044]
Further, when the foamed resin material M is injected into the product cavity C, the internal pressure in the product cavity C is substantially equal to the resin pressure of the foamed resin material M, and the cavity mold 30 rises as the injection is continued. At the same time, the high-pressure gas is discharged to the outside through the outer peripheral sealing members 32, 44, etc., so that the primary pressure molding can be performed smoothly without inducing a foaming reaction, and then the cavity mold 30 is forcibly raised. When the foaming reaction of the foamed resin body M1 is performed in a state where the foaming space S is secured, a uniform foaming reaction without uneven appearance without silver streaks or the like can be induced. There is an advantage that a foamed resin molded article excellent in molding accuracy can be molded, and the product yield is greatly improved.
[0045]
In the molding apparatus 20 used in the method of the present invention, a parting surface of the cavity mold 30 and the core mold 40 is used as a mechanism for adjusting the in-mold pressure of the product cavity C defined by the cavity mold 30 and the core mold 40. Since the simple sealing structure using the outer peripheral sealing members 32 and 44 made of urethane foam, silicone rubber or the like along the outer periphery of the product cavity is adopted, there is an advantage that the die structure can be implemented at low cost without increasing the cost.
[0046]
Further, as the high-pressure gas, dry air, an inert gas, or the like can be used, and the high-pressure gas tank 61 can be provided in the core mold 40 instead of the cavity mold 30.
[0047]
【The invention's effect】
As described above, the method for molding a foamed resin molded article according to the present invention includes the steps of: injecting a high-pressure gas into a product cavity from a high-pressure gas tank provided in one of a first mold and a second mold; Before the injection filling into the cavity, the internal pressure of the product cavity is increased and controlled so as to be substantially equal to the resin pressure of the foamed resin material. Then, the first mold is moved in the mold opening direction by the resin pressure, and the primary pressure is performed by controlling the internal pressure of the cavity by discharging the high pressure gas from the outer periphery to the outside of the mold. The foam molding process is performed to secure the foaming space by performing the foam molding process, so that appearance defects such as silver streaks do not occur, the product appearance can be maintained well, and the foam molding after injection filling is performed. Since the internal pressure of the cavity can always be kept constant in the process, a foaming reaction without foaming unevenness can be expected, and there is an effect that a foamed resin molded article excellent in molding performance with no thickness variation can be obtained.
[Brief description of the drawings]
FIG. 1 is a front view showing an automobile door trim to which a foamed resin molded article molded by the method of the present invention is partially applied.
FIG. 2 is a cross-sectional view showing a configuration of the vehicle door trim shown in FIG.
FIG. 3 is an explanatory view showing a schematic configuration of a molding apparatus used in a method for molding a foamed resin molded article according to the present invention.
FIG. 4 is a time chart showing a press stroke of a cavity mold, a change in an internal pressure of a product cavity, and an operation of a high-pressure gas generating mechanism in the method for molding a foamed resin molded article according to the present invention.
FIG. 5 is an explanatory view showing a step of injecting a high-pressure gas into a cavity in the method for molding a foamed resin molded article according to the present invention.
FIG. 6 is an explanatory view showing a lowered state of a cavity mold in the method for molding a foamed resin molded article according to the present invention.
FIG. 7 is an explanatory view showing the inside of a product cavity in an injection step of a foamed resin material in the method for molding a foamed resin molded article according to the present invention.
FIG. 8 is an explanatory view showing a state at the time of primary press in the method for molding a foamed resin molded article according to the present invention.
FIG. 9 is an explanatory view showing a foam molding step in the method for molding a foamed resin molded article according to the present invention.
FIG. 10 is an explanatory view showing a conventional method for molding a foamed resin molded article.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Automobile door trim 11 Door trim upper 12 Door trim lower 20 Molding device 30 Cavity mold 31 Elevating cylinder 32 Outer seal member 40 Core mold 41 Manifold 42 Gate 43 High pressure gas escape passage 44 Outer seal member 50 Injection molding machine 60 High pressure gas supply mechanism 61 High pressure Gas tank 62 High pressure gas inlet 63 Control valve 64 High pressure gas supply pipe 65 High pressure gas generator 66 Open / close valve C Product cavity M Foam resin material

Claims (3)

第一型（３０）と、第二型（４０）との間に画成される製品キャビティ（Ｃ）内に発泡樹脂材料（Ｍ）を射出充填することにより、所要形状に成形される発泡樹脂成形体の成形方法において、
第一型（３０）をシリンダ（３１）により所定位置まで移動させるとともに、第一型（３０）、第二型（４０）のいずれか一方側に内装された高圧ガスタンク（６１）から製品キャビティ（Ｃ）内に高圧ガスを注入して、発泡樹脂材料（Ｍ）の射出前状態の製品キャビティ（Ｃ）の内圧を樹脂圧とほぼ同等の圧空状態に維持する高圧ガスの注入工程と、
圧空状態の製品キャビティ（Ｃ）内に発泡樹脂材料（Ｍ）を射出充填し、このときの樹脂圧で第一型（３０）を型開方向に移動させるとともに、製品キャビティ（Ｃ）内の高圧ガスを型外に排出する発泡樹脂材料の射出工程と、
発泡樹脂材料（Ｍ）の樹脂圧と製品キャビティ（Ｃ）内の内圧のバランスにより、第一型（３０）の型開方向への移動が停止した状態で一次加圧を施す発泡樹脂材料の一次加圧工程と、
一次加圧工程後、第一型（３０）を強制的に所定ストローク型開方向に移動させて、発泡スペース（Ｓ）を確保して発泡樹脂材料（Ｍ）を所望厚みに発泡成形する発泡樹脂材料の発泡成形工程と、
からなることを特徴とする発泡樹脂成形体の成形方法。A foamed resin molded into a required shape by injection-filling a foamed resin material (M) into a product cavity (C) defined between a first mold (30) and a second mold (40). In the method of molding a molded article,
The first mold (30) is moved to a predetermined position by the cylinder (31), and the product cavity (61) is inserted from the high-pressure gas tank (61) provided in one of the first mold (30) and the second mold (40). A high-pressure gas injection step of injecting a high-pressure gas into C) to maintain an internal pressure of the product cavity (C) in a pre-injection state of the foamed resin material (M) in a compressed air state substantially equal to the resin pressure;
The foamed resin material (M) is injected and filled into the product cavity (C) in the compressed air state, and the first mold (30) is moved in the mold opening direction by the resin pressure at this time, and the high pressure inside the product cavity (C) is increased. An injection step of a foamed resin material for discharging gas out of the mold,
The primary pressure of the foamed resin material to be subjected to the primary pressurization while the movement of the first mold (30) in the mold opening direction is stopped by the balance between the resin pressure of the foamed resin material (M) and the internal pressure in the product cavity (C). Pressing step;
After the primary pressing step, the first mold (30) is forcibly moved in a predetermined stroke mold opening direction to secure a foaming space (S) and foam the foamed resin material (M) to a desired thickness. Material foam molding process,
A method for molding a foamed resin molded article, comprising: 第一型（３０）と第二型（４０）の双方のパーティング面における製品外周部に沿って、外周シール部材（３２，４４）が設けられており、製品キャビティ（Ｃ）内への高圧ガスの注入工程において、外周シール部材（３２，４４）間のシール性により製品キャビティ（Ｃ）の圧空状態が維持され、かつ発泡樹脂材料（Ｍ）を製品キャビティ（Ｃ）内に射出充填する発泡樹脂材料（Ｍ）の射出工程において、樹脂圧による第一型（３０）の型開方向への移動に伴ない、この外周シール部材（３２，４４）間から高圧ガスが型外に排出されることを特徴とする請求項１に記載の発泡樹脂成形体の成形方法。An outer peripheral sealing member (32, 44) is provided along the outer peripheral portion of the product on the parting surface of both the first die (30) and the second die (40), and a high pressure is introduced into the product cavity (C). In the gas injection step, the compressed air state of the product cavity (C) is maintained by the sealing property between the outer peripheral seal members (32, 44), and the foaming for injecting and filling the foamed resin material (M) into the product cavity (C). In the step of injecting the resin material (M), high-pressure gas is discharged from the space between the outer peripheral seal members (32, 44) as the first mold (30) moves in the mold opening direction due to the resin pressure. The method for molding a foamed resin molded article according to claim 1, wherein: 第二型（４０）に設けられている入れ子、あるいはエジェクタピンにより、発泡樹脂材料（Ｍ）の射出工程において、製品キャビティ（Ｃ）内の高圧ガスが入れ子、またはエジェクタピン周りから型外に排出されることを特徴とする請求項２に記載の発泡樹脂成形体の成形方法。In the injection step of the foamed resin material (M), the high-pressure gas in the product cavity (C) is discharged from the nest or around the ejector pin to the outside of the mold by the nest or the ejector pin provided in the second mold (40). The method for molding a foamed resin molded article according to claim 2, wherein the molding is performed.
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