JP2011051150A - Method and apparatus for molding foamed resin molding - Google Patents

Method and apparatus for molding foamed resin molding Download PDF

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JP2011051150A
JP2011051150A JP2009200185A JP2009200185A JP2011051150A JP 2011051150 A JP2011051150 A JP 2011051150A JP 2009200185 A JP2009200185 A JP 2009200185A JP 2009200185 A JP2009200185 A JP 2009200185A JP 2011051150 A JP2011051150 A JP 2011051150A
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mold
foamed resin
molding
product cavity
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JP5378117B2 (en
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Tatsufumi Ono
樹史 大野
Nobuaki Seki
伸明 関
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Kasai Kogyo Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To shorten a molding cycle, to reduce a load on a mold, and to eliminate a defective outside appearanec in a method and an apparatus for molding a foamed resin molding manufactured by injecting air after a movable mold and a fixed mold are clamped, starting a foaming reaction by opening the movable mold after a foamed resin material is injected and packed, and carrying out molding in a required shape. <P>SOLUTION: With regard to a periphery sealing mechanism 80 along the periphery of a product cavity C, a vertical movement type seal plate 82 is arranged in the fixed mold 60, air pressure can be secured into the product cavity C in a short time by performing preceding sealing at a high position of the movable mold 50, and the injection packing of the foamed resin material M before mold clamping becomes possible. During the foaming reaction, air accumulation is eliminated by opening the product cavity C to the atmosphere by descending the seal plate 82 in the periphery sealing mechanism 80. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

この発明は、製品キャビティ内に発泡樹脂材料を射出充填した後、可動側金型を型開方向に後退操作し、発泡スペースを確保した状態で発泡反応させて発泡樹脂成形品を所要形状に成形してなる発泡樹脂成形品の成形方法並びに成形装置に係り、特に、製品キャビティ外周のシール機構部の構造を改良することで、成形サイクルを短縮化でき、かつ成形時にかかる成形金型への負荷を軽減できるとともに、外観不良を解消でき、外観性能を高めた発泡樹脂成形品の成形方法並びに成形装置に関する。   In this invention, after foaming resin material is injected and filled into the product cavity, the movable side mold is retracted in the mold opening direction, and foaming reaction is performed with the foaming space secured to mold the foamed resin molded product into the required shape. In particular, the molding cycle can be shortened by improving the structure of the sealing mechanism around the outer periphery of the product cavity and the load applied to the molding die during molding. The present invention relates to a molding method and a molding apparatus for a foamed resin molded product that can alleviate appearance defects, eliminate appearance defects, and improve appearance performance.

図９はドアパネル（図示せず）の室内面側に装着される自動車用ドアトリム１を示すもので、このドアトリム１は、機能性を高めるために表面中央に乗員が肘を掛けて休めるアームレスト１ａが室内側に膨出するように形成されている。また、その下方には、備品を収容できるドアポケット１ｂが開設されており、更にそのフロント側には、スピーカグリル１ｃがドアトリム１と一体、あるいは別体に設けられている。そして、このドアトリム１の材質としては、軽量で耐衝撃性に優れ、かつコストも廉価なことから、ポリプロピレン（ＰＰ）樹脂内部に発泡剤を混入した発泡樹脂材料を所要形状に成形してなる発泡樹脂成形品が多用される傾向にある。   FIG. 9 shows an automotive door trim 1 mounted on the interior side of a door panel (not shown). The door trim 1 has an armrest 1a on which an occupant rests with an elbow in the center of the surface to improve functionality. It is formed so as to bulge indoors. In addition, a door pocket 1b capable of storing equipment is opened below, and a speaker grille 1c is provided integrally or separately from the door trim 1 on the front side. The door trim 1 is made of a foamed resin material in which a foaming agent is mixed into a polypropylene (PP) resin into a required shape because it is lightweight, excellent in impact resistance, and inexpensive. Resin molded products tend to be used frequently.

次に、この種発泡樹脂成形品を素材としたドアトリム１を所要形状に成形する従来の成形方法について説明する。まず、従来方法に使用する成形装置２は、図１０に示すように、可動側金型３と固定側金型４が相互に型締め、型開き可能に配置されており、ドアトリム１の製品形状に対応するように両金型３，４間で製品キャビティＣが画成される。また、固定側金型４には、製品キャビティＣに発泡樹脂材料Ｍを供給するための樹脂供給通路４ａが設定されているとともに、外部からのエア供給機構と接続するエア配管５が設けられ、エア配管５から製品キャビティＣ内にエアが注入され、製品キャビティＣ内のエア圧が適正に制御される。更に、製品キャビティＣの外周には、製品キャビティＣからエア漏れを防止するためにシールリング６が設けられている。   Next, a conventional molding method for molding the door trim 1 made of this kind of foamed resin molded product into a required shape will be described. First, as shown in FIG. 10, the molding apparatus 2 used in the conventional method has a movable mold 3 and a fixed mold 4 arranged so that they can be clamped and opened, and the product shape of the door trim 1 is obtained. A product cavity C is defined between the molds 3 and 4 so as to correspond to the above. The fixed mold 4 is provided with a resin supply passage 4a for supplying the foamed resin material M to the product cavity C and an air pipe 5 connected to an external air supply mechanism. Air is injected into the product cavity C from the air pipe 5, and the air pressure in the product cavity C is appropriately controlled. Further, a seal ring 6 is provided on the outer periphery of the product cavity C in order to prevent air leakage from the product cavity C.

そして、図１１（ａ）に示すように、可動側金型３が下降して、可動側金型３の下死点を基準として５ｍｍ上方位置で固定側金型４のシール用凸部４ｂと可動側金型３のシールリング６とが先行当接して、エアシールが開始され、その後、図１１（ｂ）に示すように、可動側金型３が下死点まで当接した時、シールリング６が５ｍｍ潰されることにより、完全シールが達成される。この時、可動側金型３からのプレス圧は固定側金型４の受圧面４ｃに集中する。   Then, as shown in FIG. 11A, the movable mold 3 is lowered, and the sealing convex portion 4b of the fixed mold 4 is positioned 5 mm above the bottom dead center of the movable mold 3. When the movable ring 3 comes into contact with the seal ring 6 in advance and air sealing is started, and then the movable mold 3 comes into contact with the bottom dead center as shown in FIG. A perfect seal is achieved by crushed 6 by 5 mm. At this time, the press pressure from the movable mold 3 is concentrated on the pressure receiving surface 4 c of the fixed mold 4.

従って、従来のドアトリム１の成形方法をタイムチャート式に見れば、図１２で示すように、発泡樹脂材料Ｍの射出のタイミングとしてはエア圧が溜まるまで待機させる必要がある。すなわち、可動側金型３を下降操作して、下死点を基準として５ｍｍ上方位置でシールリング６とシール用凸部４ｂが先行当接した後、更に５ｍｍ可動側金型３が下降して、完全シールが達成される。この時には、エア配管５を通じて製品キャビティＣ内にエアが注入されており、キャビティ内圧は適正値に維持される。そして、下死点で発泡樹脂材料Ｍが製品キャビティＣ内に射出充填され、その後、可動側金型３が型開方向に後退操作されて、発泡反応が行なわれ、所定厚みに調整されたドアトリム１が発泡成形される。尚、上記発泡樹脂成形品であるドアトリム１を成形する成形装置２の構造並びに成形装置２を使用したドアトリム１の成形方法の従来例については、特許文献１に詳細に示されている。   Therefore, if the molding method of the conventional door trim 1 is viewed in a time chart manner, as shown in FIG. 12, it is necessary to wait until the air pressure is accumulated as the injection timing of the foamed resin material M. That is, after the movable side mold 3 is lowered, the seal ring 6 and the sealing convex portion 4b are brought into contact with each other at a position 5 mm above the bottom dead center, and then the 5 mm movable side mold 3 is further lowered. A complete seal is achieved. At this time, air is injected into the product cavity C through the air pipe 5, and the internal pressure of the cavity is maintained at an appropriate value. Then, the foam resin material M is injected and filled into the product cavity C at the bottom dead center, and then the movable mold 3 is retracted in the mold opening direction to perform the foaming reaction and to adjust the door trim to a predetermined thickness. 1 is foam-molded. A conventional example of the structure of the molding apparatus 2 that molds the door trim 1 that is the foamed resin molded product and the molding method of the door trim 1 using the molding apparatus 2 is described in detail in Patent Document 1.

特開２００５−７８１８号公報Japanese Patent Laid-Open No. 2005-7818

このように、従来の発泡樹脂成形品であるドアトリム１の成形方法は、可動側金型３と固定側金型４との型締めにより画成される製品キャビティＣ内に発泡樹脂材料Ｍを射出充填するが、その射出ポイントは、可動側金型３が下死点まで到達した時に限定され、成形条件の幅が狭く、かつ製品の板厚調整が難しいとともに、型クリアランスが狭いため、発泡樹脂材料Ｍが流れにくいことから、薄肉成形には不利である。また、製品キャビティＣ内のエア圧が上昇するまで待機し、その後、発泡樹脂材料Ｍを射出充填するため、成形サイクルが長期化し、コストアップを招来するとともに、図１３に示すように、エア圧が高まるまで待機している間は可動側金型３からのプレス圧が全て固定側金型４の受圧面４ｃのみにかかり、金型に加わる負荷が大きく、金型の寿命に悪影響を及ぼす傾向にある。更に、発泡反応時には、エアを型外に除去するが、エアが抜けきらない場合は、発泡ムラやユズ肌（製品表面への凹凸発生による外観不良）等の外観不良を助長する不具合がある。   As described above, the molding method of the door trim 1, which is a conventional foamed resin molded product, injects the foamed resin material M into the product cavity C defined by clamping the movable side mold 3 and the fixed side mold 4. The injection point is limited when the movable mold 3 reaches the bottom dead center, the molding conditions are narrow, the product thickness is difficult to adjust, and the mold clearance is narrow. Since the material M is difficult to flow, it is disadvantageous for thin wall molding. In addition, the process waits until the air pressure in the product cavity C rises, and then the foamed resin material M is injected and filled, which increases the molding cycle and increases the cost. As shown in FIG. While waiting until the pressure rises, all the press pressure from the movable mold 3 is applied only to the pressure receiving surface 4c of the fixed mold 4, and the load applied to the mold is large, which tends to adversely affect the life of the mold. It is in. Furthermore, air is removed from the mold during the foaming reaction. However, if the air cannot be completely removed, there is a problem of promoting appearance defects such as foaming unevenness and crushed skin (appearance defects due to unevenness on the product surface).

このように、従来方法では、可動側金型３が下死点に到達した後、射出が行なわれるため、成形条件の幅が狭く、かつ成形サイクルが長期化し、コストアップを招来するという不具合がある。また、固定側金型４の受圧面４ｃのみでプレス圧を受けるため、金型への負荷が大きく、金型の耐久性を低下させるとともに、発泡反応時にはエアが抜けにくいため、外観不良を誘発するという種々の欠点が指摘されている。   As described above, in the conventional method, since the injection is performed after the movable die 3 reaches the bottom dead center, there is a problem in that the width of the molding condition is narrow, the molding cycle is prolonged, and the cost is increased. is there. In addition, since the pressure is received only by the pressure receiving surface 4c of the fixed side mold 4, the load on the mold is large, the durability of the mold is reduced, and air is difficult to escape during the foaming reaction. Various drawbacks have been pointed out.

この発明は、このような事情に鑑みてなされたもので、型内にエアを注入した後、発泡樹脂材料を製品キャビティ内に射出充填し、その後、型内のエアを外部に排出するとともに、可動側金型を型開方向に後退操作して所定厚みの発泡樹脂成形品を成形する発泡樹脂成形品の成形方法並びに成形装置であって、可動側金型が下死点に到達する前段階において、キャビティ内圧を高圧に維持でき、成形条件の幅を拡げることができるとともに、成形サイクルを短縮化でき、しかも、金型への負荷が小さく、更に外観不良も解消できる発泡樹脂成形品の成形方法並びに成形装置を提供することを目的としている。   This invention was made in view of such circumstances, and after injecting air into the mold, the foamed resin material was injected and filled into the product cavity, and then the air in the mold was discharged to the outside, A foaming resin molded product molding method and molding apparatus for molding a foamed resin molded product having a predetermined thickness by reversing the movable mold in the mold opening direction, and before the movable mold reaches the bottom dead center In this process, the internal pressure of the cavity can be maintained at a high pressure, the range of molding conditions can be expanded, the molding cycle can be shortened, the load on the mold is small, and the appearance defects can be eliminated. It is an object to provide a method and a molding apparatus.

上記目的を達成するために本発明者等は、鋭意研究の結果、製品キャビティ外周に設けられる外周シール機構部を可動式構造とし、可動側金型が下死点に到達する前の上方位置で完全シールを達成し、高位置での射出を可能とすることにより、成形条件の幅を拡げ、薄肉成形を可能にするとともに、金型への負荷を低減できることに着目し、本発明を完成するに至った。   In order to achieve the above object, as a result of earnest research, the present inventors have made the outer peripheral seal mechanism provided on the outer periphery of the product cavity a movable structure, and at an upper position before the movable die reaches the bottom dead center. Focusing on achieving a complete seal and enabling injection at a high position, expanding the range of molding conditions, enabling thin-wall molding, and reducing the load on the mold, thereby completing the present invention. It came to.

すなわち、本発明は、可動側金型と固定側金型との間に画成される製品キャビティ内に前もってエアを注入し、キャビティ内圧を適正値に保った状態で発泡樹脂材料を製品キャビティ内に射出充填し、その後、可動側金型を型開方向に後退操作して発泡スペースを確保した状態で発泡樹脂材料の発泡反応を行なわせ、発泡樹脂成形品を所要形状に成形してなる発泡樹脂成形品の成形方法において、前記可動側金型と固定側金型を型締めする際、製品キャビティの外周に設けた外周シール機構部におけるシールプレートを上昇操作し、可動側金型の下降動作途中において製品キャビティ外周のシールプレートが可動側金型のシールリングに先行当接するとともに、エア供給・排出機構を通じて製品キャビティ内にエアを供給し、キャビティ内圧を迅速に所定値まで高める製品キャビティ外周のシール工程と、製品キャビティの外周をシールした状態で更に可動側金型を下降操作し、可動側金型が下死点に到達する前の任意のポイントで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充填工程と、上記発泡樹脂材料を射出充填した後、外周シール機構部のシールプレートを下降操作して、製品キャビティを大気開放するとともに、可動側金型を型開方向に微小ストローク後退操作して、キャビティ内圧を低下させた状態で発泡樹脂材料の発泡反応を行なわせて、所定厚みの発泡樹脂成形品を成形する発泡工程とからなることを特徴とする。   That is, according to the present invention, air is injected in advance into a product cavity defined between the movable side mold and the fixed side mold, and the foamed resin material is placed in the product cavity with the cavity internal pressure maintained at an appropriate value. After that, the movable side mold is moved backward in the mold opening direction to allow foaming reaction of the foamed resin material in a state where the foaming space is secured, and foaming is performed by molding the foamed resin molded product into the required shape. In the molding method of the resin molded product, when the movable side mold and the fixed side mold are clamped, the seal plate in the outer peripheral seal mechanism provided on the outer periphery of the product cavity is raised, and the movable side mold is lowered. In the middle, the seal plate on the outer periphery of the product cavity comes into contact with the seal ring of the movable mold in advance, and air is supplied into the product cavity through the air supply / discharge mechanism, and the cavity internal pressure The process of quickly sealing the outer periphery of the product cavity to a predetermined value, and further lowering the movable mold while the outer periphery of the product cavity is sealed, at any point before the movable mold reaches the bottom dead center Injecting and filling the foamed resin material into the product cavity, and filling and filling the foamed resin material with the foamed resin material, lowering the seal plate of the outer peripheral seal mechanism to release the product cavity to the atmosphere A foaming step of molding a foamed resin molded product having a predetermined thickness by operating the movable side mold by retreating a minute stroke in the mold opening direction to cause a foaming reaction of the foamed resin material in a state where the cavity internal pressure is reduced. It is characterized by becoming.

更に、本発明方法に使用する成形装置は、ガス注入式射出成形工法に使用する発泡樹脂成形品の成形装置であって、この成形装置は、所定ストローク可動する可動側金型と、発泡樹脂材料の供給機構と連設する固定側金型と、上記両金型の外周に設けられ、製品キャビティ内にエアを供給・排出するエア供給・排出機構と、製品キャビティの外周に沿って配設され、製品キャビティのキャビティ内圧を適正値に保つための外周シール機構部とから構成され、上記外周シール機構部は、可動側金型に設けられるシールリングと、上記シールリングと対応するように固定側金型に配置され、シリンダにより上下動可能に支持されるシールプレートとからなり、可動側金型の型締め前にシールリングとシールプレートが先行当接することで、製品キャビティのキャビティ内圧を短時間で適正値に保つことができるようにしたことを特徴とする。   Further, the molding apparatus used in the method of the present invention is a molding apparatus for a foamed resin molded product used in a gas injection type injection molding method, and this molding apparatus includes a movable side mold movable for a predetermined stroke, and a foamed resin material. A fixed mold that is connected to the supply mechanism, an air supply / discharge mechanism that is provided on the outer periphery of the two molds and that supplies and discharges air into the product cavity, and is disposed along the outer periphery of the product cavity. An outer peripheral seal mechanism for maintaining the internal pressure of the product cavity at an appropriate value, and the outer peripheral seal mechanism includes a seal ring provided on the movable mold and a fixed side corresponding to the seal ring. The seal plate is placed on the mold and supported by the cylinder so that it can move up and down. Characterized in that to be able to maintain a proper value cavity internal pressure of the Activity in a short time.

ここで、発泡樹脂成形品の用途としては、ドアトリム、リヤパーセルシェルフ、フロアトリム、トランクトリム、ラゲージサイドトリム、ルーフトリム、リヤサイドトリム等、自動車用内装部品全般に適用できる。また、発泡樹脂成形品の素材としては、合成樹脂材料中に発泡剤が混入されており、使用できる合成樹脂は、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、ポリアミド系樹脂、ポリアセタール系樹脂、ポリカーボネート系樹脂、アイオノマー系樹脂、アクリロニトリル／ブタジエン／スチレン（ＡＢＳ）樹脂等から適宜選択して良く、合成樹脂に対して混入する発泡剤としては、アゾジカルボンアミド等の有機発泡剤、あるいは重炭酸ナトリウム等の無機発泡剤が使用できる。   Here, the use of the foamed resin molded product can be applied to all automotive interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, luggage side trims, roof trims, and rear side trims. In addition, as a material of the foamed resin molded product, a foaming agent is mixed in the synthetic resin material, and usable synthetic resins are polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin. Resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. May be an organic foaming agent such as azodicarbonamide or an inorganic foaming agent such as sodium bicarbonate.

そして、本発明方法は、製品キャビティ外周のシール工程、発泡樹脂材料の射出充填工程、発泡樹脂材料の発泡工程の３工程に大別できる。まず、製品キャビティ外周のシール工程においては、可動側金型の下降に伴ない、可動側金型が例えば下死点を基準として５〜２０ｍｍ上方位置にある時、製品キャビティ外周に設けられた外周シール機構部が先行シールする。すなわち、固定側金型に設けられたシールプレートがシリンダにより上昇し、シールプレートの上端が可動側金型に設けられているシールリングに先当たりする。そして、この状態で製品キャビティ内にエア配管を通じてエアが注入される。更に、可動側金型が下降して下死点を基準として５〜１５ｍｍの位置でシールリングが変形して完全シール状態となり、この状態で製品キャビティ内にエアが継続して注入される。   And this invention method can be divided roughly into three processes, the sealing process of a product cavity outer periphery, the injection filling process of a foamed resin material, and the foaming process of a foamed resin material. First, in the sealing process of the outer periphery of the product cavity, the outer periphery provided on the outer periphery of the product cavity when the movable die is at an upper position of 5 to 20 mm with respect to the bottom dead center as the movable die is lowered. The seal mechanism part performs a preceding seal. That is, the seal plate provided on the fixed mold is lifted by the cylinder, and the upper end of the seal plate comes into contact with the seal ring provided on the movable mold. In this state, air is injected into the product cavity through the air pipe. Further, the movable mold is lowered and the seal ring is deformed at a position of 5 to 15 mm with reference to the bottom dead center to be in a completely sealed state. In this state, air is continuously injected into the product cavity.

その後、例えば、可動側金型の位置が下死点を基準として１〜１０ｍｍ上方位置にある時、任意の位置で発泡樹脂材料が製品キャビティ内に射出充填される。この発泡樹脂材料が製品キャビティ内に射出充填される時は、キャビティ内圧が適正値を保っており、発泡樹脂材料が発泡反応を行なうことなく、カウンタープレッシャー作用により迅速にゆきわたる。   Thereafter, for example, when the position of the movable mold is 1 to 10 mm above the bottom dead center, the foamed resin material is injected and filled into the product cavity at an arbitrary position. When this foamed resin material is injected and filled into the product cavity, the internal pressure of the cavity is maintained at an appropriate value, and the foamed resin material does not undergo a foaming reaction and quickly spreads by the counter pressure action.

そして、製品キャビティ内に発泡樹脂材料の射出充填が完了すれば、製品キャビティ外周に配設されている外周シール機構部においてシールプレートがシリンダの収縮作用により下降して、エアが外部に抜けきるとともに、可動側金型を所定ストローク型開方向に後退操作して、型クリアランスを拡げた状態で発泡反応が行なわれ、所定厚みの発泡樹脂成形品が成形される。   When the injection filling of the foamed resin material is completed in the product cavity, the seal plate descends due to the contraction action of the cylinder in the outer peripheral seal mechanism disposed on the outer periphery of the product cavity, and the air is completely discharged to the outside. Then, the foaming reaction is performed in a state where the movable side mold is retracted in the predetermined stroke mold opening direction and the mold clearance is widened, and a foamed resin molded article having a predetermined thickness is molded.

以上の構成から明らかなように、本発明方法においては、製品キャビティ外周に設定される外周シール機構部は、特に固定側金型に設けた昇降式のシールプレートの動作により、可動側金型の高い位置での完全シールが達成できるため、製品キャビティ内のエア圧を短時間で所定値に高めることができることから、下死点を基準とする１〜１０ｍｍの任意の射出ポイントで成形が行なえ、射出成形における成形条件の幅を拡げることができるとともに、薄肉成形にも有利であり、造形自由度を高めることができる。また、プレス圧上昇中に射出可能であるため、プレス圧は樹脂と金型の双方で受け、金型に加わる負荷を低減できる。更に、射出完了後、エアを外周シール機構部から大気開放できるため、外観不良の要因であるエア溜まりを有効に解消できる。   As is clear from the above configuration, in the method of the present invention, the outer peripheral seal mechanism set on the outer periphery of the product cavity is formed by moving the movable side mold by the operation of the elevating seal plate provided on the fixed side mold. Since complete sealing at a high position can be achieved, the air pressure in the product cavity can be increased to a predetermined value in a short time, so molding can be performed at an arbitrary injection point of 1 to 10 mm based on the bottom dead center, While the range of molding conditions in injection molding can be expanded, it is advantageous for thin-wall molding, and the degree of freedom of modeling can be increased. Further, since injection can be performed while the press pressure is increased, the press pressure is received by both the resin and the mold, and the load applied to the mold can be reduced. Furthermore, after the injection is completed, air can be released from the outer peripheral seal mechanism, so that air accumulation that is a cause of appearance defects can be effectively eliminated.

以上説明した通り、本発明に係る発泡樹脂成形品の成形方法は、可動側金型を下降操作する際、製品キャビティ外周に設けた可動式の外周シール機構部の作用により、可動側金型が下死点よりも上方位置にある時、製品キャビティ外周のシール機能を達成できるため、成形条件の幅を拡げることができるとともに、型クリアランスが広い状態で射出でき、可動側金型の下降により発泡樹脂材料を押し拡げられるので、薄肉成形も可能となり、造形自由度を高めることができるという効果を有する。更に、プレス圧上昇中に発泡樹脂材料を射出できることから、プレス圧は樹脂と金型の双方で受けることができ、成形金型に加わる負荷を低減でき、成形金型の寿命を長期化できるという効果を有する。また、射出完了後、製品キャビティ内のエアをバキューム作用で外部に除去するとともに、外周シール機構部において製品キャビティ端末が大気に開放しているため、外観不良の要因であるエア溜まりがなく、発泡ムラ、ユズ肌等の外観不良を有効に解消できるという効果を有する。   As described above, in the molding method of the foamed resin molded product according to the present invention, when the movable side mold is lowered, the movable side mold is moved by the action of the movable outer peripheral seal mechanism provided on the outer periphery of the product cavity. When it is above the bottom dead center, it can achieve the sealing function of the outer periphery of the product cavity, so that the range of molding conditions can be expanded, the mold clearance can be widened, and foaming is achieved by lowering the movable mold Since the resin material can be expanded, it is possible to form a thin wall and increase the degree of freedom of modeling. Furthermore, since the foamed resin material can be injected while the press pressure rises, the press pressure can be received by both the resin and the mold, the load applied to the mold can be reduced, and the life of the mold can be extended. Has an effect. In addition, after the injection is completed, the air inside the product cavity is removed to the outside by a vacuum action, and the product cavity terminal is open to the atmosphere at the outer peripheral seal mechanism part, so there is no air accumulation that is a cause of appearance defects, foaming It has the effect of effectively eliminating appearance defects such as unevenness and skin damage.

本発明方法を適用して成形したドアトリムアッパーを備えた自動車用ドアトリムを示す正面図である。It is a front view which shows the door trim for motor vehicles provided with the door trim upper shape | molded by applying the method of this invention. 図１中II−II線断面図である。It is the II-II sectional view taken on the line in FIG. 本発明方法に使用する成形装置の一実施例の構成を示す全体図である。It is a general view which shows the structure of one Example of the shaping | molding apparatus used for this invention method. 本発明方法における可動側金型のプレスチャート並びに成形圧力、エア圧の相関関係を示すタイムチャート図である。It is a time chart which shows the press chart of a movable side mold in the method of the present invention, and the correlation of molding pressure and air pressure. 本発明方法における製品キャビティ外周のシール工程を示す説明図である。It is explanatory drawing which shows the sealing process of the product cavity outer periphery in this invention method. 本発明方法における発泡樹脂材料の射出充填工程を示す説明図である。It is explanatory drawing which shows the injection filling process of the foaming resin material in this invention method. 本発明方法における発泡樹脂材料の製品キャビティ内への充填完了時の状態を示す説明図である。It is explanatory drawing which shows the state at the time of completion of filling to the product cavity of the foamed resin material in the method of this invention. 本発明方法における発泡樹脂材料の発泡工程を示す説明図である。It is explanatory drawing which shows the foaming process of the foamed resin material in this invention method. 従来のドアトリムを示す正面図である。It is a front view which shows the conventional door trim. 従来のドアトリムの成形方法に使用する成形装置の全体図である。It is a general view of the shaping | molding apparatus used for the shaping | molding method of the conventional door trim. 従来の成形方法における外周シール機構部の作用を示す説明図である。It is explanatory drawing which shows the effect | action of the outer periphery sealing mechanism part in the conventional shaping | molding method. 従来のドアトリムの成形方法における可動側金型のプレスチャート並びに成形圧力、エア圧の相関関係を示すタイムチャート図である。It is a time chart which shows the correlation of the press chart of a movable side mold in the conventional door trim molding method, and molding pressure and air pressure. 従来のドアトリムの成形方法における不具合点を示す説明図である。It is explanatory drawing which shows the malfunction in the shaping | molding method of the conventional door trim.

以下、本発明に係る発泡樹脂成形品の成形方法並びに成形装置の具体的な実施例について、添付図面を参照しながら詳細に説明する。尚、念のため付言すれば、本発明の要旨は特許請求の範囲に記載した通りであり、以下に説明する実施例の内容は、本発明の一例を単に示すものに過ぎない。   Hereinafter, specific examples of a method for molding a foamed resin molded article and a molding apparatus according to the present invention will be described in detail with reference to the accompanying drawings. Note that the gist of the present invention is as described in the scope of claims, and the contents of the embodiments described below are merely examples of the present invention.

図１乃至図８は本発明の一実施例を示すもので、図１，図２は本発明方法により成形したドアトリムを示す正面図並びに断面図、図３は本発明方法に使用する成形装置の概略構成を示す説明図、図４は本発明方法に使用する可動側金型のプレスチャート並びに成形圧力、エア圧の相関関係を示すタイムチャート図、図５乃至図８は本発明方法の各工程を示す説明図である。   1 to 8 show an embodiment of the present invention. FIGS. 1 and 2 are front and sectional views showing a door trim formed by the method of the present invention, and FIG. 3 shows a molding apparatus used in the method of the present invention. FIG. 4 is an explanatory diagram showing a schematic configuration, FIG. 4 is a press chart of a movable mold used in the method of the present invention, a time chart showing the correlation between molding pressure and air pressure, and FIGS. 5 to 8 are steps of the method of the present invention. It is explanatory drawing which shows.

図１，図２において、自動車用ドアトリム１０は、ドアトリムアッパー（発泡樹脂成形品）２０とドアトリムロア（樹脂成形品）３０の上下二分割体から構成されている。上記ドアトリムアッパー２０にはインサイドハンドルユニット１１、また、乗員が肘を載せるアームレスト部にプルハンドル１２やパワーウインドウスイッチフィニッシャー１３が取り付けられている。一方、ドアトリムロア３０には備品を収容できるポケット開口１４が開設されているとともに、そのフロント側にスピーカグリル１５がドアトリムロア３０と一体、または別体に設けられている。   In FIG. 1 and FIG. 2, the automobile door trim 10 is composed of an upper and lower divided body of a door trim upper (foamed resin molded product) 20 and a door trim lower (resin molded product) 30. The door trim upper 20 is provided with an inside handle unit 11 and a pull handle 12 and a power window switch finisher 13 at an armrest portion on which an occupant places an elbow. On the other hand, the door trim lower 30 is provided with a pocket opening 14 in which equipment can be accommodated, and a speaker grill 15 is provided integrally or separately with the door trim lower 30 on the front side thereof.

更に、上記ドアトリムアッパー２０及びドアトリムロア３０の構成について説明すると、ドアトリムアッパー２０は本発明では所要形状に射出成形された発泡樹脂成形品が使用されており、合成樹脂中に発泡剤が混入された発泡樹脂材料を素材としている。使用できる合成樹脂としては、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、ポリアミド系樹脂、ポリアセタール系樹脂、ポリカーボネート系樹脂、アイオノマー系樹脂、アクリロニトリル／ブタジエン／スチレン（ＡＢＳ）樹脂等があり、この合成樹脂に対して、アゾジカルボンアミド等の有機発泡剤あるいは重炭酸ナトリウム等の無機発泡剤を混入したものを使用している。   Further, the structure of the door trim upper 20 and the door trim lower 30 will be described. In the present invention, a foamed resin molded product that is injection-molded into a required shape is used for the door trim upper 20, and a foaming agent is mixed in the synthetic resin. Made of foamed resin material. Synthetic resins that can be used include polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, polyamide resins, polyacetal resins, polycarbonate resins, ionomer resins, There are acrylonitrile / butadiene / styrene (ABS) resins and the like, and these synthetic resins are mixed with an organic foaming agent such as azodicarbonamide or an inorganic foaming agent such as sodium bicarbonate.

一方、ドアトリムロア３０は、射出成形工法、モールドプレス成形工法により量産できる合成樹脂成形品が使用されており、素材としての合成樹脂は、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、ポリアミド系樹脂、ポリアセタール系樹脂、ポリカーボネート系樹脂、アイオノマー系樹脂、アクリロニトリル／ブタジエン／スチレン（ＡＢＳ）樹脂等から適宜選択されて良く、また、所望により合成樹脂にタルク、クレイ、木粉等のフィラーを混入しても良い。   On the other hand, the door trim lower 30 uses a synthetic resin molded product that can be mass-produced by an injection molding method or a mold press molding method, and the synthetic resin as a material is a polyethylene resin, a polypropylene resin, a polystyrene resin, or a polyethylene terephthalate system. Resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. A filler such as talc, clay, or wood powder may be mixed in the resin.

そして、図１，図２に示すドアトリム１０は、ドアトリムアッパー２０とドアトリムロア３０との外観上のアクセント効果により、良好な製品外観が得られ、成形金型のコンパクト化を図るとともに、特に、ドアトリムアッパー２０を発泡樹脂成形品から構成することで軽量化にも大きく貢献できる。   The door trim 10 shown in FIGS. 1 and 2 has a good product appearance due to the accent effect on the appearance of the door trim upper 20 and the door trim lower 30, and the molding die can be made compact. By configuring the upper 20 from a foamed resin molded product, it is possible to greatly contribute to weight reduction.

ところで、上記ドアトリムアッパー２０は、軽量化に貢献できることに加えて、良好な外観性能が確保されている。以下、ドアトリムアッパー２０の成形方法に使用する成形装置４０の構成について図３を基に説明する。本発明方法に使用する成形装置４０は、カウンタープレッシャー工法を採用した発泡樹脂成形品の成形方法に適用される。具体的には、この成形装置４０は、相互に型締め、型開き可能な可動側金型５０、固定側金型６０と、発泡樹脂材料Ｍの射出充填時における製品キャビティＣの内圧を高める一方、発泡樹脂材料Ｍの発泡反応時には製品キャビティＣの内圧を低めるために、製品キャビティＣ内にエアを供給・排出するエア供給・排出機構７０と、製品キャビティＣの外周に設定される外周シール機構部８０とから大略構成されている。尚、エア供給・排出機構７０において使用するガスは、Ｎ2 ガス、ＣＯ2 ガスの他、工場エア等を使用することもできる。 By the way, the door trim upper 20 has a good appearance performance in addition to being able to contribute to weight reduction. Hereinafter, the structure of the shaping | molding apparatus 40 used for the shaping | molding method of the door trim upper 20 is demonstrated based on FIG. The molding apparatus 40 used in the method of the present invention is applied to a method for molding a foamed resin molded product employing a counter pressure method. Specifically, the molding device 40 increases the internal pressure of the product cavity C at the time of injection filling of the foamed resin material M and the movable side mold 50 and the fixed side mold 60 that can be clamped and opened with each other. In order to reduce the internal pressure of the product cavity C during the foaming reaction of the foamed resin material M, an air supply / discharge mechanism 70 for supplying and discharging air into the product cavity C and an outer peripheral seal mechanism set on the outer periphery of the product cavity C The unit 80 is roughly configured. The gas used in the air supply / discharge mechanism 70 may be N 2 gas, CO 2 gas, factory air, or the like.

次いで、上記成形装置４０の構成を更に具体的に説明する。可動側金型５０は、昇降シリンダ５１により所定ストローク上下動可能であるとともに、固定側金型６０には、図示しない射出機から供給される発泡樹脂材料Ｍの樹脂通路であるホットランナ６１、ゲート６２が設けられている。更に、エア供給・排出機構７０は、共用配管７１が固定側金型６０に配設されており、この共用配管７１は、外部のブロワ７２とバキュームポンプ７３にそれぞれ分岐接続し、切替弁７４を介して共用配管７１はエア供給管、あるいはエア排出管として機能する。   Next, the configuration of the molding apparatus 40 will be described more specifically. The movable side mold 50 can be moved up and down by a predetermined stroke by an elevating cylinder 51, and the fixed side mold 60 includes a hot runner 61 that is a resin passage of a foamed resin material M supplied from an unillustrated injection machine, a gate. 62 is provided. Further, in the air supply / discharge mechanism 70, a common pipe 71 is disposed in the fixed mold 60, and the common pipe 71 is branched and connected to an external blower 72 and a vacuum pump 73, respectively, and a switching valve 74 is provided. The common pipe 71 functions as an air supply pipe or an air discharge pipe.

次に、製品キャビティＣの外周に設けられている外周シール機構部８０の構成について説明すると、可動側金型５０には、溝部５２が設けられ、この溝部５２内にシールリング８１が収容されており、可動側金型５０と固定側金型６０の型締め時において上記シールリング８１とシールするように固定側金型６０の対応箇所には、シールプレート８２が配置されており、シールプレート８２はシリンダ８３により所定ストローク上下動可能に支持されている。そして、この外周シール機構部８０の動作により、可動側金型５０が下死点まで到達する前の可動側金型５０の高い位置でのシール機構を迅速に達成できるとともに、発泡反応時においてはシールプレート８２を下降させることで、製品キャビティＣの端末を大気開放させることができる。すなわち、外周シール機構部８０の作用により、製品キャビティＣの外周を迅速にシールすることができるため、製品キャビティＣ内のエア圧を短時間で所定値まで上昇させることができ、発泡樹脂材料Ｍの射出ポイントを可動側金型５０の下死点に到達する前の射出ポイント（１〜１０ｍｍ）で発泡樹脂材料Ｍの射出を可能とすることができる。このことに付随して、成形サイクルの短縮化並びにプレス圧を発泡樹脂材料Ｍと金型（具体的には固定側金型６０の受圧面６３）の双方で受けることができ、成形金型の耐久性を高めることができる等の種々の効果が期待できる。   Next, the configuration of the outer peripheral seal mechanism 80 provided on the outer periphery of the product cavity C will be described. The movable-side mold 50 is provided with a groove 52, and the seal ring 81 is accommodated in the groove 52. A seal plate 82 is disposed at a corresponding position of the fixed side mold 60 so as to seal with the seal ring 81 when the movable side mold 50 and the fixed side mold 60 are clamped. Is supported by a cylinder 83 so as to be movable up and down a predetermined stroke. The operation of the outer peripheral seal mechanism 80 can quickly achieve a sealing mechanism at a high position of the movable mold 50 before the movable mold 50 reaches the bottom dead center. By lowering the seal plate 82, the end of the product cavity C can be opened to the atmosphere. In other words, the outer periphery of the product cavity C can be quickly sealed by the action of the outer periphery sealing mechanism 80, so that the air pressure in the product cavity C can be raised to a predetermined value in a short time, and the foamed resin material M It is possible to inject the foamed resin material M at an injection point (1 to 10 mm) before reaching the bottom dead center of the movable mold 50. Accompanying this, shortening of the molding cycle and pressing pressure can be received by both the foamed resin material M and the mold (specifically, the pressure receiving surface 63 of the fixed side mold 60). Various effects such as an increase in durability can be expected.

以下、図５乃至図８に基づいて、本発明方法を具体的に説明する。本発明に係るドアトリムアッパー２０の成形方法は、製品キャビティ外周のシール工程、発泡樹脂材料Ｍの射出充填工程、発泡樹脂材料Ｍの発泡工程に大別できる。まず、製品キャビティ外周のシール工程については、図５に示すように、可動側金型５０が昇降シリンダ５１の動作により所定ストローク下降するが、可動側金型５０の下死点を基準として、それより５〜２０ｍｍ上方位置にある時、好ましくは２０ｍｍ程度の段階で、製品キャビティＣの外周に設けられた外周シール機構部８０が先当たりする。具体的には、固定側金型６０に設けられているシールプレート８２がシリンダ８３の伸長動作により上昇し、可動側金型５０が５〜２０ｍｍ、下死点より上方位置にある時、シールリング８１とシールプレート８２が当接する。また、エア供給・排出機構７０については、ブロワ７２から共用配管７１を通して製品キャビティＣ内にエアが供給される。   Hereinafter, the method of the present invention will be specifically described with reference to FIGS. The molding method of the door trim upper 20 according to the present invention can be broadly divided into a sealing process for the outer periphery of the product cavity, an injection filling process for the foamed resin material M, and a foaming process for the foamed resin material M. First, as shown in FIG. 5, the movable mold 50 is moved down by a predetermined stroke by the operation of the lifting cylinder 51, as shown in FIG. 5, with reference to the bottom dead center of the movable mold 50. The outer peripheral seal mechanism 80 provided on the outer periphery of the product cavity C comes into contact with the outer periphery of the product cavity C preferably at a stage of about 20 mm when it is 5 to 20 mm above. Specifically, when the seal plate 82 provided on the fixed side mold 60 is lifted by the extension operation of the cylinder 83, and the movable side mold 50 is located at a position 5 to 20 mm above the bottom dead center, the seal ring 81 and the seal plate 82 abut. As for the air supply / discharge mechanism 70, air is supplied from the blower 72 through the common pipe 71 into the product cavity C.

そして、図６に示すように、可動側金型５０の下降操作が継続して行なわれ、可動側金型５０と固定側金型６０との型クリアランスが５〜１５ｍｍで、シールリング８１が偏平状に変形して完全シール状態となる。更に、可動側金型５０の下降操作が継続して行なわれると同時に、ホットランナ６１、ゲート６２を通して製品キャビティＣ内に発泡樹脂材料Ｍが射出充填される。この発泡樹脂材料Ｍとしては、前述した通りポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、ポリアミド系樹脂、ポリアセタール系樹脂、ポリカーボネート系樹脂、アイオノマー系樹脂、アクリロニトリル／ブタジエン／スチレン（ＡＢＳ）樹脂等の合成樹脂中に発泡剤を混入した素材が使用される。従って、可動側金型５０の上方位置で発泡樹脂材料Ｍを射出充填できるため、成形条件の幅を拡げることができるとともに、可動側金型５０の下降により、発泡樹脂材料Ｍを押し拡げられることから、薄肉成形も可能になる等、造形自由度を高めることができる。   Then, as shown in FIG. 6, the lowering operation of the movable mold 50 is continued, the mold clearance between the movable mold 50 and the fixed mold 60 is 5 to 15 mm, and the seal ring 81 is flat. It is deformed into a complete seal state. Furthermore, the lowering operation of the movable mold 50 is continuously performed, and at the same time, the foamed resin material M is injected and filled into the product cavity C through the hot runner 61 and the gate 62. As the foamed resin material M, as described above, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, A material in which a foaming agent is mixed in a synthetic resin such as an ionomer resin or acrylonitrile / butadiene / styrene (ABS) resin is used. Therefore, since the foamed resin material M can be injected and filled at the upper position of the movable mold 50, the range of molding conditions can be expanded, and the foamed resin material M can be expanded by the lowering of the movable mold 50. Therefore, it is possible to increase the degree of freedom of modeling, such as enabling thin wall molding.

次いで、図７に示すように、可動側金型５０が下死点まで降下すれば、発泡樹脂材料Ｍは製品キャビティＣの隅々にまでゆきわたる。この時、可動側金型５０からのプレス圧は、固定側金型６０の受圧面６３と発泡樹脂材料Ｍの双方で受けるため、成形金型５０，６０に加わる負荷を軽減でき、可動側金型５０及び固定側金型６０の寿命を長期化することができる。そして、製品キャビティＣ内に発泡樹脂材料Ｍを射出充填した後、図８に示すように、エア供給・排出機構７０においては、切替弁７４が切り替わり、バキュームポンプ７３と共用配管７１とが接続し、共用配管７１を通して製品キャビティＣ内の余ったエアが外部に排出されるとともに、可動側金型５０が微小ストローク型開方向に後退して発泡スペースが確保され、製品キャビティＣの内圧が低下するため、発泡樹脂材料Ｍは発泡反応が有効に開始される。この時、外周シール機構部８０においては、シールプレート８２はシリンダ８３の収縮動作により固定側金型６０内に引き込まれており、製品キャビティＣは大気開放されているため、エアが完全に抜けきることで、エア溜まりを有効に抑えることができ、発泡ムラやユズ肌等の外観不良を解消できる。   Next, as shown in FIG. 7, when the movable mold 50 is lowered to the bottom dead center, the foamed resin material M is spread to every corner of the product cavity C. At this time, since the pressing pressure from the movable die 50 is received by both the pressure receiving surface 63 of the fixed die 60 and the foamed resin material M, the load applied to the molding dies 50 and 60 can be reduced, and the movable die can be reduced. The lifetimes of the mold 50 and the fixed-side mold 60 can be extended. Then, after the foamed resin material M is injected and filled into the product cavity C, as shown in FIG. 8, in the air supply / discharge mechanism 70, the switching valve 74 is switched, and the vacuum pump 73 and the common pipe 71 are connected. The excess air in the product cavity C is discharged to the outside through the common pipe 71, and the movable mold 50 is retracted in the micro stroke mold opening direction to secure a foaming space, and the internal pressure of the product cavity C is reduced. Therefore, the foaming reaction of the foamed resin material M is effectively started. At this time, in the outer peripheral seal mechanism 80, the seal plate 82 is drawn into the fixed-side mold 60 by the contraction operation of the cylinder 83, and the product cavity C is opened to the atmosphere. Thus, air accumulation can be effectively suppressed, and appearance defects such as foaming unevenness and crushed skin can be eliminated.

このように、本発明方法によれば、製品キャビティＣの外周に設定されている外周シール機構部８０は、シールプレート８２を昇降式としたため、可動側金型５０の高い位置で製品キャビティＣの外周をシールすることができる。その結果、発泡樹脂材料Ｍの射出時期を早めることが可能となり、成形サイクルの短縮化並びに薄肉成形を可能にする等、造形自由度を高めることができるという効果がある。また、可動側金型５０の下降動作中に発泡樹脂材料Ｍを射出充填するため、プレス圧を発泡樹脂材料Ｍの流動性で吸収することができるため、成形金型５０，６０に加わる負荷を軽減でき、成形金型５０，６０の寿命を長期化できるとともに、発泡反応時においては、シールプレート８２を下降操作することで、製品キャビティＣを大気開放することにより、エア溜まりをなくし外観不良を未然に防止することができ、外観性能の優れたドアトリムアッパー２０を成形することができる。   As described above, according to the method of the present invention, the outer peripheral seal mechanism 80 set on the outer periphery of the product cavity C is made up of the seal plate 82, so that the product cavity C is located at a high position of the movable mold 50. The outer periphery can be sealed. As a result, it is possible to advance the injection timing of the foamed resin material M, and it is possible to increase the degree of freedom of modeling, such as shortening the molding cycle and enabling thin-wall molding. Further, since the foamed resin material M is injected and filled during the lowering operation of the movable mold 50, the press pressure can be absorbed by the fluidity of the foamed resin material M, so that the load applied to the molding dies 50 and 60 is increased. The life of the molding dies 50 and 60 can be extended, and during the foaming reaction, the seal plate 82 is lowered to release the product cavity C to the atmosphere, thereby eliminating air accumulation and causing poor appearance. Therefore, the door trim upper 20 with excellent appearance performance can be formed.

以上説明した実施例は、上下二分割構造のドアトリム１０におけるドアトリムアッパー２０の成形に本発明方法を適用したが、適用対象はドアトリムアッパー２０に限定されることなく、発泡樹脂成形品全般に適用できる。また、本実施例では、エア供給・排出機構７０を適用したが、エア供給機構のみを採用し、バキュームポンプを廃止することもできる。   In the embodiment described above, the method of the present invention is applied to the molding of the door trim upper 20 in the door trim 10 having the upper and lower split structures. However, the application target is not limited to the door trim upper 20 and can be applied to general foamed resin molded products. . In this embodiment, the air supply / discharge mechanism 70 is applied. However, only the air supply mechanism can be adopted and the vacuum pump can be eliminated.

１０ 自動車用ドアトリム
２０ ドアトリムアッパー（発泡樹脂成形品）
３０ ドアトリムロア（樹脂成形品）
４０ 成形装置
５０ 可動側金型
５１ 昇降シリンダ
５２ 溝部
６０ 固定側金型
６１ ホットランナ
６２ ゲート
６３ 受圧面
７０ エア供給・排出機構
７１ 共用配管
７２ ブロワ
７３ バキュームポンプ
７４ 切替弁
８０ 外周シール機構部
８１ シールリング
８２ シールプレート
８３ シリンダ
Ｃ 製品キャビティ
Ｍ 発泡樹脂材料 10 Automotive door trim 20 Door trim upper (foamed resin molded product)
30 Door trim lower (resin molded product)
DESCRIPTION OF SYMBOLS 40 Molding apparatus 50 Movable side metal mold 51 Lifting cylinder 52 Groove part 60 Fixed side metal mold 61 Hot runner 62 Gate 63 Pressure receiving surface 70 Air supply / discharge mechanism 71 Common piping 72 Blower 73 Vacuum pump 74 Switching valve 80 Outer seal mechanism part 81 Seal Ring 82 Seal plate 83 Cylinder C Product cavity M Foamed resin material

Claims (2)

可動側金型（５０）と固定側金型（６０）との間に画成される製品キャビティ（Ｃ）内に前もってエアを注入し、キャビティ内圧を適正値に保った状態で発泡樹脂材料（Ｍ）を製品キャビティ（Ｃ）内に射出充填し、その後、可動側金型（５０）を型開方向に後退操作して発泡スペースを確保した状態で発泡樹脂材料（Ｍ）の発泡反応を行なわせ、発泡樹脂成形品（２０）を所要形状に成形してなる発泡樹脂成形品（２０）の成形方法において、
前記可動側金型（５０）と固定側金型（６０）を型締めする際、製品キャビティ（Ｃ）の外周に設けた外周シール機構部（８０）におけるシールプレート（８２）を上昇操作し、可動側金型（５０）の下降動作途中において製品キャビティ（Ｃ）外周のシールプレート（８２）が可動側金型（５０）のシールリング（８１）に先行当接するとともに、エア供給・排出機構（７０）を通じて製品キャビティ（Ｃ）内にエアを供給し、キャビティ内圧を迅速に所定値まで高める製品キャビティ外周のシール工程と、
製品キャビティ（Ｃ）の外周をシールした状態で更に可動側金型（５０）を下降操作し、可動側金型（５０）が下死点に到達する前の任意のポイントで発泡樹脂材料（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）の射出充填工程と、
上記発泡樹脂材料（Ｍ）を射出充填した後、外周シール機構部（８０）のシールプレート（８２）を下降操作して、製品キャビティ（Ｃ）を大気開放するとともに、可動側金型（５０）を型開方向に微小ストローク後退操作して、キャビティ内圧を低下させた状態で発泡樹脂材料（Ｍ）の発泡反応を行なわせて、所定厚みの発泡樹脂成形品（２０）を成形する発泡工程と、
からなることを特徴とする発泡樹脂成形品の成形方法。 Air is previously injected into the product cavity (C) defined between the movable mold (50) and the fixed mold (60), and the foamed resin material (with the internal pressure of the cavity maintained at an appropriate value) M) is injected and filled into the product cavity (C), and then the foaming resin material (M) is subjected to the foaming reaction with the movable side mold (50) retracted in the mold opening direction to secure the foaming space. In the molding method of the foamed resin molded product (20) formed by molding the foamed resin molded product (20) into a required shape,
When clamping the movable side mold (50) and the fixed side mold (60), the seal plate (82) in the outer peripheral seal mechanism (80) provided on the outer periphery of the product cavity (C) is raised, During the lowering operation of the movable mold (50), the seal plate (82) on the outer periphery of the product cavity (C) comes into contact with the seal ring (81) of the movable mold (50) in advance, and an air supply / discharge mechanism ( 70) supplying air into the product cavity (C) through 70) to rapidly increase the cavity internal pressure to a predetermined value;
With the outer periphery of the product cavity (C) sealed, the movable mold (50) is further moved down, and the foamed resin material (M) is added at an arbitrary point before the movable mold (50) reaches the bottom dead center. ) In the product cavity (C) by injection filling of the foamed resin material (M),
After the foamed resin material (M) is injected and filled, the seal plate (82) of the outer peripheral seal mechanism (80) is lowered to release the product cavity (C) to the atmosphere, and the movable mold (50). A foaming step of molding the foamed resin molded article (20) having a predetermined thickness by performing a micro stroke retreat operation in the mold opening direction to cause a foaming reaction of the foamed resin material (M) in a state in which the cavity internal pressure is reduced. ,
A method for molding a foamed resin molded product comprising: ガス注入式射出成形工法に使用する発泡樹脂成形品（２０）の成形装置（４０）であって、この成形装置（４０）は、所定ストローク可動する可動側金型（５０）と、発泡樹脂材料（Ｍ）の供給機構と連設する固定側金型（６０）と、上記両金型（５０，６０）の外周に設けられ、製品キャビティ（Ｃ）内にエアを供給・排出するエア供給・排出機構（７０）と、製品キャビティ（Ｃ）の外周に沿って配設され、製品キャビティ（Ｃ）のキャビティ内圧を適正値に保つための外周シール機構部（８０）とから構成され、上記外周シール機構部（８０）は、可動側金型（５０）に設けられるシールリング（８１）と、上記シールリング（８１）と対応するように固定側金型（６０）に配置され、シリンダ（８３）により上下動可能に支持されるシールプレート（８２）とからなり、可動側金型（５０）の型締め前にシールリング（８１）とシールプレート（８２）が先行当接することで、製品キャビティ（Ｃ）のキャビティ内圧を短時間で適正値に保つことができるようにしたことを特徴とする発泡樹脂成形品の成形装置。   A molding apparatus (40) for a foamed resin molded product (20) used in a gas injection type injection molding method, the molding apparatus (40) comprising a movable mold (50) movable for a predetermined stroke, and a foamed resin material (M) A fixed-side mold (60) that is connected to the supply mechanism, and an air supply / discharge unit that is provided on the outer periphery of both molds (50, 60) to supply and discharge air into the product cavity (C). The discharge mechanism (70) and an outer peripheral seal mechanism (80) disposed along the outer periphery of the product cavity (C) for maintaining the cavity internal pressure of the product cavity (C) at an appropriate value. The seal mechanism (80) is disposed on the fixed side mold (60) so as to correspond to the seal ring (81) provided on the movable side mold (50) and the seal ring (81), and the cylinder (83 ) Is supported so that it can move up and down. The seal ring (81) and the seal plate (82) come into contact with each other before the movable side mold (50) is clamped, so that the cavity internal pressure of the product cavity (C) can be reduced in a short time. A molding apparatus for foamed resin molded products, characterized in that it can be maintained at an appropriate value.
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