JP2013248847A - Method of manufacturing complex foam molded article - Google Patents

Method of manufacturing complex foam molded article Download PDF

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JP2013248847A
JP2013248847A JP2012126792A JP2012126792A JP2013248847A JP 2013248847 A JP2013248847 A JP 2013248847A JP 2012126792 A JP2012126792 A JP 2012126792A JP 2012126792 A JP2012126792 A JP 2012126792A JP 2013248847 A JP2013248847 A JP 2013248847A
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beads
foam
foamed
cavity
mold
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Tatsumi Sugimoto
達己 杉本
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TOYO CORK KK
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TOYO CORK KK
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B29C44/44—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form
    • B29C44/445—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form in the form of expandable granules, particles or beads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/3415—Heating or cooling
    • B29C44/3426—Heating by introducing steam in the mould

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  • Molding Of Porous Articles (AREA)
  • Laminated Bodies (AREA)

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a complex foam molded article, the method that facilitates manufacturig the complex foam molded article having a plurality of foaming layers comprising different desired properties.SOLUTION: A method of manufacturing a complex foam molded article is characterized by comprising: a first foaming bead filling step (S2) of filling a first foaming bead 10 in a cavity 7 of a molding mold 4; a preliminary molding step (S3) of heating the first foaming bead filled in the cavity and fuse-bonding it to a level that erecting bodies of the first foaming bead are not separated from each other; a capacity increasing step (S5) of increasing a capacity in the cavity of the molding mold; a second foaming bead filling step (S9) of filling a second foaming bead 20 different in properties from the first foaming bead into the cavity increased in the capacity; and a foaming molding step (S10) of fuse-bonding the first foaming layer 1 comprising the first foaming bead and the second foaming layer 2 comprising the second foaming bead while heating and foaming the first foaming bead and the second foaming bead filled in the cavity.

Description

本発明は、複数種類の発泡ビーズを用い、物性の異なる発泡層を複数備えた複合発泡成型体の製造方法に関する。   The present invention relates to a method for producing a composite foamed molded article using a plurality of types of foam beads and having a plurality of foam layers having different physical properties.

従来より、上述のような複合発泡成型体は、例えば精密機器等の梱包時に使用する緩衝材や運搬用容器の他、給湯機器の保温材や建築用の資材として等、あらゆるものに使用される。
例えば下記特許文献１には、硬質部と軟質部とを備えた緩衝材の製造方法が開示されている。ここには、仕切り部材により仕切られた成型用空間（以下、キャビティという）に発泡倍率の異なる発泡ビーズを充填し、仕切り部材を退避させた後に加熱融着する製造方法が記載されている。これによれば、引用文献１・図１（Ａ）に示すように上下方向に物性の異なる硬質部と軟質部とを備えた緩衝材を製造することができる。 Conventionally, the composite foam molded body as described above is used for everything, for example, as a heat insulating material for a hot water supply device and a building material, in addition to a cushioning material and a container for transportation used for packing precision equipment and the like. .
For example, Patent Document 1 below discloses a method of manufacturing a cushioning material having a hard part and a soft part. Here, a manufacturing method is described in which foaming beads having different expansion ratios are filled in a molding space (hereinafter referred to as a cavity) partitioned by a partition member, and the partition member is retracted and then heat-sealed. According to this, as shown in the cited document 1 and FIG. 1 (A), it is possible to manufacture a cushioning material including a hard portion and a soft portion having different physical properties in the vertical direction.

また特許文献２には、発泡性原料が溶融固化されてなる第１層と、発泡性原料が発泡溶着されてなる第２層と、第１層と第２層との間に積層されるとともに、第２層の発泡率に比して小さい発泡率を有するように発泡性原料を発泡溶着させて成形される中間層とからなる発泡樹脂材が記載されている。これによれば、溶融固化された高硬度の第１層と高発泡率の第２層との間を中間層によって強く接合することができるとされている。   In Patent Document 2, the first layer formed by melting and solidifying the foamable raw material, the second layer formed by foaming and welding the foamable raw material, and the first layer and the second layer are laminated. A foamed resin material comprising an intermediate layer formed by foaming and welding a foamable raw material so as to have a foaming rate smaller than that of the second layer is described. According to this, it is said that the intermediate layer can strongly bond between the melted and solidified first layer having high hardness and the second layer having high foaming rate.

特開２００２−２３４０４４号公報JP 2002-234044 A 特開２００９−２８６０３０号公報JP 2009-286030 A

ところで、特許文献１に記載のようにキャビティ内に仕切り部材を介在させて２層の複合発泡成型体を製造する場合、複合発泡成型体を上下方向に仕切り、その仕切り部材を進退自在に構成することはできても、厚み方向（引用文献１・図４では、紙面左右方向）に２層に積層された略扁平な複合発泡成型体を製造することは難しい。つまり、キャビティを厚み方向に仕切るためには、複合発泡成型体の平面視形状と略同形状の仕切り部材が必要となり、仕切り部材が大型化するため、成型装置も大型化するなどの問題がある。よって、キャビティを厚み方向（成型型の移動方向）に仕切ることなく、異なる所望の物性からなる複数の発泡層を備えた複合発泡成型体を容易に製造できる方法が求められている。   By the way, as described in Patent Document 1, when a two-layer composite foam molded body is manufactured by interposing a partition member in the cavity, the composite foam molded body is partitioned in the vertical direction, and the partition member is configured to be movable forward and backward. Although it is possible, it is difficult to manufacture a substantially flat composite foam molded body that is laminated in two layers in the thickness direction (in the cited document 1 and FIG. 4, the left-right direction on the paper surface). In other words, in order to partition the cavity in the thickness direction, a partition member having substantially the same shape as the planar view of the composite foam molded body is required, and the partition member is enlarged, so that the molding apparatus is also increased in size. . Therefore, there is a need for a method capable of easily producing a composite foam molded body having a plurality of foam layers having different desired physical properties without partitioning the cavity in the thickness direction (the moving direction of the mold).

特許文献２には、仕切り部材を用いずに複数層を備えた複合発泡成型体を製造する方法が開示されている。しかしここに記載の第１層は、完全に発泡樹脂が溶融固化された高硬度の樹脂材が前提とされているため、第１層を高硬度の樹脂層ではなく、異なる物性の発泡層とすることは考慮されていない。またこのように第１層を溶融固化させるためには、第１層を形成する際に高温高圧の蒸気を供給する工程が必須となる。   Patent Document 2 discloses a method of manufacturing a composite foam molded body having a plurality of layers without using a partition member. However, since the first layer described here is premised on a high-hardness resin material in which the foamed resin is completely melted and solidified, the first layer is not a high-hardness resin layer but a foam layer having different physical properties. It is not considered to do. Further, in order to melt and solidify the first layer in this way, a step of supplying high-temperature and high-pressure steam is essential when forming the first layer.

さらに特許文献２に記載されている第１層と中間層とは、同じ発泡性材料からなり、高圧蒸気を供給し金型の熱を真近で受けて第１層を形成した後、高圧蒸気よりも低圧の蒸気を供給して中間層を半溶融させる工程を要する。そしてその後、金型を移動させてから第２層となる発泡性材料を充填し、再度蒸気を供給し発泡溶着を行う。
よって、特許文献２に記載の方法は、特許文献２にも記載されているようにあくまで製品の外装面に適するような高硬度の溶融層を有した発泡樹脂成形体の製造方法に限られるといえる。 Furthermore, the first layer and the intermediate layer described in Patent Document 2 are made of the same foamable material, and after supplying the high pressure steam and receiving the heat of the mold in the immediate vicinity to form the first layer, the high pressure steam A process of supplying a lower pressure steam and semi-melting the intermediate layer is required. And after that, after moving a metal mold | die, it fills with the foamable material used as the 2nd layer, supplies vapor | steam again, and performs foaming welding.
Therefore, when the method described in Patent Document 2 is limited to a method for producing a foamed resin molded body having a high-hardness molten layer suitable for an exterior surface of a product as described in Patent Document 2 as well. I can say that.

本発明は、上記に鑑みなされたもので、異なる所望の物性からなる複数の発泡層を備えた複合発泡成型体を容易に製造できる複合発泡成型体の製造方法を提供することを目的としている。   The present invention has been made in view of the above, and an object of the present invention is to provide a method for manufacturing a composite foam molded body that can easily manufacture a composite foam molded body having a plurality of foam layers having different desired physical properties.

本発明に係る複合発泡成型体の製造方法は、第１発泡ビーズを成型型のキャビティ内に充填する第１発泡ビーズ充填工程と、前記キャビティ内に充填した第１発泡ビーズを加熱して、第１発泡ビーズの粒体同士が離れない程度に融着させる予備成型工程と、前記成型型を移動させて、該成型型のキャビティ内の容積を増大させる容積増大工程と、前記第１発泡ビーズとは物性の異なる第２発泡ビーズを前記容積の増大したキャビティ内に充填する第２発泡ビーズ充填工程と、前記キャビティ内に充填された前記第１発泡ビーズ及び前記第２発泡ビーズを加熱して、発泡させながら、前記第１発泡ビーズからなる第１発泡層と前記第２発泡ビーズからなる第２発泡層とを融着させる発泡成型工程とを備えたことを特徴する。
以上によれば、キャビティ内を厚み方向に分割する仕切り部材がなくとも、物性が異なる複数の発泡層を備えた複合発泡成型体を製造することができる。
予備成型工程では、第１発泡ビーズの粒体同士を完全に融着させず、第２発泡ビーズを充填後に、第１発泡層と第２発泡層とが融着するように加熱する。したがって、第１発泡層と第２発泡層の層間をしっかり接合させることができる。またこのように予備成型工程では、第１発泡ビーズの粒体同士が離れない程度にしか加熱されないので、品質のよい複合発泡成型体を製造することができる。 The method for producing a composite foamed molding according to the present invention includes a first foaming bead filling step of filling the first foamed beads into a cavity of a mold, and heating the first foamed beads filled into the cavity. A pre-molding step of fusing the foamed beads so as not to leave apart, a volume increasing step of moving the mold to increase the volume in the cavity of the mold, and the first foamed beads; Filling a second expanded bead with different physical properties into the cavity with the increased volume, heating the first expanded bead and the second expanded bead filled in the cavity, A foam molding step of fusing the first foamed layer made of the first foamed beads and the second foamed layer made of the second foamed beads while foaming is provided.
According to the above, even if there is no partition member that divides the inside of the cavity in the thickness direction, it is possible to manufacture a composite foamed molded body including a plurality of foam layers having different physical properties.
In the pre-molding step, the first foamed beads are heated so that the first foamed layer and the second foamed layer are fused after filling the second foamed beads without completely fusing the granules of the first foamed beads. Therefore, the first foam layer and the second foam layer can be firmly joined. In this way, in the pre-molding step, the first foamed beads are heated only to such an extent that the granules are not separated from each other, so that a high-quality composite foam molded article can be produced.

本発明において、前記予備成型工程を実施した後、成型された前記第１発泡ビーズからなる予備成型体をエア冷却する冷却工程をさらに備えてもよい。
以上によれば、予備成型工程の実施後に、余熱によって第１発泡ビーズが加熱されることを抑制することができ、品質のよい複合発泡成型体を製造することができる。 In the present invention, after performing the preforming step, the method may further include a cooling step of air-cooling the preformed first foamed beads.
According to the above, it is possible to suppress the first foamed beads from being heated by the residual heat after the preforming step, and it is possible to manufacture a high-quality composite foamed molded body.

本発明において、前記第１発泡ビーズ及び前記第２発泡ビーズのうち、一方は耐熱性を有する発泡ビーズであり、他方は自己消火性を有する発泡ビーズとしてもよい。
以上によれば、耐熱性を有する発泡層と自己消火性を有する発泡層を備えた複合発泡成型体を製造することができる。 In the present invention, one of the first foam beads and the second foam beads may be a heat-resistant foam bead, and the other may be a self-extinguishing foam bead.
Based on the above, it is possible to produce a composite foamed molded article having a heat-resistant foam layer and a self-extinguishing foam layer.

本発明において、前記第２発泡ビーズは、前記第１発泡ビーズとは、比重の異なるビーズとしてもよい。
以上によれば、比重が異なることによって物性が異なる２層の発泡層を備えた複合発泡成型体を製造することができる。 In the present invention, the second expanded beads may be beads having a specific gravity different from that of the first expanded beads.
According to the above, it is possible to produce a composite foamed molded body having two foam layers having different physical properties due to different specific gravity.

本発明において、前記第２発泡ビーズは、前記第１発泡ビーズとは、径の異なるビーズとしてもよい。
以上によれば、径の異なることによって物性が異なる２層の発泡層を備えた複合発泡成型体を製造することができる。 In the present invention, the second expanded beads may be beads having a diameter different from that of the first expanded beads.
According to the above, it is possible to produce a composite foamed molded article having two foam layers having different physical properties due to different diameters.

本発明において、前記第２発泡ビーズを充填する前に、前記予備成型体のうち少なくとも充填口に対向する箇所にシート材を貼付するシート材貼付工程をさらに備えてもよい。
以上によれば、シート材を貼付することで、第２発泡ビーズの充填時に、充填口から圧力が作用しても、その影響で第１発泡ビーズからなる予備成型体の形状が変形してしまうことを抑制できる。 In this invention, before filling the said 2nd foam bead, you may further provide the sheet | seat material sticking process of sticking a sheet | seat material in the location which opposes a filling port among the said preforming bodies.
According to the above, by sticking the sheet material, even when pressure is applied from the filling port at the time of filling the second foam beads, the shape of the preform formed from the first foam beads is deformed due to the influence. This can be suppressed.

本発明において、前記第１発泡ビーズ及び前記第２発泡ビーズには、発泡ポリスチレンを含むようにしてもよい。
以上によれば、特殊な種類の発泡ビーズを用いなくても、物性の異なる層構造の複合発泡成型体を製造することができる。 In the present invention, the first expanded beads and the second expanded beads may include expanded polystyrene.
According to the above, it is possible to produce a composite foamed molded article having a layer structure with different physical properties without using special types of foam beads.

本発明において、前記第１発泡ビーズ充填工程及び前記第２発泡ビーズ充填工程の少なくともいずれか一方では、成型型の移動方向に沿って進退自在な仕切り部材によって成型型のキャビティを分割した状態で各キャビティに互いに異なる物性の発泡ビーズを充填するようにしてもよい。
以上によれば、厚み方向及び幅方向において物性が異なる複数の発泡層を備えた複合発泡成型体を製造することができる。 In the present invention, in at least one of the first foamed bead filling step and the second foamed bead filling step, each of the mold cavities is divided by a partition member that can move forward and backward along the moving direction of the mold. The cavities may be filled with expanded beads having different physical properties.
According to the above, it is possible to manufacture a composite foamed molded body including a plurality of foam layers having different physical properties in the thickness direction and the width direction.

本発明の複合発泡成型体の製造方法によれば、異なる所望の物性からなる複数の発泡層を備えた複合発泡成型体を容易に製造することができる。   According to the method for producing a composite foam molded body of the present invention, a composite foam molded body having a plurality of foam layers having different desired physical properties can be easily produced.

本発明の第１実施形態に係る複合発泡成型体の製造方法の一例を概略的に示すフロー図である。It is a flowchart which shows roughly an example of the manufacturing method of the composite foaming molding which concerns on 1st Embodiment of this invention. 同製造方法に用いられる成型型の一例を示す概略的断面図である。It is a schematic sectional drawing which shows an example of the shaping | molding die used for the manufacturing method. （ａ）、（ｂ）は、同製造方法に用いられる成型型の一例を模式的に示す図であり、（ａ）はＳ１：型閉め工程、（ｂ）はＳ２：第１発泡ビーズ充填工程を示している。(A), (b) is a figure which shows typically an example of the shaping | molding die used for the manufacturing method, (a) is S1: mold closing process, (b) is S2: 1st foam bead filling process Is shown. （ａ）、（ｂ）は、同製造方法に用いられる成型型の一例を模式的に示す図であり、（ａ）はＳ３：予備成型工程（加熱）、（ｂ）はＳ４：冷却工程を示している。(A), (b) is a figure which shows typically an example of the shaping | molding die used for the manufacturing method, (a) is S3: Pre-molding process (heating), (b) is S4: Cooling process. Show. （ａ）、（ｂ）は、同製造方法に用いられる成型型の一例を模式的に示す図であり、（ａ）はＳ５：容積増大工程、（ｂ）はＳ６：型開き工程を示している。(A), (b) is a figure which shows typically an example of the shaping | molding die used for the manufacturing method, (a) shows S5: volume increase process, (b) shows S6: mold opening process. Yes. （ａ）、（ｂ）は、同製造方法に用いられる成型型の一例を模式的に示す図であり、（ａ）はＳ７：シート貼付工程、（ｂ）はＳ８：型閉め工程を示している。(A), (b) is a figure which shows typically an example of the shaping | molding die used for the manufacturing method, (a) shows S7: sheet | seat sticking process, (b) shows S8: mold closing process. Yes. （ａ）（ｂ）は、同製造方法に用いられる成型型の一例を模式的に示す図であり、（ａ）はＳ９：第２発泡ビーズ充填工程、（ｂ）はＳ１０：発泡成型工程を示している。(A) (b) is a figure which shows typically an example of the shaping | molding die used for the manufacturing method, (a) is S9: 2nd foam bead filling process, (b) is S10: Foam molding process. Show. （ａ）、（ｂ）は、同製造方法に用いられる成型型の一例を模式的に示す図であり、（ａ）はＳ１１：冷却、乾燥工程、（ｂ）はＳ１２：離型工程を示している。(A), (b) is a figure which shows typically an example of the shaping | molding die used for the manufacturing method, (a) shows S11: cooling and a drying process, (b) shows S12: mold release process. ing. 同製造方法によって得られる複合発泡成型体の例を示す断面斜視図である。It is a cross-sectional perspective view which shows the example of the composite foaming molding obtained by the manufacturing method. （ａ）、（ｂ）は本発明の第２実施形態に係る複合発泡成型体の製造方法に用いられる成型型の一例を示す概略的断面図であり、（ａ）は異原料充填工程、（ｂ）は予備成型工程（加熱）を示している。(A), (b) is a schematic sectional drawing which shows an example of the shaping | molding die used for the manufacturing method of the composite foaming molding which concerns on 2nd Embodiment of this invention, (a) is a different raw material filling process, ( b) shows a preforming step (heating). （ａ）、（ｂ）は、同製造方法に用いられる成型型の一例を示す概略的断面図であり、（ａ）は冷却工程、（ｂ）は容積増大工程を示している。(A), (b) is a schematic sectional drawing which shows an example of the shaping | molding die used for the manufacturing method, (a) has shown the cooling process, (b) has shown the volume increase process. （ａ）、（ｂ）は、同製造方法によって得られる複合発泡成型体の例を示す模式的斜視図である。(A), (b) is a typical perspective view which shows the example of the composite foaming molding obtained by the manufacturing method.

以下に、本発明に係る複合発泡成型体の製造方法の一実施形態について、添付図面を参照しながら説明する。
（第１実施形態）
まず第１実施形態として、図１〜図９を参照しながら、物性（性状）の異なる２層の発泡層（第１発泡層１、第２発泡層２）を備えた複合発泡成型体３の製造方法について説明する。
本実施形態の製造方法に用いられる成型型４は、キャビティ７内を分割する仕切り部材等を必要せず、図２に示すような成型型４を用いることができる。図中、４は成型型、５は固定型、６は可動型、７はキャビティ（成型空間）、８は各種発泡ビーズをキャビティ７内に充填する充填器（フィーダー）、８０は充填筒、８ａは充填口を示している。成型型４には、型閉弁（不図示）、押出しピン（図８（ｂ）参照）等が設けられており、固定型５、可動型６のそれぞれには、冷却エア弁、ドレン弁、排気弁、スチーム弁、バキューム弁、水冷弁等の各種弁や冷却水が通じるパイプ等が設けられている。また充填器８には、充填ピストンが出没自在に構成され、エア供給源等を備えている（不図示）。８１は、ループホースを示しており、各種発泡ビーズがループホース８１を通じて開閉自在なシャッターを備えた原料ホッパー（不図示）からキャビティ７へ運ばれる。 Below, one Embodiment of the manufacturing method of the composite foaming molding which concerns on this invention is described, referring an accompanying drawing.
(First embodiment)
First, as a first embodiment, referring to FIG. 1 to FIG. 9, a composite foam molded body 3 having two foam layers (first foam layer 1 and second foam layer 2) having different physical properties (properties). A manufacturing method will be described.
The molding die 4 used in the manufacturing method of the present embodiment does not require a partition member that divides the inside of the cavity 7, and the molding die 4 as shown in FIG. 2 can be used. In the figure, 4 is a mold, 5 is a fixed mold, 6 is a movable mold, 7 is a cavity (molding space), 8 is a filling device (feeder) for filling various foam beads into the cavity 7, 80 is a filling cylinder, 8a Indicates a filling port. The molding die 4 is provided with a die closing valve (not shown), an extrusion pin (see FIG. 8B), and the like, and each of the fixed die 5 and the movable die 6 includes a cooling air valve, a drain valve, Various valves such as an exhaust valve, a steam valve, a vacuum valve, and a water cooling valve, and a pipe through which cooling water is communicated are provided. Further, the filling device 8 is configured so that a filling piston can freely move in and out, and includes an air supply source and the like (not shown). Reference numeral 81 denotes a loop hose, and various foam beads are conveyed to the cavity 7 from a raw material hopper (not shown) provided with a shutter that can be opened and closed through the loop hose 81.

固定型５は凹状のキャビティ型５ａを備え、キャビティ型５ａには、多数の通気孔（不図示）が形成されている。また可動型６は凸状のコア型６ａを備え、コア型６ａにも、多数の通気孔（不図示）が形成されている。５０，６０はキャビティ型５ａ、コア型６ａのそれぞれの背面に設けられたチャンバーを示している。このチャンバー５０，６０は、空洞の空間とされ、スチーム弁、冷却エア弁、排気弁等の上述の各種弁が接続されており、チャンバー５０，６０はスチーム弁や冷却エア弁から供給される蒸気や空気が充満する空間となる。よって、例えば後記する発泡成型工程（Ｓ１０）でスチーム弁から蒸気が送られてきた際には、チャンバー５０，６０からキャビティ７へと通気孔を通じて蒸気が流通し、キャビティ７に充填された発泡ビーズ（１０，２０）が加熱される。   The fixed mold 5 includes a concave cavity mold 5a, and a plurality of ventilation holes (not shown) are formed in the cavity mold 5a. The movable die 6 includes a convex core die 6a, and a number of vent holes (not shown) are also formed in the core die 6a. Reference numerals 50 and 60 denote chambers provided on the back surfaces of the cavity mold 5a and the core mold 6a. The chambers 50 and 60 are hollow spaces, to which the above-described various valves such as a steam valve, a cooling air valve, and an exhaust valve are connected. The chambers 50 and 60 are steam supplied from the steam valve or the cooling air valve. And a space filled with air. Therefore, for example, when steam is sent from the steam valve in the foam molding step (S10) described later, the steam is circulated from the chambers 50 and 60 to the cavity 7 through the vent holes, and the foam beads filled in the cavity 7 are filled. (10, 20) is heated.

図２において、６１，６１はエアシリンダを示している。このエアシリンダ６１，６１は、コア型６ａを左右のいずれの方向にも動くようにコア型６ａを支持している（図２の矢印ｄ１参照）。エアシリンダ６１，６１は、エアの給気及び排気に伴いロッドが出没自在とされている。そして、エアシリンダ６１，６１のロッドが没入すると、コア型６ａが紙面右側に移動し、キャビティ７の容積が増大するように構成されている。このとき、可動型６のハウジング自体は可動せず、コア型６ａのみがエアシリンダ６１，６１の作用で可動する。   In FIG. 2, 61 and 61 have shown the air cylinder. The air cylinders 61 and 61 support the core mold 6a so that the core mold 6a can move in either the left or right direction (see arrow d1 in FIG. 2). The air cylinders 61 and 61 are configured such that the rods can be moved in and out as air is supplied and exhausted. When the rods of the air cylinders 61 and 61 are immersed, the core mold 6a moves to the right side of the page, and the volume of the cavity 7 increases. At this time, the housing of the movable mold 6 itself does not move, and only the core mold 6 a is moved by the action of the air cylinders 61 and 61.

本実施形態の製造方法に用いられる発泡ビーズ（第１発泡ビーズ１０、第２発泡ビーズ２０）は、求められる物性に応じて選択され、発泡ビーズ自体の種類は、特に限定されず、一般に用いられる種類のものを使用可能で、この製造方法を実施するために特殊な種類の発泡ビーズを用意する必要はない。つまり、後述する予備成形工程（図１・Ｓ３）は、第１発泡ビーズ１０が過度に加熱されることはないため、例えば耐熱性の高い特殊なビーズ（例えば、ブタジエンを５〜２０％含有する発泡ビーズ）を用いなくても、厚み方向に複数の発泡層が積層された複合発泡成型体を製造することができる。したがって、例えば発泡ポリスチレン（ＥＰＳ）を用いることができる他、発泡ポリエチレン（ＥＰＥ）等を用いてもよい。すなわち、蒸気等により加熱した際に互いに接合可能な２種の発泡ビーズの組み合わせであればよい。よって例えば、発泡ポリスチレン同士の他、発泡ポリスチレンと発泡ポリエチレンの組み合わせでもよい。
また求められる物性に応じて自己消火性、耐熱性を備えた発泡ビーズを用いることができる。これらを用いた複合発泡成型体を製造する場合は、例えば給湯機器の保温筒の外周を覆うことができる形状にするとよい。この場合、保温筒との接触面側に耐熱性を備えた発泡層、外面側に自己消火性を備えた発泡層が配設されるようにすればよい。また、その他の用途として、耐熱性が要求される建築材（例えば壁材）に使用してもよい。すなわち、上述のような耐熱性を備えた発泡ビーズを用いた複合発泡成型体は、一側面（一方面）に耐熱性が要求される用途に使用する場合に有利である。
さらに発泡ビーズに着色が施されているものを用いてもよい。これによれば、インテリア性、デザイン性に優れた複合発泡成型体を製造することができる。 The foam beads (the first foam beads 10 and the second foam beads 20) used in the manufacturing method of the present embodiment are selected according to the required physical properties, and the kind of the foam beads is not particularly limited and is generally used. Various types can be used, and it is not necessary to prepare a special type of expanded beads in order to carry out this manufacturing method. That is, in the preforming step (FIG. 1, S3) to be described later, the first foamed beads 10 are not excessively heated. For example, special beads having high heat resistance (for example, containing 5 to 20% butadiene) Even without using foam beads, it is possible to manufacture a composite foam molded body in which a plurality of foam layers are laminated in the thickness direction. Therefore, for example, expanded polystyrene (EPS) can be used, and expanded polyethylene (EPE) or the like may be used. That is, any combination of two types of foam beads that can be joined together when heated by steam or the like may be used. Therefore, for example, a combination of expanded polystyrene and expanded polyethylene may be used in addition to expanded polystyrene.
Also, foamed beads having self-extinguishing properties and heat resistance can be used according to the required physical properties. When manufacturing the composite foam molding using these, it is good to make it the shape which can cover the outer periphery of the heat insulation cylinder of a hot-water supply apparatus, for example. In this case, a foam layer having heat resistance may be disposed on the contact surface side with the heat insulating cylinder, and a foam layer having self-extinguishing properties may be disposed on the outer surface side. Moreover, you may use for building materials (for example, wall material) in which heat resistance is requested | required as another use. That is, the composite foamed molded article using the above-described foamed beads having heat resistance is advantageous when used in applications requiring heat resistance on one side (one side).
Furthermore, you may use what colored the foam bead. According to this, the composite foam molding excellent in interior property and design property can be manufactured.

また各発泡ビーズの比重を異ならせてもよい。比重が大きい発泡ビーズ程、硬く強度の高い発泡層となる。よって、例えば第１発泡ビーズ１０より、比重の大きい第２発泡ビーズ２０を用いた場合、第２発泡層２が第１発泡層１よりも硬くて強度の高い発泡層を備えた複合発泡成型体３になる。
さらに各発泡ビーズの径（粒径）を異ならせてもよい。径が大きいほど衝撃吸収が若干よくなり、また径が小さい程と見栄えがよくなる。よって、例えば第１発泡ビーズ１０より、径の小さい第２発泡ビーズ２０を用いた場合、第２発泡層２が第１発泡層１よりも見栄えがよく、第１発泡層１が第２発泡層２より耐衝撃性がよくなる。具体的には例えば、第１発泡ビーズ１０及び第２発泡ビーズ２０として原粒を用いる場合には、第１発泡ビーズ１０の平均粒径を１．３ｍｍ〜１．０ｍｍとし、第２発泡ビーズ２０の平均粒径を０．４ｍｍ〜０．８ｍｍ等としてもよい。なお、第１発泡ビーズ１０及び第２発泡ビーズ２０は、原粒に限らず、予め低倍率で発泡させた低発泡粒を用いてもよい。
また各発泡ビーズの発泡倍率を異ならせてもよい。発泡倍率が大きいほど軟質となり、発泡倍率が小さいほど硬質になる。よって、例えば第１発泡ビーズ１０より、発泡倍率の小さい第２発泡ビーズ２０を用いた場合、第２発泡層２が第１発泡層１より硬度が高い物性を備えた複合発泡成型体３になる。具体的には例えば、第１発泡ビーズ１０の発泡倍率を４０〜６５倍とし、第２発泡ビーズ２０の発泡倍率を１０〜３０倍等としてもよい。 Moreover, you may vary the specific gravity of each foam bead. A foamed bead having a higher specific gravity is a harder and stronger foamed layer. Therefore, for example, when the second foamed beads 20 having a higher specific gravity than the first foamed beads 10 are used, the second foamed layer 2 is harder than the first foamed layer 1 and has a foamed layer having a higher strength. It becomes 3.
Further, the diameter (particle diameter) of each foamed bead may be varied. The larger the diameter, the better the impact absorption, and the smaller the diameter, the better the appearance. Therefore, for example, when the second foamed beads 20 having a smaller diameter than the first foamed beads 10 are used, the second foamed layer 2 looks better than the first foamed layer 1, and the first foamed layer 1 is the second foamed layer. 2 better impact resistance. Specifically, for example, when raw particles are used as the first expanded beads 10 and the second expanded beads 20, the average particle diameter of the first expanded beads 10 is set to 1.3 mm to 1.0 mm, and the second expanded beads 20 The average particle size may be 0.4 mm to 0.8 mm or the like. Note that the first foam beads 10 and the second foam beads 20 are not limited to raw grains, and low foam grains that have been foamed at a low magnification in advance may be used.
Moreover, you may vary the expansion ratio of each foam bead. The larger the expansion ratio, the softer, and the smaller the expansion ratio, the harder. Therefore, for example, when the second foamed beads 20 having a smaller expansion ratio than the first foamed beads 10 are used, the second foamed layer 2 becomes a composite foamed molded article 3 having physical properties higher in hardness than the first foamed layer 1. . Specifically, for example, the expansion ratio of the first foam beads 10 may be 40 to 65 times, and the expansion ratio of the second foam beads 20 may be 10 to 30 times.

本実施形態の製造方法は、第１発泡ビーズ１０を成型型４のキャビティ７内に充填する第１発泡ビーズ充填工程（図１・Ｓ２）と、キャビティ７内に充填した第１発泡ビーズ１０を加熱して、第１発泡ビーズ１０の粒体同士が離れない程度に融着させる予備成型工程（図１・Ｓ３）と、成型型４を移動させて、成型型４のキャビティ７内の容積を増大させる容積増大工程（図１・Ｓ５）と、第１発泡ビーズ１０とは物性の異なる第２発泡ビーズ２０を容積の増大したキャビティ７内に充填する第２発泡ビーズ充填工程（図１・Ｓ９）と、キャビティ７内に充填された第１発泡ビーズ１０、第２発泡ビーズ２０を加熱して、発泡させながら、第１発泡ビーズ１０からなる第１発泡層１と第２発泡ビーズ２０からなる第２発泡層２とを融着させる発泡成型工程（図１・Ｓ１０）とを少なくとも備えている。後記するシール材貼付工程（Ｓ７）を含む型開き工程（Ｓ６）〜型閉め工程（Ｓ８）は、必須の工程ではなく、予備成型体１１が充填口８ａからの充填エアの圧力により変形する可能性がある場合等に有効である。   In the manufacturing method of the present embodiment, a first foamed bead filling step (FIG. 1, S <b> 2) for filling the first foamed beads 10 into the cavities 7 of the mold 4, and the first foamed beads 10 filled in the cavities 7 are performed. The pre-molding step (FIG. 1, S3) for heating and fusing the particles of the first foam beads 10 so as not to separate each other, and the mold 4 is moved so that the volume in the cavity 7 of the mold 4 is increased. Volume increasing step (FIGS. 1 and S5) to be increased, and second foaming bead filling step (FIG. 1 and S9) in which the second expanded beads 20 having different physical properties from the first expanded beads 10 are filled in the cavity 7 having an increased volume. And the first foamed beads 10 and the second foamed beads 20 filled in the cavity 7 are heated and foamed, and the first foamed layer 1 made of the first foamed beads 10 and the second foamed beads 20 are made. Fusing the second foam layer 2 Foam molding process comprises at least (1 · S10 Figure) and. The mold opening process (S6) to the mold closing process (S8) including the sealing material sticking process (S7) to be described later are not essential processes, and the preformed body 11 can be deformed by the pressure of the filling air from the filling port 8a. It is effective when there is sex.

以下、製造工程について詳しく説明する。
なお、図３〜図８では成型型４を模式的に示しているため、成型型４に設けられたエアシリンダ等の図示や断面箇所のハッチングを省略している。また図３〜図８ではキャビティ７の容積を増大させるクラッキング状態のときに固定型５と可動型６との間に隙間が形成されているように示すが、本実施形態では、型閉めされた状態でコア型６ａが移動し、キャビティ型５ａとコア型６ａとの間に形成されるキャビティ７の容積が増大した状態をさし、可動型６が可動する型開き状態（図６（ａ））とは区別して説明する。なお、後記するように可動型６を移動して固定型５と可動型６との突合せ部の間に隙間を空け、キャビティ７の容積が増大した状態をクラッキング状態としてもよい。 Hereinafter, the manufacturing process will be described in detail.
3 to 8 schematically illustrate the mold 4, illustration of an air cylinder and the like provided in the mold 4 and hatching of cross-sectional portions are omitted. 3 to 8 show that a gap is formed between the fixed mold 5 and the movable mold 6 in the cracking state in which the volume of the cavity 7 is increased. In this embodiment, the mold is closed. In this state, the core mold 6a is moved, and the volume of the cavity 7 formed between the cavity mold 5a and the core mold 6a is increased, and the mold 6 is opened (FIG. 6A). ) And will be described separately. As described later, the movable mold 6 may be moved to create a gap between the abutting portions of the fixed mold 5 and the movable mold 6 so that the volume of the cavity 7 is increased.

＜Ｓ１：型閉め工程＞
まずは、固定型５と可動型６との間に隙間が生じないように対向して設けられた固定型５と可動型６とを突き合せる型閉めを行う。このとき、固定型５及び可動型６のそれぞれに設けられた排気弁及びドレン弁は開状態とする（図３（ａ）参照）。
＜Ｓ２：第１発泡ビーズ充填工程＞
そして固定型５の冷却エア弁を開としてチャンバー５０内に空気を送って固定型５内の圧力を高めていく。すると、固定型５と可動型６との間に圧力差が生じ、エアシリンダ（図２参照）が押されてコア型６ａが紙面右側に移動しクラッキング状態となる。この状態で、充填器８によってエアをキャビティ７に送り込み、キャビティブローを行う（１．キャビティブロー）。そして図３（ｂ）に示すように第１発泡ビーズ１０を充填口８ａからキャビティ７へ投入していく（２．充填）。具体的には充填器８の充填ピストンが作動すると充填エアが放出され、原料ホッパーのシャッターが開き、充填器８のループホース８１、充填筒８０を通じて第１発泡ビーズ１０がキャビティ７に充填される。キャビティ７に所定量の第１発泡ビーズ１０が充填されたら、ループホース８１内に残った第１発泡ビーズ１０をブローバックにより原料ホッパー内に回収する（３．ブローバック）。
なお、ここでは第１発泡ビーズ１０をクラッキング状態でキャビティ７に充填していく例を説明したが、これに限定されず、ノークラッキング状態で第１発泡ビーズ１０を充填してもよい。 <S1: Mold closing process>
First, mold closing is performed such that the fixed mold 5 and the movable mold 6 which are provided facing each other so as not to generate a gap between the fixed mold 5 and the movable mold 6 are abutted. At this time, the exhaust valve and the drain valve provided in each of the fixed mold 5 and the movable mold 6 are opened (see FIG. 3A).
<S2: First foam bead filling step>
Then, the cooling air valve of the fixed mold 5 is opened and air is sent into the chamber 50 to increase the pressure in the fixed mold 5. Then, a pressure difference is generated between the fixed mold 5 and the movable mold 6, the air cylinder (see FIG. 2) is pushed, and the core mold 6a moves to the right side of the paper surface to be in a cracking state. In this state, air is sent into the cavity 7 by the filler 8 to perform cavity blow (1. cavity blow). Then, as shown in FIG. 3B, the first foam beads 10 are introduced into the cavity 7 from the filling port 8a (2. filling). Specifically, when the filling piston of the filling device 8 is operated, filling air is released, the shutter of the raw material hopper is opened, and the first foamed beads 10 are filled into the cavity 7 through the loop hose 81 and the filling cylinder 80 of the filling device 8. . When the cavity 7 is filled with a predetermined amount of the first foam beads 10, the first foam beads 10 remaining in the loop hose 81 are collected in the raw material hopper by blow back (3. blow back).
In addition, although the example which fills the cavity 7 in the cracking state was demonstrated here, it is not limited to this, You may fill the 1st foam bead 10 in a no cracking state.

＜Ｓ３：予備成型工程（加熱）＞
そして、固定型５及び可動型６のスチーム弁、ドレン弁を開状態とし、スチーム弁から蒸気をチャンバー５０，６０に送り込んで（図４（ａ）の矢印ｄ２参照）第１発泡ビーズ１０の粒同士が離れない程度に融着させ予備成型体１１を作製する（図４（ａ）参照）。このときの蒸気圧力や蒸気をかける時間は特に限定されず、用いられる第１発泡ビーズ１０の種類や粒の大きさ等によって異なるが、要は粒同士が完全に発泡して融着してしまうことがないように、また予備成型体１１の形がくずれない程度に粒同士がくっつくように蒸気を当てればよい。言い換えると、予備成型工程では、蒸気が粒と粒の隙間を通り、第１発泡ビーズ１０が発泡し始める（膨らもうとする）と同時に、表面がメルト（溶着）し始めようとした時点で、蒸気を止めることにより、粒同士を部分的に溶着させる。よって、蒸気圧力は極力低く、蒸気をかける時間は短い方がよく、具体的には、例えば蒸気圧力は、０．２〜０．３ｋｇ／ｃｍ2、時間はおよそ２〜４秒間としてもよい。 <S3: Pre-molding step (heating)>
Then, the steam valve and drain valve of the fixed mold 5 and the movable mold 6 are opened, and steam is sent from the steam valve to the chambers 50 and 60 (see the arrow d2 in FIG. 4A). The preforms 11 are produced by fusing them so that they are not separated from each other (see FIG. 4A). At this time, the vapor pressure and the time for applying the vapor are not particularly limited and vary depending on the type of first foam beads 10 used, the size of the grains, and the like, but in summary, the grains are completely foamed and fused. The steam may be applied so that the grains adhere to each other so that the shape of the preform 11 does not collapse. In other words, in the preforming process, when the vapor passes through the gaps between the grains and the first foam beads 10 start to foam (expand), the surface starts to melt (weld). The particles are partially welded by stopping the steam. Therefore, the steam pressure is as low as possible, and it is better that the steam is applied for a short time. Specifically, for example, the steam pressure may be 0.2 to 0.3 kg / cm 2 , and the time may be approximately 2 to 4 seconds.

＜Ｓ４：冷却工程＞
上述の予備成型工程（Ｓ３）を実施した後、成型された第１発泡ビーズからなる予備成型体１１をエア冷却する冷却工程を実施する（図４（ｂ）参照）。このとき、固定型５及び可動型６の冷却エア弁、ドレン弁を開状態とする。エア冷却（空冷）を行う時間は、特に限定されず、予備成型工程（Ｓ３）での加熱状態によりその時間が変わることがあるが、例えば２〜３秒間実施すればよい。すなわち、予備成型工程（Ｓ３）時の蒸気による余熱で、加熱後に第１発泡ビーズ１０の発泡が進んで膨らまないように、エア冷却によりキャビティ７の温度を６０℃以下に下げられればよい。
なお、冷却手段としては、エア冷却の他、水冷を行うことも考えられるが、第１発泡ビーズ１０の粒同士の融着が促進されない程度に冷却すれば十分であるので、冷やしすぎないようにすることを考慮すれば、エア冷却が望ましい。
以上によれば、予備成型工程（Ｓ３）の実施後に、余熱によって第１発泡ビーズ１０が加熱されることを抑制することができ、品質のよい複合発泡成型体３を製造することができる。 <S4: Cooling step>
After performing the above-mentioned preforming process (S3), the cooling process which air-cools the preforming body 11 which consists of the shape | molded 1st foam bead is implemented (refer FIG.4 (b)). At this time, the cooling air valve and the drain valve of the fixed mold 5 and the movable mold 6 are opened. The time for performing air cooling (air cooling) is not particularly limited, and the time may vary depending on the heating state in the pre-molding step (S3). For example, it may be performed for 2 to 3 seconds. That is, the temperature of the cavity 7 may be lowered to 60 ° C. or less by air cooling so that the foaming of the first foamed beads 10 proceeds and does not swell after heating due to the residual heat due to the steam in the preforming step (S3).
In addition to air cooling, water cooling may be considered as a cooling means, but it is sufficient to cool the first foamed beads 10 so that the fusion between the grains of the first foamed beads 10 is not promoted. Considering this, air cooling is desirable.
According to the above, it is possible to suppress the first foam beads 10 from being heated by the residual heat after the pre-molding step (S3), and it is possible to manufacture the composite foam molded body 3 having a high quality.

続いて、冷却工程（Ｓ４）の後、第２発泡ビーズ２０を充填する前に、第２発泡層２を形成するための容積を確保するための容積増大工程（Ｓ５）を実施する。
一方、予備成型体１１の形状が変形してしまうことを抑制するため、第２発泡ビーズ２０を充填する前に、予備成型体１１のうち少なくとも充填口８ａに対向する箇所にシート材９を貼付してもよい。このシート材貼付工程（Ｓ７）を行う場合は、型開き工程（Ｓ６）を行う。
すなわち、シール材９を貼り付けない場合は、冷却工程（Ｓ４）の後に容積増大工程（Ｓ５）を行い、シール材９を貼り付ける場合は、冷却工程（Ｓ４）の後に後記する型開き工程（Ｓ６）〜型閉め工程（Ｓ８）を行う。
まずはシール材９を貼り付けずに容積増大工程（Ｓ５）を行う場合を説明する。 Subsequently, after the cooling step (S4), before filling the second expanded beads 20, a volume increasing step (S5) for securing a volume for forming the second expanded layer 2 is performed.
On the other hand, in order to prevent the shape of the preformed body 11 from being deformed, the sheet material 9 is affixed to at least a portion of the preformed body 11 facing the filling port 8a before filling the second foamed beads 20. May be. When performing this sheet material sticking process (S7), a mold opening process (S6) is performed.
That is, when the sealing material 9 is not attached, the volume increasing step (S5) is performed after the cooling step (S4), and when the sealing material 9 is attached, the mold opening step (described later) after the cooling step (S4) ( S6) to mold closing step (S8) are performed.
First, the case where the volume increasing step (S5) is performed without attaching the sealing material 9 will be described.

＜Ｓ５：容積増大工程＞
冷却工程（Ｓ４）の後、容積増大工程（Ｓ５）では、コア型６ａを移動させ、第２発泡層２を形成するための容積分だけキャビティ７の容積を増大させた状態（クラッキング状態）とする。具体的には、コア型６ａをエアシリンダ６１，６１（図２参照）によって紙面右側に移動させる。その後、又は同時に、固定型５のエア弁を開き、チャンバー５０内に空気を送り、予備成型体１１をコア型６ａ側（右側・図５（ａ）の矢印ｄ３参照）に移動させる。このときキャビティ７に供給する空気の圧力は特に限定されず、その数値は成型型４の形状、大きさ等にもよるが、例えばおよそ１．０〜５．０ｋｇ／ｃｍ2としてもよい。
成型型４を移動させて容積を増大させる工程は上述に限定されず、例えば、５ｍｍ〜１５ｍｍ程度の範囲内の第２発泡層２を成型する場合には、コア型６ａをエアシリンダ６１，６１で作動させる必要もなく、金型作成時にクラッキング幅を大きくとれるようにして、可動型６を移動させてキャビティ７の容積を増大させてもよい。 <S5: Volume increasing step>
After the cooling step (S4), in the volume increasing step (S5), the core mold 6a is moved, and the volume of the cavity 7 is increased by the volume for forming the second foamed layer 2 (cracking state); To do. Specifically, the core mold 6a is moved to the right side of the drawing by the air cylinders 61 and 61 (see FIG. 2). Thereafter, or simultaneously, the air valve of the fixed mold 5 is opened, air is sent into the chamber 50, and the preformed body 11 is moved to the core mold 6a side (see the arrow d3 in the right side, FIG. 5A). At this time, the pressure of the air supplied to the cavity 7 is not particularly limited, and the numerical value may be, for example, approximately 1.0 to 5.0 kg / cm 2 although it depends on the shape and size of the mold 4.
The step of increasing the volume by moving the molding die 4 is not limited to the above. For example, when molding the second foamed layer 2 within the range of about 5 mm to 15 mm, the core die 6a is moved to the air cylinders 61, 61. It is also possible to increase the volume of the cavity 7 by moving the movable die 6 so that the cracking width can be increased when creating the die.

次にシール材９を貼り付ける場合を説明する。
＜Ｓ６：型開き工程＞
冷却工程（Ｓ４）の後、シール材９を予備成型体１１に貼り付ける場合は、一旦可動型６を動かして型開きを行う（図５（ｂ）参照）。このとき、固定型５及び可動型６の排気弁、ドレン弁は開状態としておく。
＜Ｓ７：シート材貼り付け工程＞
次に予備成型体１１のうち、少なくとも充填口８ａに対向する箇所（充填位置１１ａ）にシート材９を貼り付ける（図６（ａ）参照）。このようにシート材９を貼付することで、第２発泡ビーズ２０の充填時に、充填口８ａから圧力が作用しても、シート材９によって予備成型体１１の充填位置１１ａが保護され、その影響で第１発泡ビーズ１０からなる予備成型体１１の形状が変形してしまうことを抑制できる。シート材９の材質は特に限定されないが、第１発泡ビーズ１０や第２発泡ビーズ２０と同じ材質で形成されたものが望ましい。また、例えばガムテープ等、接着面を有した粘着テープ等であってもよい。
＜Ｓ８：型閉め工程＞
そして可動型６を再び移動させて型閉めを行い、コア型６ａを移動させて上述の容積増大工程（Ｓ５）を行った後と同じ状態とする（図６（ｂ）参照）。すなわち、固定型５と可動型６との間に隙間が生じないように固定型５と可動型６とを突き合せる型閉めを行う。そして容積増大工程（Ｓ５）と同様に、エアシリンダの作用によって可動型６を移動させ、第２発泡層２を形成するための容積分だけ、キャビティ７の容積を増大させる。 Next, the case where the sealing material 9 is affixed will be described.
<S6: Mold opening process>
When the sealing material 9 is affixed to the preformed body 11 after the cooling step (S4), the movable mold 6 is once moved to open the mold (see FIG. 5B). At this time, the exhaust valves and drain valves of the fixed mold 5 and the movable mold 6 are kept open.
<S7: Sheet material pasting step>
Next, the sheet | seat material 9 is affixed on the location (filling position 11a) at least facing the filling port 8a among the preforming bodies 11 (refer Fig.6 (a)). By sticking the sheet material 9 in this way, even when pressure is applied from the filling port 8a when the second foamed beads 20 are filled, the filling position 11a of the preformed body 11 is protected by the sheet material 9 and the influence thereof. Thus, it is possible to suppress the deformation of the shape of the preform 11 made of the first foam beads 10. The material of the sheet material 9 is not particularly limited, but is preferably made of the same material as the first foam beads 10 and the second foam beads 20. Further, for example, an adhesive tape having an adhesive surface such as a gum tape may be used.
<S8: Mold closing process>
Then, the movable mold 6 is moved again to close the mold, and the core mold 6a is moved to the same state as after the volume increasing step (S5) is performed (see FIG. 6B). That is, mold closing is performed so that the fixed mold 5 and the movable mold 6 abut each other so that no gap is generated between the fixed mold 5 and the movable mold 6. Similarly to the volume increasing step (S5), the movable die 6 is moved by the action of the air cylinder, and the volume of the cavity 7 is increased by the volume for forming the second foamed layer 2.

＜Ｓ９：第２発泡ビーズ充填工程＞
こうして容積増大工程（Ｓ５）或いは型閉め工程（Ｓ８）を経て成型型４をクラッキング状態とした後、充填器８によってエアをキャビティ７内に送り込み、キャビティブローを行う（１．キャビティブロー）。そしてキャビティ７の容積が増大した箇所に第２発泡ビーズ２０を充填口８ａから投入していく（２．充填・図７（ａ）参照）。具体的には充填器８の充填ピストンが作動すると充填エアが放出され、原料ホッパーのシャッターが開き、充填器８のループホース８１、充填筒８０を通じて第２発泡ビーズ２０がキャビティ７に充填される。このとき、第１発泡ビーズ１０の粒同士は離れない程度に融着しているため、第２発泡ビーズ２０は、キャビティ７に充填された際に第１発泡ビーズ１０と混ざることなく、予備成型体１１に積層される。キャビティ７に所定量の第２発泡ビーズ２０が充填されたら、ループホース８１内に残った第２発泡ビーズ２０をブローバックにより原料ホッパー内に回収する（３．ブローバック）。
なお、本工程における１．キャビティブローの工程は省略してもよい。
また図７〜図９では、シール材９の図示を省略しているが、シート材９を貼付した場合は、シート材９を介在させたまま第２発泡ビーズ充填工程以降の工程を進めていけばよい。複合発泡成型体３を製造するにあたって、第１発泡層１と第２発泡層２の間にシール材９が介在しても、なんら品質に影響を与えることはない。
さらにシール材９を貼り付けなくても、予備成型体１１が後の品質に影響するほど、変形することはないが、シール材９を充填位置１１ａに貼り付けておけば、上述したように予備成型体１１の形状が変形してしまうことを抑制できる。 <S9: Second foam bead filling step>
Thus, after the volume increasing step (S5) or the mold closing step (S8), the mold 4 is brought into a cracking state, and then air is fed into the cavity 7 by the filler 8 to perform cavity blow (1. cavity blow). Then, the second foam beads 20 are introduced from the filling port 8a into the portion where the volume of the cavity 7 is increased (2. Filling; see FIG. 7A). Specifically, when the filling piston of the filling device 8 is operated, filling air is released, the shutter of the raw material hopper is opened, and the second foamed beads 20 are filled into the cavity 7 through the loop hose 81 and the filling cylinder 80 of the filling device 8. . At this time, since the particles of the first expanded beads 10 are fused so as not to be separated from each other, the second expanded beads 20 are preliminarily molded without being mixed with the first expanded beads 10 when the cavities 7 are filled. Laminated on the body 11. When the cavity 7 is filled with a predetermined amount of the second foam beads 20, the second foam beads 20 remaining in the loop hose 81 are collected in the raw material hopper by blow back (3. blow back).
In this step, 1. The cavity blowing step may be omitted.
7 to 9, the sealing material 9 is not shown. However, when the sheet material 9 is attached, the processes after the second foamed bead filling process can be performed with the sheet material 9 interposed. That's fine. Even when the sealing material 9 is interposed between the first foamed layer 1 and the second foamed layer 2 in manufacturing the composite foamed molded body 3, the quality is not affected at all.
Further, even if the sealing material 9 is not applied, the preform 11 is not deformed to the extent that it affects the subsequent quality. However, if the sealing material 9 is applied to the filling position 11a, the preliminary material 11 is preliminarily used as described above. It can suppress that the shape of the molded object 11 deform | transforms.

＜Ｓ１０：発泡成型工程（加熱）＞
次に発泡成型を行う。まず固定型５及び可動型６のスチーム弁、ドレン弁を開状態とし、固定型５及び可動型６のチャンバー５０，６０内の温度を上げる（１．排気１・図７（ｂ）参照）。詳しくは、固定型５及び可動型６のそれぞれスチーム弁から蒸気を送り、チャンバー５０，６０内の冷たい空気を固定型５及び可動型６のそれぞれドレン弁から排気させていく。これにより、スチーム弁から送られた蒸気は、チャンバー５０，６０内に流れ込み、チャンバー５０，６０内の温度を上げ、キャビティ型５ａ、コア型６ａを加熱する。 <S10: Foam molding process (heating)>
Next, foam molding is performed. First, the steam valves and drain valves of the fixed mold 5 and the movable mold 6 are opened, and the temperatures in the chambers 50 and 60 of the fixed mold 5 and the movable mold 6 are raised (1. Exhaust 1, see FIG. 7B). Specifically, steam is sent from the steam valves of the fixed mold 5 and the movable mold 6, and the cold air in the chambers 50 and 60 is exhausted from the drain valves of the fixed mold 5 and the movable mold 6. Thereby, the steam sent from the steam valve flows into the chambers 50 and 60, raises the temperature in the chambers 50 and 60, and heats the cavity mold 5a and the core mold 6a.

キャビティ型５ａ及びコア型６ａが所定の温度まで温まったら、次いで、固定型５のスチーム弁及び可動型６のドレン弁を開状態とし、固定型５のドレン弁及び可動型６のスチーム弁を閉状態として、キャビティ７内に蒸気を通す（２．タイムラグ）。詳しくは、固定型５のスチーム弁から吹き出した蒸気が固定型５のチャンバー５０内に充満する。このとき、開状態だった固定型５のドレン弁が閉状態とされているので、ドレン弁から蒸気が排気されることがなく、行き場をなくした蒸気は、キャビティ型５ａに形成された通気孔を通じてキャビティ７内へ流入する。そしてキャビティ７に充填された第２発泡ビーズ２０、第１発泡ビーズ１０を通じコア型６ａに形成された通気孔を通じて可動型６のチャンバー６０内へと蒸気が通じる。このとき、第２発泡ビーズ２０及び第１発泡ビーズ１０は随時加熱されている。そして可動型６のチャンバー６０内に至った蒸気は、開状態の可動型６のドレン弁から排気される。なお、ここでは、蒸気を固定型５のスチーム弁から可動型６のドレン弁へ通じさせる流れを説明しているが、これに限らず、逆であってもよい。すなわち、可動型６のスチーム弁から蒸気を送り、固定型５のドレン弁から排気させてもよい。なお、発泡成型工程における加熱方法は、前記の方法に限定されず、他にも種々あり、各メーカーや各工場の要求に応じて種々の加熱方法に変更してもよい。   When the cavity mold 5a and the core mold 6a are heated to a predetermined temperature, the steam valve of the fixed mold 5 and the drain valve of the movable mold 6 are opened, and the drain valve of the fixed mold 5 and the steam valve of the movable mold 6 are closed. As a state, steam is passed through the cavity 7 (2. time lag). Specifically, the vapor blown from the steam valve of the fixed mold 5 fills the chamber 50 of the fixed mold 5. At this time, since the drain valve of the fixed mold 5 that has been opened is closed, the steam is not exhausted from the drain valve, and the steam that has lost its place is the vent hole formed in the cavity mold 5a. Through the cavity 7. Then, the vapor passes through the second foamed beads 20 and the first foamed beads 10 filled in the cavity 7 into the chamber 60 of the movable mold 6 through the air holes formed in the core mold 6a. At this time, the second foam beads 20 and the first foam beads 10 are heated at any time. Then, the vapor that has reached the chamber 60 of the movable mold 6 is exhausted from the open drain valve of the movable mold 6. Here, the flow of passing the steam from the steam valve of the fixed mold 5 to the drain valve of the movable mold 6 has been described, but this is not restrictive, and the reverse may be possible. That is, steam may be sent from the steam valve of the movable mold 6 and exhausted from the drain valve of the fixed mold 5. In addition, the heating method in a foam molding process is not limited to the said method, There are various others, You may change into various heating methods according to the request | requirement of each manufacturer or each factory.

次いで、固定型５及び可動型６のスチーム弁、可動型６のドレン弁を開状態とし、固定型５のドレン弁を閉状態として、さらに加熱を行う（３．排気２）。これにより、所望するスチーム圧まで上げていくことができる。なお、この工程でも、ドレン弁のどちらを開状態にするかは限定されず、固定型５のドレン弁を開状態としてもよい。
そして固定型５及び可動型６のスチーム弁を開状態とし、固定型５及び可動型６のドレン弁を閉状態として、さらに加熱を行う（４．加熱）。これにより、熱の温度で表面が溶けて複合発泡成型体３の表裏層を形成する第１発泡ビーズ１０及び第２発泡ビーズ２０がしっかりと発泡する。そして、第１発泡ビーズ１０が充填された箇所は、第１発泡ビーズ１０の各粒体全体がそれぞれ溶着し合って空隙のない第１発泡層１になり、第２発泡ビーズ２０が充填された箇所は、第２発泡ビーズ２０の各粒体全体がそれぞれ溶着し合って空隙のない第２発泡層２になる。そして第１発泡層１と第２発泡層２とが融着されひとつの成型体をなす。 Next, the steam valves of the fixed mold 5 and the movable mold 6 and the drain valve of the movable mold 6 are opened, and the drain valve of the fixed mold 5 is closed, and further heating is performed (3. Exhaust 2). Thereby, it is possible to increase to a desired steam pressure. In this process, which of the drain valves is opened is not limited, and the drain valve of the fixed mold 5 may be opened.
Then, the steam valves of the fixed mold 5 and the movable mold 6 are opened, and the drain valves of the fixed mold 5 and the movable mold 6 are closed, and further heating is performed (4. heating). Thereby, the surface melts at the temperature of heat, and the first foam beads 10 and the second foam beads 20 forming the front and back layers of the composite foam molded body 3 are firmly foamed. And the place with which the 1st foam bead 10 was filled became the 1st foam layer 1 without the space | gap where the whole each particle body of the 1st foam bead 10 each welded, and the 2nd foam bead 20 was filled. The part becomes the 2nd foaming layer 2 without the space | gap, and the whole each granular body of the 2nd foaming bead 20 welds each other. Then, the first foam layer 1 and the second foam layer 2 are fused to form a single molded body.

＜Ｓ１１：冷却、乾燥工程＞
次に冷却、乾燥工程を行う。まず固定型５及び可動型６の水冷弁及びドレン弁を開状態とし、チャンバー５０，６０に通じる銅管に冷却水を流し冷却を行う（１．水冷・図８（ａ）参照）。銅管を通じた冷却水は、ドレン弁から排出される。
そして固定型５及び可動型６の水冷弁を閉状態とし、冷却エア弁を開として、空気を送り空冷を行う（２．空冷）。
次いで、固定型５及び可動型６の排気弁を開状態として型内にかかった圧力を抜き、その後、排気弁、水冷弁、冷却エア弁を閉状態とし、バキューム弁を開状態としてバキュームで成型型４内の空気を吸引して真空状態とし、発泡成型工程で１００℃以上に加熱された成型型４の潜熱を取る（３．放冷）。
なお、成型型４の冷却方法は特に限定されないが、上述の要領によれば、バキュームで真空引きするため、１．水冷は３〜５秒で十分である。 <S11: Cooling and drying process>
Next, a cooling and drying process is performed. First, the water cooling valve and the drain valve of the fixed mold 5 and the movable mold 6 are opened, and cooling is performed by flowing cooling water through the copper pipes leading to the chambers 50 and 60 (1. Water cooling, see FIG. 8A). Cooling water through the copper pipe is discharged from the drain valve.
Then, the water cooling valves of the fixed mold 5 and the movable mold 6 are closed, the cooling air valve is opened, and air is sent to perform air cooling (2. air cooling).
Next, the pressure applied to the mold is released by opening the exhaust valves of the fixed mold 5 and the movable mold 6, and then the exhaust valve, the water cooling valve and the cooling air valve are closed, and the vacuum valve is opened and molding is performed by vacuum. Air in the mold 4 is sucked into a vacuum state, and the latent heat of the mold 4 heated to 100 ° C. or higher in the foam molding process is taken (3. cooling).
In addition, although the cooling method of the shaping | molding die 4 is not specifically limited, According to the above-mentioned point, in order to evacuate with vacuum, 1. 3 to 5 seconds is sufficient for water cooling.

＜Ｓ１２：離型工程＞
次に離型工程を行う。ここで、成型された複合発泡成型体３を固定型５側によせてから離型する例を説明するが、これに限定されず可動型６側によせてから離型するようにしてもよい。
まず成型型４の真空状態を解除するため、可動型６の冷却エア弁を開とし、固定型５のバキューム弁は開状態として空気の吸引（バキューム）を続ける。これにより複合発泡成型体３が瞬間的に固定型５側へ寄る。
そして可動型６を紙面右側に移動させて型開きし、固定型５の冷却エア弁、可動型６の排気弁、ドレン弁を開状態とし、固定型５では空気を送りながら、押出しピンで複合発泡成型体３を押出し、複合発泡成型体３を成型型４から取り出す（図８（ｂ）参照）。
＜Ｓ１３：複合発泡成型体・完成＞
以上によって、図９に示すような複合発泡成型体３を製造することができる。 <S12: Mold release process>
Next, a mold release process is performed. Here, an example in which the molded composite foamed molded body 3 is released after being placed on the fixed mold 5 side will be described. However, the present invention is not limited to this and may be released after being placed on the movable mold 6 side. .
First, in order to release the vacuum state of the mold 4, the cooling air valve of the movable mold 6 is opened, and the vacuum valve of the fixed mold 5 is opened and air suction (vacuum) is continued. As a result, the composite foamed molding 3 instantaneously approaches the stationary mold 5 side.
Then, the movable mold 6 is moved to the right side of the drawing to open the mold, the cooling air valve of the fixed mold 5, the exhaust valve of the movable mold 6, and the drain valve are opened. The foam molded body 3 is extruded, and the composite foam molded body 3 is taken out from the mold 4 (see FIG. 8B).
<S13: Composite Foam Molded Body / Completed>
By the above, the composite foam molding 3 as shown in FIG. 9 can be manufactured.

上述の製造方法によれば、キャビティ７を厚み方向（例えば図２における紙面左右方向）に分割する仕切り部材がなくとも、物性が異なる第１発泡層１、第２発泡層２が厚み方向に積層された複合発泡成型体３を製造することができる。よって、成型型の構造が複雑化したり大型化すること等を抑制できる。
予備成型工程（Ｓ３）では、第１発泡ビーズ１０の粒体同士を完全に融着させず、第２発泡ビーズ２０を充填後に、第１発泡層１と第２発泡層２とが融着するように加熱する。したがって、第１発泡層１と第２発泡層２の層間が分離してしまうことなく、第１発泡層１と第２発泡層２とをしっかり接合することができる。またこのように予備成型工程（Ｓ３）では、第１発泡ビーズ１０の粒体同士を完全に融着させないので、粒と粒の間に蒸気が通過可能な隙間が存在し、また発泡力（発泡ガス）も残っている。したがって、発泡成型工程において、再度、第１発泡ビーズ１０を加熱しても、品質のよい所望の複合発泡成型体３を製造することができる。 According to the manufacturing method described above, the first foamed layer 1 and the second foamed layer 2 having different physical properties are laminated in the thickness direction even without a partition member that divides the cavity 7 in the thickness direction (for example, the left-right direction in FIG. 2). The composite foam molded body 3 can be manufactured. Therefore, it can suppress that the structure of a shaping | molding die becomes complicated or enlarges.
In the pre-molding step (S3), the first foamed beads 1 and the second foamed layer 2 are fused after filling the second foamed beads 20 without completely fusing the particles of the first foamed beads 10 together. To heat. Therefore, the first foamed layer 1 and the second foamed layer 2 can be firmly joined without separation between the first foamed layer 1 and the second foamed layer 2. In this way, in the preforming step (S3), the particles of the first foamed beads 10 are not completely fused together, so there is a gap through which steam can pass between the particles and the foaming force (foaming) Gas) also remains. Therefore, even if the first foamed beads 10 are heated again in the foam molding step, the desired composite foam molded body 3 with good quality can be manufactured.

図９には、本実施形態の製造方法によって得られた複合発泡成型体３の一例が示されている。
図９に示す複合発泡成型体３は、側面視において凹状の板体に形成されており、この複合発泡成型体３は、上下に２層の物性の異なる第１発泡層１と第２発泡層２とを備えている（図９のＸ部拡大図参照）。複合発泡成型体３の用途は特に限定されないが、上述したように筒体等を覆う保温材として用いてもよい。
なお、図９に示す複合発泡成型体３の形状、構成は一例にすぎず、用途に応じて様々な形状のものを製造することができる。 FIG. 9 shows an example of the composite foam molded body 3 obtained by the manufacturing method of the present embodiment.
The composite foam molded body 3 shown in FIG. 9 is formed as a concave plate body in a side view, and the composite foam molded body 3 is composed of a first foam layer 1 and a second foam layer having two physical properties different from each other in the vertical direction. 2 (see the enlarged view of the portion X in FIG. 9). The use of the composite foamed molded body 3 is not particularly limited, but as described above, it may be used as a heat insulating material that covers a cylindrical body or the like.
Note that the shape and configuration of the composite foam molded body 3 shown in FIG. 9 is merely an example, and various shapes can be manufactured depending on the application.

（第２実施形態）
続いて第２実施形態に係る複合発泡成型体の製造方法について、図１０〜図１２を参照しながら、第１実施形態と異なる点を主に説明し、第１実施形態と共通する箇所には共通の符号を付し、共通する箇所の説明は省略する。
なお、図１２（ａ）、（ｂ）は説明のため、複合発泡成型体３Ａ，３Ｂの形状は簡略化して示している。
この第２実施形態は、キャビティ７の厚み方向に分割するような仕切り部材を設けていない点では第１実施形態と共通するが、成型型４の移動方向（キャビティ７の厚み方向）に沿って進退自在な仕切り部材５１ａ，６２ａが設けられている点で相違する。そして、第２実施形態は、第１実施形態のように厚み方向（図１０（ａ）において紙面左右方向）だけでなく、幅方向（図１０（ａ）において紙面上下方向）にも物性の異なる発泡層を備えたものを製造できる点で異なる。 (Second Embodiment)
Then, about the manufacturing method of the composite foam molding which concerns on 2nd Embodiment, a different point from 1st Embodiment is mainly demonstrated, referring FIGS. 10-12, In the location which is common in 1st Embodiment, A common code | symbol is attached | subjected and description of a common location is abbreviate | omitted.
In addition, FIG. 12 (a), (b) has simplified and shown the shape of composite foaming molding 3A, 3B for description.
This second embodiment is common to the first embodiment in that no partition member that divides in the thickness direction of the cavity 7 is provided, but along the moving direction of the mold 4 (the thickness direction of the cavity 7). It is different in that the partition members 51a and 62a which can freely move back and forth are provided. The second embodiment has different physical properties not only in the thickness direction (left and right direction in FIG. 10A) as in the first embodiment, but also in the width direction (up and down direction in FIG. 10A). It differs in that it can be manufactured with a foam layer.

具体的には、第１発泡ビーズ充填工程（Ｓ２）及び第２発泡ビーズ充填工程（Ｓ９）の少なくともいずれか一方の工程で、成型型４の移動方向に沿って進退自在な仕切り部材５１ａ，６２ａによって成型型４のキャビティ７を分割した状態で各キャビティに互いに異なる物性の発泡ビーズ（１２Ａ，１２Ｂ）を充填する。それ以外の工程は第１実施形態と同様に行えばよい。   Specifically, the partition members 51a and 62a that can be moved back and forth along the moving direction of the mold 4 in at least one of the first expanded bead filling step (S2) and the second expanded bead filling step (S9). In this state, the cavities 7 of the mold 4 are divided, and the cavities are filled with foam beads (12A, 12B) having different physical properties. Other steps may be performed in the same manner as in the first embodiment.

本実施形態において使用する成型型４は、コア型６ａのさらに背面に支持板６ｂが設けられ、この支持板６ｂにシャッター用シリンダ６２が取り付けられている。シャッター用シリンダ６２には、可動型６の移動方向に沿って進退自在（図１０（ａ）の矢印ｄ４参照）とされた仕切り部材としてのコア側シャッター６２ａが設けられている。
キャビティ型５ａにもシャッター用シリンダ５１が設けられており、このシャッター用シリンダ５１にも、可動型６の移動方向に沿って進退自在（図１０（ａ）の矢印ｄ５参照）とされた仕切り部材としてのキャビティ側シャッター５１ａが設けられている。シャッター用シリンダ５１は固定型５のハウジング本体５ｂに取り付けられている。
シャッター用シリンダ５１，６２は、エアシリンダ６１，６１と同様に、空気圧によってコア側シャッター６２ａとキャビティ側シャッター５１ａとが進退自在とされる。コア側シャッター６２ａとキャビティ側シャッター５１ａとは、板体からなり、キャビティ７に突出させた状態では、キャビティ７を上下二つに仕切るように設けられる。 The molding die 4 used in the present embodiment is provided with a support plate 6b on the back side of the core die 6a, and a shutter cylinder 62 is attached to the support plate 6b. The shutter cylinder 62 is provided with a core-side shutter 62a as a partition member that can be moved back and forth along the moving direction of the movable die 6 (see arrow d4 in FIG. 10A).
The cavity mold 5a is also provided with a shutter cylinder 51, and the shutter cylinder 51 is also a partition member that can move forward and backward along the moving direction of the movable mold 6 (see arrow d5 in FIG. 10A). A cavity side shutter 51a is provided. The shutter cylinder 51 is attached to the housing body 5 b of the fixed mold 5.
As with the air cylinders 61 and 61, the shutter cylinders 51 and 62 allow the core-side shutter 62a and the cavity-side shutter 51a to move forward and backward by air pressure. The core-side shutter 62a and the cavity-side shutter 51a are made of plates, and are provided so as to partition the cavity 7 into two in the upper and lower directions when protruding into the cavity 7.

キャビティ７は、コア側シャッター６２ａとキャビティ側シャッター５１ａとの先端が付き合わされて上下ふたつに分割されるように構成される。よって、キャビティ７をふたつに分割するときには、コア側シャッター６２ａはキャビティ型５ａ側に突出し、キャビティ側シャッター５１ａはコア型６ａ側に突出する（図１０（ａ）参照）。一方、キャビティ７をふたつに分割しないときには、コア側シャッター６２ａはコア型６ａ側に没し、キャビティ側シャッター５１ａはキャビティ型５ａ側に没する（図１０（ｂ）参照）。
図例は、コア側シャッター６２ａの突出量が多く、コア側シャッター６２ａでキャビティ７を分割している例を示しているが、これに限定されず、キャビティ７を分割できればよく、コア側シャッター６２ａの突出量とキャビティ側シャッター５１ａの突出量とを同程度或いはキャビティ側シャッター５１ａでキャビティ７を分割するようにしてもよい。 The cavity 7 is configured so that the tips of the core-side shutter 62a and the cavity-side shutter 51a are attached to each other and divided into upper and lower parts. Therefore, when the cavity 7 is divided into two, the core-side shutter 62a protrudes toward the cavity mold 5a, and the cavity-side shutter 51a protrudes toward the core mold 6a (see FIG. 10A). On the other hand, when the cavity 7 is not divided into two, the core-side shutter 62a is submerged on the core mold 6a side, and the cavity-side shutter 51a is submerged on the cavity mold 5a side (see FIG. 10B).
The illustrated example shows an example in which the protrusion amount of the core side shutter 62a is large and the cavity 7 is divided by the core side shutter 62a. However, the present invention is not limited to this. The cavity 7 may be divided by the same amount or the cavity-side shutter 51a.

充填器は、分割されたキャビティ７のそれぞれに物性の異なる２種の発泡ビーズが充填できるよう２台用意してもよい。この場合、成型型４は２つの原料供給口を備え、一方の充填器８Ａは、上下に分割されたキャビティ７の上方空間に発泡ビーズ１２Ａを充填できるように設け、他方の充填器８Ｂは、上下に分割されたキャビティ７の下方空間に発泡ビーズ１２Ｂを充填できるように設ける。
また本実施形態の製造方法に用いられる発泡ビーズ１２Ａ，１２Ｂは、第１実施形態と同様に求められる物性に応じて選択され、異なる物性を備えた発泡ビーズ１２Ａ，１２Ｂが用いられる。
その他の成型型４等の構成は第１実施形態と同様である。 Two fillers may be prepared so that each of the divided cavities 7 can be filled with two types of foam beads having different physical properties. In this case, the mold 4 is provided with two raw material supply ports, and one filler 8A is provided so that the foam beads 12A can be filled in the upper space of the cavity 7 divided vertically, and the other filler 8B It is provided so that the foam beads 12B can be filled in the lower space of the cavity 7 divided vertically.
Further, the expanded beads 12A and 12B used in the manufacturing method of the present embodiment are selected according to the required physical properties as in the first embodiment, and the expanded beads 12A and 12B having different physical properties are used.
Other configurations such as the mold 4 are the same as those in the first embodiment.

本実施形態の製造方法は、上述の成型型４を使って、第１発泡ビーズ充填工程（Ｓ２）及び第２発泡ビーズ充填工程（Ｓ９）の少なくともいずれか一方で、キャビティ７を分割した状態で各キャビティに互いに異なる物性の発泡ビーズ１２Ａ，１２Ｂを充填して複合発泡成型体を製造する。よって、ここではその一例として、第１発泡ビーズ充填工程（Ｓ２）で物性の異なる発泡ビーズ１２Ａ，１２Ｂを充填する例を説明する。   In the manufacturing method of the present embodiment, the mold 7 is used to divide the cavity 7 in at least one of the first foam bead filling step (S2) and the second foam bead filling step (S9). Each cavity is filled with foam beads 12A and 12B having different physical properties to produce a composite foam molding. Therefore, here, as an example, an example in which the expanded beads 12A and 12B having different physical properties are filled in the first expanded bead filling step (S2) will be described.

まずは、第１実施形態の＜Ｓ１：型閉め工程＞と同様に固定型５と可動型６とを突き合せる型閉めを行う。
＜異原料充填（２種類）工程：第１発泡ビーズ充填工程＞
次に、＜第１発泡ビーズ充填工程＞を行う。第１実施形態ではここで第１発泡ビーズ１０を充填したが、本実施形態では、この工程で第１発泡ビーズとして、異なる物性を備えた発泡ビーズ１２Ａ，１２Ｂを充填する（図１０（ａ）参照）。
具体的には、まずシャッター用シリンダ５１，６２にエアを作動させることによってコア側シャッター６２ａとキャビティ側シャッター５１ａとを突出させてキャビティ７を上下に分割する。この状態で充填器８Ａ，８Ｂによってエアを分割されたそれぞれのキャビティ７へ送りこみ、キャビティブローを行う（１．キャビティブロー）。そして図１０（ａ）に示すように発泡ビーズ１２Ａ，１２Ｂをそれぞれの充填口８ａからキャビティ７へ投入していく（２．充填）。
キャビティ７に所定量の発泡ビーズ１２Ａ，１２Ｂが充填されたら、ループホース８１内に残った発泡ビーズ１２Ａ，１２Ｂをブローバックにより原料ホッパー内に回収する（３．ブローバック）。 First, in the same manner as in <S1: mold closing step> of the first embodiment, mold closing is performed in which the fixed mold 5 and the movable mold 6 are abutted.
<Different raw material filling (two types) step: first foaming bead filling step>
Next, a <first foam bead filling step> is performed. In the first embodiment, the first foam beads 10 are filled here, but in this embodiment, the foam beads 12A and 12B having different physical properties are filled as the first foam beads in this step (FIG. 10A). reference).
Specifically, first, the air is operated to the shutter cylinders 51 and 62 to cause the core-side shutter 62a and the cavity-side shutter 51a to protrude, thereby dividing the cavity 7 vertically. In this state, air is fed into the respective cavities 7 divided by the fillers 8A and 8B, and cavity blow is performed (1. cavity blow). Then, as shown in FIG. 10A, the foam beads 12A and 12B are introduced into the cavity 7 from the respective filling ports 8a (2. filling).
When the cavity 7 is filled with a predetermined amount of foam beads 12A and 12B, the foam beads 12A and 12B remaining in the loop hose 81 are collected in the raw material hopper by blow back (3. blow back).

＜予備成型工程（加熱）＞
次にシャッター用シリンダ５１，６２のエアの力（空気圧の作用）でコア側シャッター６２ａとキャビティ側シャッター５１ａをキャビティ７外に退避させる。
そして固定型５及び可動型６のスチーム弁、ドレン弁を開状態とし、スチーム弁から蒸気をチャンバー５０，６０に送り込んで（図１０（ｂ）の矢印参照）発泡ビーズ１２Ａ，１２Ｂの粒同士が離れない程度に融着させ予備成型体１３を作製する（図１０（ｂ）参照）。このときの蒸気圧力や蒸気をかける時間は特に限定されず、要は粒同士が完全に発泡して融着してしまうことがないように、また予備成型体１３の形がくずれない程度に粒同士がくっつくように蒸気を当てればよい点は第１実施形態と同様である。 <Preliminary molding process (heating)>
Next, the core-side shutter 62 a and the cavity-side shutter 51 a are retracted out of the cavity 7 by the air force (pneumatic action) of the shutter cylinders 51 and 62.
Then, the steam valve and drain valve of the stationary mold 5 and the movable mold 6 are opened, and steam is sent from the steam valve to the chambers 50 and 60 (see the arrows in FIG. 10B) so that the beads of the foam beads 12A and 12B The preform 13 is produced by fusing it so as not to separate (see FIG. 10B). At this time, the steam pressure and the time for applying the steam are not particularly limited. In short, the grains are not so foamed that they are completely foamed and fused, and the grains of the preform 13 are not deformed. The point which should just apply | coat a vapor | steam so that it may stick together is the same as that of 1st Embodiment.

＜冷却工程＞
続いて固定型５及び可動型６の冷却エア弁、ドレン弁を開状態とし、エア冷却を行う（図１１（ａ）参照）。エア冷却（空冷）を行う時間が特に限定されない点は、第１実施形態と同様である。
＜容積増大工程＞
容積増大工程では、コア型６ａを移動させ、第２発泡層２を形成するための容積分だけキャビティ７の容積を増大させてクラッキング状態とする（図１１（ｂ）参照）。具体的には、コア型６ａをエアシリンダ６１，６１で紙面右側へ移動させる（図１１（ｂ）の矢印ｄ６参照）。その後、又は同時に固定型５のエア弁を開き、チャンバー５０内に空気を送り、予備成型体１１を図１１（ｂ）の矢印ｄ６で示すようにコア型側（紙面右側）に移動させる。 <Cooling process>
Subsequently, the cooling air valve and the drain valve of the fixed mold 5 and the movable mold 6 are opened to perform air cooling (see FIG. 11A). The point which does not specifically limit the time which performs air cooling (air cooling) is the same as that of 1st Embodiment.
<Volume increase process>
In the volume increasing step, the core mold 6a is moved, and the volume of the cavity 7 is increased by the volume for forming the second foamed layer 2 so as to be in a cracking state (see FIG. 11B). Specifically, the core mold 6a is moved to the right side of the page by the air cylinders 61 and 61 (see arrow d6 in FIG. 11B). Thereafter, or simultaneously, the air valve of the fixed mold 5 is opened, air is sent into the chamber 50, and the preformed body 11 is moved to the core mold side (right side on the paper surface) as shown by an arrow d6 in FIG.

この工程の後は、上述の第２発泡ビーズ充填工程（Ｓ９）と同様にキャビティ７の容積が増大した箇所に第２発泡ビーズ２０を充填していく。そして上述の発泡成型工程（Ｓ１０）、冷却、乾燥工程（Ｓ１１）、離型工程（Ｓ１２）を経れば、第１発泡層１は２つの異なる物性を備えた層となり、第２発泡層２が第１発泡層１とは異なる物性を備えた層を備えた複合発泡成型体３Ａを製造できる（図１２（ａ）参照）。すなわち、図１２（ａ）における「Ａ」〜「Ｃ」のそれぞれの物性が異なるものを製造できる。   After this step, the second foamed beads 20 are filled into the portion where the volume of the cavity 7 is increased as in the second foamed bead filling step (S9) described above. And if it passes through the above-mentioned foam molding process (S10), cooling, a drying process (S11), and a mold release process (S12), the 1st foam layer 1 will become a layer provided with two different physical properties, and the 2nd foam layer 2 However, a composite foam molded body 3A having a layer having physical properties different from those of the first foamed layer 1 can be manufactured (see FIG. 12A). In other words, products having different physical properties “A” to “C” in FIG.

本実施形態においては、上述したように第１発泡ビーズ充填工程で異なる物性の発泡ビーズ１２Ａ，１２Ｂを充填する例に限定されず、第２発泡ビーズ充填工程でも、異なる物性の発泡ビーズを充填するようにしてもよい。この場合は、＜容積増大工程＞の後、キャビティ側シャッター５１ａを予備成型体１３の表面まで突出させ、キャビティ７を上下に分割すればよい。これによれば、第１発泡層１だけでなく、第２発泡層２も異なる物性を備えたものとなるので、計４種の異なる物性を備えた複合発泡成型体３Ｂ（図１２（ｂ）参照）を製造できる。すなわち、図１２（ｂ）における「Ａ」〜「Ｄ」のそれぞれの物性が異なるものを製造できる。
また第２発泡ビーズ充填工程でのみ、キャビティ側シャッター５１ａを突出させて、計３種の異なる物性を備えた複合発泡成型体を形成することもできる。
さらに第１発泡層１を２種の異なる物性を備えたものとした後、同じ２種の異なる物性を互い違いになるようにして第２発泡層２を形成することもできる。すなわち、図１２（ｂ）において「Ａ」と「Ｄ」が同じ物性、「Ｂ」と「Ｃ」が同じ物性とし、「Ａ」と「Ｂ」が異なる物性を備えたものも製造することができる。 In the present embodiment, as described above, the embodiment is not limited to the example of filling the expanded beads 12A and 12B having different physical properties in the first expanded bead filling step, and the expanded beads having different physical properties are also filled in the second expanded bead filling step. You may do it. In this case, after the <volume increasing step>, the cavity-side shutter 51a may be projected to the surface of the preformed body 13, and the cavity 7 may be divided vertically. According to this, since not only the first foam layer 1 but also the second foam layer 2 has different physical properties, a composite foam molded body 3B having a total of four different physical properties (FIG. 12B). Can be manufactured). In other words, products having different physical properties “A” to “D” in FIG.
Further, only in the second foaming bead filling step, the cavity-side shutter 51a can be projected to form a composite foamed molded article having a total of three different physical properties.
Furthermore, after the first foamed layer 1 has two different physical properties, the second foamed layer 2 can also be formed by staggering the same two different physical properties. That is, in FIG. 12B, “A” and “D” have the same physical properties, “B” and “C” have the same physical properties, and “A” and “B” have different physical properties. it can.

以上によれば、厚み方向（図１０（ａ）において紙面左右方向）だけでなく、幅方向（図１０（ａ）において紙面上下方向）においても物性が異なる発泡層を備えた複合発泡成型体を製造することができる。
また本実施形態においても、予備成型工程では、発泡ビーズ同士を完全に融着させずに発泡成型工程で複数層を同時に加熱するので、発泡ビーズ１２Ａ，１２Ｂに対する過加熱を防いで（行っていないので）品質のよい複合発泡成型体を製造することができる。
さらに本実施形態においても、＜冷却工程＞の後、＜容積増大工程＞の前にシール材９を貼り付ける工程を行ってもよい。 According to the above, the composite foamed molded article provided with the foam layers having different physical properties not only in the thickness direction (left and right direction in FIG. 10A) but also in the width direction (up and down direction in FIG. 10A). Can be manufactured.
Also in this embodiment, in the pre-molding process, the foam beads are not completely fused together, and a plurality of layers are heated simultaneously in the foam molding process, so that overheating of the foam beads 12A and 12B is prevented (not performed). Therefore, it is possible to produce a high-quality composite foam molding.
Furthermore, also in this embodiment, the process of sticking the sealing material 9 may be performed after the <cooling process> and before the <volume increasing process>.

以上、前記各実施形態で説明した工程の加熱・冷却要領、また型開き要領やコア型６ａの可動構成等は、上述の例に限定されない。また固定型５及び可動型６の形状も複合発泡成型体３の形状に応じて形成される。さらに複合発泡成型体３，３Ａ，３Ｂの形状も図例に限定されず、用途に応じて形成され、例えば断面視において扁平な半円等のＲ形状を含む形状でもよい。さらに図では、第１発泡ビーズ１０、発泡ビーズ１２Ａを第２発泡ビーズ２０、発泡ビーズ１２Ｂよりも径が大きい発泡ビーズとして示しているが、これも図例に限定されるものではない。   As described above, the heating / cooling procedure, the mold opening procedure, the movable configuration of the core mold 6a, and the like in the steps described in the above embodiments are not limited to the above-described examples. The shapes of the fixed mold 5 and the movable mold 6 are also formed in accordance with the shape of the composite foam molded body 3. Further, the shapes of the composite foamed molded bodies 3, 3 </ b> A, 3 </ b> B are not limited to the illustrated examples, and may be formed according to the application, and may be, for example, a shape including an R shape such as a flat semicircle in a sectional view. Further, in the figure, the first expanded beads 10 and expanded beads 12A are shown as expanded beads having a diameter larger than that of the second expanded beads 20 and expanded beads 12B, but this is not limited to the illustrated example.

１ 第１発泡層
１０ 第１発泡ビーズ
１１ 予備成型体
２ 第２発泡層
２０ 第２発泡ビーズ
３，３Ａ，３Ｂ 複合発泡成型体
４ 成型型
７ キャビティ DESCRIPTION OF SYMBOLS 1 1st foam layer 10 1st foam bead 11 Pre-molded body 2 2nd foam layer 20 2nd foam bead 3,3A, 3B Composite foam molded body 4 Mold 7 cavities

Claims (8)

第１発泡ビーズを成型型のキャビティ内に充填する第１発泡ビーズ充填工程と、
前記キャビティ内に充填した第１発泡ビーズを加熱して、第１発泡ビーズの粒体同士が離れない程度に融着させる予備成型工程と、
前記成型型を移動させて、該成型型のキャビティ内の容積を増大させる容積増大工程と、
前記第１発泡ビーズとは物性の異なる第２発泡ビーズを前記容積の増大したキャビティ内に充填する第２発泡ビーズ充填工程と、
前記キャビティ内に充填された前記第１発泡ビーズ及び前記第２発泡ビーズを加熱して、発泡させながら、前記第１発泡ビーズからなる第１発泡層と前記第２発泡ビーズからなる第２発泡層とを融着させる発泡成型工程とを備えたことを特徴する複合発泡成型体の製造方法。 A first foam bead filling step of filling the first foam beads into the cavity of the mold;
A pre-molding step of heating the first foam beads filled in the cavity and fusing the first foam beads so that the particles of the first foam beads are not separated from each other;
A volume increasing step of moving the mold to increase the volume in the cavity of the mold;
A second foaming bead filling step of filling the second foamed beads having different physical properties from the first foamed beads into the cavity having the increased volume;
A first foamed layer made of the first foamed beads and a second foamed layer made of the second foamed beads while heating and foaming the first foamed beads and the second foamed beads filled in the cavity. A method for producing a composite foamed molded product, comprising: a foam molding process for fusing the two. 請求項１に記載の複合発泡成型体の製造方法において、
前記予備成型工程を実施した後、成型された前記第１発泡ビーズからなる予備成型体をエア冷却する冷却工程をさらに備えたことを特徴とする複合発泡成型体の製造方法。 In the manufacturing method of the composite foaming molding of Claim 1,
A method for producing a composite foamed molded article, further comprising a cooling step of air-cooling the preformed body composed of the molded first foamed beads after the preforming step. 請求項１又は請求項２に記載の複合発泡成型体の製造方法において、
前記第１発泡ビーズ及び前記第２発泡ビーズのうち、一方は耐熱性を有する発泡ビーズであり、他方は自己消火性を有する発泡ビーズであることを特徴とする複合発泡成型体の製造方法。 In the manufacturing method of the composite foam molding of Claim 1 or Claim 2,
One of the first foam beads and the second foam beads is a foam bead having heat resistance, and the other is a foam bead having self-extinguishing properties. 請求項１〜請求項３のいずれか１項に記載の複合発泡成型体の製造方法において、
前記第２発泡ビーズは、前記第１発泡ビーズとは、比重の異なるビーズであることを特徴とする複合発泡成型体の製造方法。 In the manufacturing method of the composite foaming molding of any one of Claims 1-3,
The method for producing a composite foamed molded article, wherein the second foamed beads are beads having a specific gravity different from that of the first foamed beads. 請求項１〜請求項４のいずれか１項に記載の複合発泡成型体の製造方法において、
前記第２発泡ビーズは、前記第１発泡ビーズとは、径の異なるビーズであることを特徴とする複合発泡成型体の製造方法。 In the manufacturing method of the composite foaming molding of any one of Claims 1-4,
The method for producing a composite foam molded article, wherein the second foam beads are beads having a diameter different from that of the first foam beads. 請求項１〜請求項５のいずれか１項に記載の複合発泡成型体の製造方法において、
前記第２発泡ビーズを充填する前に、前記予備成型体のうち少なくとも充填口に対向する箇所にシート材を貼付するシート材貼付工程をさらに備えたことを特徴とする複合発泡成型体の製造方法。 In the manufacturing method of the composite foaming molding of any one of Claims 1-5,
A method for producing a composite foam molded body, further comprising a sheet material pasting step of pasting a sheet material to at least a portion facing the filling port of the preform before filling the second foam beads. . 請求項１〜請求項６のいずれか１項に記載の複合発泡成型体の製造方法において、
前記第１発泡ビーズ及び前記第２発泡ビーズには、発泡ポリスチレンを含むことを特徴とする複合発泡成型体の製造方法。 In the manufacturing method of the composite foaming molding of any one of Claims 1-6,
The first foamed beads and the second foamed beads contain foamed polystyrene, and a method for producing a composite foamed molded product. 請求項１〜請求項７のいずれか１項に記載の複合発泡成型体の製造方法において、
前記第１発泡ビーズ充填工程及び前記第２発泡ビーズ充填工程の少なくともいずれか一方では、成型型の移動方向に沿って進退自在な仕切り部材によって成型型のキャビティを分割した状態で各キャビティに互いに異なる物性の発泡ビーズを充填することを特徴とする複合発泡成型体の製造方法。 In the manufacturing method of the composite foaming molding of any one of Claims 1-7,
At least one of the first foamed bead filling step and the second foamed bead filling step is different for each cavity in a state where the mold cavity is divided by a partition member that can be moved back and forth along the moving direction of the mold. A method for producing a composite foamed molded article, comprising filling foam beads having physical properties.
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