JP5605807B2 - Molding device for foamed resin moldings - Google Patents

Molding device for foamed resin moldings Download PDF

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JP5605807B2
JP5605807B2 JP2010176267A JP2010176267A JP5605807B2 JP 5605807 B2 JP5605807 B2 JP 5605807B2 JP 2010176267 A JP2010176267 A JP 2010176267A JP 2010176267 A JP2010176267 A JP 2010176267A JP 5605807 B2 JP5605807 B2 JP 5605807B2
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cavity
gas
mold
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foamed resin
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大徳 松尾
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Sekisui Techno Molding Co Ltd
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Description

本発明は、成形金型のキャビティ内にガスを注入してそのガス圧により発泡樹脂材料の発泡を抑制しながらキャビティ内に発泡樹脂材料を射出充填するカウンタープレッシャー法を用いて自動車の内装部品であるドアトリム等の発泡樹脂成形体を成形する装置に関する。 The present invention is an interior part of an automobile using a counter pressure method in which gas is injected into a cavity of a molding die and the foamed resin material is injected and filled into the cavity while suppressing foaming of the foamed resin material by the gas pressure. It molded foamed resin molded article of a door trim concerning equipment.

射出機によって成形金型のキャビティ内に射出充填される発泡樹脂材料をカウンタープレッシャー法を採用して発泡成形する方法としては、例えば、特許文献１に記載された方法が知られている。この射出成形方法は、成形金型の型締めと同時にガス供給・排出機構からキャビティ内にガスを注入したのち、キャビティ内に発泡樹脂材料を射出充填する際に、成形金型内に配設している圧力センサによってキャビティ内の圧力を検出してその信号により上記圧力が規定の圧力になるように、ガス供給・排出機構の開閉弁を作動させてキャビティ内の圧力を制御することにより、発泡樹脂材料の発泡を抑制しながら安定した射出速度でもって発泡樹脂材料を射出充填し、充填完了後、真空ポンプにより上記ガス供給・排出機構を通じてキャビティ内の残留ガスを急速に排除すると共に成形金型における可動金型を微小ストロークだけ後退させて発泡させている。   For example, a method described in Patent Document 1 is known as a method of foaming a foamed resin material that is injected and filled into a cavity of a molding die by an injection machine using a counter pressure method. This injection molding method is arranged in the mold when the foamed resin material is injected and filled into the cavity after injecting the gas into the cavity from the gas supply / discharge mechanism simultaneously with the mold clamping. The pressure in the cavity is detected by the pressure sensor, and the pressure in the cavity is controlled by operating the on / off valve of the gas supply / discharge mechanism so that the above pressure becomes the specified pressure by the signal. Injecting and filling the foamed resin material with a stable injection speed while suppressing the foaming of the resin material, and after the filling is completed, the residual gas in the cavity is rapidly eliminated through the gas supply / discharge mechanism by the vacuum pump and the molding die The movable mold is made to recede by a small stroke for foaming.

特開２００５−１５３４４６号公報JP 2005-153446 A

カウンタープレッシャー法による射出成形法においては、キャビティ内に射出充填される発泡樹脂材料の発泡を、キャビティ内に注入するガス圧によって抑制しながら射出成形を行うものであるから、キャビティ内への発泡樹脂材料の充填完了後にはキャビティを形成している金型の内面とキャビティ内に充填された発泡樹脂材料との間に発泡樹脂材料を囲むようにしてガスが残留することになる。   In the injection molding method by the counter pressure method, the foaming resin material injected and filled in the cavity is injection-molded while suppressing the foaming by the gas pressure injected into the cavity. After the filling of the material, the gas remains so as to surround the foamed resin material between the inner surface of the mold forming the cavity and the foamed resin material filled in the cavity.

この残留ガスを排除するには、上記射出成形方法においては、キャビティ内への発泡樹脂材料の充填完了後に、真空ポンプにより上記ガス供給・排出機構を通じてキャビティ内の残留ガスを急速に吸引、排除しているが、このようにキャビティ内のガス圧を高圧から常圧へと急激に変化させると、キャビティ内に臨ませているガス通路の排気口からの吸引力によってこの排気口近傍部分の発泡樹脂材料の表面の一部が金型内面に向かって膨出変形し、排気口に対する通気を阻止して排気口から離れた部分に存在する残留ガスを円滑に吸引、排除することができなくなり、排除されずに残留した一部のガス溜まりによって製品表面に凹跡（ひけ）が生じて外観不良が発生し、商品価値を低下させるといった問題点がある。   In order to eliminate the residual gas, in the injection molding method, after the filling of the foamed resin material into the cavity is completed, the residual gas in the cavity is rapidly sucked and removed by the vacuum pump through the gas supply / discharge mechanism. However, if the gas pressure in the cavity is suddenly changed from high pressure to normal pressure in this way, the foamed resin in the vicinity of the exhaust port is caused by the suction force from the exhaust port of the gas passage facing the cavity. A part of the surface of the material bulges and deforms toward the inner surface of the mold, preventing ventilation to the exhaust port, making it impossible to smoothly suck and eliminate the residual gas present in the part away from the exhaust port. There is a problem in that a part of the remaining gas pool causes a dent (sink) on the surface of the product, resulting in poor appearance and a reduction in commercial value.

本発明はこのような問題点に鑑みてなされたもので、その目的とするところは、キャビティ内にガスを注入してそのガス圧により発泡樹脂材料の発泡を抑制しながらキャビティ内に発泡樹脂材料を射出充填するカウンタープレッシャー法を用いた発泡樹脂成形体の成形装置において、残留ガスによる凹跡等の発生をなくして優れた外観を呈する発泡樹脂成形体を得ることができる成形装置を提供するにある。 The present invention has been made in view of such problems. The object of the present invention is to inject a gas into the cavity and suppress the foaming of the foamed resin material by the gas pressure. provided in the molding apparatus of the foamed resin molded body using counter pressure method of injecting and filling the formed KatachiSo location can be obtained a foamed resin molded article exhibiting superior appearance by eliminating the occurrence of凹跡due to residual gas There is.

上記目的を達成するために、本発明の発泡樹脂成形体の成形方法を実施するための装置は、請求項１に記載したように、固定金型と可動金型とからなる成形金型のキャビティ内に発泡樹脂材料を射出充填して発泡させることにより発泡樹脂成形体を製造する成形装置において、成形金型の固定金型内にキャビティの一端部に連通するガス通路を設けてこのガス通路を金型外に設けた給気弁を有する給気通路と排気弁を有する排気通路とに連結、連通させていると共に、キャビティ内のガス圧を検出してその検出信号によりキャビティ内のガス圧を所定値に制御する圧力センサを配設してあり、さらに、成形金型の可動金型内に、金型外に設けている強制排気源に排気弁を介して連通しているガス強制排出通路を設けてこのガス強制排出通路の開口端をキャビティの両端間の中央部に臨ませていると共にこの開口端部に多数の微細孔を有する焼結金属又は焼結セラミックからなる多孔質部材を設け、この多孔質部材のキャビティに面した端面をキャビティを形成している金型の内面と面一の平滑面に形成していることを特徴とする。 In order to achieve the above object, an apparatus for carrying out the method for molding a foamed resin molded body of the present invention is a cavity of a molding die comprising a fixed die and a movable die as described in claim 1. In a molding apparatus for producing a foamed resin molding by injecting and filling a foamed resin material into a foam, a gas passage communicating with one end of the cavity is provided in a fixed mold of the molding die, and this gas passage is provided. It is connected to and communicated with an air supply passage having an air supply valve and an exhaust passage having an exhaust valve provided outside the mold, and the gas pressure in the cavity is detected by the detection signal. A gas forced exhaust passage having a pressure sensor controlled to a predetermined value and communicating with a forced exhaust source provided outside the mold through an exhaust valve in the movable mold of the molding die Of this gas forced exhaust passage A porous member made of a sintered metal or sintered ceramic having a number of micropores mouth end to the open end with which to face the central portion between both ends of the cavity is provided, the surface in the cavity of the porous member The end face is formed on a smooth surface flush with the inner surface of the mold forming the cavity .

請求項１に係る発明によれば、発泡樹脂成形体の成形方法を実施するための装置において、成形金型にキャビティの一端部に連通するガス通路を設けてこのガス通路を金型外に設けた給気弁を有する給気通路と排気弁を有する排気通路とに連結、連通させていると共に、キャビティ内のガス圧を検出してその検出信号によりキャビティ内のガス圧を所定値に制御する圧力センサを配設しているので、この圧力センサの検出信号を上記給気弁を有する給気通路と排気弁を有する排気通路にフィードバック処理して、成形機からキャビティ内に射出充填された発泡樹脂材料の発泡を抑制しながら且つ発泡樹脂材料の射出速度を安定した状態に維持しながらキャビティ内に射出充填することができる。 According to the first aspect of the present invention, in the apparatus for carrying out the method for molding a foamed resin molded body , the molding die is provided with a gas passage communicating with one end of the cavity, and the gas passage is provided outside the die. In addition, the gas passage in the cavity is detected and connected to the air supply passage having the air supply valve and the exhaust passage having the exhaust valve, and the gas pressure in the cavity is controlled to a predetermined value by the detection signal. Since the pressure sensor is provided, the detection signal of this pressure sensor is fed back to the air supply passage having the above air supply valve and the exhaust passage having the exhaust valve, and the foam injected into the cavity from the molding machine The cavity can be injected and filled while suppressing foaming of the resin material and maintaining the injection speed of the foamed resin material in a stable state.

その上、成形金型内に上記排気通路とは別に、金型外に設けている真空ポンプ等の強制排気源に排気弁を介して連通しているガス強制排出通路を設けてこのガス強制排出通路の開口端をキャビティに臨ませていると共にこの開口端部に多数の微細孔を有する焼結金属又は焼結セラミックからなる多孔質部材を設けているので、強制排気源からの強力な吸気力を多孔質部材の多数の微細孔の通気抵抗によって低下させ且つこれらの微細孔にその吸気力を分散させてキャビティ内に面している微細孔の開口端からキャビティ内の残留ガスを比較的弱い吸気力でもって吸引することができ、さらに、上記排気弁の開度を制御することによって給気量の調整と共に所定時間内にキャビティ内の残留ガスを吸引、排除できる吸気力に正確に調整することができ、従って、上述したようにキャビティ内のガス圧を高圧から常圧にまでなだらかに低下させながらキャビティ内に残理をする全ての残留ガスを排除したのち、発泡させることができて、表面に凹跡などの不良箇所が発生していない均一な品質の成形品を安定的に製造することができる。   In addition to this exhaust passage, a gas forced exhaust passage communicating with a forced exhaust source such as a vacuum pump provided outside the mold via an exhaust valve is provided in the molding die. Since the opening end of the passage faces the cavity and a porous member made of sintered metal or sintered ceramic having a large number of fine holes is provided at the opening end portion, a powerful intake force from a forced exhaust source Is reduced by the ventilation resistance of a large number of micropores in the porous member, and the suction force is dispersed in these micropores so that the residual gas in the cavity is relatively weak from the open end of the micropore facing the cavity. Suction can be performed with the intake force, and by adjusting the opening of the exhaust valve, the intake air amount can be adjusted and the intake gas can be accurately adjusted so that the residual gas in the cavity can be sucked and removed within a predetermined time. about Therefore, as described above, the gas pressure in the cavity can be gradually reduced from high pressure to normal pressure, and all residual gas remaining in the cavity can be removed and then foamed to the surface. It is possible to stably produce a molded product of uniform quality in which no defective portion such as a dent is generated.

さらに、本発明によれば、カウンタープレッシャー法によって射出充填時にキャビティ内の圧力を一定圧に保持するためのガス通路やこのガス通路に連通した給気弁を有する給気通路及び排気弁を有する排気通路等を固定金型側に、ガス強制排出通路を可動金型内にそれぞれ設けているので、カウンタープレッシャ法によって射出充填時にキャビティ内の圧力を一定圧に保持することができる上記ガス通路等を備えた既存の成形装置に上記ガス強制排出通路を設けることによって、表面に残留ガスによる凹跡などの不良箇所が発生していない品質のよい成形品を製造できる装置に改良することができる。 Further, according to the present invention , the exhaust having the gas passage for holding the pressure in the cavity at a constant pressure at the time of injection filling by the counter pressure method, the air supply passage having the air supply valve communicating with the gas passage, and the exhaust valve. Since the passage and the like are provided on the fixed mold side and the gas forced discharge passage is provided in the movable mold, the gas passage and the like that can maintain the pressure in the cavity at a constant pressure at the time of injection filling by the counter pressure method. By providing the gas forcible discharge passage in the existing molding apparatus provided, the apparatus can be improved to an apparatus capable of producing a molded product of good quality in which a defective portion such as a dent due to residual gas does not occur on the surface.

又、キャビティに面したガス強制排出通路の開口端部に設けている多孔質部材の端面をキャビティを形成している金型の内面と面一の平滑面に形成しているので、発泡樹脂材料が発泡した際に、この多孔質部材の端面に圧接する表面も金型内面に圧接する表面と同じ綺麗な面に仕上げることができ、さらに、ガス強制排出通路の多孔質部材を設けている開口端部をキャビティの両端間の中央部に臨ませているので、キャビティの中央部からキャビティ内の両端に向かってキャビティ内の残留ガスを均等に且つ効率よく吸引、排除することができて、残留ガスの排除処理が可能となり、短時間の間にキャビティ内の全ての残留ガスを円滑且つ確実に排除することができる。 Further, since the end face of the porous member provided at the open end of the gas forced discharge passage facing the cavity is formed on the smooth surface flush with the inner face of the mold forming the cavity, the foamed resin material When foamed, the surface pressed against the end surface of the porous member can be finished to the same clean surface as the surface pressed against the inner surface of the mold, and further, an opening provided with the porous member of the gas forced discharge passage the end than that have to face the central portion between both ends of the cavity, uniformly and efficiently suck the remaining gas in the cavity toward the central portion of the cavity at both ends of the cavity, it can be eliminated, Residual gas can be eliminated, and all residual gas in the cavity can be smoothly and reliably eliminated in a short time.

射出発泡成形金型の簡略縦断側面図。The simplified vertical side view of an injection foaming mold. 型締めから型開きに至る成形過程のプレスチャートとこのプレスチャートに対応した型内のガス圧状態を示すチャート図。FIG. 3 is a chart showing a press chart of a molding process from mold clamping to mold opening and a gas pressure state in the mold corresponding to the press chart. 発泡樹脂材料の射出圧力と射出速度とガス圧との相対関係を示す線図。The diagram which shows the relative relationship of the injection pressure of a foamed resin material, the injection speed, and gas pressure. キャビティ内にガスを供給している状態を示す説明図。Explanatory drawing which shows the state which is supplying the gas in a cavity. キャビティ内からガスを排除している状態を示す説明図。Explanatory drawing which shows the state which has excluded gas from the inside of a cavity. ガス強制排出通路を通じてガスを排除している状態を示す説明図。Explanatory drawing which shows the state which is excluding gas through a gas forced discharge passage.

次に、本発明の具体的な実施の形態を図面について説明すると、図１において、成形金型10は、キャビティ13を形成するための凹部を設けている固定金型11と、この固定金型11の凹部に摺動自在に挿嵌させて固定金型11との合わせ面間で上記キャビティ13を形成する可動金型12とからなり、固定金型11内には射出機14から射出される溶融状態の発泡樹脂材料をキャビティ13に射出充填するためのゲート21を設けていると共に、固定金型11の一端部内に、キャビティ13の一端側における可動金型12との合わせ面に設けている溝（図示せず）を通じてキャビティ13内に連通したガス通路22を設けてあり、このガス通路22を金型外で分岐させてその一方を管又はホースからなるガス供給通路23に、他方を同じく管又はホースからなるガス排出通路24にそれぞれ連結、連通させている。   Next, a specific embodiment of the present invention will be described with reference to the drawings. In FIG. 1, a molding die 10 includes a stationary die 11 provided with a recess for forming a cavity 13, and the stationary die. 11 includes a movable mold 12 that is slidably inserted into a recess of 11 and forms the cavity 13 between the mating surfaces with the fixed mold 11, and is injected from the injection machine 14 into the fixed mold 11. A gate 21 for injecting and filling the foamed resin material in the molten state into the cavity 13 is provided, and is provided in one end portion of the fixed mold 11 on the mating surface with the movable mold 12 on one end side of the cavity 13. A gas passage 22 communicating with the inside of the cavity 13 through a groove (not shown) is provided. The gas passage 22 is branched outside the mold, one of which is a gas supply passage 23 formed of a pipe or a hose, and the other is the same. It is connected to the gas discharge passage 24 consisting of a pipe or hose. , It is communicated.

さらに、これらのガス供給通路23とガス排出通路24には給気制御弁25と排気制御弁26をそれぞれ設けていると共に、ガス供給通路23は不活性ガスを充填しているガスボンベからなる給気源27に接続している。   Further, the gas supply passage 23 and the gas discharge passage 24 are provided with an air supply control valve 25 and an exhaust control valve 26, respectively, and the gas supply passage 23 is an air supply comprising a gas cylinder filled with an inert gas. Connected to source 27.

一方、上記可動金型12には、固定金型11に設けている上記ガス通路22とは別にキャビティ13内の残留ガスを積極的に吸引、排除するためのガス強制排出通路28が設けられてあり、このガス強制排出通路28の一端開口部をこの通路よりも大径に形成してその開口端をキャビティ13における両端間の中央部に連通させた状態で臨ませていると共にこの開口部内に、多数の微細孔を設けている焼結金属又は焼結セラミックからなる多孔質部材29を嵌合することによって配設して、キャビティ13に面したこの多孔質部材29の平滑な端面を可動金型12の面と面一にしてキャビティ13に向けている多数の微細孔を通じてキャビティ13内のガスをガス強制排出通路28に排出可能に構成している。   On the other hand, the movable mold 12 is provided with a gas forced discharge passage 28 for actively sucking and removing the residual gas in the cavity 13 in addition to the gas passage 22 provided in the fixed mold 11. There is an opening at one end of the gas forced discharge passage 28 having a diameter larger than that of the passage, and the opening end faces the central portion between both ends of the cavity 13 and faces inside the opening. The porous member 29 made of sintered metal or sintered ceramic provided with a large number of micropores is disposed by fitting, and the smooth end face of the porous member 29 facing the cavity 13 is movable metal The gas inside the cavity 13 can be discharged to the gas forced discharge passage 28 through a large number of fine holes directed to the cavity 13 so as to be flush with the surface of the mold 12.

可動金型12内に設けているこのガス強制排出通路28の他端開口部は金型外に配管した管又はホースからなる型外ガス強制排出通路30に連結、連通してあり、この型外ガス強制排出通路28に排気制御弁31が設けられてあり、この排気制御弁31を有する型外ガス強制排出通路28を真空ポンプからなる排気源32に接続している。   The other end opening of this gas forced discharge passage 28 provided in the movable mold 12 is connected to and communicated with an out-mold gas forced discharge passage 30 consisting of a pipe or hose piped outside the mold. An exhaust control valve 31 is provided in the gas forced exhaust passage 28, and the out-of-mold gas forced exhaust passage 28 having the exhaust control valve 31 is connected to an exhaust source 32 including a vacuum pump.

また、固定金型11と可動金型12内におけるキャビティ13の周囲の複数箇所には、キャビティ13内のガス圧を検出する圧力センサ33が配設されてあり、これらの圧力センサ33からの信号を制御装置（図示せず）に入力してこの制御装置を介してその信号を上記給気制御弁25を有するガス供給路と排気制御弁26を有するガス排気通路側にフィードバックさせることにより給気制御弁25と排気制御弁26とを作動させ、キャビティ13内が所定の圧力となるようにキャビティ13内に対するガスの供給、排出量を調整するように構成している。また、成形装置には、型締めから型開きまでのタイムスケジュールに応じた制御回路を有する上記制御装置やタイマー（図示せず）が設けられている。なお、以下においては、上記固定金型11に設けている上記ガス通路22に連結、連通したガス排出通路24側の排気制御弁を第１排気制御弁26とし、上記型外ガス強制排出通路28に設けている排気制御弁を第２排気制御弁31として説明する。   Further, pressure sensors 33 for detecting the gas pressure in the cavity 13 are arranged at a plurality of locations around the cavity 13 in the fixed mold 11 and the movable mold 12, and signals from these pressure sensors 33 are provided. Is supplied to a control device (not shown) and the signal is fed back to the gas supply passage having the air supply control valve 25 and the gas exhaust passage having the exhaust control valve 26 via the control device. The control valve 25 and the exhaust control valve 26 are operated to adjust the supply and discharge amounts of gas to the cavity 13 so that the inside of the cavity 13 has a predetermined pressure. Further, the molding apparatus is provided with the above-described control apparatus and timer (not shown) having a control circuit corresponding to a time schedule from mold clamping to mold opening. In the following, the exhaust control valve on the side of the gas discharge passage 24 connected to and communicated with the gas passage 22 provided in the fixed mold 11 will be referred to as a first exhaust control valve 26, and the out-of-mold gas forced discharge passage 28 will be described. The exhaust control valve provided in FIG. 2 will be described as a second exhaust control valve 31.

このように構成した成形装置を使用して自動車の内装部品であるドアトリム等の発泡樹脂成形品を成形する方法を図２〜図６に基づいて説明すると、まず、成形金型10における可動金型12を図２に示す型開き位置Ａから型締め位置Ｂまで固定金型11側に移動させて型締めを行う。この型締めが完了すると同時にタイマーがスタートし、制御装置を介して各部の制御が行われる。   A method of molding a foamed resin molded product such as a door trim, which is an interior part of an automobile, using the molding apparatus configured as described above will be described with reference to FIGS. 2 to 6. First, the movable mold in the molding mold 10 is described. Clamping is performed by moving 12 to the fixed mold 11 side from the mold opening position A to the mold clamping position B shown in FIG. As soon as the mold clamping is completed, a timer is started and each part is controlled through the control device.

そして、型締め完了と同時に図４に示すように給気制御弁25が開弁して給気源17からガス給気通路23を通じて固定金型11内に設けているガス通路22に不活性ガス等のガスが供給され、このガス通路22からキャビティ13内に注入される。なお、このガス注入時には第１排気制御弁26と第２排気制御弁31とは閉止している。   When the mold clamping is completed, the air supply control valve 25 is opened as shown in FIG. 4, and the inert gas enters the gas passage 22 provided in the fixed mold 11 from the air supply source 17 through the gas supply passage 23. Gas is supplied and injected into the cavity 13 from the gas passage 22. Note that the first exhaust control valve 26 and the second exhaust control valve 31 are closed during the gas injection.

給気源17からガス給気通路23、ガス通路22を通じてキャビティ13内に注入されるガス圧は、複数個の圧力センサ33によって常時、検出されてあり、キャビティ13内のガス圧が、キャビティ13内に射出充填される発泡樹脂材料の発泡を抑制し、且つ、キャビティ13内に発泡樹脂材料を一定の射出速度でもって射出充填可能にするガス圧と同等の設定圧に達した際に、圧力センサ33からの信号によって制御装置を介して給気制御弁25を閉止させると同時に、射出機14から固定金型１に設けているゲート21を通じて、発泡剤を混練しているポリプロピレン樹脂等の溶融樹脂からなる発泡樹脂材料を所定の射出圧力でもってキャビティ３内に射出、充填する。なお、図２において、Ｃはキャビティ13内への射出充填開始位置であり、Ｄが充填完了位置である。   The gas pressure injected into the cavity 13 from the supply source 17 through the gas supply passage 23 and the gas passage 22 is constantly detected by a plurality of pressure sensors 33, and the gas pressure in the cavity 13 is When the pressure reaches a set pressure equivalent to a gas pressure that suppresses foaming of the foamed resin material injected and filled in the cavity 13 and allows the foamed resin material to be injected and filled into the cavity 13 at a constant injection speed. The air supply control valve 25 is closed via the control device in response to a signal from the sensor 33, and at the same time, the polypropylene resin or the like kneaded with the foaming agent is melted from the injector 14 through the gate 21 provided in the fixed mold 1. A foamed resin material made of resin is injected and filled into the cavity 3 with a predetermined injection pressure. In FIG. 2, C is the injection filling start position into the cavity 13, and D is the filling completion position.

射出機14からキャビティ13内に発泡樹脂材料が射出充填されると、それに伴ってキャビティ13内のガス圧が上記設定圧よりも上昇するが、この上昇を上記圧力センサ33によって検出してその検出信号により制御装置を介して図５に示すように第１排気制御弁26を開弁させ、キャビティ13内への発泡樹脂材料の射出充填量に応じた量のガスをキャビティ13内からガス通路22、ガス排出通路24を通じて排出させる。この際、ガスの排出量が多くてキャビティ13内のガス圧が上記設定圧よりも低くなった場合には、給気制御弁25を開いてキャビティ13内にガスを注入することにより所定圧に復帰させる。   When the foamed resin material is injected and filled into the cavity 13 from the injection machine 14, the gas pressure in the cavity 13 rises above the set pressure, and this rise is detected by the pressure sensor 33. As shown in FIG. 5, the first exhaust control valve 26 is opened by the signal through the control device, and an amount of gas corresponding to the injection filling amount of the foamed resin material into the cavity 13 is sent from the cavity 13 to the gas passage 22. The gas is discharged through the gas discharge passage 24. At this time, if the gas discharge amount is large and the gas pressure in the cavity 13 becomes lower than the set pressure, the supply control valve 25 is opened and the gas is injected into the cavity 13 to reach the predetermined pressure. Return.

このように、キャビティ13内の圧力を圧力センサ33によって検出させ、その信号を上記給気制御弁25と第１排気制御弁26側にフィードバックさせることによってキャビティ13内を上記設定圧に制御しながらキャビティ13内への発泡樹脂材料の射出充填を行う。なお、キャビティ13内への発泡樹脂材料の射出充填の開始から発泡開始直前までのキャビティ13内のガス圧と、発泡樹脂材料の射出速度及び射出圧力の変動状態を図３に示す。   In this way, the pressure in the cavity 13 is detected by the pressure sensor 33, and the signal is fed back to the air supply control valve 25 and the first exhaust control valve 26, thereby controlling the inside of the cavity 13 to the set pressure. Injection filling of the foamed resin material into the cavity 13 is performed. FIG. 3 shows the gas pressure in the cavity 13 from the start of injection filling of the foamed resin material into the cavity 13 and immediately before the start of foaming, and the fluctuation state of the injection speed and injection pressure of the foamed resin material.

こうして、キャビティ13内に発泡樹脂材料を射出充填し、その射出充填完了直前、又は射出充填完了時に、給気制御弁25と排気制御弁26を閉止した状態にして図６に示すようにガス強制排出通路30に設けている第２排気制御弁31を開くことにより、キャビティ13内における発泡樹脂材料の表面とキャビティ13内に面した金型内面との間に残存している残留ガスを排除する。   In this way, the resin foam material is injected and filled into the cavity 13, and immediately before the injection filling is completed or at the completion of the injection filling, the air supply control valve 25 and the exhaust control valve 26 are closed, as shown in FIG. By opening the second exhaust control valve 31 provided in the discharge passage 30, residual gas remaining between the surface of the foamed resin material in the cavity 13 and the inner surface of the mold facing the cavity 13 is eliminated. .

詳しくは、キャビティ13内に対する発泡樹脂材料の射出充填が完了又は完了直前に、型外ガス強制排出通路30に設けている第２排気制御弁31を開くと共に真空ポンプからなる排気源32を作動させるように設定してあり、第２排気制御弁31が開くと、排気源32による吸気力が型外ガス強制排出通路30を通じて可動金型12内に設けているガス強制排出通路28に作用し、このガス強制排出通路28の先端部に設けられてキャビティ13内に臨ませている多孔質部材29の多数の微細孔を通じて上記吸気力をキャビティ13内に作用させ、発泡樹脂材料の表面とキャビティ13内に面した金型内面との間に残存している残留ガスを多孔質部材29の多数の微細孔を通じてガス強制排出通路28内に吸引し、型外ガス強制排出通路30を通じて排気源32側に排除する。   Specifically, immediately after the injection filling of the foamed resin material into the cavity 13 is completed or just before the completion, the second exhaust control valve 31 provided in the out-of-mold gas forced discharge passage 30 is opened and the exhaust source 32 including a vacuum pump is operated. When the second exhaust control valve 31 is opened, the intake force by the exhaust source 32 acts on the gas forced exhaust passage 28 provided in the movable mold 12 through the out-of-mold gas forced exhaust passage 30. The suction force is applied to the cavity 13 through a large number of fine holes in the porous member 29 provided at the tip of the gas forced discharge passage 28 and facing the cavity 13, and the surface of the foamed resin material and the cavity 13 Residual gas remaining between the inner surface of the mold facing the inside is sucked into the gas forced exhaust passage 28 through the numerous fine holes of the porous member 29, and the exhaust gas forced exhaust passage 30 through the exhaust gas forced exhaust passage 30 side. To eliminate.

この際、排気源32からの吸気力を多孔質部材29の多数の微細孔によって分散させることができると共に微細孔の通気抵抗によって低下させることができ、さらに、第２排気制御弁31の開弁度を制御することによって吸気力を調整することができ、従って、キャビティ13内に向かって開口している全ての微細孔からの吸気力が緩やかになってキャビティ13内に射出充填された発泡樹脂材料にその吸引力による排気を遮断する盛り上がりのような変形を生じさせることなく、残留ガスを残存させている空間部を多孔質部材29に向かって連通させた状態を保持しながら、発泡樹脂材料の表面と金型内面に沿って全ての残留ガスを多孔質部材29に向かって円滑に流動させて多孔質部材29の微細孔を通じて吸引、排除することができ、キャビティ内のガス圧を常圧にまで徐々に低下させることができる。その上、多孔質部材29をキャビティ13の中央部に臨ませているので、キャビティ13内の隅々まで残留ガスを短時間で効率よく吸引、排除することができる。   At this time, the intake force from the exhaust source 32 can be dispersed by a large number of fine holes in the porous member 29 and can be reduced by the ventilation resistance of the fine holes. Further, the second exhaust control valve 31 is opened. By controlling the degree, the suction force can be adjusted, and therefore the suction force from all the fine holes opening toward the inside of the cavity 13 becomes gentle and the foamed resin injected and filled into the cavity 13 Foamed resin material while maintaining the state in which the space part in which the residual gas remains is communicated toward the porous member 29 without causing deformation such as a bulge that blocks the exhaust gas due to the suction force of the material. All the residual gas can flow smoothly toward the porous member 29 along the surface of the mold and the inner surface of the mold, and can be sucked and eliminated through the fine holes of the porous member 29, and the gas pressure in the cavity can be reduced. The pressure can be gradually reduced to normal pressure. In addition, since the porous member 29 faces the central portion of the cavity 13, it is possible to efficiently suck and remove the residual gas to every corner of the cavity 13 in a short time.

こうして、キャビティ13内への発泡樹脂材料の射出充填完了又は完了直前から発泡樹脂材料の発泡開始（図２におけるＥの位置）に至る間に、多孔質部材29を備えたガス強制排出通路28から型外のガス強制排出通路30を通じてキャビティ13内の残留ガスを排除してキャビティ13内のガス圧を常圧にまで低下させたのち、図２におけるＥからＦの位置まで可動金型12を微小ストロークだけ後退させることにより発泡樹脂材料を発泡させ、その状態でＦからＧに至るまで冷却させて発泡を完了させ、しかるのち、型開き（図２におけるＧ−Ｈ）して発泡樹脂成形体を脱型させる。なお、以上の実施例においては、ガス強制排出通路28を可動金型12側に設けているが、固定金型11側に設けてその先端開口部に設けている多孔質部材29をキャビティ13内に臨ませた構造としておいてもよい。   Thus, from the completion of the injection filling of the foamed resin material into the cavity 13 or immediately before the completion of foaming of the foamed resin material (position E in FIG. 2), from the gas forced discharge passage 28 provided with the porous member 29. After the residual gas in the cavity 13 is removed through the gas forced discharge passage 30 outside the mold and the gas pressure in the cavity 13 is reduced to normal pressure, the movable mold 12 is made minute from position E to F in FIG. The foamed resin material is foamed by retreating only by the stroke, and in that state, the foamed resin material is cooled from F to G to complete the foaming, and then the mold is opened (G-H in FIG. 2) to obtain the foamed resin molded body. Demold. In the above embodiment, the gas forced discharge passage 28 is provided on the movable mold 12 side, but the porous member 29 provided on the fixed mold 11 side and provided at the front end opening is provided in the cavity 13. It may be a structure facing the surface.

10 成形金型
11 固定金型
12 可動金型
13 キャビティ
14 射出機
21 発泡樹脂材料狂気を通路
22 ガス通路
23 ガス供給通路
24 ガス排出通路
25 給気弁
26 第１排気弁
27 給気源
28 ガス強制排出通路
29 多孔質部材
30 型外ガス強制排出通路
31 第２排気弁
32 排気源
33 圧力センサ 10 Mold
11 Fixed mold
12 Movable mold
13 cavity
14 Injection machine
21 Foam resin material madness passage
22 Gas passage
23 Gas supply passage
24 Gas exhaust passage
25 Air supply valve
26 First exhaust valve
27 Air supply source
28 Gas forced exhaust passage
29 Porous material
30 Outlet gas forced exhaust passage
31 Second exhaust valve
32 Exhaust source
33 Pressure sensor

Claims (1)

固定金型と可動金型とからなる成形金型のキャビティ内に発泡樹脂材料を射出充填して発泡させることにより発泡樹脂成形体を製造する成形装置において、成形金型の固定金型内にキャビティの一端部に連通するガス通路を設けてこのガス通路を金型外に設けた給気弁を有する給気通路と排気弁を有する排気通路とに連結、連通させていると共に、キャビティ内のガス圧を検出してその検出信号によりキャビティ内のガス圧を所定値に制御する圧力センサを配設してあり、さらに、成形金型の可動金型内に、金型外に設けている強制排気源に排気弁を介して連通しているガス強制排出通路を設けてこのガス強制排出通路の開口端をキャビティの両端間の中央部に臨ませていると共にこの開口端部に多数の微細孔を有する焼結金属又は焼結セラミックからなる多孔質部材を設け、この多孔質部材のキャビティに面した端面をキャビティを形成している金型の内面と面一の平滑面に形成していることを特徴とする発泡樹脂成形体の成形装置。 In a molding apparatus for producing a foamed resin molding by injecting and foaming a foamed resin material into a cavity of a molding die composed of a fixed die and a movable die, the cavity is formed in the stationary die of the molding die. A gas passage communicating with one end of the gas passage is provided, and this gas passage is connected to and communicated with an air supply passage having an air supply valve provided outside the mold and an exhaust passage having an exhaust valve, and the gas in the cavity A pressure sensor that detects the pressure and controls the gas pressure in the cavity to a predetermined value based on the detection signal is provided. Further, forced exhaust is provided outside the mold in the movable mold of the molding mold. A gas forced exhaust passage communicating with the source via an exhaust valve is provided so that the open end of the gas forced exhaust passage faces the center between both ends of the cavity , and a large number of fine holes are formed in the open end. Sintered metal or sintered ceramic A porous member made of a click provided, foamed resin molding, characterized by forming the end surface facing the cavity of the porous member to the inner surface flush with the smooth surface of the mold forming the cavity Body shaping device.
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