阅读说明：本技术 发泡成型体的制造方法及装置 (Method and apparatus for producing foamed molded body ) 是由 小野寺正明 大野庆词 五十岚优 于 2016-09-28 设计创作，主要内容包括：提供一种能够以简单的工序抑制折弯壁的产生的发泡成型体的制造方法。根据本发明,提供一种发泡成型体的制造方法,具备：型坯形成工序,从环状缝隙将包含发泡剂的熔融混炼树脂朝夹在一对分割模具之间的成型区域的挤出方向挤出,从而形成发泡型坯；以及成型工序,对位于所述成型区域的所述发泡型坯进行所述分割模具的闭模而进行发泡成型体的成型,在所述型坯形成工序中,以相对于所述挤出方向为45度以上135度以下的方向,向所述发泡型坯的内表面喷射空气而进行预吹塑。(Provided is a method for producing a foamed molded body, wherein the occurrence of a folded wall can be suppressed by a simple process. According to the present invention, there is provided a method for producing a foamed molded article, comprising: a parison forming step of forming a foamed parison by extruding a molten kneaded resin containing a foaming agent from an annular gap in an extrusion direction in a molding region sandwiched between a pair of divided molds; and a molding step of molding a foamed molded body by closing the split mold with respect to the foamed parison positioned in the molding region, wherein in the parison forming step, air is injected into an inner surface of the foamed parison in a direction of 45 degrees to 135 degrees with respect to the extrusion direction to perform preliminary blowing.)

1. A method for producing a foamed molded body, comprising:

a parison forming step of forming a foamed parison by extruding a molten kneaded resin containing a foaming agent from an annular gap in an extrusion direction in a molding region sandwiched between a pair of divided molds; and

a molding step of molding a foam molded body by closing the split mold with respect to the foam parison positioned in the molding region,

in the parison forming step, pre-blowing is performed by injecting air into the inner surface of the foamed parison in a direction of 45 degrees to 135 degrees with respect to the extrusion direction.

2. The method for producing a foam molding according to claim 1,

the pre-blow molding is carried out using a pre-blow nozzle located above or below the molding zone.

3. The method for producing a foam molding according to claim 1 or 2, wherein,

in the parison forming step, the foamed parison is first positioned over substantially the entire molding region, and then the foamed parison is clamped and sealed by clamping, and then the pre-blow molding is performed.

4. The method for producing a foam molding according to claim 1,

in the parison forming step, the pre-blow is started before the lower end of the foamed parison reaches the lower end of the molding region.

5. The method for producing a foam molding according to claim 1,

in the parison forming step, the foamed parison is clamped and sealed by a clamp portion before a lower end of the foamed parison reaches a lower end of the molding region, and the preliminary blow molding is performed while the clamp portion is lowered as the lower end of the foamed parison is lowered.

6. The method for producing a foam molding according to claim 4 or 5, wherein,

in the parison forming step, the foamed parison formed so as to be positioned at a part of or above the upper side of the molding region is clamped and sealed by upper clamping.

7. An apparatus for producing a foam molded body, comprising:

a foaming extruder for extruding a molten and kneaded resin containing a foaming agent in an extrusion direction through an annular gap to form a foamed parison in at least a part of a molding region;

a pre-blowing nozzle that performs pre-blowing by injecting air into an inner surface of the foamed parison in a direction of 45 degrees to 135 degrees with respect to the extrusion direction; and

and a pair of split molds that mold the foamed parison into a foamed molded body by closing the molds.

8. The apparatus for producing a foam molding according to claim 7,

the pre-blowing nozzle is arranged above or below the molding area.

9. The apparatus for producing a foam molding according to claim 7 or 8, wherein,

the apparatus for producing a foamed molded article further includes a clamping portion that clamps and seals the foamed parison.

10. The apparatus for producing a foam molding according to claim 9,

the clamp portion performs a lower clamp for clamping and sealing the foamed parison formed to be located substantially over the entire molding region.

11. The apparatus for producing a foam molding according to claim 9,

the clamp portion performs an upper clamp for clamping and sealing the foamed parison formed to be positioned at or above a part of an upper side of the molding region.

[ technical field ] A method for producing a semiconductor device

The present invention relates to a method and an apparatus for producing a foamed molded article.

[ background of the invention ]

In an air conditioning apparatus such as an automobile, a tubular air conditioning duct for ventilation is used.

As an air conditioning pipe, a foamed molded article using a foamed resin obtained by foaming a thermoplastic resin with a foaming agent is known. In the case of foam molding, high heat insulation and weight reduction are widely required.

As a method for producing such a foamed molded article, a foam blow molding method is widely known in which a foamed resin in a molten state is closed by a split mold and air is blown into the inside to expand the resin.

In recent years, there is a tendency that the expansion ratio of the foamed molded article is increased from the demand for weight reduction, but when the expansion ratio is increased, the outer surfaces of the foamed parison are fused to form stripes on the outer surface of the foamed molded article, and a phenomenon called "wall bending" is likely to occur. In patent document 1, in order to suppress the occurrence of the folded wall, a lower portion of a cylindrical foamed parison is closed, the foamed parison is sandwiched before or/and between molds, and a gas is blown into the parison to expand the parison.

[ Prior art documents ]

[ patent document ]

[ patent document 1 ] Japanese laid-open publication No. 2002-192601

[ summary of the invention ]

[ problem to be solved by the invention ]

However, in the method of patent document 1, since it is necessary to blow gas into the parison before the mold is closed, the manufacturing process becomes complicated.

The present invention has been made in view of such circumstances, and provides a method for producing a foamed molded article, which can suppress the occurrence of a folded wall in a simple process.

[ means for solving problems ]

According to the present invention, there is provided a method for producing a foamed molded article, comprising: an extrusion step of extruding a molten kneaded resin containing a foaming agent from an annular gap between a core and a mold shell surrounding the core to form a cylindrical foamed parison, and extruding the parison between a pair of divided molds; a lower clamping step of clamping the foamed parison at a lower clamping portion disposed below the split mold; and a molding step of molding the foamed parison by closing the split mold after the lower clamping step, wherein the diameter of the core is D, the distance between the lower surface of the core and the upper surface of the split mold is H, the distance between the lower surface of the split mold and the upper surface of the lower clamping portion is L, H/D is 1.33 to 3.33, and L/D is 0.33 to 2.00.

According to the experiments of the inventors, it was found that when the diameter of the core is D, the distance between the lower surface of the core and the upper surface of the split mold is H, and the distance between the lower surface of the split mold and the upper surface of the lower clamp is L, the core, the split mold, and the lower clamp are arranged such that H/D is 1.33 to 3.33 and L/D is 0.33 to 2.00, and the occurrence of a folded wall can be suppressed, and the present invention was completed.

Various embodiments of the present invention are exemplified below. The embodiments shown below can be combined with each other.

The expansion ratio of the foamed molded article is preferably 2.5 or more.

Preferably, the foamed molded article is a tubular body having a main passage and a sub-passage connected to the main passage, and an angle between the main passage and the sub-passage is 45 to 90 degrees.

Preferably, the blow-up ratio of the foamed molded article is 0.5 to 0.8 in a cross section at an angle of 0 to 45 degrees with respect to the extrusion direction of the foamed parison.

Preferably, the molding step includes a step of depressurizing each of the split molds to cause the foamed parison to adhere to each of the split molds, and the depressurization start timing of one of the split molds is delayed by 1 second or more from the depressurization start timing of the other of the split molds.

In the extrusion step, the thickness of the foamed parison is preferably controlled so that the thickness of the foamed parison at a portion where a folded wall is likely to be formed is smaller than the thickness of the foamed parison at another portion.

Preferably, in the extrusion step, the preliminary blow molding is performed by injecting air into the inner surface of the foamed parison in a direction of 45 degrees to 135 degrees with respect to the direction in which the melt-kneaded resin is extruded.

The pre-blowing is preferably performed using a pre-blowing nozzle located above or below between the split molds.

Preferably, the foamed parison is positioned substantially entirely between the divided molds, and then the foamed parison is clamped and sealed by a lower clamp, and then the pre-blow molding is performed.

[ description of the drawings ]

Fig. 1 shows a configuration of an apparatus for producing a foamed molded article according to embodiment 1 of the present invention.

Fig. 2 is a cross-sectional view of die 12 of fig. 1.

Fig. 3 is a sectional view of the die head 12, the split mold 14, and the vicinity of the lower clamping portion 15 in fig. 1.

Fig. 4 is a cross-sectional view showing a state in which the foamed parison 13 is clamped by the lower clamp portion 15 from the state of fig. 3.

Fig. 5 is a cross-sectional view showing a state in which the mold 14 is closed by dividing from the state of fig. 4.

Fig. 6A is a plan view showing the structure of a foamed molded article 16 to which the present invention is applied.

Fig. 6B shows a section a-a or a section B-B in fig. 6A.

Fig. 7A is a diagram showing the collapse of the parison shape.

Fig. 7B is a view showing a bent wall failure (curtain phenomenon) in the cross section C-C in fig. 7A.

Fig. 8 is a diagram showing a state in which a foamed parison 13 is formed according to embodiment 2 of the present invention.

Fig. 9 is a view showing a state in which the foamed parison 13 is clamped by the lower clamp portion 15 from the state of fig. 8.

Fig. 10 is a diagram showing a state in which pre-blowing is performed in the outer circumferential direction of the parison from the state of fig. 9.

Fig. 11 is a diagram showing a state in which the split mold 14 is closed from the state of fig. 10.

Fig. 12 is a diagram showing embodiment 3 of the present invention.

Fig. 13 is a view showing a state in which the foamed parison 13 is clamped by the lower clamp portion 15 from the state of fig. 12.

Fig. 14 shows embodiment 4 of the present invention.

Fig. 15 is a view showing a state in which the foamed parison 13 is clamped by the upper clamping portion 15a from the state of fig. 14.

Fig. 16 shows a modification of embodiment 4 of the present invention.

[ detailed description ] embodiments

The following describes embodiments of the present invention. Various features shown in the following embodiments may be combined with each other. The invention is established independently for each feature item.

In addition, according to the 1 st aspect of the present invention, there is provided a method for producing a foamed molded article, comprising: an extrusion step of extruding a molten kneaded resin containing a foaming agent from an annular gap between a core and a mold shell surrounding the core to form a cylindrical foamed parison, and extruding the parison between a pair of divided molds; a lower clamping step of clamping the foamed parison at a lower clamping portion disposed below the split mold; and a molding step of closing the split mold after the lower clamping step to perform the foamed parison. And if the diameter of the mold core is D, the distance between the lower surface of the mold core and the upper surface of the cutting mold is H, and the distance between the lower surface of the cutting mold and the upper surface of the lower clamping part is L, H/D is 1.33-3.33, and L/D is 0.33-2.00.

Further, according to the 2 nd aspect of the present invention, there is provided a method for producing a foamed molded article, comprising: a parison forming step of forming a foamed parison by extruding a molten kneaded resin containing a foaming agent through an annular gap in an extrusion direction in a molding region sandwiched between a pair of divided molds; and a molding step of molding a foamed molded body by closing the split mold with respect to the foamed parison located in the molding region, wherein in the parison forming step, air is injected into an inner surface of the foamed parison in a direction of 45 degrees to 135 degrees with respect to the extrusion direction to perform preliminary blowing.

1. Embodiment 1

First, an apparatus for producing a foamed molded article suitable for carrying out the method for producing a foamed molded article according to embodiment 1 of the present invention will be described, and then, the method for producing a foamed molded article according to embodiment 1 will be described.

1.1 apparatus for producing foamed molded article

As shown in fig. 1 to 5, the apparatus for producing a foamed molded article according to embodiment 1 of the present invention includes a foaming extruder 1, a split die 14, and a lower clamp 15. The foaming extruder 1 includes a column 3, a resin inlet 5, a screw 7, a blowing agent injection port P, a temperature control section 9, a resin extrusion port 11, and a die 12.

The respective constituent elements are described in detail below.

< resin inlet 5 >

The resin inlet 5 is a so-called hopper, and the raw material resin is charged therein. The form of the raw material resin is not particularly limited, and is usually in the form of pellets. The raw material resin is, for example, a thermoplastic resin such as polyolefin, and examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, an ethylene-propylene copolymer, and a mixture thereof. The raw material resin is introduced into the column 3 through the resin inlet 5, and then heated and melted in the column 3 to form a molten resin. The resin is conveyed to a resin extrusion port 11 provided at one end of the column body 3 by rotation of the screw 7 disposed in the column body 3.

< helix 7 >

The screw 7 is disposed in the cylinder 3 and conveys the molten resin to the resin extrusion port 11 while rotating and kneading the resin. One end of the screw 7 is provided with a gear arrangement 30, and the screw 7 is rotationally driven by the gear arrangement 30. The number of the spirals 7 arranged in the column 3 may be 1, or 2 or more.

< blowing agent injection port P >

The column 3 is provided with a foaming agent injection port P for injecting a foaming agent into the column 3. The position of the blowing agent injection port P is not particularly limited, and when the position of the end of the column 3 on the resin inlet 5 side is 0 and the position of the end on the resin outlet 11 side is L, the blowing agent injection port P is preferably set at a position of 0.3L to 0.7L (preferably 0.4L to 0.6L). If the foam injection port P is provided at a position closer to the resin injection port 5 than 0.3L, the foam may be injected and the dispersion of the foam may be insufficient in a state where the kneading of the molten resin is insufficient. Further, since the temperature of the molten resin is controlled to be generally gradually lowered toward the resin extrusion port 11, when the resin is provided at a position closer to the resin extrusion port 11 than the blowing agent injection port P0.7L, the temperature of the molten resin at the position where the blowing agent is injected may be too low, and the injection amount of the blowing agent may be lowered.

The blowing agent injected from the blowing agent injection port P includes a physical blowing agent, a chemical blowing agent, and a mixture thereof, but the physical blowing agent is preferable. As the physical foaming agent, an inorganic physical foaming agent such as air, carbon dioxide gas, nitrogen gas, or water, an organic physical foaming agent such as butane, pentane, hexane, dichloromethane, or dichloroethane, or a supercritical fluid thereof can be used. The supercritical fluid is preferably prepared using carbon dioxide, nitrogen or the like, and in the case of nitrogen, the supercritical fluid is obtained by adjusting the critical temperature to-149.1 ℃, the critical pressure to 3.4MPa or more, and the critical temperature to 31 ℃, and the critical pressure to 7.4MPa or more. The chemical foaming agent may be a chemical foaming agent that generates carbon dioxide gas by a chemical reaction between an acid (e.g., citric acid or a salt thereof) and a base (e.g., sodium bicarbonate). The chemical foaming agent may be injected from the resin inlet instead of being injected from the foaming agent injection port P.

< temperature control part 9 >

The temperature control unit 9 is configured to control the temperature of each part of the column 3 by controlling each of a plurality of temperature control units provided along the column 3. The temperature control unit 9 may control the temperature of the die 12 for forming the foamed parison 13 and the temperature of the connection portion 10 between the column 3 and the die 12.

< resin extrusion opening 11. die 12 >

A molten kneaded resin obtained by melting and kneading a raw material resin and a blowing agent is extruded from a resin extrusion port 11 and injected into a die 12 through a connecting portion 10. As shown in fig. 2, the die head 12 includes a cylindrical die outer cylinder 41 and a mandrel bar 43 accommodated therein, and a space 46 therebetween stores a molten kneaded resin extruded from the cylinder 3. The die head 12 has a core 47 and a mold shell 48 surrounding the core at the front end thereof, and an annular gap 49 is provided therebetween. After a predetermined amount of the melt-kneaded resin is stored in the space 46, the ring-shaped piston 45 is vertically pressed to extrude the melt-kneaded resin from the ring-shaped slit 49, thereby forming the cylindrical foamed parison 13. The foamed parison 13 is extruded between a pair of divided molds 14.

< cutting die 14, lower clamping part 15 >

The pair of split molds 14 is used for molding the foamed parison 13 to obtain a foamed molded article. As shown in fig. 3, each divided mold 14 is provided with a cut portion 14a surrounding the cavity 14 b. Further, a burr discharging portion 14c is provided so as to surround the cut portion 14. The foamed parison 13 has a portion sandwiched by the cut portions 14a as a boundary line PL shown in fig. 6B, and a portion outside the cut portion 14a is a burr. The distance R from the upper surface of cutting die 14 to cutting stoppers 14a is, for example, 50 mm. For example, the height Q of the cut part 14a seen from the side of the burr discharging part 14c is, for example, 5 to 10 mm.

The method of molding the split mold 14 to be used is not particularly limited, and may be blow molding in which air is blown into the cavity of the split mold 14 to mold it, vacuum molding in which the cavity is decompressed from the inner surface of the cavity of the split mold 14 to mold the foamed parison 13, or a combination of these. As shown in fig. 3 to 4, the lower clamp portion 15 is for clamping a lower portion (lower clamp) of the foamed parison 13 to form a closed space 13a in the foamed parison 13. The split mold 14 is closed after the lower clamping is performed.

As shown in fig. 2 to 3, the split mold 14 is arranged such that (the distance H between the lower surface of the core 47 and the upper surface of the split mold 14)/(the diameter D of the core 47) is 1.33 to 3.33, and the lower clamp 15 is arranged such that (the distance L between the lower surface of the split mold 14 and the upper surface of the lower clamp 15)/(the diameter D of the core 47) is 0.33 to 2.00. If the value of H/D or L/D is too small, the internal pressure of the closed space 13a of the foamed parison 13 becomes too large before the completion of mold closing when the split mold 14 is closed after the lower clamping, and the foamed parison 13 may be broken. If the value of H/D or L/D is too large, when the split mold 14 is closed after the lower clamping, the internal pressure of the closed space 13a of the foamed parison 13 in the cavity 14b becomes insufficient, and the difference between the shape of the foamed parison 13 in the cavity 14b after the closing and the shape of the foamed molded article as the final product becomes large, so that the folded wall is likely to occur. Specifically, H/D is, for example, 1.33, 1.50, 2.00, 2.50, 3.00, 3.33, and may be in a range between any 2 values exemplified herein. Specifically, L/D is, for example, 0.33, 0.50, 1.00, 1.50, 2.00, and may be in a range between any 2 values exemplified herein. D is 50 to 300mm, specifically 50, 100, 150, 200, 250, 300mm, for example, and may be in a range of any 2 values exemplified herein.

2. Method for producing foamed molded article

The method for producing a foamed molded article according to embodiment 1 of the present invention includes an extrusion step, a lower clamping step, and a molding step.

As shown in fig. 3, in the extrusion step, a molten kneaded resin containing a foaming agent is extruded from an annular gap 49 between a core 47 and a mold shell 48 surrounding the core, so that a cylindrical foamed parison 13 is extruded between a pair of split molds 14. In the extrusion step, the split die 14 and the lower clamp 15 are opened.

As shown in fig. 3 to 4, in the lower clamping step, the foamed parison 13 is clamped by the lower clamping portion 15 disposed below the split mold 14. Specifically, the lower clamp portion 15 is moved in the arrow X direction of fig. 3 to be in the lower clamp state shown in fig. 4. Thereby, the closed space 13a is formed in the foamed parison 13.

As shown in fig. 4 to 5, in the molding step, after the lower clamping step, the mold 14 is divided and closed to mold the foamed parison 13. Specifically, the split mold 14 can be closed by moving the split mold 14 in the direction of arrow Y in fig. 4. The foamed parison 13 may be formed by blow molding, vacuum molding, or a combination thereof. In embodiment 1, since the (distance H between the lower surface of the core 47 and the upper surface of the split mold 14)/(diameter D of the core 47) is 1.33 to 3.33, and the (distance L between the lower surface of the split mold 14 and the upper surface of the lower clamp 15)/(diameter D of the core 47) is 0.33 to 2.00, it is possible to suppress the breakage of the foamed parison 13 at the time of mold closing or the occurrence of a folded wall at the time of molding of the foamed parison 13.

In view of this, when the step of sucking the foamed parison 13 to the split molds 14 by depressurizing the split molds 14 is provided, it is preferable that the timing of starting depressurization of one of the split molds 14 is delayed by 1 second or more (for example, 1 to 5 seconds) from the timing of starting depressurization of the other of the split molds 14. In particular, it is preferable to delay the timing of starting the decompression of the split mold 14 on the side where the bent wall is likely to occur. For example, when the decompression of the right split mold 14 is started first, the foamed parison 13 in the cavity 14b is shifted to the right side, and the gap between the left split mold 14 and the foamed parison 13 is increased. When the decompression of the left split mold 14 is started in this state, the expanded space of the foamed parison 13 is large, and therefore wrinkles in the foamed parison 13 are easily stretched, and the occurrence of a folded wall is difficult. Therefore, when the left side portion of the foamed parison 13 is likely to have a folded wall, it is preferable to start the decompression of the right split mold 14. Conversely, when the right side portion of the foamed parison 13 is likely to have a folded wall, it is preferable to start the decompression of the left split mold 14.

In the extrusion step, the thickness of the foamed parison 13 is preferably controlled so that the thickness T1 of the foamed parison 1 at a portion where a folded wall is likely to occur is smaller than the thickness T2 of the foamed parison 13 at another portion. T1/T2 is preferably 0.8 to 0.9. In this case, the foamed parison 13 is easily stretched at a portion where the folded wall is likely to be generated, and the generation of the folded wall is suppressed. As shown in fig. 6B, when the foamed molded article has a tubular body having a main passage 17 and a sub-passage 18 connected thereto, a bent wall is likely to be generated at a connecting portion 19 between the main passage 17 and the sub-passage 18, and it is preferable that the wall thickness of the foamed parison 13 at a portion corresponding to the connecting portion 19 is thin.

3. Foamed molded article

The method for producing an expanded molded article according to embodiment 1 can be suitably used for producing an expanded molded article having an arbitrary shape and expansion ratio, but is a method for effectively suppressing the occurrence of a bent wall, and is therefore particularly suitable for producing an expanded molded article in which the shape of a bent wall and the expansion ratio are likely to occur.

From such a viewpoint, the expansion ratio of the foamed molded article is preferably 2.5 times or more. This is because the higher the expansion ratio, the lower the strength of the foamed parison 13, and wrinkles are likely to occur in the foamed parison 13, and a folded wall is likely to occur. The upper limit of the expansion ratio is not limited, but is, for example, 5 times. Specifically, the expansion ratio is, for example, 2.5, 3, 3.5, 4, 4.5, 5 times, and may be in a range between any 2 numerical values exemplified herein. The average thickness of the foamed molded article is preferably 2mm or more. This is because, if the amount of resin used is the same, the larger the average wall thickness, the higher the expansion ratio, the lower the strength of the foamed parison 13, and the more likely a wall fold occurs. The upper limit of the average wall thickness is not limited, and is, for example, 6 mm. Specifically, the average wall thickness is, for example, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6mm, and may be in a range between any 2 values exemplified herein.

As shown in fig. 6A, in one example, the foamed molded body 16 is a tubular body having a main passage 17 and a sub-passage 18 connected thereto. The angle alpha between the main passage 17 and the sub passage 18 is preferably 45 to 90 degrees. In the example of fig. 6A, the angle α is 90 degrees. With such a shape, a bent wall is likely to be formed at the connection portion 19 between the main passage 17 and the sub-passage 18. The sub passage 18 is a branch passage in fig. 6A, but may be a passage bent in a substantially L shape.

Preferably, the blow-up ratio of the cross section S at an angle beta of 0 to 45 degrees with respect to the extrusion direction of the foamed parison 13 is 0.5 to 0.8. The angle β is 45 degrees in the section a-a in fig. 6A, and 0 degree in the section B-B. The cross section S is preferably a cross section at the sub passage 18 or at the connection portion 19, and more preferably a cross section at the connection portion 19. This is because the calculation of the inflation ratio of the cross section at such a portion improves the accuracy of prediction of the ease with which the folded wall is likely to occur. The inflation ratio can be calculated by the following method. First, as shown in fig. 6B, in the cross section S, the outermost points of the opposing boundary lines are connected to each other by a straight line W. Next, in the cross section S, a point T farthest from the straight line W and the straight line W are connected by a straight line V. Next, the inflation ratio is calculated from the expression (length of the straight line V)/(length of the straight line W) where the inflation ratio is set. The blow-up ratio is specifically, for example, 0.5, 0.6, 0.7, and 0.8, and may be in a range between any 2 values exemplified herein.