JP3669382B2

JP3669382B2 - Molding apparatus and molding method for foamed resin molded product

Info

Publication number: JP3669382B2
Application number: JP18343295A
Authority: JP
Inventors: 裕一中村
Original assignee: SANPOU KANAGATA SEISAKUSHO LTD.; Kaneka Corp; Sekisui Kasei Co Ltd
Current assignee: SANPOU KANAGATA SEISAKUSHO LTD.; Kaneka Corp; Sekisui Kasei Co Ltd
Priority date: 1995-06-26
Filing date: 1995-06-26
Publication date: 2005-07-06
Anticipated expiration: 2020-07-06
Also published as: JPH0911268A

Description

【０００１】
【産業上の利用分野】
本発明は発泡樹脂成形品の成形装置及び成形方法に関し、特に、雄形金型と雌形金型とを備えて成る成形金型の移動方向と交叉する方向に貫通孔や凹入部、湾曲部などのアンダーカット部を有する発泡樹脂成形品の成形装置及び成形方法に関する。
【０００２】
【従来の技術】
ポリスチレン系樹脂やポリオレフィン系樹脂などから成る発泡性樹脂ビーズを成形金型内で発泡させるビーズ成形法で成形された発泡樹脂成形品は、保温・断熱性、緩衝性、軽量性などの優れた特性を有する。このことから、発泡樹脂成形品として特に鮮度の保持が要求される魚函、野菜函などの運搬用の容器や、梱包などに用いる緩衝材、あるいは構造部材などに広く用いられている。これら各種の発泡樹脂成形品は雄形金型と雌形金型とを備えて成る成形金型により形成されたキャビティ内に発泡性樹脂ビーズを充填し、加熱発泡させた後、冷却して成形される。その後、いずれか一方の金型を移動させて型開きして、成形された発泡樹脂成形品が取り出される。
【０００３】
この発泡樹脂成形品の製造装置は、雄形金型と雌形金型のうち一方を他方に接近させ又は離隔させるように、一方向へのみ移動させるように構成されている。したがって、発泡樹脂成形品の製造効率を向上させる観点などから、発泡樹脂成形品を成形金型の移動方向と交叉する方向に貫通孔や凹入部、湾曲部などのアンダーカット部を有しない単純な形状にするとともに、１回の成形工程で多数の発泡樹脂成形品を製造し得るように構成している。
【０００４】
ところが、たとえば主として高級魚を入れる魚函において、排水孔を備えた魚函が要求されている。魚函の排水孔は、魚函の中に鮮魚とともに入れた氷が解けた水や魚から出た血液その他の体液を随時排出して、鮮魚の鮮度を維持するために必要とされる。しかしながら、従来、魚函に設けられた排水孔は通常、函の底や底部角部に開口させられていて、常に水などを排出することができる一方、外部から大気が函の中に流入して、中の氷を早く解かしてしまうという問題があった。更に、氷を使用しない場合などにあっては、魚函の排水孔を通して空気が出入りするため、収納されている鮮魚の表面が乾燥してしまったり、あるいは冷気が流入することによって鮮魚の表面がいわゆる冷凍焼けなどによって変色、変質してしまうことがあるなど、商品価値を大幅に低下させる原因になるという問題があった。
【０００５】
このため、本願発明者は特願平４−２０９１６８号などにおいて、たとえば、保冷容器の側壁底部に、容器の内側の開口部より外側の開口部の位置が高い貫通孔を形成し、容器内に蓄積した水位が容器の外側の開口部の位置（高さ）よりも高くなったとき、その高い分だけ水が排出されるように構成した保冷容器を各種提案した。そして、かかる保冷容器の構造とともに、その製造方法と成形装置についても種々開示した（特願平４−２０９１６８号、特願平４−２２７０７６号、特願平５−１６４５１０号、特願平５−１９１４０３号）。この容器は内部に蓄積した水が容器の外側の開口部の位置（高さ）よりも高い分だけ水が排出されて、その開口部の位置よりも低い分は内部に水が蓄積されるため、その水によって貫通孔が塞がれることになる。その結果、余分な水を排出することができる一方、貫通孔を水で塞ぎ、容器の内外の空気の出入りを止めることができ、上記問題を解決することができる。しかも、内部に若干蓄積する水によって、鮮魚などの収納物の乾燥を防ぎ、且つ潤いを与えることができるなど、優れた効果を奏する容器を提供することが可能となった。なお、この保冷容器は魚函に限られず、野菜箱などのあらゆる容器に適用することができるものである。
【０００６】
【発明が解決しようとする課題】
この保冷容器の成形装置は、金型によって構成されるキャビティ内に配置されるアンダーカット成形駒がキャビティから出入りし得るように金型に配設され、その成形駒がキャビティから出入りし得るように往復駆動させる駆動手段と、その駆動手段の駆動力を成形駒に伝達する可撓性を有する伝動体とを備えて構成されている。また、その製造方法は、雄形金型と雌形金型とを型合わせした後、いずれか一方又は双方の金型からアンダーカット成形駒をキャビティ内に駆動手段によって突出させて配設し、その後、キャビティ内に発泡性樹脂ビーズを充填した後、加熱発泡させ、冷却後に成形駒を抜き去り、次いで雄形金型と雌形金型とを離隔させて形成された発泡樹脂成形品を離型させるのである。
【０００７】
この保冷容器の成形装置及び製造方法に用いられるアンダーカット成形駒は金属その他の剛性を有する部材で所定の形状に形成されていて、この成形駒を金型に設けたガイド孔から突出させて相手方の金型の面に当接させたり、あるいは成形駒同志を当接させることによって、位置決めし、形成される貫通孔の形状を定めるものであった。このため、貫通孔を正確に形成することができるが、成形駒はガイド孔内をスライドさせられるため、成形駒とガイド孔の両者の形状を精密に製造しなければならず、製造コストが高くつくという問題があった。また、成形駒の突出量は、雄形金型と雌形金型とを型合わせした状態で設定しなければならず、調整が若干困難であった。一方、成形駒の突出量を微調整しなくても良いように構成することも可能であるが、そのためには新たな機構が必要となり、装置コストが高くつくという問題があった。
【０００８】
また、金属製などの成形駒は発泡性樹脂ビーズを加熱発泡させたときに、成形駒と発泡溶融した発泡性樹脂ビーズとが被着又は密着し、成形駒を抜き去るのに大きな力を要するという問題があった。本発明者は上記問題を解決するとともに、更に新たな成形方法を開発するために鋭意研究を重ねた結果、本発明の発泡樹脂成形品の成形装置及び成形方法を想到した。
【０００９】
【課題を解決するための手段】
本発明に係る発泡樹脂成形品の成形装置の要旨とするところは、少なくともいずれか一方が離隔接近させられる雄形金型と雌形金型とを備えた発泡樹脂成形品の成形装置において、該雄形金型又は雌形金型のいずれか一方又は双方に設けられたガイド孔を有するガイド部材と、該ガイド孔に導かれてキャビティ内を該金型の移動方向と少なくとも一部が交叉する方向に進入させられる可撓性を有する成形部材と、該成形部材を前進及び後退させる駆動手段とを備えることにある。
【００１０】
かかる発泡樹脂成形品の成形装置において、前記成形部材がフッ素樹脂、ポリテトラフッ素化エチレン、又はフッ化ピッチなどの発泡性樹脂に対して剥離性に優れた樹脂により、又は該樹脂を可撓性部材に被覆して形成されていることにある。
【００１１】
また、かかる発泡樹脂成形品の成形装置において、前記成形部材が進入させられたキャビティ内で湾曲させられる形状を記憶させられていることにある。
【００１２】
更に、かかる発泡樹脂成形品の成形装置において、前記ガイド孔及び／又はガイド孔から進入させられた成形部材が当接させられる金型が、該成形部材に形状を付与し得るように構成されていることにある。
【００１３】
次に、本発明に係る発泡樹脂成形品の成形方法の要旨とするところは、離隔させられた雄形金型と雌形金型の少なくともいずれか一方を接近させてキャビティを形成し、該形成されたキャビティ内に発泡性樹脂ビーズを充填した後、加熱発泡させて、発泡樹脂成形品を成形する方法において、前記雄形金型及び雌形金型のいずれか一方又は双方に設けたガイド孔から可撓性を有する成形部材をキャビティ内に該金型の移動方向と少なくとも一部が交叉する方向に進入させて所定の位置形状に配設した後、キャビティ内に発泡性樹脂ビーズを充填して加熱発泡させ、その後、成形部材を後退させて成形された発泡樹脂成形品から除去した後、該発泡樹脂成形品を離型させることにある。
【００１４】
また、かかる発泡樹脂成形品の成形方法において、前記可撓性を有する成形部材をガイド孔及び／又は当接させられる金型によって変形させることにある。
【００１５】
更に、本発明に係る発泡樹脂成形品の成形方法の他の要旨とするところは、離隔させられた雄形金型と雌形金型の少なくともいずれか一方を接近させてキャビティを形成し、該形成されたキャビティ内に発泡性樹脂ビーズを充填した後、加熱発泡させて、発泡樹脂成形品を成形する方法において、前記雄形金型及び雌形金型のいずれか一方又は双方に設けたガイド孔から可撓性を有する成形部材をキャビティを構成する空間内に該金型の移動方向と少なくとも交叉する方向に進入させて突設した後、雄形金型と雌形金型とを型合わせをすることにより、該突設された成形部材と対向する金型を、又は双方から突設された成形部材同志を接触させて、成形部材を変形させ、次いで、キャビティ内に発泡性樹脂ビーズを充填して加熱発泡させ、その後、成形部材を後退させて成形された発泡樹脂成形品から除去した後、該発泡樹脂成形品を離型させることにある。
【００１６】
【作用】
本発明に係る発泡樹脂成形品の成形装置は、雄形金型又は雌形金型のいずれか一方又は双方にガイド孔を有するガイド部材が配設されるとともに、そのガイド孔に導かれて金型の移動方向と少なくとも一部が交叉する方向にキャビティ内に進入させられる可撓性を有する成形部材と、その成形部材を前進及び後退させる駆動手段を備えて構成されている。この成形装置による成形方法は、ガイド孔から成形部材をキャビティ内に進入させて、金型の移動方向と交叉する方向に配設した後、そのキャビティ内に発泡性樹脂ビーズを充填し、常法によりその発泡性樹脂ビーズを加熱発泡させるとともに融着させて発泡樹脂成形品が形成される。その後、成形部材を後退させて発泡樹脂成形品から除去した後、発泡樹脂成形品が雌形金型から離型させられる。
【００１７】
この発泡樹脂成形品の成形方法における成形部材のキャビティ内への配設方法として、たとえば雄形金型と雌形金型が相対的に接近させられるのに伴い、成形部材をキャビティ内に進入させ、発泡性樹脂ビーズを充填する直前の金型停止位置で、成形部材の進入を停止させる。このとき、成形部材はキャビティ内で、金型の移動方向と少なくとも一部が交叉する方向に配設されていて、成形部材の一部が相対向する金型に当接したり、あるいは接触させられて、所定の形状を成すことになる。また、成形部材の他の配設方法として、一方の金型から予め成形部材をガイド孔から突出させておき、その後、両金型を相対的に接近させて、突出された成形部材を他方の金型に当接させ、あるいは接触させることにより、成形部材を所定の形状に変形させることができる。更に、成形部材の他の配設方法として、成形部材を形状記憶樹脂により形成し、あるいは樹脂の中に形状記憶合金を埋設して形成しておき、あるいは成形部材を所定の形状に形成しておき、一方の金型から成形部材をガイド孔から突出させた後、その成形部材を加熱して予め記憶させた形状に変形させ、あるいはガイド孔から突出させることにより予め形成された所定の形状にするのである。そして、その後、発泡性樹脂ビーズをキャビティ内に充填した後、常法により加熱発泡させて発泡樹脂成形品を形成し、次いで発泡樹脂成形品から成形部材を除去するのである。
【００１８】
ここで、成形部材がテフロン樹脂などのフッ素樹脂や、ポリテトラフッ素化エチレン、あるいはフッ素と炭素から成るフッ化ピッチなどの発泡性樹脂に対して剥離性に優れた樹脂によって形成され、又はこれら発泡性樹脂に対して剥離性に優れた樹脂を可撓性部材に被覆して形成されることにより、成形部材と一体的に成形された発泡樹脂成形品からその成形部材を除去するのが容易となる。
【００１９】
【実施例】
次に、本発明に係る発泡樹脂成形品の成形装置及び成形方法の実施例を図面に基づき、詳しく説明する。
【００２０】
図１に示すように、発泡樹脂成形品の成形装置１０は雄形金型１２と雌形金型１４とを備え、雄形金型１２は雌形金型１４に接近又は離隔させられるように図示しない基台に対して移動し得る移動フレーム１６に金型取付板１７を介して固定され、他方、雌形金型１４はその基台に対して移動し得ない固定フレーム１８に金型取付板１９を介して固定されている。
【００２１】
ここで、雄形金型１２と移動フレーム１６及び裏板２０によって囲まれて密閉された空間は雄形金型１２の加熱・冷却室２２とされ、他方、雌形金型１４と固定フレーム１８及び裏板２４によって囲まれて密閉された空間は雌形金型１４の加熱・冷却室２６とされ、これら加熱・冷却室２２，２６には図示を省略するが、加熱蒸気などの加熱媒体を導入する導入管、加熱に使用した加熱媒体を排出する排出管、金型１２，１４を冷却する冷却配管とスプレーノズル、冷却水などを排出するドレン排出管などが配設されている。更に、雌形金型１４などの固定側には、同様に図示を省略するが、雄形金型１２と雌形金型１４とによって構成されたキャビティ２８内に予備発泡させられた発泡性樹脂ビーズ（３０）を充填するための原料充填機と、成形された発泡樹脂成形品３０を雌形金型１４から離型させて押し出すためのエジェクトピンと押出し装置が配設されている。
【００２２】
雄形金型１２と雌形金型１４にはそれぞれ図示を省略する多数のコアベントが配設されていて、コアベントを通して加熱媒体がキャビティ２８内に導入されるとともに、他のコアベントを通して発泡性樹脂ビーズの加熱に寄与した加熱媒体が排出されるように構成されている。これら成形金型のうち雌形金型１４の背面である加熱・冷却室２６には、成形される発泡樹脂成形品３０の一部に雄形金型１２の移動方向と交叉する方向にたとえば貫通する貫通孔３２を開けるアンダーカット形成装置３４が配設されている。
【００２３】
アンダーカット形成装置３４は図２及び図３に詳しく示すように、雌形金型１４の一部に取り付けられるガイド部材３６と、可撓性を有する成形部材３８と、その成形部材３８を駆動させる駆動手段４０を備えて構成されている。ガイド部材３６は雌形金型１４の一部に開けられた孔４２の中に装着されて雌形金型１４の表面の一部を構成する金型面４３を有し、その金型面４３から進退させられる成形部材３８を導くガイド孔４４が形成されている。ガイド孔４４は成形部材３８が通過させられることによって形状を付与して円弧を描くように、円弧状に形成されている。なお、このガイド部材３６は同図３(b) 乃至(d) に示すように、２つの部材４５，４６を組み合わせて構成することができる。
【００２４】
アンダーカット形成装置３４における成形部材３８は可撓性を有する部材、たとえば樹脂によって形成された部材、あるいは板バネなどの可撓性部材の周りを柔軟性を有する樹脂で被覆した部材などで形成される。この成形部材３８は本実施例では板状（帯状）に形成されたものが用いられ、ガイド部材３６の円弧状に形成されたガイド孔４４を通過させられることにより、帯状の成形部材３８が円弧状に湾曲させられる。
【００２５】
また、この成形部材３８として、特に好ましくは、いわゆるテフロンなどのフッ素樹脂、ポリテトラフッ素化エチレン、又はフッ素と炭素の化合物から成るフッ化ピッチなど、発泡性樹脂に対して剥離性に優れた樹脂により、あるいはこれらの発泡性樹脂に対して剥離性に優れた樹脂を可撓性部材に被覆して形成されたものが用いられる。成形部材３８の少なくとも表面に発泡性樹脂に対して剥離性に優れた樹脂を用いるのは、発泡性樹脂ビーズが加熱発泡させられるとともに溶融させられて、ビーズ同志が融着するときに、ビーズと成形部材３８とが融着しないようにし、成形部材３８を発泡樹脂成形品３０から容易に抜き取ることができるようにするためである。
【００２６】
次に、成形部材３８を前進又は後退させる駆動手段４０は、成形部材３８の一端を固定するとともにスライドさせられるスライド部材４８と、このスライド部材４８を収納してスライドさせるボックス５０と、成形部材３８を常に後退させる方向に付勢する圧縮コイルバネ５２と、成形部材３８を前進させる方向にスライド部材４８を押圧する棒状部材５４とから構成されている。スライド部材４８は箱型形状を成し、このスライド部材４８と圧縮コイルバネ５２を収納するボックス５０には蓋５１が被せられ、図示しないネジにより蓋５１がボックス５０に固定されている。また、前述のガイド部材３６は蓋５１に固定されていて、これらガイド部材３６やボックス５０などは図示しないボルトによって雌形金型１４に固定される。
【００２７】
圧縮コイルバネ５２は成形された発泡樹脂成形品３０に一体的に埋設されている成形部材３８の先端部を抜き取るのに充分な力が得られる大きさのものが選定される。また、この圧縮コイルバネ５２の付勢力に抗してスライド部材４８を押圧する棒状部材５４は、前記図１に示すように、雄形金型１２を移動フレーム１６に取り付ける金型取付板１７に配設されていて、この棒状部材５４の金型取付板１７からの突出量を適宜調整することにより、スライド部材４８のスライド量すなわち成形部材３８の突出量が調整される。
【００２８】
この成形部材３８の突出量は、キャビティ２８内に発泡性樹脂ビーズ（３０）を充填するときにおける雄形金型１２の位置において、突出された成形部材３８の端部が雄形金型１２の表面に当接するように設定される。したがって、クラッキングを行う場合であっても、発泡性樹脂ビーズ（３０）を充填するときには成形部材３８の端部は雄形金型１２の表面に当接させられていて、その後、型締めを行うことにより、成形部材３８と雄形金型１２との位置関係がずれることになるが、発泡性樹脂ビーズ（３０）により覆われているため、成形部材３８によって形成される貫通孔３２の形状が変わることはほとんどない。また、型締めを行うことにより、スライド部材４８がスライドさせられることになるが、成形部材３８がボックス５０の中で撓むのみで、貫通孔３２の形状に影響を及ぼすことはほとんどない。
【００２９】
以上の構成に係る発泡樹脂成形品の成形装置は従来の発泡樹脂成形品の成形装置と同様に作動させられる。すなわち、所定の雄形金型１２と雌形金型１４にアンダーカット形成装置３４を装着した後、常法により型締めを行うため、雄形金型１２を雌形金型１４に接近させる。このとき、雄形金型１２の金型取付板１７に取り付けられた棒状部材５４がスライド部材４８に当接した後は、そのスライド部材４８を押圧し、成形部材３８を前進させてキャビティ２８内に進入させ、発泡性樹脂ビーズ（３０）を充填する雄形金型１２の停止位置で、成形部材３８の先端が雄形金型１２の表面に当接させられる。その際、棒状部材５４の突出量を若干長く設定しておき、成形部材３８が確実に雄形金型１２の表面に当接して若干撓む程度に設定することができる。
【００３０】
型合わせが終了した後、図示しない原料充填機から予備発泡させられた発泡性樹脂ビーズ（３０）が形成されたキャビティ２８内に充填される。発泡性樹脂ビーズはポリスチレン系樹脂やポリオレフィン系樹脂など各種のビーズ発泡成形に用いられる樹脂を粒子状に形成し、その粒子に発泡剤を含浸させ、予め所定の発泡倍率にまで予備発泡させたものが用いられ、特に限定されない。発泡性樹脂ビーズ（３０）を充填した後、クラッキングを行った場合は更に型締めをし、次いで、常法に従って加熱媒体である加熱蒸気により発泡性樹脂ビーズ（３０）を加熱発泡させるとともに融着させて発泡樹脂成形品３０を形成した後、金型１２，１４を冷却する。
【００３１】
次に、雄形金型１２を移動させて型開きをする。このとき、雄形金型１２を固定する金型取付板１７が後退するのに伴い、棒状部材５４も後退して、スライド部材４８の押圧が解除される。その結果、スライド部材４８は圧縮コイルバネ５２の付勢力により、後退するスライド部材４８とともに後退し、成形部材３８が発泡樹脂成形品３０から抜け出て、貫通孔３２が形成される。雄形金型１２が充分に後退し、且つ成形部材３８が発泡樹脂成形品３０から完全に抜け出た後、図示しないエジェクトピンにより雌形金型１４から発泡樹脂成形品３０が押し出される。
【００３２】
このように、本実施例に係る発泡樹脂成形品の成形装置及び成形方法によれば、従来の成形金型のうちたとえば雌形金型１４及び金型取付板１７にアンダーカット形成装置３４を取り付けるだけで、雄形金型１２の移動方向と交叉する方向に貫通孔３２の形成された発泡樹脂成形品３０を製造することができる。また、かかる発泡樹脂成形品を製造するのにあたり、新たな動力源を必要とせず、しかも発泡樹脂成形品の成形サイクルは従来と同じであるため、製造コストが上昇することはほとんどない。更に、可撓性を有する成形部材を用いることにより、この成形部材のスライド量を調整する棒状部材の突出量を若干多めに調整することができ、この調整作業が非常に容易となる。また、成形部材を導くガイド部材のガイド孔の加工は精度を必要としないため、成形部材及びガイド部材の製造コストを大幅に低減させることができる。
【００３３】
以上、本実施例に係る発泡樹脂成形品の成形装置及び成形方法を説明したが、本発明は上述の実施例に限定されるものではない。
【００３４】
たとえば、図４に示すように、１台の成形装置５５に複数の雌形金型５６，５７...と雄形金型５８，５９...を配設して、同時に複数の発泡樹脂成形品を製造する装置にあっては、前述と同様の構成のアンダーカット形成装置６０と、成形部材３８が２方向に延び出すように構成されたアンダーカット形成装置６２を配設することができる。このアンダーカット形成装置６２は１個のスライド部材６４に２枚の成形部材３８が取り付けられ、それぞれの成形部材３８はガイド部材６６によってガイドされていて、スライド部材６４が圧縮コイルバネ５２と棒状部材５４によって押圧させられることにより、前進及び後退させられる。このような構造のアンダーカット形成装置６２を用いることにより、雌形金型５６と５７の間隔を狭めることができ、装置の小型化を図ることができる。
【００３５】
また、図５に示すように、成形部材３８を前進及び後退させる駆動手段６８は、成形部材３８の一端が固定されるスライド部材７０と、そのスライド部材７０を成形部材３８が後退する方向に付勢する圧縮コイルバネ５２と、その圧縮コイルバネ５２の付勢力に抗してスライドさせる押圧調整部材７２とから構成され、押圧調整部材７２の先端が雄形金型１２の金型取付板１７に当接されるように構成しても良い。押圧調整部材７２は雌ねじが形成された筒状部材７３と、その筒状部材７３の雌ねじに螺合させられる雄ねじ部材７４とから構成され、雄ねじ部材７４と筒状部材７３との螺合長さを調整することによって、スライド部材７０のスライド量を調整することができる。本実施例によれば、雄形金型１２を取り付ける金型取付板１７に押圧調整部材７２の一端が当接させられるだけであるため、金型取付板１７に加工を施す必要がなく、スライド部材７０のスライド量の調整も容易となる。
【００３６】
更に、アンダーカット形成装置の駆動手段として、上述したように雄形金型が雌形金型に対して離隔・接近させられる金型の駆動力と圧縮コイルバネの付勢力を利用するのが最も経済的であるが、その他、圧縮コイルバネに代えて引張りコイルバネを用いたり、各種の弾性部材を用いることが可能である。また、金型の駆動力とこれらの付勢力から成る駆動手段に代えて、専用の駆動手段を配設することも可能である。
【００３７】
たとえば、図６に示すように、ボックス５０内をスライドさせられるスライド部材７６の一端に、エアーシリンダ７８によって往復駆動させられるシャフト７９を接続し、スライド部材７６をエアーシリンダ７８により強制的に往復駆動させるように駆動手段８０を構成しても良い。スライド部材７６を強制的に往復駆動させることにより、成形部材３８を成形された発泡樹脂成形品の中から確実に引き抜くことができる。また、エアーシリンダ７８により成形部材３８を雄形金型１２の移動とは無関係にキャビティ２８内に配設し、あるいは逆に除去することができる。なお、エアーシリンダ７８は圧縮空気を利用するだけでなく、真空ポンプによる真空力によって作動させるように構成しても良い。また、エアーシリンダ７８に代えて、油圧その他の液圧シリンダを用いても良く、更に、電磁ソレノイドを用いることもできる。また、電動モーターを駆動源として、機械的に成形部材３８を前進及び後退させ得るように構成することも可能であり、特に限定されない。
【００３８】
また、図７に示すように、１又は複数の雌形金型８２のそれぞれの雌形金型８２に対して、１箇所以上に成形部材８４を配設して、同時に製造される発泡樹脂成形品にアンダーカット部を形成する場合、複数の成形部材８４を１箇所にまとめて、１つの駆動手段８６により駆動させるように構成しても良い。すなわち、図８に要部を拡大して示すように、それぞれの雌形金型８２の一部にガイド孔８８を有するガイド部材９０を取り付け、そのガイド部材９０の雌形金型８２の背面側から駆動手段８６までの間を可撓性を有するチューブ９２にて連結し、これらガイド孔８８とチューブ９２の内部に成形部材８４を通す。そして、チューブ９２の駆動手段８６側の端部に剛性を有する筒状部材９４を配設する一方、その筒状部材９４の中を摺動させられる摺動部材９５を配設して、その摺動部材９５の一端を成形部材８４と接続し、摺動部材９５の他端を駆動手段８６のピストン９６に接続する。このピストン９６は油圧その他の液圧シリンダ９８や、あるいはエアーシリンダ、電磁ソレノイド、電動モーターなどを用いた駆動装置などによって、前進及び後退させられる。
【００３９】
このような構成を採用することにより、成形部材８４は確実にキャビティ２８内に挿入され、また後退させられることになる。また、１つの駆動手段８６によって多数の成形部材８４を同時に作動させることができ、経済的である。更に、成形部材８４を雌形金型８２に配設するのにあたり、ガイド部材９０を雌形金型８２に取り付ける作業だけで良いため、配設作業が容易となり、しかもスペースをほとんど必要としないため、金型の配置を考慮することなく、適宜、金型の任意の箇所に取り付けることができる。なお、上記チューブ９２によりガイド部材９０と駆動手段８６との間を接続している箇所においては、成形部材８４に代えて他の可撓性部材を使用することは可能である。
【００４０】
以上、本発明に係る発泡樹脂成形品の成形装置及び成形方法の実施例を種々説明したが、上述の成形装置及び成形方法によって、種々の形状をした貫通孔などのアンダーカット部を発泡樹脂成形品に形成することができる。
【００４１】
たとえば図９(a) に示すように、ガイド部材のガイド孔を円弧などの曲線状に形成し、そのガイド孔に成形部材１００を通過させることによって、形成される発泡樹脂成形品１０２の側壁部に円弧などの曲線状の貫通孔１０４を一体的に形成することができる。また、同図(b)
に示すように、少なくともガイド孔の出口部分を直線状に形成することにより、そのガイド孔を通過させられる成形部材１００はほぼ直線状にキャビティ内に挿入されることになる。したがって、成形部材１００を斜め方向に進入させることにより、直線斜め方向の貫通孔１０４を形成することができ、また、同図(c)
に示すように、成形部材１００を直角方向に進入させることにより、直角方向の直線状をなす貫通孔１０４を形成することができる。
【００４２】
更に、同図(d) に示すように、成形部材１００を雌形金型から雄形金型（１０６）に向かってほぼ直角方向に進入させるように構成し、更に、成形部材１００の先端部が当接する雄形金型（１０６）の箇所に斜め方向の凹陥部（１０８）を形成しておく。このような構成において、成形部材１００をキャビティ内に進入させ、雄形金型（１０６）の凹陥部（１０８）に当接させた後、更に成形部材１００を押し込んで湾曲させる。このとき、凹陥部（１０８）が斜め方向に形成されているため、進入させられた成形部材１００は凹陥部（１０８）に沿って湾曲させられ、成形部材１００は常に同じ方向に湾曲させられることになる。成形部材１００を湾曲させた状態で、キャビティ内に発泡性樹脂ビーズを充填し、常法により加熱発泡させて成形した後、成形部材１００を後退させ、その後、発泡樹脂成形品１０２を取り出す。かかる作動により、発泡樹脂成形品１０２の側壁部に湾曲した貫通孔１０４を形成することができる。
【００４３】
また、図１０(a) に示すように、雌形金型１１０から進入させられる成形部材１００の先端部が当接する雄形金型１１２の表面に、成形部材１００の先端を一定の方向に導くガイド溝１１４を設けておく。そして、雌形金型１１０と雄形金型１１２とを型合わせした後、雌形金型１１０からほぼ直角方向に進入させた成形部材１００を雄形金型１１２のガイド溝１１４に当接させた後も更に一定量前進させることによって、成形部材１００をガイド溝１１４に沿わせて湾曲させるのである。その後、キャビティ１１６内に発泡性樹脂ビーズを充填して、常法により加熱発泡させて発泡樹脂成形品１０２を形成した後、成形部材１００を取り除き、同図(b)
に示すように、発泡樹脂成形品１０２に貫通孔１０４を形成するのである。
【００４４】
このように、成形部材１００をガイド部材によって湾曲させる形状を付与する必要はなく、成形部材１００が当接させられる雄形金型１１２の表面にガイド溝１１４を設けることにより、成形部材１００に形状を付与することができる。成形部材１００の湾曲形状は前述の図９(d) に示す実施例も同様に、成形部材１００を進入させる長さによって調整することができる。
【００４５】
また、図１０に示す実施例において、雌形金型１１０と雄形金型１１２とを型合わせする前に、予め成形部材１００を充分に突出させておき、その後、型合わせをすることによって雄形金型１１２の一部を成形部材１００の一部と接触させて、その成形部材１００を湾曲させることができる。かかる成形方法によれば、雄形金型１１２の一部にガイド溝などを設ける必要がない。なお、成形部材１００は雌形金型１１０からほぼ直角方向にキャビティ内へ突出させられる必要はなく、たとえば斜め上方向あるいは斜め下方向であっても良く、更に、左右いずれかの方向に傾いていても良く、特に限定されない。
【００４６】
次に、成形部材は雌形金型の側壁側からキャビティ内に進入させるように構成するだけでなく、雌形金型の底側からキャビティ内に進入させるように構成することもできる。たとえば、図示しない雌形金型にガイド部材を設け、図１１(a)に示すように、成形部材１００をガイド孔によって湾曲させながらキャビティ内に挿入し、成形部材１００の一部と雄形金型の一部を接触させた状態で、発泡性樹脂ビーズを充填して、常法により発泡樹脂成形品１０２を形成するのである。このような手法により、発泡樹脂成形品１０２の底部に湾曲した貫通孔１０４を形成することができる。
【００４７】
更に同様にして、同図(b) に示すように、挿入された成形部材１００がガイドされる溝（１１８）を雄形金型に設けておいても良く、更に、キャビティ内で湾曲させられた成形部材１００の先端が雌形金型の内面に当接するまで進入させ、２つの貫通孔１０４を同時に形成することも可能である。また、同図(c)
に示すように、成形部材１００を雌形金型に設けたガイド部材によって湾曲させることなく、直線状にキャビティ内に挿入した後、成形部材１００の進入方向に配設されている雄形金型の一部の面に成形部材１００を沿わせることによって湾曲させて、貫通孔１０４を形成するように構成しても良い。
【００４８】
更に、図１２(a) に示すように、雌形金型のガイド部材から成形部材１００をキャビティ内へ斜め方向に真っ直ぐ進入させ、成形部材１００の先端が当接する雄形金型（１２０）に係止部（１２２）を設けておき、成形部材１００が係止部（１２２）に係止した後も、一定の長さだけ押し込むことにより、成形部材１００を湾曲させる。かかる状態で発泡性樹脂ビーズをキャビティ内に充填し、常法により発泡樹脂成形品１０２を形成する。そして、成形部材１００を除去することにより、発泡樹脂成形品１０２に湾曲した貫通孔１０４を形成することができる。
【００４９】
また、同図(b) に示すように、雄形金型（１２０）に設ける係止部（１２４）を、成形部材１００の先端部を受入れるとともに、一種の座屈を生じさせる方向に捩じるように構成する。かかる構成により、キャビティ内に押し込まれた成形部材１００はＳ字状に湾曲させられ、この状態で同様に発泡樹脂成形品１０２を形成する。発泡樹脂成形品１０２から成形部材１００を取り除くことにより、Ｓ字状の貫通孔１２６が得られ、貫通孔１２６のＳ字状の谷の高さと山の高さに差を付けることによってトラップ構造とすることができる。
【００５０】
次に、図１３(a) に示すように、雌形金型１２８から成形部材１００を斜め方向にほぼ直線状に突出させておき、その後、雄形金型１３０を雌形金型１２８に接近させて型合わせをする。このとき、雄形金型１３０の一部によって成形部材１００の一部を押圧し、湾曲させる。その後、上述と同様にして発泡樹脂成形品１０２を得ることにより、同図(b)に示すように、湾曲した貫通孔１０４を形成することができる。
【００５１】
また、図１４(a) に示すように、前述の実施例と同様に、雌形金型１２８から成形部材１００を斜め方向にほぼ直線状に突出させておき、その後、雄形金型１３０を雌形金型１２８に接近させて型合わせをする。ここで、成形部材１００は前述の実施例と比較して、雄形金型１３０の移動方向に向かうようにし、且つ突出量を長くするのが好ましい。そして、雄形金型１３０の一部によって成形部材１００の一部を押圧し、折り曲げるように湾曲させる。その後、上述と同様にして発泡樹脂成形品１０２を得ることにより、同図(b)に示すように、湾曲した貫通孔１０４を形成することができる。
【００５２】
上述の実施例において、成形部材１００が一定の断面形状に形成されている場合、所定の箇所で折り曲げることが困難なときがある。このような場合、図１５(a) に示すように、両面又は片面に勾配を付けて成形部材１３２を形成したり、あるいは同図(b) に示すように、断面を減少させた成形部材１３４を形成することによって、折曲げたりあるいは湾曲させたりするのが容易となる。しかも、このような構成を採用することにより、一体的に形成された発泡樹脂成形品から成形部材を引き抜くのが容易となる。なお、成形部材に設ける勾配や段差は２箇所以上で変化させても良く、あるいは両者を組み合わせて構成することも可能であり、種々設定することができるものである。
【００５３】
次に、上述の実施例では成形部材を導くガイド部材は雌形金型にその金型の表面の一部を成し、且つ面一になるように構成されていたが、たとえば図１６(a)に示すように、ガイド部材１３６を雌形金型１２８の底側から雄形金型１３０の移動方向と平行に突出させ、その突出されたガイド部材１３６から雄形金型１３０に向かって成形部材１３８を前進及び後退させ得るように構成しても良い。この実施例において、成形部材１３８をガイド部材１３６から前進させた状態で発泡樹脂成形品１４０を形成し、成形部材１３８をガイド部材１３６の中に後退させた後、発泡樹脂成形品１４０を雌形金型１２８とガイド部材１３６とから離型させる。得られた発泡樹脂成形品１４０には同図(b)
に示すように、貫通孔１４２が形成されることになる。
【００５４】
更に、成形部材は単一の材料、特に発泡溶融させた発泡性樹脂ビーズと付着性を有しない材料、たとえば前述したフッ素樹脂などで形成するのが好ましいが、その他、たとえば形状記憶樹脂を用いることも可能である。更に、図１７(a) に示すように、形状記憶合金から成る芯材１４４の周りをフッ素樹脂などの被覆層１４６で覆って、成形部材１４８を構成することも可能である。この成形部材１４８にあっては、たとえば同図(b)
に示すように、予めＳ字状のトラップ構造１５０を記憶させておき、成形部材１４８をキャビティ内で所定の形状に変形させてから型合わせをし、その後、常法により発泡樹脂成形品１５２を形成することになる。
【００５５】
また、図１８(a) に示すように、雌形金型１５４から成形部材１５６を突出させるとともに、雄形金型１５８からも成形部材１６０を突出させ、かかる状態で同図(b)
に示すように、型合わせをして、それぞれ突出された成形部材１５６と１６０とを接触させて湾曲させる。その後、常法により、発泡性樹脂ビーズ（１６２）を充填して、加熱発泡させ、融着成形により発泡樹脂成形品１６２を成形する。次いで、成形部材１５６，１６０を発泡樹脂成形品１６２から除去した後、離型して、同図(c)
に示すように、貫通孔１６４が形成された発泡樹脂成形品１６２が得られる。
【００５６】
更に、図１９(a) に示すように、ガイド部材１６６を雌形金型１２８の底側から雄形金型１３０の移動方向と平行に突出させ、その突出されたガイド部材１６６から雌形金型１２８に向かって斜め上方向あるいは直角方向に成形部材１６８を前進及び後退させ得るように構成しても良い。この実施例において、成形部材１６８をガイド部材１６６から前進させた状態で、ガイド部材１６６とともに発泡樹脂成形品１７０を形成し、その後、成形部材１６８をガイド部材１６６の中に後退させた後、発泡樹脂成形品１７０を雌形金型１２８とガイド部材１６６とから離型させて発泡樹脂成形品１７０を得ることができる。なお、この実施例と同様に、同図(b)
に示すように、ガイド部材１７２の形状を成形部材１６８の形状に近似させて構成しても良く、特に限定されない。
【００５７】
このようにして得られた発泡樹脂成形品１７０は、たとえば図２０に示すように、側壁１７１部に貫通孔１７２が形成されることになる。この貫通孔１７２に紐１７４を通して結ぶことにより、持ち運びに便利な容器を構成することが可能となる。
【００５８】
以上、本発明に係る発泡樹脂成形品の成形装置及び成形方法の実施例と、その発泡樹脂成形品の実施例を図面を用いて種々説明したが、本発明は図示した実施例に限定されるものではないのは言うまでもない。
【００５９】
たとえば成形部材を導くガイド孔を有するガイド部材は、ガイド孔の加工などの観点から、金型とは別部材で形成し、金型に取り付けるように構成するのが好ましいが、成形部材の断面形状が円形などで加工が容易な場合は、金型に直接ガイド孔を加工して、金型をガイド部材として利用することも可能である。また、ガイド部材は金型に対して固定しておいても良いが、このガイド部材も成形部材と同様に、金型から前進・後退するように構成することも可能である。更に、ガイド部材の形状や構造、あるいは材質などは特に限定されるものではない。
【００６０】
また、このガイド部材やそのガイド孔に導かれる成形部材、及びその成形部材を駆動させる駆動手段は上述の実施例では雌形金型に取り付ける実施例を示したが、これらを雄形金型に取り付けたり、あるいは雌形金型と雄形金型の双方に取り付けることができ、なんら限定されるものではない。
【００６１】
その他、成形部材の断面形状は板状すなわち長方形に限られず、正方形や六角形、円形、楕円形、長円形などの種々の形状を採用することが可能である。また、アンダーカット部の形状は貫通孔に限らず、凹入部や湾曲部などのあらゆる形状を含むものである。更に、本発明に係る発泡樹脂成形品の成形装置及び成形方法は魚函や野菜函などを初めとする各種の容器や、各種の緩衝部材、梱包用部材などのあらゆる発泡樹脂成形品の製造に用いることができるものであるなど、本発明はその趣旨を逸脱しない範囲内で、当業者の知識に基づき種々なる改良、修正、変形を加えた態様で実施し得るものである。
【００６２】
【発明の効果】
本発明に係る発泡樹脂成形品の成形装置及び成形方法によれば、成形される発泡樹脂成形品に金型の移動方向と少なくとも一部が交叉する方向のアンダーカット部を一体的に形成するための成形部材が可撓性、すなわち弾力性あるいは柔軟性を有するため、駆動手段によって駆動させられた成形部材がキャビティ内を前進させられて、他方の金型表面に強く当接させられても、その金型表面を傷つけることがなく、また成形部材が弾性変形することによって余分に押し出された長さ分は吸収されることになる。したがって、成形部材が前進させられる量の調整は若干長めにすることができ、調整作業が容易になり、また、かかる調整ミスによって駆動手段を壊すこともなくなる。更に、成形部材が可撓性を有することから、たとえば成形部材をＳ字状などの湾曲形状に変形させて、アンダーカット部を一体的に形成した後、発泡樹脂成形品のアンダーカット部から成形部材を引き抜くことができ、複雑な形状のアンダーカット部の形成が可能となる。
【００６３】
また、成形部材をテフロン樹脂などのフッ素樹脂などの発泡性樹脂に対して剥離性に優れた樹脂によって形成するなどにより、成形部材と一体的に発泡溶融させて成形された発泡樹脂成形品からその成形部材を除去するのが容易となる。特に、アンダーカット部の形状が湾曲している場合に、成形部材が発泡性樹脂に対して剥離性に優れ、且つ可撓性，柔軟性などに優れた樹脂によって形成されていることにより、成形部材を除去するのが容易となる。
【００６４】
更に、成形部材が形状記憶合金あるいは形状記憶樹脂によって変形させるべき形状が記憶させられていたり、あるいは成形すべき形状で形成されていることにより、所望の形状をしたアンダーカット部を形成することが可能となる。
【００６５】
また、ガイド部材のガイド孔や金型が成形部材に所定の形状を付与し得るように構成されていることにより、常に成形サイクル毎に成形部材に形状を付与することができ、安定的にアンダーカット部を形成することができる。
【図面の簡単な説明】
【図１】本発明に係る発泡樹脂成形品の成形装置及び成形方法の一実施例を説明するための要部断面説明図である。
【図２】図１に示す成形装置に用いられるアンダーカット形成装置を示す要部破砕斜視図である。
【図３】図１に示す成形装置に用いられるアンダーカット形成装置を示す図であり、同図(a)
はアンダーカット形成装置の側面断面図、同図(b) はガイド部材の正面図、同図(c) 及び(d) はいずれもガイド部材を分解して示す正面図である。
【図４】本発明に係る発泡樹脂成形品の成形装置及び成形方法の他の実施例を説明するための要部断面説明図である。
【図５】本発明に係る発泡樹脂成形品の成形装置及び成形方法の更に他の実施例を説明するための要部断面説明図である。
【図６】本発明に係る発泡樹脂成形品の成形装置及び成形方法の更に他の実施例を説明するための要部断面説明図である。
【図７】本発明に係る発泡樹脂成形品の成形装置及び成形方法の更に他の実施例を説明するための要部断面説明図である。
【図８】図７に示す発泡樹脂成形品の成形装置におけるガイド部材などを示す要部断面図である。
【図９】図(a) 乃至図(d) はいずれも、本発明に係る発泡樹脂成形品の成形装置及び成形方法によって形成することができるアンダーカット部の形状を示す要部断面説明図である。
【図１０】図(a) は本発明に係る発泡樹脂成形品の成形装置及び成形方法の他の実施例を示す要部断面図であり、図(b)
は図(a) に示す成形方法によって形成されたアンダーカット部の形状を示す要部断面図である。
【図１１】図(a) 乃至図(c) はいずれも、本発明に係る発泡樹脂成形品の成形装置及び成形方法によって形成することができるアンダーカット部の他の形状を示す要部断面説明図である。
【図１２】図(a) 及び図(b) はいずれも、本発明に係る発泡樹脂成形品の成形装置及び成形方法によって形成することができるアンダーカット部の更に他の形状を示す要部断面説明図である。
【図１３】図(a) は本発明に係る発泡樹脂成形品の成形装置及び成形方法の更に他の実施例を示す要部断面図であり、図(b)
は図(a) に示す成形方法によって形成されたアンダーカット部の形状を示す要部断面図である。
【図１４】図(a) は本発明に係る発泡樹脂成形品の成形装置及び成形方法の更に他の実施例を示す要部断面図であり、図(b)
は図(a) に示す成形方法によって形成されたアンダーカット部の形状を示す要部断面図である。
【図１５】図(a) 及び図(b) はいずれも、本発明に係る発泡樹脂成形品の成形装置及び成形方法に用いられる成形部材の他の実施例を示す要部側面図である。
【図１６】図(a) は本発明に係る発泡樹脂成形品の成形装置及び成形方法の更に他の実施例を示す要部断面図であり、図(b)
は図(a) に示す成形方法によって形成されたアンダーカット部の形状を示す要部断面図である。
【図１７】図(a) は本発明に係る発泡樹脂成形品の成形装置及び成形方法に用いられる成形部材の他の実施例を示す要部側面図であり、図(b)
は図(a) に示す成形部材を用いて形成される発泡樹脂成形品の実施例を示す要部断面説明図である。
【図１８】図(a) 乃至(c) は本発明に係る発泡樹脂成形品の成形装置及び成形方法の他の実施例における各工程を示す要部断面説明図である。
【図１９】図(a) 及び(b) はいずれも本発明に係る発泡樹脂成形品の成形装置及び成形方法の他の実施例を示す要部断面説明図である。
【図２０】図１９に示す本発明に係る発泡樹脂成形品の成形装置及び成形方法によって形成される発泡樹脂成形品の一例を示す破砕断面説明図である。
【符号の説明】
１０：成形装置
１２，５８，５９，１０６，１１２，１２０，１３０，１５８：雄形金型
１４，５６，５７，８２，１１０，１２８，１５４：雌形金型
２２，２６：加熱・冷却室
２８，１１６：キャビティ
３０，１０２，１４０，１５２，１６２，１７０：発泡樹脂成形品
３２，１０４，１２６，１４２，１５０，１６４，１７２：貫通孔（アンダーカット）
３４，６０，６２：アンダーカット形成装置
３６，６６，９０，１３６，１６６，１７２：ガイド部材
３８，８４，１００，１３２，１３４，１３８，１４８，１５６，１６０，１６８：成形部材
４０，６８，８０，８６：駆動手段
４４，８８：ガイド孔
４８，６４，７０，７６：スライド部材
５２：圧縮コイルバネ
５４：棒状部材
７８：エアーシリンダ
９８：液圧シリンダ
１０８：凹陥部
１１４：ガイド溝[0001]
[Industrial application fields]
  The present invention relates to a molding apparatus and a molding method for a foamed resin molded product, and in particular, a through hole, a recessed portion, or a curved portion in a direction crossing a moving direction of a molding die including a male die and a female die. The present invention relates to a molding apparatus and a molding method for a foamed resin molded article having an undercut portion such as.
[0002]
[Prior art]
  Foamed resin molded products molded by a bead molding method in which foamable resin beads made of polystyrene resin, polyolefin resin, etc. are foamed in the mold, have excellent properties such as heat retention, heat insulation, buffering, and lightness. Have For this reason, it is widely used as a foamed resin molded product for transport containers such as fish boxes and vegetable boxes that are particularly required to maintain freshness, cushioning materials used for packaging, and structural members. These various foamed resin molded products are filled with foamable resin beads in a cavity formed by a molding die comprising a male die and a female die, heated and foamed, and then cooled and molded. Is done. Thereafter, one of the molds is moved to open the mold, and the molded foamed resin molded product is taken out.
[0003]
  This foamed resin molded product manufacturing apparatus is configured to move only in one direction so that one of the male mold and the female mold approaches or separates from the other. Therefore, from the viewpoint of improving the manufacturing efficiency of the foamed resin molded product, the foamed resin molded product has a simple structure that does not have an undercut portion such as a through hole, a recessed portion, or a curved portion in a direction crossing the moving direction of the molding die. In addition to the shape, a large number of foamed resin molded products can be manufactured in a single molding process.
[0004]
  However, for example, in fish boxes mainly containing high-quality fish, fish boxes having drain holes are required. The drainage hole of the fish box is necessary to maintain the freshness of the fresh fish by draining the ice melted with the fresh fish and the blood and other body fluids from the fish as needed. However, conventionally, the drainage holes provided in the fish box are usually opened at the bottom and bottom corners of the box and can always discharge water, etc., while the air flows into the box from the outside. There was a problem that the ice inside was quickly melted. Furthermore, when ice is not used, air enters and exits through the drainage hole of the fish box, so that the surface of the fresh fish stored is dried or the surface of the fresh fish flows due to the inflow of cold air. There has been a problem that the product value is greatly reduced, such as discoloration and alteration due to so-called freeze-burning.
[0005]
  For this reason, the inventor of the present application, for example, in Japanese Patent Application No. 4-209168, forms a through-hole in the bottom of the side wall of the cold storage container where the position of the opening outside the container is higher than the inner opening, Various kinds of cold storage containers were proposed in which the accumulated water level was higher than the position (height) of the opening on the outside of the container, so that water was discharged by that amount. Along with the structure of the cold storage container, various manufacturing methods and molding apparatuses have also been disclosed (Japanese Patent Application No. 4-209168, Japanese Patent Application No. 4-227076, Japanese Patent Application No. Hei 5-164510, Japanese Patent Application No. Hei 5- 191403). This container is drained by the amount of water accumulated in the interior that is higher than the position (height) of the opening on the outside of the container, and water is accumulated in the interior below the position of the opening. The through hole is blocked by the water. As a result, excess water can be discharged, while the through-hole is closed with water, so that air in and out of the container can be stopped, and the above problem can be solved. In addition, it has become possible to provide a container that exhibits excellent effects such as preventing the stored items such as fresh fish from being dried and moisturized by the water accumulated slightly inside. This cold storage container is not limited to a fish box, and can be applied to any container such as a vegetable box.
[0006]
[Problems to be solved by the invention]
  The cold container forming apparatus is arranged in a mold so that an undercut molding piece arranged in a cavity constituted by the mold can enter and exit from the cavity, and the molding piece can enter and exit from the cavity. The driving means is configured to reciprocate and a flexible transmission body that transmits the driving force of the driving means to the molding piece. In addition, the manufacturing method is such that after the male mold and the female mold are matched, the undercut molding piece is protruded from the mold of either one or both into the cavity by the driving means, After that, after filling the cavity with expandable resin beads, it is heated and foamed, the molded piece is removed after cooling, and then the expanded resin molded product formed by separating the male mold and female mold is separated. Make it mold.
[0007]
  The undercut forming piece used in the cold container forming apparatus and manufacturing method is formed of a metal or other rigid member into a predetermined shape, and this forming piece protrudes from a guide hole provided in the mold and is mated The shape of the through hole to be formed is determined by abutting against the surface of the metal mold or by bringing the molding pieces into contact with each other. For this reason, the through hole can be formed accurately, but since the molding piece can be slid in the guide hole, the shape of both the molding piece and the guide hole must be precisely manufactured, and the manufacturing cost is high. There was a problem of sticking. Further, the protruding amount of the molding piece has to be set in a state where the male mold and the female mold are matched with each other, and adjustment is slightly difficult. On the other hand, it is possible to configure so that the protruding amount of the molding piece does not need to be finely adjusted. However, for this purpose, a new mechanism is required, and there is a problem that the cost of the apparatus is high.
[0008]
  In addition, when a foaming resin bead is heated and foamed with a molding piece made of metal or the like, the molding piece and the foamed resin bead that has been foamed and melted adhere or adhere to each other, and a large force is required to remove the molding piece. There was a problem. The present inventor has solved the above-mentioned problems and, as a result of intensive research to develop a new molding method, has come up with the molding apparatus and molding method for a foamed resin molded product of the present invention.
[0009]
[Means for Solving the Problems]
  A gist of a molding apparatus for a foamed resin molded product according to the present invention is that a molding apparatus for a foamed resin molded product comprising a male mold and a female mold, at least one of which is spaced apart from each other, A guide member having a guide hole provided in one or both of the male mold and the female mold, and at least a part of the moving direction of the mold intersects the cavity guided by the guide hole. The object is to include a flexible molding member that is allowed to enter in a direction, and drive means for moving the molding member forward and backward.
[0010]
  In such a foamed resin molded product molding apparatus, the molded member is made of a resin excellent in peelability from a foamable resin such as fluororesin, polytetrafluorinated ethylene, or fluorinated pitch, or the resin is flexible. It exists in covering and forming a member.
[0011]
  Further, in the molding apparatus for the foamed resin molded product, the shape that is curved in the cavity into which the molding member is inserted is stored.
[0012]
  Furthermore, in the molding apparatus for the foamed resin molded product, the guide hole and / or the mold on which the molded member entered from the guide hole is brought into contact are configured so as to give a shape to the molded member. Be in.
[0013
  Next, the gist of the molding method of the foamed resin molded product according to the present invention is to form a cavity by bringing at least one of the separated male mold and female mold close to each other and forming the cavity. In the method of filling foamed resin beads into the formed cavity and then heating and foaming to form a foamed resin molded product, guide holes provided in one or both of the male mold and the female mold A flexible molding member is inserted into the cavity in a direction that intersects at least partly with the direction of movement of the mold and is disposed in a predetermined position shape, and then the foamed resin beads are filled into the cavity. Then, the foamed resin molded article is released from the molded foamed resin molded article by retracting the molded member and then removing it from the molded foamed resin molded article.
[0014]
  Further, in the method of molding a foamed resin molded product, the flexible molded member is deformed by a guide hole and / or a mold that is brought into contact with the molded member.
[0015]
  Furthermore, another gist of the method for molding a foamed resin molded product according to the present invention is to form a cavity by bringing at least one of the separated male mold and female mold close to each other, In the method of filling a foamed resin bead into the formed cavity and then heating and foaming to form a foamed resin molded product, a guide provided on one or both of the male mold and the female mold A flexible molding member is projected from the hole into the space forming the cavity in a direction that intersects at least the direction of movement of the mold, and then the male mold and the female mold are aligned. The molded member is deformed by bringing the mold opposed to the projecting molded member or the molded members projecting from both sides into contact with each other, and then the expandable resin beads are placed in the cavity. Fill and heat foam. After, after removal from the molded resin foam product is retracted molding member is to be demolded foam resin molded article.
[0016
[Action]
A molding apparatus for a foamed resin molded product according to the present invention is provided with a guide member having a guide hole in one or both of a male mold and a female mold, and is guided to the guide hole to The molding member includes a flexible molding member that is allowed to enter the cavity in a direction at least partially intersecting the moving direction of the mold, and driving means for moving the molding member forward and backward. The molding method using this molding apparatus is to insert a molding member into a cavity from a guide hole and dispose it in a direction crossing the moving direction of the mold, and then fill the cavity with expandable resin beads. Thus, the foamed resin beads are heated and foamed and fused to form a foamed resin molded product. Thereafter, the molded member is retracted and removed from the foamed resin molded product, and then the foamed resin molded product is released from the female mold.
[0017]
  As a method for disposing the molded member in the cavity in the molding method of the foamed resin molded product, for example, as the male mold and the female mold are relatively moved closer, the molded member is caused to enter the cavity. The entry of the molding member is stopped at the mold stop position immediately before the filling of the expandable resin beads. At this time, the molding member is disposed in the cavity in a direction crossing at least a part of the moving direction of the mold, and a part of the molding member is brought into contact with or brought into contact with the opposing mold. Thus, a predetermined shape is formed. As another arrangement method of the molded member, the molded member is protruded from the guide hole in advance from one mold, and then the two molds are relatively approached, and the protruded molded member is moved to the other mold. The molded member can be deformed into a predetermined shape by contacting or contacting the mold. Furthermore, as another arrangement method of the molded member, the molded member is formed of a shape memory resin, or a shape memory alloy is embedded in the resin, or the molded member is formed into a predetermined shape. Then, after the molding member is projected from the guide hole from one mold, the molding member is heated to be deformed into a previously memorized shape, or is projected from the guide hole into a predetermined shape. To do. Then, after filling the foamable resin beads into the cavity, the foamed resin molded product is formed by heating and foaming by a conventional method, and then the molded member is removed from the foamed resin molded product.
[0018]
  Here, the molded member is formed of a resin excellent in peelability with respect to a foaming resin such as a fluororesin such as Teflon resin, polytetrafluorinated ethylene, or a fluoride pitch composed of fluorine and carbon, or these foams. It is easy to remove the molded member from the foamed resin molded product formed integrally with the molded member by forming the flexible member with a resin excellent in peelability with respect to the flexible resin. Become.
[0019
【Example】
Next, embodiments of a molding apparatus and a molding method for a foamed resin molded product according to the present invention will be described in detail with reference to the drawings.
[0020]
  As shown in FIG. 1, a molding apparatus 10 for a foamed resin molded product includes a male mold 12 and a female mold 14, and the male mold 12 is moved closer to or away from the female mold 14. A movable frame 16 that is movable relative to a base (not shown) is fixed via a mold mounting plate 17, while the female mold 14 is mounted on a fixed frame 18 that is not movable relative to the base. It is fixed via a plate 19.
[0021]
  Here, the space enclosed and sealed by the male mold 12, the moving frame 16 and the back plate 20 is a heating / cooling chamber 22 of the male mold 12, while the female mold 14 and the fixed frame 18. The space surrounded by the back plate 24 and sealed is a heating / cooling chamber 26 of the female mold 14. Although not shown, these heating / cooling chambers 22 and 26 are provided with a heating medium such as heating steam. An introduction pipe to be introduced, a discharge pipe for discharging the heating medium used for heating, a cooling pipe and spray nozzle for cooling the molds 12 and 14, a drain discharge pipe for discharging cooling water, and the like are provided. Further, on the fixed side of the female mold 14 and the like, a foamable resin preliminarily foamed in a cavity 28 constituted by the male mold 12 and the female mold 14 is similarly omitted. A raw material filling machine for filling the beads (30), an eject pin for extruding the molded foamed resin molded product 30 from the female mold 14 and an extrusion device are disposed.
[0022]
  The male mold 12 and the female mold 14 are each provided with a large number of core vents (not shown). A heating medium is introduced into the cavity 28 through the core vents, and the foamable resin beads are passed through the other core vents. The heating medium that has contributed to the heating is discharged. Of these molding dies, a heating / cooling chamber 26 which is the back surface of the female die 14 is penetrated into a part of the foamed resin molding 30 to be molded, for example, in a direction crossing the moving direction of the male die 12. An undercut forming device 34 for opening the through hole 32 is disposed.
[0023]
  As shown in detail in FIGS. 2 and 3, the undercut forming device 34 drives a guide member 36 attached to a part of the female die 14, a flexible molding member 38, and the molding member 38. The driving means 40 is provided. The guide member 36 has a mold surface 43 that is mounted in a hole 42 formed in a part of the female mold 14 and constitutes a part of the surface of the female mold 14. A guide hole 44 is formed to guide the molding member 38 that is moved forward and backward. The guide hole 44 is formed in an arc shape so as to give a shape and draw an arc when the molding member 38 is passed therethrough. The guide member 36 can be configured by combining two members 45 and 46 as shown in FIGS. 3 (b) to 3 (d).
[0024]
  The molding member 38 in the undercut forming device 34 is formed of a flexible member, for example, a member formed of resin, or a member in which a flexible member such as a leaf spring is covered with a flexible resin. The In this embodiment, the formed member 38 is formed in a plate shape (band shape), and is passed through a guide hole 44 formed in an arc shape of the guide member 36, whereby the band-shaped formed member 38 is circular. Curved in an arc.
[0025]
  The molded member 38 is particularly preferably a resin excellent in releasability from a foamable resin such as a fluororesin such as so-called Teflon, polytetrafluorinated ethylene, or a fluorinated pitch composed of a compound of fluorine and carbon. Alternatively, those formed by coating a flexible member with a resin excellent in peelability with respect to these foamable resins are used. The resin having excellent releasability with respect to the foamable resin is used on at least the surface of the molded member 38 when the foamable resin beads are heated and foamed and melted so that the beads are fused. This is to prevent the molded member 38 from being fused and to easily remove the molded member 38 from the foamed resin molded product 30.
[0026]
  Next, the driving means 40 for moving the molding member 38 forward or backward fixes a slide member 48 that fixes and slides one end of the molding member 38, a box 50 that houses and slides the slide member 48, and the molding member 38. The compression coil spring 52 is urged in a direction in which the slide member 48 is always retreated, and a rod-like member 54 that presses the slide member 48 in a direction in which the forming member 38 is advanced. The slide member 48 has a box shape, and a box 51 that houses the slide member 48 and the compression coil spring 52 is covered with a lid 51, and the lid 51 is fixed to the box 50 with screws (not shown). The above-described guide member 36 is fixed to the lid 51, and the guide member 36, the box 50, and the like are fixed to the female mold 14 by bolts (not shown).
[0027]
  The compression coil spring 52 is selected to have a size sufficient to obtain a force sufficient to extract the tip of the molded member 38 embedded in the molded foamed resin molded product 30 integrally. Further, the rod-shaped member 54 that presses the slide member 48 against the urging force of the compression coil spring 52 is arranged on the mold mounting plate 17 that attaches the male mold 12 to the movable frame 16 as shown in FIG. The amount of sliding of the slide member 48, that is, the amount of protrusion of the molding member 38 is adjusted by adjusting the amount of protrusion of the rod-shaped member 54 from the mold mounting plate 17 as appropriate.
[0028]
  The protruding amount of the molding member 38 is such that the end of the protruding molding member 38 is at the position of the male die 12 at the position of the male die 12 when the foamable resin beads (30) are filled in the cavity 28. It is set to contact the surface. Therefore, even when cracking is performed, the end of the molding member 38 is brought into contact with the surface of the male mold 12 when the foamable resin beads (30) are filled, and then the mold clamping is performed. As a result, the positional relationship between the molding member 38 and the male mold 12 is shifted. However, since the molding member 38 is covered with the foamable resin beads (30), the shape of the through hole 32 formed by the molding member 38 is different. There is very little change. Further, by performing the mold clamping, the slide member 48 is slid, but the molding member 38 is only bent in the box 50 and the shape of the through hole 32 is hardly affected.
[0029]
  The molding apparatus for a foamed resin molded product according to the above configuration is operated in the same manner as a conventional molding apparatus for a foamed resin molded product. That is, after the undercut forming device 34 is mounted on the predetermined male mold 12 and female mold 14, the male mold 12 is brought close to the female mold 14 in order to perform clamping in a usual manner. At this time, after the rod-like member 54 attached to the die mounting plate 17 of the male die 12 comes into contact with the slide member 48, the slide member 48 is pressed and the molding member 38 is advanced to move into the cavity 28. The tip of the molding member 38 is brought into contact with the surface of the male mold 12 at the stop position of the male mold 12 filled with the expandable resin beads (30). At that time, the protruding amount of the rod-shaped member 54 can be set to be slightly longer, and can be set so that the molding member 38 is surely in contact with the surface of the male mold 12 and slightly bent.
[0030]
  After completion of mold matching, the resin is filled into the cavity 28 in which expandable resin beads (30) pre-foamed from a raw material filling machine (not shown) are formed. Expandable resin beads are made of various resins used for foam molding, such as polystyrene resins and polyolefin resins, in the form of particles, impregnated with a foaming agent, and pre-expanded to a predetermined expansion ratio. Is used and is not particularly limited. When cracking is performed after filling the expandable resin beads (30), the mold is further clamped, and then the expandable resin beads (30) are heated and foamed by heating steam as a heating medium according to a conventional method and fused. After forming the foamed resin molded product 30, the molds 12 and 14 are cooled.
[0031]
  Next, the male mold 12 is moved to open the mold. At this time, as the mold mounting plate 17 for fixing the male mold 12 is retracted, the rod-shaped member 54 is also retracted, and the pressing of the slide member 48 is released. As a result, the slide member 48 is retracted together with the retracting slide member 48 by the urging force of the compression coil spring 52, and the molding member 38 comes out of the foamed resin molded product 30 to form the through hole 32. After the male mold 12 is sufficiently retracted and the molding member 38 is completely removed from the foamed resin molded product 30, the foamed resin molded product 30 is pushed out from the female mold 14 by an eject pin (not shown).
[0032]
  Thus, according to the molding apparatus and the molding method of the foamed resin molded product according to the present embodiment, the undercut forming device 34 is attached to, for example, the female die 14 and the die mounting plate 17 among the conventional molding dies. The foamed resin molded product 30 in which the through holes 32 are formed in the direction intersecting with the moving direction of the male mold 12 can be manufactured simply. Further, in manufacturing such a foamed resin molded product, a new power source is not required, and the molding cycle of the foamed resin molded product is the same as the conventional one, so that the manufacturing cost hardly increases. Further, by using a flexible molded member, the protruding amount of the rod-shaped member for adjusting the slide amount of the molded member can be adjusted slightly larger, and this adjustment operation becomes very easy. In addition, since the processing of the guide hole of the guide member that guides the molded member does not require accuracy, the manufacturing cost of the molded member and the guide member can be significantly reduced.
[0033]
  As mentioned above, although the shaping | molding apparatus and the shaping | molding method of the foamed resin molded product which concern on a present Example were demonstrated, this invention is not limited to the above-mentioned Example.
[0034]
  For example, as shown in FIG. 4, a plurality of female molds 56, 57... And male molds 58, 59. In an apparatus for manufacturing a molded product, an undercut forming apparatus 60 having the same configuration as described above and an undercut forming apparatus 62 configured so that the molded member 38 extends in two directions can be provided. . In this undercut forming device 62, two molding members 38 are attached to one slide member 64, and each molding member 38 is guided by a guide member 66, and the slide member 64 is composed of the compression coil spring 52 and the rod-shaped member 54. By being pushed by, it is moved forward and backward. By using the undercut forming device 62 having such a structure, the distance between the female molds 56 and 57 can be reduced, and the size of the device can be reduced.
[0035]
  As shown in FIG. 5, the driving means 68 for moving the molding member 38 forward and backward includes a slide member 70 to which one end of the molding member 38 is fixed, and the slide member 70 in the direction in which the molding member 38 moves backward. The compression coil spring 52 is urged, and a pressure adjusting member 72 is slid against the urging force of the compression coil spring 52, and the tip of the pressure adjusting member 72 is in contact with the mold mounting plate 17 of the male mold 12. It may be configured as described above. The pressure adjusting member 72 includes a cylindrical member 73 in which a female screw is formed, and a male screw member 74 that is screwed into the female screw of the cylindrical member 73, and the screwing length between the male screw member 74 and the cylindrical member 73. The slide amount of the slide member 70 can be adjusted by adjusting. According to this embodiment, since only one end of the pressure adjusting member 72 is brought into contact with the mold mounting plate 17 to which the male mold 12 is mounted, there is no need to process the mold mounting plate 17, and the slide Adjustment of the slide amount of the member 70 is also facilitated.
[0036]
  Further, as the driving means of the undercut forming apparatus, it is most economical to use the driving force of the mold and the urging force of the compression coil spring that allow the male mold to be separated from and approach the female mold as described above. As a matter of course, a tension coil spring can be used instead of the compression coil spring, or various elastic members can be used. Further, in place of the driving means composed of the driving force of the mold and these urging forces, a dedicated driving means can be provided.
[0037]
  For example, as shown in FIG. 6, a shaft 79 that is reciprocated by an air cylinder 78 is connected to one end of a slide member 76 that is slid within the box 50, and the slide member 76 is forcibly reciprocated by the air cylinder 78. The drive unit 80 may be configured to do so. By forcibly driving the slide member 76 back and forth, the molding member 38 can be reliably pulled out from the molded foamed resin molded product. Further, the molding member 38 can be disposed in the cavity 28 by the air cylinder 78 regardless of the movement of the male mold 12, or can be removed conversely. The air cylinder 78 may be configured not only to use compressed air but also to be operated by a vacuum force by a vacuum pump. In place of the air cylinder 78, a hydraulic or other hydraulic cylinder may be used, and an electromagnetic solenoid may be used. Further, it is possible to configure the molding member 38 so that it can be moved forward and backward mechanically using an electric motor as a drive source, and is not particularly limited.
[0038]
  In addition, as shown in FIG. 7, the foamed resin molding is manufactured simultaneously by disposing a molding member 84 at one or more locations for each of the one or more female dies 82. When forming an undercut part in a product, a plurality of molding members 84 may be combined into one place and driven by one driving means 86. That is, as shown in an enlarged view in FIG. 8, a guide member 90 having a guide hole 88 is attached to a part of each female die 82, and the back side of the female die 82 of the guide member 90 is attached. To the driving means 86 are connected by a flexible tube 92, and the molding member 84 is passed through the guide hole 88 and the inside of the tube 92. Then, a rigid cylindrical member 94 is disposed at the end of the tube 92 on the drive means 86 side, while a sliding member 95 that is slidable in the cylindrical member 94 is disposed, and the sliding member 95 is disposed. One end of the moving member 95 is connected to the molding member 84, and the other end of the sliding member 95 is connected to the piston 96 of the driving means 86. The piston 96 is moved forward and backward by a hydraulic pressure or other hydraulic cylinder 98 or a driving device using an air cylinder, an electromagnetic solenoid, an electric motor, or the like.
[0039]
  By adopting such a configuration, the molding member 84 is reliably inserted into the cavity 28 and retracted. In addition, a large number of molding members 84 can be operated simultaneously by one driving means 86, which is economical. Further, when the molding member 84 is disposed on the female die 82, only the work of attaching the guide member 90 to the female die 82 is required, so that the disposing operation is facilitated and the space is hardly required. It can be appropriately attached to any part of the mold without considering the arrangement of the mold. In addition, it is possible to use another flexible member in place of the forming member 84 at a location where the guide member 90 and the driving means 86 are connected by the tube 92.
[0040]
  As described above, various embodiments of the molding apparatus and molding method for the foamed resin molded product according to the present invention have been described. By using the molding apparatus and the molding method described above, undercut portions such as through holes having various shapes can be molded by foaming resin molding. Can be formed into a product.
[0041]
  For example, as shown in FIG. 9 (a), the guide hole of the guide member is formed in a curved shape such as an arc, and the molded member 100 is passed through the guide hole, whereby the side wall portion of the formed foamed resin molded product 102 is formed. In addition, a curved through hole 104 such as an arc can be integrally formed. Figure (b)
As shown in FIG. 4, by forming at least the exit portion of the guide hole in a straight line, the molding member 100 that can pass through the guide hole is inserted into the cavity in a substantially straight line. Therefore, by allowing the molding member 100 to enter in the oblique direction, the straight through-hole 104 in the oblique direction can be formed, and FIG.
As shown in FIG. 5, by allowing the molding member 100 to enter in a perpendicular direction, the through-hole 104 having a linear shape in the perpendicular direction can be formed.
[0042]
  Further, as shown in FIG. 4 (d), the molding member 100 is configured to enter from the female mold toward the male mold (106) in a substantially right angle direction, and further, the distal end portion of the molding member 100 is formed. An oblique concave portion (108) is formed at the location of the male mold (106) on which the abuts. In such a configuration, after the molding member 100 enters the cavity and is brought into contact with the concave portion (108) of the male mold (106), the molding member 100 is further pushed in and bent. At this time, since the recessed portion (108) is formed in an oblique direction, the molded member 100 that has entered is bent along the recessed portion (108), and the molded member 100 is always bent in the same direction. become. In a state where the molded member 100 is curved, the foamed resin beads are filled into the cavities and molded by heating and foaming by a conventional method. Then, the molded member 100 is retracted, and then the foamed resin molded product 102 is taken out. By such an operation, the curved through hole 104 can be formed in the side wall portion of the foamed resin molded product 102.
[0043]
  Further, as shown in FIG. 10 (a), the tip of the molding member 100 is guided in a certain direction to the surface of the male die 112 with which the tip of the molding member 100 that enters from the female die 110 abuts. A guide groove 114 is provided. After the female mold 110 and the male mold 112 are aligned, the molding member 100 that has entered from the female mold 110 in a substantially right angle direction is brought into contact with the guide groove 114 of the male mold 112. After that, the molding member 100 is bent along the guide groove 114 by further advancing by a certain amount. Thereafter, the foamed resin beads are filled into the cavity 116 and heated and foamed by a conventional method to form the foamed resin molded product 102. Then, the molded member 100 is removed, and FIG.
As shown, the through-hole 104 is formed in the foamed resin molded product 102.
[0044]
  In this way, it is not necessary to give a shape for bending the molding member 100 by the guide member. By providing the guide groove 114 on the surface of the male mold 112 on which the molding member 100 is brought into contact, the molding member 100 is shaped. Can be granted. The curved shape of the molded member 100 can also be adjusted by the length of the molded member 100 that enters the embodiment shown in FIG. 9 (d).
[0045]
  Further, in the embodiment shown in FIG. 10, before the female mold 110 and the male mold 112 are matched with each other, the molding member 100 is sufficiently protruded in advance, and then the male mold is aligned with each other. A part of the mold 112 can be brought into contact with a part of the molding member 100 to bend the molding member 100. According to such a molding method, it is not necessary to provide a guide groove or the like in a part of the male mold 112. The molding member 100 does not need to protrude from the female die 110 into the cavity in a substantially right angle direction, and may be, for example, an obliquely upward direction or an obliquely downward direction, and is further inclined to either the left or right direction. There is no particular limitation.
[0046]
  Next, the molding member can be configured not only to enter the cavity from the side wall side of the female mold, but also to enter the cavity from the bottom side of the female mold. For example, a guide member is provided in a female mold (not shown), and as shown in FIG. 11A, the molding member 100 is inserted into the cavity while being curved by the guide hole, and a part of the molding member 100 and the male mold are inserted. In a state where a part of the mold is in contact, the foamed resin beads are filled, and the foamed resin molded article 102 is formed by a conventional method. By such a method, the curved through hole 104 can be formed at the bottom of the foamed resin molded product 102.
[0047]
  Similarly, a groove (118) for guiding the inserted molding member 100 may be provided in the male mold, as shown in FIG. It is also possible to form the two through holes 104 at the same time by allowing the molded member 100 to enter until the tip of the molded member 100 contacts the inner surface of the female mold. (C)
As shown in FIG. 3, the male mold is arranged in the direction in which the molding member 100 enters after the molding member 100 is linearly inserted into the cavity without being bent by the guide member provided in the female mold. Alternatively, the through hole 104 may be formed by bending the molding member 100 along a part of the surface.
[0048]
  Further, as shown in FIG. 12 (a), the molding member 100 is made to enter the cavity straightly from the female mold guide member into the cavity, and the male mold (120) with which the tip of the molding member 100 abuts is inserted. Even after the locking portion (122) is provided and the molding member 100 is locked to the locking portion (122), the molding member 100 is bent by being pushed in a certain length. In this state, the foamed resin beads are filled into the cavities, and the foamed resin molded product 102 is formed by a conventional method. Then, by removing the molded member 100, the curved through hole 104 can be formed in the foamed resin molded product 102.
[0049]
  Further, as shown in FIG. 5B, the locking portion (124) provided on the male mold (120) is twisted in a direction that receives the tip of the molded member 100 and causes a kind of buckling. Configure as follows. With this configuration, the molded member 100 pushed into the cavity is curved in an S shape, and the foamed resin molded product 102 is similarly formed in this state. By removing the molding member 100 from the foamed resin molded product 102, an S-shaped through hole 126 is obtained, and the trap structure is formed by making a difference between the height of the S-shaped valley and the height of the mountain of the through hole 126. can do.
[0050]
  Next, as shown in FIG. 13 (a), the molding member 100 is protruded from the female die 128 in a substantially straight line in an oblique direction, and then the male die 130 is moved closer to the female die 128. Let the mold match. At this time, a part of the molding member 100 is pressed and curved by a part of the male mold 130. Thereafter, by obtaining the foamed resin molded article 102 in the same manner as described above, a curved through hole 104 can be formed as shown in FIG.
[0051]
  Further, as shown in FIG. 14 (a), as in the above-described embodiment, the molding member 100 is protruded from the female mold 128 in a substantially straight line in an oblique direction, and then the male mold 130 is mounted. The mold is matched by bringing it closer to the female mold 128. Here, it is preferable that the molding member 100 is directed in the moving direction of the male mold 130 and the protruding amount is longer than that in the above-described embodiment. Then, a part of the molding member 100 is pressed by a part of the male mold 130 and bent so as to be bent. Thereafter, by obtaining the foamed resin molded article 102 in the same manner as described above, a curved through hole 104 can be formed as shown in FIG.
[0052]
  In the above-described embodiment, when the molded member 100 is formed in a certain cross-sectional shape, it may be difficult to bend at a predetermined location. In such a case, as shown in FIG. 15 (a), the molding member 132 is formed with a gradient on both sides or one side, or the molding member 134 having a reduced cross section as shown in FIG. 15 (b). By forming this, it becomes easy to bend or curve. In addition, by adopting such a configuration, it becomes easy to pull out the molded member from the integrally formed foamed resin molded product. In addition, the gradient and level | step difference provided in a shaping | molding member may be changed in two or more places, or it is also possible to comprise combining both and can set variously.
[0053]
  Next, in the above-described embodiment, the guide member for guiding the molding member is configured to be part of the surface of the die and to be flush with the female die. For example, FIG. ), The guide member 136 is projected from the bottom side of the female die 128 in parallel to the moving direction of the male die 130, and the guide member 136 is molded toward the male die 130 from the projected guide member 136. The member 138 may be configured to be able to advance and retract. In this embodiment, the foamed resin molded product 140 is formed with the molded member 138 advanced from the guide member 136, the molded member 138 is retracted into the guide member 136, and then the foamed resin molded product 140 is formed into a female shape. The mold 128 and the guide member 136 are released from the mold. The obtained foamed resin molded product 140 has the same figure (b).
As shown, the through-hole 142 is formed.
[0054]
  Further, the molded member is preferably formed of a single material, particularly a foamed and melted foamable resin bead and a material that does not adhere to the material, for example, the above-mentioned fluororesin, but otherwise, for example, a shape memory resin is used. Is also possible. Further, as shown in FIG. 17 (a), the molding member 148 can be configured by covering the periphery of the core material 144 made of a shape memory alloy with a coating layer 146 such as a fluororesin. In the molding member 148, for example, FIG.
As shown in FIG. 5, the S-shaped trap structure 150 is stored in advance, the molding member 148 is deformed into a predetermined shape in the cavity, and then the mold is aligned. Will form.
[0055]
  18A, the molding member 156 is projected from the female mold 154, and the molding member 160 is also projected from the male mold 158. In this state, FIG.
As shown in FIG. 3, the molds are aligned, and the protruding molding members 156 and 160 are brought into contact with each other to be bent. Thereafter, the foamable resin beads (162) are filled and heated and foamed by a conventional method, and the foamed resin molded product 162 is molded by fusion molding. Next, after removing the molded members 156 and 160 from the foamed resin molded product 162, they are released from the mold, and FIG.
As shown in FIG. 4, a foamed resin molded product 162 in which through-holes 164 are formed is obtained.
[0056]
  Further, as shown in FIG. 19A, a guide member 166 is projected from the bottom side of the female die 128 in parallel with the moving direction of the male die 130, and the female die is protruded from the projected guide member 166. You may comprise so that the shaping | molding member 168 can be advanced and retracted diagonally upward or perpendicularly toward the mold 128. In this embodiment, a foamed resin molded product 170 is formed together with the guide member 166 in a state where the molded member 168 is advanced from the guide member 166, and then the molded member 168 is retracted into the guide member 166 and then foamed. The resin molded product 170 can be released from the female mold 128 and the guide member 166 to obtain the foamed resin molded product 170. As in this example, the same figure (b)
As shown, the shape of the guide member 172 may be configured to approximate the shape of the molding member 168, and is not particularly limited.
[0057]
  In the foamed resin molded product 170 obtained in this way, through holes 172 are formed in the side wall 171 as shown in FIG. 20, for example. By tying the through-hole 172 through the string 174, a container that is convenient to carry can be configured..
[0058]
  As mentioned above, although the Example of the shaping | molding apparatus and molding method of the foamed resin molded product which concerns on this invention, and the Example of the foamed resin molded product were demonstrated variously using drawing, this invention is limited to the illustrated embodiment. It goes without saying that it is not a thing.
[0059]
  For example, the guide member having a guide hole for guiding the molded member is preferably formed from a member different from the mold and attached to the mold from the viewpoint of processing the guide hole. In the case of a circular shape or the like, which is easy to process, it is possible to process the guide hole directly in the mold and use the mold as a guide member. Further, the guide member may be fixed to the mold, but the guide member may be configured to move forward and backward from the mold in the same manner as the molded member. Furthermore, the shape, structure, or material of the guide member is not particularly limited.
[0060]
  In addition, in this embodiment, the guide member, the molding member guided to the guide hole, and the driving means for driving the molding member are attached to the female mold in the above embodiment. It can be attached, or can be attached to both a female mold and a male mold, and is not limited at all.
[0061]
  In addition, the cross-sectional shape of the molded member is not limited to a plate shape, that is, a rectangle, and various shapes such as a square, a hexagon, a circle, an ellipse, and an oval can be employed. Further, the shape of the undercut portion is not limited to the through hole, and includes all shapes such as a recessed portion and a curved portion. Furthermore, the molding apparatus and molding method of the foamed resin molded product according to the present invention are suitable for manufacturing various foamed resin molded products such as various containers such as fish boxes and vegetable boxes, various buffer members, and packing members. The present invention can be used in a mode in which various improvements, modifications and variations are added based on the knowledge of those skilled in the art without departing from the spirit of the present invention.
[0062]
【The invention's effect】
  According to the molding apparatus and the molding method for a foamed resin molded product according to the present invention, an undercut portion in a direction intersecting at least partly with the moving direction of the mold is integrally formed on the molded foamed resin molded product. Since the molding member of the above has flexibility, that is, elasticity or flexibility, even if the molding member driven by the driving means is advanced in the cavity and strongly brought into contact with the other mold surface, The mold surface is not damaged, and the extra extruded length is absorbed by the elastic deformation of the molded member. Therefore, the adjustment of the amount by which the molded member is advanced can be made slightly longer, the adjustment work becomes easy, and the driving means is not broken by such an adjustment error. Further, since the molded member is flexible, for example, the molded member is deformed into a curved shape such as an S shape, and the undercut portion is integrally formed, and then molded from the undercut portion of the foamed resin molded product. The member can be pulled out and an undercut portion having a complicated shape can be formed.
[0063]
  In addition, the molded member is formed from a foamed resin molded product that is molded by foaming and melting integrally with the molded member, for example, by forming the molded member with a resin having excellent releasability with respect to a foamable resin such as Teflon resin. It becomes easy to remove the molded member. In particular, when the shape of the undercut portion is curved, the molded member is formed of a resin that is excellent in releasability from foamable resin and excellent in flexibility and flexibility. It becomes easy to remove the member.
[0064]
  Furthermore, the shape to be deformed by the shape memory alloy or shape memory resin is stored in the molded member, or the undercut portion having a desired shape can be formed by forming the molded member in the shape to be molded. It becomes possible.
[0065]
  In addition, since the guide hole and the mold of the guide member are configured so that a predetermined shape can be imparted to the molded member, it is possible to always impart a shape to the molded member for each molding cycle, and stably Cut part can be formed.
[Brief Description of Drawings]
FIG. 1 is a cross-sectional explanatory view of an essential part for explaining one embodiment of a molding apparatus and a molding method for a foamed resin molded product according to the present invention.
FIG. 2 is a fragmentary perspective view showing an undercut forming apparatus used in the molding apparatus shown in FIG.
3 is a view showing an undercut forming apparatus used in the forming apparatus shown in FIG. 1, and FIG.
1 is a side sectional view of the undercut forming apparatus, FIG. 2B is a front view of the guide member, and FIGS. 2C and 2D are front views showing the guide member in an exploded manner.
FIG. 4 is a cross-sectional explanatory view of an essential part for explaining another embodiment of a molding apparatus and a molding method for a foamed resin molded product according to the present invention.
FIG. 5 is a cross-sectional explanatory view of an essential part for explaining still another embodiment of the molding apparatus and molding method for a foamed resin molded product according to the present invention.
FIG. 6 is a cross-sectional explanatory view of an essential part for explaining still another embodiment of the molding apparatus and molding method for a foamed resin molded product according to the present invention.
FIG. 7 is a cross-sectional explanatory view of an essential part for explaining still another embodiment of the molding apparatus and molding method for a foamed resin molded product according to the present invention.
8 is a cross-sectional view of a main part showing a guide member and the like in the molding apparatus for the foamed resin molded product shown in FIG.
FIGS. 9 (a) to 9 (d) are cross-sectional explanatory views showing the shapes of undercut portions that can be formed by the foamed resin molded product molding apparatus and molding method according to the present invention. is there.
FIG. 10 (a) is a cross-sectional view of an essential part showing another embodiment of a molding apparatus and molding method for a foamed resin molded product according to the present invention, and FIG.
FIG. 2 is a cross-sectional view of the main part showing the shape of an undercut part formed by the molding method shown in FIG.
FIGS. 11 (a) to 11 (c) are cross-sectional views of relevant parts showing other shapes of undercut portions that can be formed by the foamed resin molded product molding apparatus and molding method according to the present invention. FIG.
FIGS. 12 (a) and 12 (b) are cross-sectional views showing the main part of an undercut portion that can be formed by the foamed resin molded product molding apparatus and molding method according to the present invention. It is explanatory drawing.
FIG. 13 (a) is a cross-sectional view of an essential part showing still another embodiment of a molding apparatus and a molding method for a foamed resin molded product according to the present invention.
FIG. 2 is a cross-sectional view of the main part showing the shape of an undercut part formed by the molding method shown in FIG.
FIG. 14 (a) is a cross-sectional view of an essential part showing still another embodiment of a molding apparatus and a molding method for a foamed resin molded product according to the present invention. FIG.
FIG. 2 is a cross-sectional view of the main part showing the shape of an undercut part formed by the molding method shown in FIG.
FIGS. 15 (a) and 15 (b) are principal part side views showing another embodiment of a molded member used in a molding apparatus and a molding method for a foamed resin molded product according to the present invention.
FIG. 16 (a) is a cross-sectional view of an essential part showing still another embodiment of a molding apparatus and a molding method for a foamed resin molded product according to the present invention, and FIG.
FIG. 2 is a cross-sectional view of the main part showing the shape of an undercut part formed by the molding method shown in FIG.
FIG. 17 (a) is a side view of an essential part showing another embodiment of a molding member used in the molding apparatus and molding method for a foamed resin molded product according to the present invention, and FIG.
FIG. 2 is a cross-sectional explanatory view of a main part showing an embodiment of a foamed resin molded product formed using the molded member shown in FIG.
FIGS. 18 (a) to (c) are cross-sectional explanatory views of main parts showing respective steps in another embodiment of a molding apparatus and a molding method for a foamed resin molded product according to the present invention.
FIGS. 19 (a) and 19 (b) are cross-sectional views for explaining a main part of another embodiment of a molding apparatus and molding method for a foamed resin molded product according to the present invention.
20 is a cross-sectional explanatory view showing an example of a foamed resin molded product formed by the foamed resin molded product molding apparatus and molding method according to the present invention shown in FIG.
[Explanation of symbols]
10: Molding device
12, 58, 59, 106, 112, 120, 130, 158: male mold
14, 56, 57, 82, 110, 128, 154:Female mold
22, 26: Heating / cooling chamber
28, 116: cavity
30, 102, 140, 152, 162, 170:Foamed resin molded product
32, 104, 126, 142, 150, 164, 172: Through hole (undercut)
34, 60, 62: Undercut forming device
36, 66, 90, 136, 166, 172: guide members
38,84,100,132,134,138,148,156,160,168:Molded member
40, 68, 80, 86: Driving means
44, 88: guide holes
48, 64, 70, 76: slide member
52: Compression coil spring
54: Rod-shaped member
78: Air cylinder
98: Hydraulic cylinder
108: Recessed part
114: Guide groove

Claims

In a molding apparatus for a foamed resin molded product comprising a male mold and a female mold, at least one of which is spaced apart, provided on either or both of the male mold and the female mold A guide member having a guide hole, a flexible molding member that is guided by the guide hole and is allowed to enter the cavity in a direction crossing at least a part of the moving direction of the mold, and the molding member. An apparatus for molding a foamed resin molded product, comprising drive means for moving forward and backward.

The molded member is formed of a resin excellent in releasability from a foamable resin such as fluororesin, polytetrafluorinated ethylene, or fluorinated pitch, or by covering the resin with a flexible member. The molding apparatus for a foamed resin molded product according to claim 1.

The molding apparatus for a foamed resin molded product according to claim 1 or 2, wherein a shape that is curved in the cavity into which the molding member is inserted is stored.

2. The guide hole and / or a mold on which a molding member entered from the guide hole is brought into contact is configured to be able to impart a shape to the molding member. 3. A molding apparatus for a foamed resin molded product according to any one of 3 above.

A cavity is formed by bringing at least one of the separated male mold and female mold close to each other, and after filling the foamed resin beads into the formed cavity, the foamed resin is heated and foamed. In the method of molding a molded product, a flexible molded member is inserted into a cavity from a guide hole provided in one or both of the male mold and the female mold, and at least one of the movement direction of the mold. From the foamed resin molded product, which is inserted in the crossing direction and arranged in a predetermined position shape, then filled with foamable resin beads in the cavity and heated and foamed, and then the molded member is retracted A method for molding a foamed resin molded product, comprising removing the foamed resin molded product after the removal.

The method for molding a foamed resin molded article according to claim 6, wherein the flexible molding member is deformed by a guide hole and / or a metal mold to be brought into contact therewith.

A cavity is formed by bringing at least one of the separated male mold and female mold close to each other, and after filling the foamed resin beads into the formed cavity, the foamed resin is heated and foamed. In the method of molding a molded product, the mold is moved into a space forming a cavity from a guide hole provided in one or both of the male mold and the female mold. After projecting in a direction that intersects at least the direction, the mold opposite to the projecting molded member is formed by aligning the male mold and the female mold, or from both Molded resin molded product formed by contacting the projecting molded members to deform the molded member, then filling foamed resin beads into the cavity and heating and foaming, and then retracting the molded member After removal from Method of molding a resin foam product, characterized in that to release the foam resin molded article.