JP4880435B2 - Resin molded body manufacturing apparatus, resin molded body stock solution storage tank, and resin molded body manufacturing method - Google Patents

Description

  The present invention relates to a resin molded body manufacturing apparatus for producing a resin molded body by pouring a resin molded body forming stock solution into a molding die and curing the resin molded body forming stock solution that can be used in the manufacturing apparatus. The present invention relates to a tank and a method for producing the resin molded body.

  An example of such a resin molded body is a polyurethane molded body. The polyurethane molded product is prepared by pouring a urethane stock solution containing a polyol compound as a main component and a solution containing an isocyanate as a main component into a tank, mixing them, and pouring the resulting mixture into a mold having a predetermined shape for reaction curing. Can be manufactured. The following Patent Documents 1 to 4 disclose a method for producing a polyurethane foam.

  Patent Document 3 below discloses a method of discharging a mixed liquid from an upper opening by inclining a tank and a method of discharging a mixed liquid from a valve provided at the bottom of the tank when pouring the mixed liquid into a mold. ing. However, in the former method, when the tank is tilted, the liquid mixture adhering to the inner wall of the tank may drip, and if it drops on the liquid surface, unnecessary air is entrained and air voids are generated, resulting in poor quality. Cause. On the other hand, in the latter method, although there is a relatively low possibility of generating air voids, it takes a long time to discharge the mixed liquid, and there is a possibility that reaction hardening occurs in the tank.

Thus, it is conceivable to use the tank as a bottomless cylinder, in a state where the tank is pressed against the mold and the bottom is closed. According to this configuration, when the mixed liquid is poured into the mold, the mixed liquid can be discharged from the bottom of the opened tank by separating the tank from the mold. However, in the vicinity of the bottom of the tank, a region where the mixed liquid is not sufficiently stirred may be formed, and even the mixed liquid with insufficient stirring is poured into the mold in the above method, which causes the quality defect. There is a risk of becoming.
Japanese Patent Laid-Open No. 11-322877 Japanese National Patent Publication No. 8-500622 JP 2002-226537 A JP 2002-226608 A

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a resin that can stably flow a stock solution for forming a resin molded body from a tank into a mold while preventing unnecessary air from being caught. An object of the present invention is to provide an apparatus for manufacturing a molded body, a storage tank for a stock solution for forming a molded resin body, and a method for manufacturing the molded resin body.

  The above object can be achieved by the present invention as described below. That is, the resin molded body manufacturing apparatus according to the present invention includes a tank having an opening formed on a side surface and a door member configured to be displaceable between a position where the opening is closed and a position where the opening is opened. And a molding die disposed below the opening, and a stock solution for forming a resin molding accommodated in the tank is poured into the molding die from the opening that is opened by opening the door member. It is comprised as follows.

  The apparatus for producing a resin molded body according to the present invention includes a tank having an opening formed on a side surface, and a stock solution for forming a resin molded body is charged into the tank. The opening of the tank is configured so as to be able to be closed with a door member, so that the stock solution can be accommodated. A molding die for molding the resin molded body is disposed below the opening of the tank, and the stock solution is poured into the molding die from the opening opened by opening the door member. Therefore, unnecessary air entrainment can be prevented without causing the stock solution adhering to the inner wall of the tank to drop on the liquid surface. In addition, when the stock solution in the tank is mixed and stirred with a mixer, the operation of pulling out the mixer is not necessary, so that the stock solution adhering to the mixer blade can be prevented from dropping. And since the said undiluted | stock solution is not discharged from the bottom part of a tank, the said undiluted | unstocked stock solution is not poured into a shaping | molding die, and generation | occurrence | production of a quality defect can be suppressed. The size of the opening can be appropriately set so that the stock solution can be discharged quickly.

  In the above, the door member is preferably a double door. According to such a configuration, the openings can be uniformly opened on both sides, and the resin molded body forming stock solution can be discharged stably and uniformly, so that unnecessary air entrainment due to discharge disturbance can be suppressed.

  In the above, it is preferable to include a bowl-shaped retainer that constitutes a flow path of the resin molding forming stock solution from the opening to the mold, and a transport device that moves the mold relative to the retainer. . According to such a configuration, by providing the bowl-shaped retainer that constitutes the flow path of the resin molded body forming stock solution from the opening to the mold, the above-mentioned stock solution discharged from the opening is molded through the retainer. Can be poured into a predetermined place. And by providing the conveying device for moving the mold relative to the retainer, the pouring position of the stock solution can be moved, and the stock solution having high viscosity and poor fluidity can be uniformly and stably placed in the mold. Can be supplied.

  The resin molded body forming stock tank according to the present invention has a bottomed cylindrical body with an opening formed on a side surface, and is displaced between a position where the opening is closed and a position where the opening is opened. A door member which is a double door with a possible structure is provided, and can be used as a tank provided in the above-described manufacturing apparatus of the present invention.

  In addition, the method for producing a resin molded body according to the present invention includes a first step of charging a stock solution for forming a resin molded body into a tank, and a hardening process by pouring the stock solution for forming a resin molded body into the mold into the mold. In the method of manufacturing a resin molded body comprising the second step, the first step is performed in a state where an opening formed on a side surface of the tank is closed with a door member, and the second step In the step, the door member is opened to open the opening, and the resin molding forming stock solution is poured into the mold placed below the opening.

  In the method for producing a resin molded body according to the present invention, first, a stock solution for forming a resin molded body is put into a tank. This process is performed in a state where the opening formed on the side surface of the tank is closed by the door member. Next, the stock solution in the tank is poured into a mold and cured to form a resin molded body. At this time, the door member is opened to open the opening, and the stock solution is discharged from the side surface of the tank and poured into the mold so that the stock solution adhering to the inner wall of the tank is not dropped on the liquid surface. Unnecessary air entrainment can be prevented. In addition, when the stock solution in the tank is mixed and stirred with a mixer, the operation of pulling out the mixer from the stock solution is unnecessary, and the stock solution adhering to the mixer blade can be prevented from dropping. And since the said undiluted | stock solution is not discharged from a bottom part, the said undiluted | mixed undiluted | stock solution is not poured into a shaping | molding die, and generation | occurrence | production of a quality defect can be suppressed.

  In the above, it is preferable that the door member is a double door, and in the second step, the door member is opened on both sides substantially simultaneously to open the opening. According to such a method, the openings are uniformly opened on both sides, and the stock solution for forming a resin molding is stably and uniformly discharged, so that unnecessary air entrainment due to discharge disturbance can be suppressed.

  In the above, preferably, in the first step, the height of the liquid surface of the resin molding forming stock solution stored in the tank does not exceed the upper end of the opening. By this method, when the stock solution for forming the resin molded body does not adhere to the tank inner wall above the opening portion, and the opening portion is opened and the stock solution is discharged in the second step, unnecessary air due to dropping off is unnecessary. Can be prevented.

  Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a side view schematically showing a configuration of a manufacturing apparatus according to the present invention.

  The production apparatus shown in the present embodiment is for producing a polyurethane foam (an example of a resin molded body) by pouring a polyurethane foam-forming composition (an example of a stock solution for forming a resin molded body) into a mold and reaction curing. It is a device. The composition for forming polyurethane foam includes a predetermined amount of a first component (for example, prepolymer), a foam stabilizer, and a second component that reacts with the first component to form polyurethane (for example, containing active hydrogen). Compound).

  The manufacturing apparatus shown in FIG. 1 includes a tank 1 (a storage tank for a resin molding forming stock solution) into which a polyurethane foam forming composition is charged, and a mixer 2 for foaming and mixing the liquid in the tank 1. ing. The tank 1 is charged with a prepolymer, a foam stabilizer and a dissolved active hydrogen-containing compound as a polyurethane foam-forming composition. A molding die 3 into which the mixed liquid is poured is disposed below the tank 1, and a bowl-shaped retainer 4 extending toward the molding die 3 is connected to the lower side of the tank 1.

  2a is a front view of the tank 1 as viewed from the right side of FIG. 1, and FIG. 2b is a plan view thereof. The tank 1 is a bottomed cylindrical body having a rectangular opening 10 formed on the side surface and is mounted on and supported by a substantially C-shaped support arm 8 in plan view while being placed on the support base 7. ing. The support base 7 and the support arm 8 are extended from a column (not shown) erected substantially vertically, and are configured to be integrally movable up and down so as to raise and lower the tank 1.

  The size of the opening 10 can be appropriately set so that a mixed liquid described later is discharged quickly. In this embodiment, side walls each having a height of several tens of millimeters are provided above and below the opening 10, and the width of the opening 10 is larger than the radius of the tank 1 and smaller than the diameter in a front view. Yes. The upper end of the opening 10 is formed at a height exceeding the liquid level of the mixed liquid produced in the tank 1. The height of the liquid level is determined by the amount of the composition charged according to the size of the polyurethane foam block to be molded.

  The tank 1 is configured to be displaceable (openable and closable) between a position for closing the opening 10 shown in FIGS. 2a and 2b and a position for opening the opening 10 shown in FIGS. 3a and 3b. The member 11 is included. The door member 11 of the present embodiment is a double door with left and right doors opening from the center to both sides, and is fixed to the outer peripheral surface of the tank 1 via hinges 12 provided on both sides of the opening 10. The door member 11 may be configured to be manually opened and closed, but is preferably configured to be automatically opened and closed by being connected to a cylinder rod. The door member 11 can be provided with a sealing means for preventing liquid leakage, a locking means for maintaining the closed state, and the like as necessary.

  The mixer 2 is suspended and supported at the tip of the chain 9, and is configured to be movable up and down by operating a handle (not shown). The mixer 2 includes a mixer blade having a rotation axis in the vertical direction, and the liquid in the tank 1 can be bubbled and mixed by rotating the mixer blade. In addition, the structure of a mixer is not specifically limited, For example, the shape of a mixer blade | wing and the raising / lowering mechanism as described in the said patent documents 3 and 4 are applicable.

  The inner diameter of the tank 1 is preferably about several times the outer diameter of the mixer blades, and the height of the tank 1 is preferably such that the mixed liquid stirred by the mixer 2 does not overflow. When the size of the polyurethane foam block to be molded is 700 (mm) × 1500 (mm) × 30 (mm), the required volume of the tank 1 is 31.5 L (liter).

  The molding die 3 has a shape and size corresponding to a block of polyurethane foam to be molded, and is configured to be movable in the direction of arrow A in FIG. 1 by a transport mechanism (not shown) constituted by, for example, a belt conveyor. ing. On the opposite side of the mold 3 in the direction of arrow A, a receiving tray 5 for pouring the remaining mixed liquid not supplied to the mold 3 is arranged.

  The retainer 4 is fixed below the opening 10 on the outer peripheral surface of the tank 1 and constitutes a flow path for the mixed liquid from the opening 10 to the mold 3. A slight clearance is provided between the lower end of the retainer 4 and the inner surface of the bottom of the mold 3, and the lower end of the retainer 4 is disposed at a position lower than the side wall of the mold 3.

  The inclination angle θ of the retainer 4 is preferably 15 to 75 °. However, in the case of producing a foam as in the present embodiment, turbulence when the mixed liquid is poured into the mold 3 is prevented, and the air Is more preferably less than 40 °, and more preferably 25 to 35 ° from the viewpoint of more appropriately suppressing the entrainment. By setting the angle θ to 25 ° or more, the fluidity of the mixed liquid can be ensured and poured quickly, and by setting it to 35 ° or less, generation of turbulent flow can be avoided more reliably.

  Next, a method for producing a polyurethane foam using the above production apparatus will be described.

  The standard formulation of the composition for forming polyurethane foam is SH-192 (foam stabilizer (surfactant)) for 100 parts (70 ° C) of adiprene L-325 (manufactured by Uniroyal) as the isocyanate-terminated prepolymer. 1-20 parts of Toray Dow Corning Silicone Co., Ltd., and 26 parts (120 ° C.) of methylene bis (O-chloraniline) (MBOCA) (Ihara Chemical Co., Ltd.) as the active hydrogen-containing compound.

  First, a predetermined amount of adiprene L-325, SH-192, and dissolved MBOCA are charged into the tank 1 (corresponding to the first step), and the mixture is stirred and bubbled and mixed. By this stirring, air can be entrained into the liquid mixture and foamed. In addition, about the order which throws adiprene L-325, SH-192, and MBOCA into the tank 1, these may be thrown in simultaneously, some of these are thrown in first and are stirred and mixed, and predetermined time passes. The rest may be added later and stirred and mixed.

  In the step of charging and mixing the composition, the opening 10 of the tank 1 is closed by the door member 11. Such mixing time is preferably about several minutes. The retainer 4 is disposed at a position away from the side wall of the mold 3 by a distance L.

  When the frothing mixing by the mixer 2 is completed, the obtained mixed solution is poured into the mold 3 and reaction-cured (corresponding to the second step). In the present invention, the door member 11 is opened to open the opening 10, and the liquid mixture is discharged from the side surface of the tank 1 and poured into the mold 3. At this time, the operation of pulling up the mixer blade from the mixed solution is unnecessary, and the generation of air voids due to the drop of the mixed solution adhering to the mixer blade can be prevented.

  In the present embodiment, as described above, the door member 11 is a double door and opens at both sides substantially simultaneously to open the opening 10. As a result, the opening 10 is uniformly opened on both sides, and the mixed liquid F is uniformly discharged as shown in FIG. 3b, so that unnecessary air entrainment due to discharge disturbance can be suppressed. On the other hand, when the door member 21 with a single opening as shown in FIG. 4 is provided, the discharge of the liquid mixture F may be offset when it is opened, and unnecessary air may be entrained.

  The door member 11 is in contact with the upper side or the inner side of the side wall of the retainer 4 in a state where the opening 10 is opened, and the mixed liquid adhering to the inner side of the door member 11 flows down along the side wall of the retainer 4 to the liquid level. The lid drop is prevented. In addition, by adjusting the amount of the composition so that the liquid level of the liquid mixture does not exceed the upper end of the opening 10, the liquid mixture does not adhere to the tank inner wall above the opening 10, Unnecessary air entrainment due to dropping off is prevented.

  In the present embodiment, the mold 3 is moved in the arrow A direction after a predetermined time has elapsed since the door member 11 was opened. The predetermined time is experimentally determined in accordance with the length of the distance L, the inclination angle θ of the retainer, the fluidity of the mixed liquid, and the like, and is 0 second (starts moving simultaneously with opening of the opening 10). It doesn't matter. The distance L is set so that the poured mixed liquid can reach the side wall of the mold 3 without causing turbulent flow in consideration of the predetermined time and the fluidity of the mixed liquid. The liquid mixture that has started to thicken has high viscosity and poor fluidity, but by appropriately controlling the moving speed of the mold 3, the liquid mixture can be smoothly and stably poured into the mold 3, Generation of turbulent flow can be prevented and unnecessary air entrainment can be suppressed.

  When the mold 3 moves in the direction of the arrow A and the retainer 4 approaches the side wall opposite to the direction of the arrow A, the tank 1 rises, and the retainer 4 rises and crosses the side wall accordingly. Then, the tip of the retainer 4 is disposed above the tray 5, and the remaining mixed liquid that is not supplied to the mold 3 is poured into the tray 5.

  When the mixed solution poured into the mold 3 is cured, a polyurethane foam block is formed and processed into a desired shape in a subsequent step. The obtained polyurethane foam can be used for CMP (Chemical Mechanical Polishing) polishing pads and glass polishing. The polyurethane foam for CMP polishing pad holds the polishing slurry by fine concave portions formed on the surface, and therefore, it is important that the polyurethane foam is uniform and has little variation in specific gravity.

  According to the present invention, as in the embodiment described above, the polyurethane foam-forming composition charged in the tank is foamed and mixed with a mixer, thereby forcibly entraining a gas such as air and performing foaming. In addition, as described above, it is possible to obtain a polyurethane foam that is uniform and has little variation in specific gravity while preventing air entrainment, and is particularly useful in the production of a polyurethane foam for CMP polishing pads. Examples of a method for producing a microcellular polyurethane foam using the present invention include a prepolymer method and a one-shot method.

  When foaming is performed using an inflatable hollow balloon, the density of the reaction solution and the hollow balloon is large because the specific gravity of the hollow balloon is about 0.04 g / cm3. Since the hollow balloon is lifted, it is difficult to blend with the urethane liquid and mix it uniformly. In addition, hollow balloons may contain hollow balloons with holes in the pre-expansion stage, which will adhere to the piping etc. during the expansion process and become hard foreign objects when burned by heat, so they remain in the urethane. This causes a problem of causing scratches in the polishing process.

[Other Embodiments]
(1) In the above-described embodiment, the example in which the flow path of the mixed liquid from the opening of the tank to the mold is configured by the retainer 4 is shown, but the present invention is not limited to this. In the example shown in FIG. 5, the mold 3 is tilted, and the side located above the mold 3 is disposed near the lower part of the opening 10 of the tank 1. Moreover, the shaping | molding die 3 is comprised from the inclined state of illustration so that the side located below can be lifted and it can be displaced to a horizontal state. The mixed liquid is discharged from the opening 10 on the side surface of the tank 1 in the same manner as described above, and flows down toward the side located below the mold 3. At that time, the mixed liquid can be poured smoothly and stably by displacing the mold 3 in a horizontal state at an appropriate speed.

  (2) In the above-described embodiment, an example in which the door member is a double door is shown. However, the present invention is not limited to this, and may be a single door as shown in FIG. However, as described above, the door member is preferably a double door from the viewpoint of preventing the mixed liquid from being displaced. Further, the door member may be configured to slide open and close along the outer peripheral surface of the tank. In such a case, it is preferable that the left and right doors open from the center to both sides.

  (3) The shape of the opening is not limited to that shown in the above embodiment, and the shape of the door member is not particularly limited as long as it can close the opening. For example, the upper side of the opening may be curved so that the center is upwardly convex. According to such a configuration, even when the mixed liquid adheres to the tank inner wall above the opening, the mixed liquid flows down along the curved shape, so that the dripping onto the liquid surface can be suppressed. In the above-described embodiment, the example in which the retainer extends linearly is shown. However, the retainer is curved so as to follow the flow of the discharged mixed liquid, and the mixed liquid can be poured more smoothly and stably. I do not care.

  (4) In the above-described embodiment, an example in which a polyurethane foam is produced as a resin molded body has been shown. However, the present invention is not limited to this, and a non-foamed body may be used, and a resin material other than polyurethane is used. You can also.

  For example, in the case of producing a polyurethane non-foamed body, as a forming stock solution, a liquid mainly composed of isocyanate (P liquid) and a urethane stock liquid mainly composed of a polyol compound (R liquid) are prepared, which are described above. In the same manner as in the embodiment, after being put into the tank and mixed and stirred by the mixer, the door member is opened, and the mixed liquid is discharged from the side surface of the tank and poured into the mold.

  In the above, A75-85 manufactured by Toyo Tire & Rubber Co., Ltd. can be used as the P liquid, B75-85 manufactured by the same company can be used as the R liquid, and the viscosity of the P liquid measured at 25 ° C. using a B-type viscometer is 7700 mPa · s, The viscosity of the R liquid at 25 ° C. with a B-type viscometer is 5700 mPa · s, the mixing ratio of the P liquid and the R liquid is 1: 1, the initial viscosity when mixing the P liquid and the R liquid is 9500 mPa · s, pot life Can be exemplified by 50 minutes.

The side view which shows schematically the structure of the manufacturing apparatus which concerns on this invention Front view in a state where the opening on the side of the tank is closed Plan view in a state where the opening on the side of the tank is closed Front view with the opening on the side of the tank open Plan view with the opening on the side of the tank open The top view which shows the tank which concerns on another form of this invention The conceptual diagram which shows the positional relationship of the tank which concerns on another form of this invention, and a shaping | molding die

Explanation of symbols

1 Tank 2 Mixer 3 Mold 4 Retainer 10 Opening 11 Door Member F Mixed Solution

Claims (5)

A tank having an opening formed on a side surface, and a double door configured to be displaceable between a position for closing and opening the opening;
A mold disposed below the opening,
An apparatus for manufacturing a resin molded body, wherein the stock solution for forming a resin molded body accommodated in the tank is poured into the mold from the opening that is opened by opening the double door . A gutter-shaped retainer constituting the flow path of the resin molded body stock from the opening to the mold, according to the mold to claim 1 and a conveyance device which relatively moves with respect to the retainer Production equipment for resin moldings.   Resin molding in which an opening is formed on the side surface of a bottomed cylindrical body, and a door member that is a double door that is configured to be displaceable between a position where the opening is closed and a position where the opening is opened Storage tank for stock solution for body formation. A method for producing a resin molded body comprising: a first step of charging a stock solution for forming a resin molded body into a tank; and a second step of pouring the stock solution for forming a resin molded body charged into the tank into a mold and curing it. In
The first step is performed in a state where the opening formed on the side surface of the tank is closed with a double door .
In the second step, the double doors are opened substantially simultaneously on both sides to open the opening, and the resin molding forming stock solution is poured into the molding die disposed below the opening. Manufacturing method of resin molding. The manufacturing of the resin molding of Claim 4 which makes the height of the liquid level of the stock solution for resin molding formation accommodated in the said tank not exceed the upper end of the said opening part in the said 1st process. Method.

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