JP5222098B2 - Soap manufacturing method and manufacturing apparatus - Google Patents

Description

  The present invention relates to a soap manufacturing method and manufacturing apparatus.

  Conventionally, a frame kneading method is known as a method for producing soap. In the frame kneading method, molten soap is filled into a mold of a predetermined shape and dried to obtain an original soap, the original soap is cut into a predetermined size, and further subjected to a plurality of treatments such as bathing, molding and drying. It is a method of applying soap to obtain soap. Transparent soaps and the like may be manufactured by this frame kneading method. However, since the frame kneading method takes a long time to manufacture, a more efficient manufacturing method is desired.

  As a method for producing soap that is more efficient than the frame kneading method and takes a short time for production, there is a production method in which molten soap is filled in the cavity of a mold having a cavity of a predetermined shape and solidified under pressure. It is known (see, for example, Patent Document 1). Such a pressure type molding method is also known in the field of plastic molding (see, for example, Patent Document 2).

  In the conventional pressure-type soap molding method, the pressure applied to the molding filled in the cavity is generally about 0.2 MPa or more. However, in such a high-pressure molding method, distortion and burrs are generated when the molten soap is solidified, and a desired shape may not be obtained. Depending on the type of soap, molding at a lower pressure may be essential. For example, when producing a transparent soap, if a conventional high-pressure molding method is used, the crystallinity is different from that of a transparent soap obtained by a frame kneading method, and the transparency may be lowered. In addition, for example, when manufacturing foamed soap, if a conventional high-pressure mold forming method is used, the contents in the cavity are scattered due to the pressure difference between the inside and outside when the mold is opened after pressurization. There is a risk. In addition, for example, when manufacturing encapsulated soap containing various auxiliaries such as fragrances, using a conventional high-pressure molding method, the encapsulated material is crushed by pressurization, and a desired product is obtained. There is a risk of not.

JP-T-2001-525881 JP-A-5-8267

  Accordingly, an object of the present invention is to provide a soap manufacturing method and a manufacturing apparatus capable of efficiently manufacturing a soap having a desired shape.

  According to the present invention, a molding cavity is formed by assembling a plurality of split molds including a lid mold connected to a drive source and capable of reciprocating in a predetermined direction, and the lid mold is operated using the drive source. Filling the cavity of the mold that can adjust the volume of the cavity by cooling, and cooling and solidifying the molten soap, and the pressure applied to the lid mold is completed from the start of filling the molten soap Soap that solidifies the molten soap while increasing / decreasing the volume of the cavity so that it is maintained within the range of 0.2 MPa or less during the time, and from 0.03 to 0.2 MPa from the completion of the filling of the molten soap to the completion of the cooling The above-described object is achieved by providing the manufacturing method.

  In the present invention, a molding cavity is formed by assembling a plurality of split molds including a lid mold connected to a drive source and capable of reciprocating in a predetermined direction, and the lid mold is formed using the drive source. A soap manufacturing apparatus comprising: a mold that can adjust the volume of the cavity by operating; and an injection device that injects molten soap into the cavity, wherein the lid mold has a protrusion protruding from one surface thereof. And the molding die penetrates between the lid die, a first surface opposite to one surface of the lid die, a second surface located on the opposite side of the first surface, and both of the convex surfaces. An intermediate mold having a through-hole into which the part can be inserted, and a concave mold in which a concave part is formed on a parting surface that comes into contact with the second surface of the intermediate mold, are assembled in this order, thereby the convex part inside. The cavity defined by the through hole and the recess An elastic member that expands and contracts in the operation direction of the lid mold is disposed between one surface of the lid mold and the first surface of the intermediate mold, and the elastic member is interposed through the elastic member. The lid mold and the intermediate mold are connected in a state where the convex portion is inserted into the through hole, and the second surface of the intermediate mold is in contact with the concave parting surface. The object is achieved by providing a soap manufacturing apparatus in which the volume of the cavity can be adjusted by reciprocating the inside of the through-hole to the convex portion by expanding and contracting an elastic member. .

  According to the present invention, since the molten soap is solidified under a low pressure, distortion and burrs are hardly generated at the time of solidification, and a homogeneous soap having a desired shape can be efficiently produced with a small apparatus. The present invention is particularly effective for the production of transparent soap, soap with bubbles, soap with encapsulated material, and the like.

  Hereinafter, the present invention will be described based on preferred embodiments with reference to the drawings. The principal part of one Embodiment of the soap manufacturing apparatus of this invention is shown by FIG. The manufacturing apparatus 5 of the present embodiment shown in FIG. 1 has a molding cavity inside by assembling a plurality of split molds including a lid mold 1A connected to a servo motor 20 (drive source) and capable of reciprocating in a predetermined direction. A mold 1 that is formed and can adjust the volume of the cavity by operating the lid mold 1A using the drive source 20, a mold unit 2 that opens and closes the mold 1, and the mold 1 And an injection device 3 for injecting molten soap into the inside (cavity). The manufacturing apparatus 5 of this embodiment is suitably used for manufacturing transparent soap.

  As shown in FIGS. 1 and 2, the mold 1 is composed of a set of three split molds, that is, a lid mold 1A, an intermediate mold 1B, and a concave mold 1C. Each split mold has a rectangular block shape made of a rigid body such as metal. As shown in FIG. 3, the mold 1 is assembled in the order of the lid mold 1 </ b> A, the intermediate mold 1 </ b> B, and the concave mold 1 </ b> C by assembling these three sets of split molds in the order of the lid mold 1 </ b> A, intermediate mold 1 </ b> B, and concave mold 13. The cavity 10 defined by the above is formed.

  The lid mold 1 </ b> A has a convex portion 11 protruding from one surface (convex portion forming surface) 1 </ b> Aa, and the other surface (back surface) opposite to the convex portion forming surface 1 </ b> Aa is connected to the servo motor 20. 24. The convex portion 11 is located at the approximate center of the convex portion forming surface 1Aa of the lid mold 1A, and has a rectangular shape with rounded corners in plan view.

  The intermediate mold 1B includes a first surface (back surface) 1Ba facing the convex portion forming surface 1Aa of the lid mold 1A, a second surface PL1 located on the opposite side of the back surface 1Ba, and a space between the both surfaces 1Ba, PL1. It has a through-hole 12 through which the convex portion 11 can be inserted. The second surface PL1 of the intermediate mold 1B is a parting surface with a concave mold 1C (fixed mold) of the movable mold 1D described later. The through-hole 12 is located substantially at the center of the intermediate die 1B and has the same shape as the convex portion 11 (rectangular shape with rounded corners) in plan view.

  The concave mold 1C has a concave portion 13 on a parting surface PL2 that comes into contact with the second surface (parting surface) PL1 of the intermediate mold 1B. The recess 13 is formed as a recess having a substantially U-shaped cross section at a position that is substantially lower than the parting surface PL2 of the concave mold 1C and one step lower than the parting surface PL2.

  Further, between the convex portion forming surface (one surface) 1Aa of the lid mold 1A and the back surface (first surface) 1Ba of the intermediate mold 1B, elasticity that expands and contracts in the operation direction of the lid mold 1A (left-right direction in FIG. 1). A member 14 is arranged, and the lid mold 1 </ b> A and the intermediate mold 1 </ b> B are connected via the elastic member 14 in a state where the convex portion 11 is inserted into the through-hole 12. In the present embodiment, four metal springs are fixed as the elastic members 14 at the four corners of the opposing rectangular convex portion forming surface 1Aa and back surface 1Ba. In the natural state of each elastic member 14, a part (tip portion) of the convex portion 11 of the lid mold 1 </ b> A is inserted into the through-hole 12 of the intermediate mold 1 </ b> B.

  As described above, the lid mold 1A and the intermediate mold 1B, which can reciprocate in a predetermined direction, out of a set of three split molds constituting the mold 1, are integrated through the elastic member 14, and the movable mold 1D is integrated. It is composed. On the other hand, the concave mold 1C is a fixed mold as is apparent from the description of FIG. The parting surface (second surface of the intermediate mold 1B) PL1 in the movable mold 1D has a concave cavity 10 formation surface (hereinafter also referred to as a cavity formation surface) composed of the top of the projection 11 and the wall surface of the through-hole 12. ) Is formed. As shown in FIG. 3, the cavity forming surface of the movable mold 1D and the concave portion 13 of the concave mold 1C are formed by dividing the movable mold 1D and the concave mold 1C by the parting surface PL1 of the movable mold 1D and the parting surface PL2 of the concave mold 1C. A cavity 10 having a shape that matches the shape of the soap to be manufactured is formed when they are combined with each other.

  As shown in FIG. 3, the molding die 1 having the above-described configuration is substantially natural with the parting surface PL1 of the movable die 1D (the lid die 1A and the intermediate die 1B) being in contact with the parting surface PL2 of the concave die 1C. By expanding and contracting the elastic member 14 in a state, the volume of the cavity 10 can be adjusted by causing the convex portion 11 to reciprocate in the through-hole 12. That is, from the state shown in FIG. 3, the servo motor 20 (see FIG. 1) is driven to advance the lid mold 1A toward the intermediate mold 1B in contact with the concave mold 1C (move to the right in FIG. 3). By contracting the elastic member 14, the convex portion 11 of the lid mold 1A advances toward the concave portion 13 of the concave mold 1C, thereby reducing the volume of the cavity 10, and at this time the contents of the cavity 10 are reduced. Is compressed. Also, from the state shown in FIG. 3, the servo motor 20 is driven to retract the lid mold 1A from the intermediate mold 1B (move to the left in FIG. 3), and the elastic member 14 is extended, whereby the lid mold The convex portion 11 of 1A retreats from the concave portion 13 of the concave mold 1C, thereby increasing the volume of the cavity 10, and at this time, the contents of the cavity 10 are relaxed.

  As shown in FIG. 3, in the state in which the set of three split molds 1 </ b> A to 1 </ b> C is assembled, a molten soap supply path 15 that leads to the cavity 10 is disposed below the cavity 10. The supply path 15 is an assembly direction when the runner 15A extending downward from the lower part of the cavity 10 and the split molds 1A to 1C that are orthogonal to the runner 15A and are assembled in one set (the left-right direction in FIGS. 1 and 3). And has a substantially L-shape when viewed from the side of the mold 1. The runner 15 </ b> A extends substantially vertically from the lowermost part (bottom part) of the cavity 10 to the vicinity of the lower end of the mold 1. The spool 15B extends substantially horizontally from the lower end of the runner 15A to the outer surface of the mold 1 (the back surface of the concave mold 1C). As will be described later, the molten soap is filled upward from the lower portion of the cavity 10 through the supply path 15 including the runner 15A and the spool 15B.

  As shown in FIG. 2, the runner 15A is formed by cutting out part of the parting surface PL2 of the concave mold 1C. The runner 15A has a cross-sectional shape in which a part of a circle is cut out along the parting surface PL2, and the diameter thereof is substantially constant over the entire length of the runner 15A. One end (upper end) of the runner 15A is opened by the recess 13 and the other end (lower end) thereof is closed. The spool 15B is formed by drilling a through-hole penetrating the concave mold 1C in the thickness direction at a predetermined portion of the concave mold 1C. The diameter of the spool 15B is gradually reduced toward the back side of the concave mold 1C.

  As described above, in the present embodiment, among the plurality of split molds constituting the mold 1, the molten soap supply path 15 (runner 15 </ b> A and spool 15 </ b> B) leading to the cavity 10 is formed in the concave mold 1 </ b> C that is a fixed mold. The movable soap 1D (the lid mold 1A and the intermediate mold 1B) connected to the servo motor 20 is not provided with a supply path for molten soap. In other words, in the present embodiment, one servo motor 20 is connected to the non-supply side mold [movable mold 1D (lid mold 1A)] opposite to the molten soap supply side mold (concave mold 1C). By operating the non-supply side mold using the individual servo motors 20, the mold clamping of the mold 1 and the pressure control of the cavity 10 are performed. Such a configuration of the present embodiment is particularly effective when the pressure applied to the cavity in the mold (pressure applied to the cover mold) is maintained at a low pressure of 0.2 MPa or less, as in the soap manufacturing method described later. . On the other hand, in the plastic molding field, the pressure applied to the cavity in the mold is often higher than 0.2 MPa, and such a high-pressure mold molding method is described in, for example, Patent Document 2. In this molding apparatus, that is, a servo motor for clamping is connected to a movable mold in the mold, and a supply path for molding material is provided in the fixed mold in the mold, and the cavity volume is adjusted. Therefore, a plurality of drive sources are required.

  An air vent (not shown) is provided at a position on the parting surface PL2 of the concave mold 1C that faces the runner 15A through at least the concave portion 13. The air vent functions as a deaeration hole for discharging the air in the cavity to the outside when the cavity is filled with molten soap. The air vent is not limited to the concave mold 1C, but can be installed in the intermediate mold 1B, or can be installed in the split molds 1B and 1C. Although not shown, the cavity forming surface of the movable mold 1D (the lid mold 1A and the intermediate mold 1B) and the concave section 13 of the concave mold 1C are provided with slits and / or micropores with a fine width for blowing out air and sucking air. (Hereinafter also referred to as a slit or the like), and a block for forming each split mold 1A to 1C is provided with a circulation path for cooling water.

  The mold 1 is attached to a mold unit 2 including a servo motor 20. Specifically, the concave mold 1 </ b> C in the mold 1 is attached to a support plate 22 erected from the base plate 21, and is a fixed mold. On the other hand, the movable die 1D (the lid die 1A and the intermediate die 1B) has a back surface (the other surface of the lid die 1A) attached to a movable plate 24 connected to the servo motor 20 via a feed screw 23. The servo motor 20 is attached to a support plate 25 erected from the base plate 21 so that the feed screw 23 slides in a direction orthogonal to the movable plate 24. Therefore, the movable mold 1D is movable in the horizontal direction. The mold 1 is fixed so that the supply path 15 is positioned below the cavity 10. As a result, the molten soap is filled upward from the bottom of the cavity 10.

  A servo motor 20 that performs mold clamping of the mold 1 and pressure control of the cavity 10 is electrically connected to a numerical control device (not shown). The numerical control apparatus stores a CPU such as a microcomputer that substantially controls the entire manufacturing apparatus 5 including the servo motor 20 and necessary fixed information such as a control program executed by the CPU and various data. A ROM, a RAM used as a work area at the time of execution of processing by the CPU, an operator input device for the numerical control device, and the like are provided.

  As shown in FIG. 1, a molten soap injection device 3 is disposed on the back side of the concave mold 1C. The pouring device 3 includes a molten soap pouring part 39 corresponding to the supply path 15. The injection part 39 includes a supply pipe 30 having one end connected to the circulation line 42. The other end of the supply pipe 30 is a molten soap liquid reservoir 31, and an injection nozzle 32 projects from the liquid reservoir 31. In the nozzle 32, a push-in plug 33 having the same outer shape as the inner shape of the nozzle 32 is disposed. The plug 33 is advanced and retracted in the nozzle 32 by an air cylinder 38 attached to the rear end thereof. As the plug 33 moves backward, a gap is formed between the nozzle 32 and the plug 33, and the molten soap is supplied to the mold 1 through this gap. On the other hand, when the plug 33 moves forward, the nozzle 32 and the plug 33 are fitted together, there is no gap between them, and the supply of molten soap is stopped. That is, as the plug 33 advances and retreats, the molten soap is supplied and the supply is blocked.

  A cylinder 34 and a piston 36 as an example of a constant capacity supply device are attached to a position upstream of the injection nozzle 32 in the supply pipe 30 with respect to the flowing direction of the molten soap (the direction indicated by the arrow A in FIG. 1). Yes. The cylinder 34 is provided so as to intersect with the supply pipe 30. A switching rotary valve 35 is disposed in the cylinder 34 to selectively communicate the upstream or downstream side of the supply pipe 30 with the cylinder 34 with the cylinder 34 as a boundary. At the same time, a piston 36 is arranged in the cylinder 34 so as to be able to advance and retreat in the cylinder. The cylinder 34 and the piston 36 constitute a constant capacity supply device for molten soap. The advance / retreat of the piston 36 is precisely controlled by a servo motor 37 attached to the rear end thereof. As the piston 36 moves backward, a space for accommodating the molten soap is formed in the cylinder 34. After this space is filled with molten soap, the piston 36 is pushed into the cavity 10 so that the molten soap is filled under pressure. The supply volume of the molten soap to the cavity 10 is determined by the retraction distance or the push-in distance of the piston 36. Specifically, 1) a method of determining the supply volume based on the retreat distance of the piston 36 with the position of the piston 36 before retreat as the origin, or 2) supply with the push-in distance of the piston 36 with the position of the piston 36 after retreat as the origin There is a way to determine the volume. When the molten soap to be measured is bubbled, this is a compressible fluid. Therefore, in the method 1), the origin is set so that the molten soap does not remain in the cylinder 34 as much as possible at the origin of the piston 36. It is preferable from the viewpoint of increasing the accuracy of the product weight.

  The manufacturing method of the transparent soap using the manufacturing apparatus which has the above structure is demonstrated. First, before starting molding, the servomotor 20 of the mold unit 2 is driven to push out the feed screw 23, and the movable mold 1D (lid mold 1A and intermediate mold 1B) and the concave mold 1C are closed as shown in FIG. To do. Specifically, the numerical control device (not shown) drives the servo motor 20, pushes the feed screw 23 to move the movable plate 24 toward the concave mold 1C, and moves the movable mold 1D (the lid mold 1A and the intermediate mold). The parting surface PL1 in 1B) is brought into contact with the parting surface PL2 of the concave mold 1C. The movement of the movable plate 24 (movable mold 1D) is performed, for example, by position control with a target position that is slightly beyond the mold closing positions of the split molds 1D and 1C.

  When the movable mold 1D reaches and contacts the parting surface PL2 of the concave mold 1C, the numerical controller reads a signal from a pressure sensor (not shown) attached to the lid mold 1A, and the signal is When the preset pressure value P0 is reached, the position control drive of the servo motor 20 is switched to torque control drive, and the torque limit value is set to the current value, that is, a value corresponding to the pressure value P0. For this reason, the movable plate 24 stops at that position. The pressure monitor attached to the lid mold 1A and the current monitor value of the servomotor 20 proportional to the torque of the servomotor 20 are attached to the lid mold 1A when the servomotor 20 balances the force. Therefore, the pressure sensor attached to the lid mold 1A can be estimated from the current monitor value by omitting the pressure sensor. The sensor value may be used instead.

  In the movable mold 1D and the concave mold 1C, water is circulated through the above-described cooling water circulation path. Further, the injection device 3 is attached to the back side of the concave mold 1C in the molding die 1, and the tip of the injection nozzle 32 in the injection part 39 and the opening of the spool 15B in the concave mold 1C are connected as shown in FIG.

  In the state shown in FIG. 4, the communication between the cylinder 34 and the circulation conduit 42 in the injection part 39 is blocked by the rotary valve 35. The piston 36 disposed in the cylinder 34 remains in a predetermined position. Further, in this state, as shown in FIG. 5, the push plug 33 in the injection portion 39 is completely inserted into the nozzle 32 so that the molten soap is not supplied. Molten soap is stored in a storage tank (not shown) and circulates in a circulation line 42 passing through the storage tank.

  In this state, a part of the molten soap circulating through the circulation pipe 42 is fed into the injection part 39. In order to send the molten soap to the injection portion 39, the rotary valve 35 is rotated by a predetermined angle to cause the cylinder 34 and the circulation line 42 to communicate with each other. At the same time, the servo motor 37 is operated to retract the piston 36. Thereby, a space is formed in the cylinder 34, and the molten soap flows into the space. The retraction of the piston 36 is continued until a predetermined amount of molten soap is filled in the cylinder 34.

  When a predetermined amount of molten soap is filled in the cylinder 34, the operation of the servo motor 37 is stopped and the backward movement of the piston 36 is stopped. Next, the rotary valve 35 is inverted by a predetermined angle to cut off the communication between the cylinder 34 and the circulation conduit 42 and the cylinder 34 and the nozzle 32 are communicated. Subsequently, the air cylinder 38 is operated to pull out the plug 33 from the nozzle 32, and a gap is formed between them. This state is shown in FIG. As a result, a supply path for molten soap is formed that includes the cylinder 34, the supply pipe 30, the liquid reservoir 31, the nozzle 32, the spool 15B, the runner 15A, and the cavity 10. Under this condition, the servo motor 37 is operated to push the piston 36 in the cylinder 34. Thereby, the molten soap filled in the cylinder 34 is pressurized and injected into the cavity 10 of the mold 1 through the supply path. As described above, the supply amount of the molten soap is determined by the stroke amount of the piston 34, but the stroke amount is precisely controlled by the servo motor 37. As the cavity 10 is filled with the molten soap, the air in the cavity 10 is discharged to the outside from the air vent (not shown) and replaced with the molten soap. In the mold 1, the molten soap is filled upward from the lower part of the cavity 10 through the supply path 15 (runner 15 </ b> A and spool 15 </ b> B), so that the defoaming of the molten soap is performed more reliably.

  When the filling of the predetermined amount of molten soap into the cavity 10 and the supply path 15 is completed, the push plug 33 in the injection portion 39 is completely inserted into the nozzle 32 again (see FIG. 5). As described above, the movable mold 1D (the lid mold 1A and the intermediate mold 1B) and the concave mold 1C are cooled to a predetermined temperature by the circulation of the cooling water, thereby promoting the cooling and solidification of the molten soap in the cavity 10 and the supply path 15. The

  In this embodiment, the pressure applied to the lid mold 1A is 0.2 MPa or less, preferably 0.15 MPa or less from the start of filling of the molten soap to the completion of filling, and is 0 from the completion of filling of the molten soap to the completion of cooling. In the mold 1 while operating the lid mold 1A (movable mold 1D) to increase or decrease the volume of the cavity 10 so as to be maintained in the range of 0.03 to 0.2 MPa, preferably 0.05 to 0.15 MPa. Let the molten soap solidify. That is, in this embodiment, the cavity 10 has a pressure of 0.2 MPa or less so that the pressure applied to the lid mold 1A is 0.2 MPa or less over a continuous time from the start of the filling of the molten soap to the completion of the cooling after the completion of the filling. Increase or decrease the volume. Here, the time when the molten soap starts filling is the time when the molten soap flows into the space filled with the molten soap for the first time, and in this embodiment, when the molten soap flows into the cavity 10 for the first time. This “time when molten soap first flows into the cavity 10” is substantially equal to the time when the servo motor 37 for pushing the piston 36 into the cylinder 34 is started after the molten soap supply passage is formed. In this case, the operation start time of the servo motor 37 can be regarded as the start time of filling the molten soap. Further, the completion of the filling of the molten soap is a time when the flow of the molten soap into the space filled with the molten soap is completed, and in this embodiment, the mold 1 (the cavity 10 and the supply path 15) is filled. Is the time when the filling of the predetermined amount of molten soap is completed (immediately before the push plug 33 is inserted into the nozzle 32). Further, when the cooling of the molten soap is completed, the molten soap filled in the predetermined space is immediately before being cooled and solidified to such an extent that it can be taken out from the space. Immediately before 1D (the lid mold 1A and the intermediate mold 1B) and the concave mold 1C are opened.

  Thus, in the present embodiment, A) The time when molten soap first flows into the cavity 10 (the time when the servo motor 37 for pushing the piston 36 into the cylinder 34 starts) is set as the initial stage, and the mold 1 (cavity 10 and a continuous time starting with the completion of filling of the molten soap into the supply passage 15) (immediately before the push plug 33 is inserted into the nozzle 32), and B) starting with the completion of filling of the molten soap, By maintaining the pressure applied to the lid mold 1A in the above-mentioned range at each of the continuous time periods immediately before the movable mold 1D and the concave mold 1C are opened to take out the cooled and solidified molten soap, The shrinkage and sinking of the soap, which is a concern when the molten soap is cooled and solidified, is suppressed, and a soap having a desired shape can be obtained. In particular, when a transparent soap is produced as in this embodiment, the pressure applied to the lid mold 1A is determined from the viewpoint of preventing transparency from being reduced by increasing the molding pressure and preventing distortion, burrs, and the like. ) And B) are preferably adjusted to the above ranges. If the pressure applied to the lid mold 1A exceeds 0.2 MPa during the period from the start of filling of the molten soap until the completion of cooling, the solidification rate of the molten soap increases and the productivity is improved. Or burrs are likely to occur, transparency may be lowered, and a desired shape may not be obtained.

  Adjustment (increase / decrease) of the volume of the cavity 10 by the operation of the lid mold 1A (movable mold 1D) described above is controlled by the numerical controller (not shown). Specifically, as described above, the numerical control device switches the position control drive of the servo motor 20 to the torque control drive when the movable die 1D reaches and contacts the parting surface PL2 of the concave die 1C, While reading a signal from a pressure sensor (not shown) attached to the lid mold 1A, the motor torque of the servo motor 20 is controlled so that the signal is maintained in a range of 0.2 MPa or less. Under such torque control, the servo motor 20 is driven, whereby the piston 23 is pushed out or returned to move the movable plate 24 forward or backward toward the concave mold 1C, and the convex portion 11 of the lid mold 1A is the concave mold 1C. The volume of the cavity 10 increases or decreases by moving forward or backward toward the recess 13. The pressure applied to the lid mold 1A is substantially equal to the pressure applied to the contents of the cavity 10, and the pressure applied to the molten soap in the cavity 10 during this volume increase / decrease is approximately 0.03 to 0.2 MPa.

  B) (hereinafter also referred to as pressure adjustment time after filling), that is, from the completion of filling of the molten soap to the completion of cooling (the pressure applied to the lid mold 1A is maintained in the range of 0.03 to 0.2 MPa. The time) is not particularly limited, but is preferably 10 to 150 seconds, more preferably 20 to 60 seconds, from the viewpoint of productivity and energy efficiency. The post-filling pressure adjustment time is managed by the numerical controller (not shown). Usually, at the time when a predetermined pressure adjustment time has elapsed after filling, at least the surface layer of the soap in the mold 1 is solidified.

  When a predetermined post-filling pressure adjustment time elapses, the numerical controller (not shown) drives the servo motor 20 to move the movable plate 24 backward (moves to the left in FIG. 8) as shown in FIG. The movable mold 1D (the lid mold 1A and the intermediate mold 1B) and the concave mold 1C are opened. Further, the injection device 3 is removed from the concave mold 1C. When the movable mold 1D and the concave mold 1C are opened, suction is performed through the slits (not shown) formed on the cavity forming surface of the movable mold 1D. At the same time, air is blown from the recess 13 toward the soap bar S through the slit (not shown) formed in the recess 13 of the recess 1C, and from the recess 13 and the supply path 15 (runner 15A and spool 15B). The release of the solid soap S is promoted. By these operations, the soap bar S is held on the cavity forming surface of the movable mold 1D.

  Subsequently, the solid soap S held on the movable mold 1D is taken out by a predetermined gripping means (not shown). At this time, air is blown toward the solid soap S from the cavity forming surface through the slits or the like (not shown) formed in the movable mold 1D to promote the release of the solid soap S from the movable mold 1D. Thereafter, the movable mold 1D and the concave mold 1C are closed and returned to the state shown in FIG. 4, and the operations described so far are repeated.

  The solid soap S thus taken out from the mold 1 is melted in the portion S1 where the molten soap is solidified in the cavity 10 and in the supply path 15 (runner 15A and spool 15B) as shown in FIG. And a portion S2 where the soap is solidified. On the other hand, in the conventional soap manufacturing method, the molten soap in the supply channel (gate) has already been pushed out into the cavity by the gate pin at the time of starting the cooling and solidification of the molten soap, and is thus removed from the mold. The soap bar is composed only of the portion S1, and does not include the portion S2. The soap obtained by the so-called gate pin method is contaminated due to distortion or abrasion of the inner surface of the gate at the site located around the gate (runner) due to the above-described operation of pushing out the remaining molten soap with the gate pin. There is a problem that is likely to occur. In the present embodiment, such a problem in the gate pin system is solved by providing the portion S2 in the solid soap S taken out from the mold 1.

  After the solid soap S is taken out from the mold 1, the boundary between the part S1 and the part S2 is cut by a predetermined cutting means (not shown), and the part S1 is used as a final product. Portion S2 can be recovered and used to make new soap.

  As described above, according to the present embodiment, the pressure applied to the lid mold 1A constituting the mold 1 is 0.2 MPa over a continuous time from the start of the filling of the molten soap to the completion of the cooling after the completion of the filling. By maintaining a low pressure below (0.03-0.2 MPa in the pressure adjustment time after filling), a high-quality transparent soap that is highly transparent and has a uniform shape with less sink, distortion, and dirt is obtained. Can be manufactured efficiently and at low cost.

  Examples of the ingredients constituting the transparent soap include fatty acid soaps, nonionic surfactants, inorganic salts, polyols, nonsoap anionic surfactants, free fatty acids, fragrances, and water. Furthermore, you may mix | blend suitably additives, such as an antibacterial agent, a pigment, dye, oil agent, and a plant extract, as needed.

  As mentioned above, although this invention was demonstrated based on the preferable embodiment, this invention is not restrict | limited to the said embodiment. For example, for example, the number and arrangement of the elastic members 14 in the mold 1 are not limited to the above embodiment, and can be set as appropriate. As the elastic member 14, a hard rubber, an air spring, or the like can be used in addition to a metal or plastic spring.

  Moreover, in order to hold solid soap S by one movable mold | type 1D reliably, you may make the surface area of the said cavity formation surface in movable mold | type 1D larger than the surface area of the recessed part 13 in the concave mold | type 1C. As a method of providing a difference between the surface areas of the two, for example, a method of making the surface roughness different between the two is mentioned.

  Moreover, although the said embodiment concerns the manufacturing method of transparent soap, this invention is applicable similarly to manufacture of soap other than this. For example, in the production of foamed soap, if the pressure at the time of molding the molten soap becomes high, the soap may scatter due to the pressure difference between the inside and outside when the mold is opened after solidification. Thus, since the molding pressure (pressure applied to the lid mold) in the present invention is low, such inconveniences are unlikely to occur according to the present invention. In addition, in the manufacture of a soap containing an encapsulated product containing various auxiliaries such as fragrances, the encapsulated product may be crushed by the pressure when the molten soap is molded, and the desired product may not be obtained. On the other hand, according to the present invention having a low molding pressure, a high-quality encapsulated soap can be obtained without causing such disadvantages.

  Hereinafter, the present invention will be described in more detail with reference to examples. However, the scope of the present invention is not limited to such embodiments.

(Preparation of molten soap)
A molten soap was prepared using the following ingredients. Unless otherwise specified, “%” means “% by weight”.
Isoprene glycol (penetration enhancer) 13.6%
Leodool Super TW-L120 (foam stabilizer) 5.4%
Amphital 20HD (cleaning base) 5.4%
LUNAC L-98 (cleaning base) 10.5%
LUNAC MY-98 (cleaning base) 10.5%
LUNAC S-90 (cleaning base) 5.3%
LUNAC P-95 (cleaning base) 5.3%
BHT (antioxidant) 0.1%
DISQUEST 2010CS (chelating agent) 0.1%
48% sodium hydroxide aqueous solution (neutralizing agent) 12.0%
Xylitol (humectant) 9.1%
Sorbitol (humectant) 13.6%
Sodium chloride (viscosity modifier) 1.1%
Purified water 8.2%

[Example 1]
Transparent soap was manufactured according to the manufacturing method mentioned above using the molten soap prepared in this way and the manufacturing apparatus shown in FIG. That is, after filling the cavity 10 and the supply passage 15 with a predetermined amount of molten soap, the molten soap is cooled for a predetermined time, and the lid mold is formed over a continuous time from the start of filling the molten soap to the completion of cooling. 1A was operated to solidify the molten soap while increasing or decreasing the volume of the cavity 10. The volume of the cavity was adjusted by controlling the motor torque of the servo motor. The temperature of the molten soap was 70 ° C. After 60 seconds from the start of filling with molten soap, cooling water for cooling each of the split molds 1A, 1B and 1C is circulated to cool these split molds for 10 minutes, and the temperature of the mold 1 filled with the molten soap 1 Was brought to 10 ° C. The period from the completion of filling with the molten soap to the completion of cooling (the pressure adjustment time after filling) was 125 seconds. After a predetermined pressure adjustment time after filling, the molding die 1 was opened to obtain a transparent soap having a shape as shown in FIG.

  In FIG. 10, the pressure waveform at the time of shaping | molding of the molten soap in Example 1, etc. are shown. FIG. 10 shows the elapsed time (seconds) since the movable mold 1D (the lid mold 1A and the intermediate mold 1B) and the concave mold 1C are clamped, the horizontal axis the pressure at a predetermined portion, the left vertical axis, the position of the piston, etc. 10 is the right vertical axis. In FIG. 10, A indicates the position of the piston 36 for adjusting the amount of molten soap supplied, and B indicates the pressure applied to the lid mold 1A (pressure in the cavity 10). C indicates the filling pressure of the molten soap, and D indicates the clamping position. A symbol Z on the horizontal axis of FIG. 10 indicates a point in time when filling of the molten soap into the mold 1 is completed (when filling is completed). As is apparent from FIG. 10, the pressure B applied to the lid mold 1A is within a range of 0.2 MPa or less from the start of filling the molten soap to the completion of filling (during the filling of the molten soap), and the cooling is completed from the completion of the filling. In the period up to the time (from the completion of filling of the molten soap until immediately before the mold 1 is opened), it is maintained in the range of 0.03 to 0.2 MPa. Cooling and solidification of the molten soap is performed under such a low pressure (0.2 MPa or less) over a continuous time from the start to the completion of cooling.

[Comparative Example 1]
A transparent soap was obtained in the same manner as in Example 1 except that the pressure applied to the lid mold 1A was maintained at 0.3 MPa over a continuous time from the start of filling the molten soap to the completion of cooling.

[Comparative Example 2]
A transparent soap was obtained in the same manner as in Example 1 except that the pressure applied to the lid mold 1A was maintained at 0.02 MPa over a continuous time from the start of filling of the molten soap to the completion of cooling.

  The transparent soap obtained in Example 1 had high transparency and no sink marks, distortions or stains were seen, whereas the transparent soaps obtained in Comparative Examples 1 and 2 were all sink marks, distortions or burrs. The quality was inferior to that of the transparent soap obtained in Example 1.

FIG. 1 is a schematic diagram showing a mold, a mold unit, and an injection device in an embodiment of the soap production apparatus of the present invention. FIG. 2 is a perspective view schematically showing a mold open state of the mold in the manufacturing apparatus shown in FIG. FIG. 3 is a side view schematically showing a state in which the split mold of the mold shown in FIG. 2 is assembled. FIG. 4 is a schematic diagram illustrating a state at the start of molding of the manufacturing apparatus illustrated in FIG. 1. FIG. 5 is an enlarged view of a main part of FIG. FIG. 6 is a view corresponding to FIG. 5 schematically showing a state in which molten soap is poured into the mold. FIG. 7 is a schematic view showing a state in which filling of the molten soap into the mold is completed in the manufacturing apparatus shown in FIG. FIG. 8 is a schematic view showing a state where the mold is opened in the manufacturing apparatus shown in FIG. FIG. 9 is a side view schematically showing soap manufactured using the manufacturing apparatus shown in FIG. 1. FIG. 10 is an explanatory diagram showing a pressure waveform and the like during molding of the molten soap in Example 1 of the present invention.

Explanation of symbols

1 Mold 1A Lid 1Aa One side of the lid (projection forming surface)
1B Intermediate mold 1Ba First face (back) of the intermediate mold
PL1 Intermediate type second surface (parting surface)
1C Concave type PL2 Concave parting surface 1D Movable type (lid type and intermediate type)
2 Mold unit 3 Injection device 5 Manufacturing device 10 Cavity 11 Convex part 12 Through-hole 13 Concave part 14 Elastic member 15 Supply path 15A Runner 15B Spool 20 Servo motor (drive source)

Claims (7)

A mold cavity is formed by assembling a plurality of split molds including a lid mold connected to a drive source and capable of reciprocating in a predetermined direction, and the lid mold is operated by operating the lid mold using the drive source. A step of filling the cavity of the mold with adjustable cavity volume with molten soap, cooling and solidifying,
The pressure applied to the lid mold is maintained in a range of 0.2 MPa or less from the start of filling of the molten soap to the completion of filling, and from 0.03 to 0.2 MPa from the completion of filling of the molten soap to the completion of cooling. Thus, the manufacturing method of the soap which solidifies this molten soap, increasing / decreasing the volume of the said cavity.   The method for producing soap according to claim 1, wherein the time between completion of filling of the molten soap and completion of cooling is 10 to 150 seconds.   The soap manufacturing method according to claim 1 or 2, wherein the drive source is a servo motor, and the volume of the cavity is adjusted by controlling a motor torque of the servo motor. The lid mold has a convex portion protruding from one surface thereof, and the molding die is positioned on the lid mold, a first surface facing the one surface of the lid mold, and a first surface opposite to the first surface. An intermediate mold having a through-hole through which the two surfaces and the both surfaces can be inserted and the convex portion can be inserted, and a concave mold in which a concave portion is formed on a parting surface contacting the second surface of the intermediate mold, By assembling in this order, the cavity defined by the convex portion, the through hole and the concave portion is formed inside,
Between the one surface of the lid mold and the first surface of the intermediate mold, an elastic member that expands and contracts in the operating direction of the lid mold is disposed, and the lid mold and the intermediate mold are interposed via the elastic member. Is connected in a state where the convex portion is inserted into the through-hole,
The volume of the cavity is adjusted by reciprocating the inside of the through-hole to the convex portion by expanding and contracting the elastic member in a state where the second surface of the intermediate mold is in contact with the concave parting surface. The method for producing soap according to any one of claims 1 to 3, which is made possible.   The soap manufacturing method according to claim 4, wherein a supply path for the molten soap that leads to the cavity is formed in the concave mold. A mold cavity is formed by assembling a plurality of split molds including a lid mold connected to a drive source and capable of reciprocating in a predetermined direction, and the lid mold is operated by operating the lid mold using the drive source. A soap production apparatus comprising a mold capable of adjusting the volume of a cavity and an injection device for injecting molten soap into the cavity,
The lid mold has a convex portion protruding from one surface thereof, and the molding die is positioned on the lid mold, a first surface facing the one surface of the lid mold, and a first surface opposite to the first surface. An intermediate mold having a through-hole through which the two surfaces and the both surfaces can be inserted and the convex portion can be inserted, and a concave mold in which a concave portion is formed on a parting surface contacting the second surface of the intermediate mold, By assembling in this order, the cavity defined by the convex portion, the through hole and the concave portion is formed inside,
Between the one surface of the lid mold and the first surface of the intermediate mold, an elastic member that expands and contracts in the operating direction of the lid mold is disposed, and the lid mold and the intermediate mold are interposed via the elastic member. Is connected in a state where the convex portion is inserted into the through-hole,
The volume of the cavity is adjusted by reciprocating the inside of the through-hole to the convex portion by expanding and contracting the elastic member in a state where the second surface of the intermediate mold is in contact with the concave parting surface. Soap manufacturing equipment made possible.   The soap manufacturing apparatus according to claim 6, wherein a supply path for molten soap leading to the cavity is formed in the concave mold.

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