JP2007106021A - Resin foamed molding and its manufacturing process - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin foamed molding which, is although lightweight, is hard to suffer the buckling by a compression force to the thickness direction, thus giving good resilience and good feeling of touch as an interior material for an automobile and which also can give high sound absorbing property. <P>SOLUTION: The resin foamed molding M10 is formed by: making to be 1.0-10.0 mm the distance between one pair of molding dies 11, 12 at the approach position L1; making to be 1.0-50.0 mm the separation distance from the approach position L1 to the core back position L2; and, while forming the foam-free skin layers M16 on the surfaces, making the bubbles continuous to the separation direction D1 of the molding dies 11, 12 so that they become below the above separation distance and ≥1.0 mm and elongating the foam cells M13 in the shape of frost columns. Further, by making different the temperature distribution of the separation direction within the resin molding material filled in the cavity, to the direction D2 vertical to the separation direction and by separating the molding dies 11, 12 from each other, the voids corresponding to the difference of the temperature distribution are formed in the inside, and thus the resin foamed molding is molded. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a resin foam molded body used for automobile interior materials and the like, and a method for producing the same.

Conventionally, a foamed resin molding material is injection molded by separating a pair of molds (core back) as follows.
First, a resin molding material containing a foaming agent is heated and melted and filled in a cavity formed by clamping a male and female mold, and after a predetermined number of seconds, the male and female molds are placed at a predetermined distance from each other. The cavity volume is expanded by being spaced apart by a distance. Then, the resin molding material filled in the cavity is released from the internal pressure, and the foaming agent contained therein expands to follow the cavity and expand. Thereafter, the resin molding material is solidified in a state having a large number of bubbles to form a resin foam molding.
The resin foam molded body has a structure having a skin layer on the surface formed by cooling in contact with a mold at an early stage of molding, and a foam layer formed along with foaming of the foaming agent inside the skin layer. Has been. The obtained resin foam molded article is lightweight and soft to the touch, and has applications in automobile interior panels and the like. In addition, there is a reasonable advantage that the molding process is completed in one step.

  Patent Document 1 contains at least three types of layers, a skin layer, a low foam layer, and a high foam layer, in this order, and the diameter (Da1) in the thickness direction of the bubbles present in the high foam layer near the low foam layer. The ratio (Da1 / Da2) to the diameter (Da2) in the direction perpendicular to the thickness direction is 1 to 4, the diameter (Db1) in the thickness direction of the bubble near the center of the thickness direction of the high foam layer and the thickness direction A thermoplastic resin foam molded article having a ratio (Db1 / Db2) to a diameter (Db2) in a vertical direction of more than 4 and 10 or less is described. In paragraph 0015 of the same document, for the enlarged photograph of the high foam layer part, an area corresponding to 0.5 mm square of the part in contact with the low foam layer is taken, and the bubbles contained in this area and most of them are 0.5 mm square. It is described that the bubbles contained in the region are obtained by measuring the diameter (Da1) in the thickness direction and the diameter (Da2) in the direction perpendicular to the thickness direction and calculating the number average value.

Patent Document 2 discloses a flooring material including a cushion layer and a surface layer made of a polyolefin foam in which inner cells extend in a spindle shape in the thickness direction, the cushion layer having a thickness of 2 to 15 mm, and an expansion ratio. Is 4 to 20 times, and the average value of the aspect ratio Dz / Dxy of the underlying cell is 1.1 to 4 is described.
JP-A-2005-59224 JP 2002-317548 A

The thermoplastic resin foam molded article described in Patent Document 1 has a diameter Da1, Da2 obtained from bubbles contained in a 0.5 mm square region, and has a large number of small bubbles with a maximum long diameter of about 0.5 mm. is there. For this reason, there is no air permeability inside the foam molded article, and it cannot be said that the tactile sensation as an automobile interior material is good, and the sound absorption is not high.
Since the shock absorbing floor material described in Patent Document 2 also has an average aspect ratio of 1.1 to 4, which is smaller than the thermoplastic resin foam molded body described in Patent Document 1, the maximum major axis is very large, reaching 1 mm. There are no elongated cells. Further, as shown in FIG. 1B, since the cells are not communicated with each other, there is no air permeability inside the flooring, and it cannot be said that the tactile sensation as an interior material is good, and the sound absorption is high. I couldn't say that.

  The present invention has been made in view of the above-mentioned problems, and is lightweight and hardly buckled against a compressive force in the thickness direction, and can provide good elasticity and good tactile sensation as an automobile interior material, and has high sound absorption. It is an object of the present invention to provide a resin foam molded product capable of obtaining the above.

  In order to achieve the above-mentioned object, the present invention fills a cavity formed when a pair of molds capable of approaching and separating from each other are brought close to a predetermined proximity position with a resin molding material containing a foaming agent, and then A resin foam molded body formed by forming a foam cell in a resin molding material in the cavity by separating a pair of molds to a predetermined separation position and expanding the cavity, and when the resin is in the proximity position The distance between the pair of molds is set to 1.0 to 10.0 mm, and the separation distance from the proximity position to the separation position is set to 1.0 to 50.0 mm to form a non-foamed skin layer on the surface. However, the foamed cells were formed by extending the foamed cells in the form of frost columns so that the distance between the pair of molds is 1.0 mm or more in the separation direction.

  The resin foamed molded article has a non-foamed skin layer formed on the surface thereof, and a very elongated open-cell frosted columnar foam cell of 1 mm or more in the separation direction is formed inside. Even if the volume of each foam cell is large and the structure of the molded product is low in density, the distance between the foam cell walls in the direction perpendicular to the separation direction is small, so it is lightweight but can withstand the compressive force in the thickness direction. It is hard to buckle and can provide good elasticity and good tactile sensation as an automobile interior material. In addition, since the foam cell is formed in the shape of a very elongated open-cell frost column, the inside of the resin foam molded body has air permeability, and high sound absorption can be obtained.

Further, the resin foam molded body of the present invention separates the pair of molds by varying the temperature distribution in the separation direction in a direction perpendicular to the separation direction in the resin molding material filled in the cavity. Thus, a non-foamed skin layer is formed on the surface, and a cavity corresponding to the difference in temperature distribution is formed inside and molded.
In the resin foam molded body, cavities are formed in the resin molding material filled in the cavities according to the difference in temperature distribution in the separation direction which is different in the direction perpendicular to the separation direction. Thereby, since the air permeability inside the resin foam molding is increased, it is possible to obtain light weight and high sound absorption.

  The invention also exists in the method for producing the resin foam molded body described above, and the same action and effect can be obtained.

According to the first and tenth aspects of the invention, while being lightweight, it is difficult to buckle against compressive force in the thickness direction, and can provide good elasticity and good tactile sensation as an automobile interior material, and also has high sound absorption It is possible to provide a resin foam molded article capable of obtaining the above.
In the invention according to claim 2, the nucleating agent becomes an appropriate nucleating material, the bubbles are formed in a moderately dense and uniform manner, and the tactile sensation as the interior material can be improved while maintaining high sound absorption. .
In the invention according to the third aspect, the sound absorption can be improved, and the elasticity and tactile sensation as the interior material can be further improved.

In the invention according to claim 4, since the foamed cell can be stably formed in a frost column shape, the elasticity and tactile sensation as the interior material can be further improved while maintaining high sound absorption.
In the invention concerning Claim 5 and Claim 6, the resin foam molded object which further improved the sound-absorbing property can be obtained.
In the invention concerning Claim 7, a favorable sound-absorbing resin foam molded article can be easily obtained.
In the invention according to claim 8, since the foam cell can be stably formed in a frost column shape, the elasticity and tactile sensation as the interior material can be further improved while maintaining high sound absorption.

According to the ninth and eleventh aspects of the present invention, it is possible to provide a resin foam molded body that is lightweight and capable of obtaining high sound absorption.
In the invention according to claim 12, the resin foam molded article can be produced by adjusting the sound absorption by adjusting the amount of talc.

Hereinafter, embodiments of the present invention will be described in the following order.
(1) Manufacturing method of resin foam molding:
(2) Modification:
(3) Example:

(1) Manufacturing method of resin foam molding:
FIG. 1 is a diagram schematically showing a method of manufacturing a resin foam molded body M10 according to an embodiment of the present invention, FIG. 2 is a diagram schematically showing a foam injection molding machine 10 used in the present manufacturing method, and FIG. FIG. 4 is a diagram showing the structure of the resin foam molded body M10 in a vertical section, FIG. 4 is a diagram showing the structure of another resin foam molded body in a vertical section, FIG. 5 is a timing chart showing the amount of movement of the molding die 11, and FIG. These are timing charts showing the amount of movement of the mold 11 in the modified example.
The resin foam molded body M10 is used for automobile interior materials and the like.

In this manufacturing method, the resin molding material M1 containing a foaming agent is filled into the cavity C1 formed when a pair of molds 11 and 12 that can approach and separate from each other are brought close to a predetermined proximity position L1, and then the above-mentioned The pair of molds 11 and 12 are separated (core back) to a predetermined separation position L2 to expand the cavity C1, thereby forming a frost column-shaped foam cell M13 in the resin molding material in the expanded cavity C1. Resin foam molding M10 is molded. The molded body M10 is formed in a thin and wide shape such as a flat plate shape, a curved plate shape, a sheet shape, and the surface of the molded body may have various shapes such as a planar shape, a curved surface shape, and an uneven shape. it can.
Here, the distance d1 between the pair of molds 11 and 12 when in the proximity position L1 is set to 1.0 to 10.0 mm. When the distance d1 is greater than or equal to the lower limit, the foamed cells are not cut in the middle of the thickness direction (separating direction D1), and the frost columnar foamed cells are sufficiently long in the thickness direction to increase the internal air permeability, thereby providing good sound absorption. The obtained interior material is preferable in terms of obtaining good elasticity and good tactile sensation, and if the distance d1 is set to the upper limit or less, the resin foam molded body does not become too hard and the frost columnar foam cell becomes sufficiently long in the thickness direction and the inside. This is because it is preferable in that good air-absorbing property can be obtained and good elasticity and good tactile sensation can be obtained. Further, the separation distance (core back distance) d2 from the proximity position L1 to the separation position L2 is 1.0 to 50.0 mm, more preferably 4.0 to 7.0 mm. It is preferable that the distance d2 is not less than the lower limit in that the foamed cell is sufficiently long as 1.0 mm or more in the separation direction D1 and the internal air permeability is increased so that good sound absorption can be obtained. Then, it is because it is preferable at the point from which a favorable elasticity and a favorable tactile sensation are obtained as an interior material by a foam cell not being cut | disconnected in the middle of the thickness direction. The thickness d3 of the resin foam molded body M10 is d1 + d2.
Then, in this manufacturing method, while forming the non-foamed skin layer M16 on the surface, the air bubbles are adjusted to 1.0 mm or more in the range of the separation distance d2 or less in the separation direction D1 of the pair of molds 11 and 12. The foamed cell M13 is elongated in a frost column shape to form a resin foam molded body M10.

In the resin foam molded body M10, non-foamed skin layers M16 and M16 are formed on both surfaces in contact with the molding surfaces of the pair of molds 11 and 12, and the inside sandwiched between the skin layers M16 and M16 is foamed. The layer is M12.
The skin layer M16 is in a non-foamed state because the temperature of the resin molding material in contact with the molding surfaces of the molding dies 11, 12 having a temperature lower than that of the liquid resin molding material is rapidly lowered and solidified without foaming. Formed with. As a result, the porosity of the skin layer is less than 1%.
The thickness d4 of the skin layer is controlled by the temperature of the resin molding material, the temperature of the molding surfaces of the molding dies 11 and 12, and the timing of the separation of the molding dies 11 and 12. If the temperature of the resin molding material or the molding surface of the molding die is lowered or the timing of separating the molding die is delayed, the skin layer becomes thick, and the temperature of the resin molding material or the molding surface of the molding die is increased or molded. If the mold separation timing is advanced, the skin layer becomes thinner. The thickness d4 of the skin layer is preferably 0.1 to 1.0 mm within a range less than half of the distance d1 between the molds 11 and 12. When the thickness d4 is not less than the above lower limit, good elasticity and good tactile sensation can be obtained as an interior material, and when the thickness d4 is not more than the above upper limit, the resin foam molded article is not too hard and good elasticity and good tactile sensation can be obtained. This is because it is preferable.

The foamed layer M12 is formed with foamed cells M13 that are expanded in a frost column shape by continuing bubbles of 1.0 mm or more in the separation direction D1 with a separation distance d2 or less.
Referring to FIG. 3, a large number of micro bubbles in the resin molding material generated at the initial stage of the core back expand in the separation direction D1 due to the separation of the mold and the foaming action of the foaming agent, and in the substantially separation direction. A connection port M13a is formed between other adjacent bubbles, and is connected in a columnar shape in the separation direction. In the example of the figure, it is shown that bubbles a1, a2, a3, and a4 communicate with each other in the separating direction to form a columnar continuous cell. On the other hand, in the direction D2 perpendicular to the separation direction, the growth is suppressed by the presence of other adjacent bubbles, but the connection port M13b is formed between the other adjacent bubbles due to the thin wall of the cell. As a result, a frost column-like foam cell M13 extending in the separation direction D1 is formed. In the example of the figure, it is shown that the bubbles a2 and the bubbles b2 communicate with each other, the bubbles a1 and the bubbles c1 communicate with each other, and the foamed cells are organized in a frost column shape.
The foam cell M13 has a length d5 in the separation direction that is very large with respect to the diameter of each columnar cell in the vertical direction D2, and has a shape different from the concept of an ellipsoid or spindle. Here, the length d5 of the foam cell in the separation direction is the length of the longest portion of the connected bubbles in the separation direction D1, that is, the vertical position that is the uppermost of the bubbles communicated in FIG. The length of the difference in the vertical direction from the lowest vertical position is assumed. Further, when viewed in the cross section in the vertical direction D2, as a result of the bubbles being connected in a staggered manner like the bubbles a1, a2, a3, and a4, the cross section of the cell becomes zigzag, which is different from the concept of a circle or ellipse. Tend to be. In addition, a foam cell may become the length connected with the both skin layers in the both sides of a foam layer.

The foam layer M12 is formed so as to have air permeability in the direction D1 perpendicular to the separation direction as a result of the formation of the frost column-like foam cell M13. Here, when the foamed layer is formed so that the air permeability according to the fragile method of JIS L1096 when cut to a thickness of 5.0 mm in the vertical direction D2 is 0.4 cc / cm ² / sec or more, it is high. A sound-absorbing resin foam molding is obtained. Here, in order to increase the air permeability of the foam layer in the vertical direction D2, for example, the foam cell M13 may be elongated in the separation direction D1, and the separation distance d2 of the mold may be increased. Further, the air permeability in the vertical direction D2 of the foam layer can be adjusted by adjusting the separation distance d2 of the mold.
Furthermore, when the resin foam molded body is molded so that the density of the foamed layer is 0.03 to 0.5 g / cm ^3, it is less likely to buckle against the compressive force in the thickness direction and has good elasticity and good as an interior material. It becomes possible to obtain tactile sensation and high sound absorption. Here, in order to reduce the density of the foam layer, for example, the foam cell M13 may be lengthened in the separation direction D1, and the separation distance d2 of the mold may be lengthened. Further, the density of the foam layer can be adjusted by adjusting the separation distance d2 of the mold. The expansion ratio is (d1 + d2) / d1, where d1 is the distance between the pair of molds when they are close to each other, and d2 is the separation distance. Since the approximate density of the foamed layer can be obtained from the required foaming ratio, the density of the resin molding material, and the thickness d4 of the skin layer, the density of the foamed layer can be determined by examining the foaming ratio, the density of the resin molding material, and the thickness d4 of the skin layer. The density can be adjusted.

  As shown in FIG. 4, an intermediate layer M <b> 14 having a foam cell M <b> 15 that is short in the separation direction D <b> 2 may be formed on the surface side of the foam layer M <b> 12 that contacts the skin layers M <b> 16 and M <b> 16. The foam cell M15 may be an independent cell in which adjacent bubbles are not connected or communicated.

The resin constituting the resin molding material M1 is preferably a thermoplastic resin (a kind of synthetic resin) from the viewpoint of being able to be heated and melted, but various thermosetting resins (such as a phenolic resin and a urea resin) 1 type), a modified resin in which a soft component such as a rubber component is blended with a synthetic resin to improve elastomeric properties, and the like can be used.
As the thermoplastic resin, an olefin resin, an olefin thermoplastic elastomer, or the like can be used. Either a homopolymer or a copolymer obtained by copolymerizing two or more types of monomers, an olefin and an unsaturated carboxylic acid can be used. Copolymerized copolymers or combinations thereof may be used. Specifically, polypropylene, polyethylene, acrylonitrile butadiene styrene resin (ABS resin), polyethylene terephthalate (PET), polyamide, polystyrene, combinations thereof, these resins For example, a modified resin in which a rubber component is blended can be used.

  The foaming agent contained in the resin molding material M1 includes a physical foaming agent such as a gas inert gas or a volatile organic compound at a normal temperature of 1 atm, a chemical foaming agent that decomposes or reacts by heating to generate gas, and a combination thereof. Can be used. It is preferable to use an inert gas for the foaming agent because it does not react with the resin and does not deteriorate the resin. As the inert gas, carbon dioxide, nitrogen, argon, helium, neon, a combination thereof, or the like can be used. As the volatile organic compound, a volatile foaming agent that generates hydrocarbons such as butane and pentane can be used. As the chemical foaming agent, an inorganic foaming agent that generates a carbon dioxide gas such as ammonium carbonate or sodium hydrogen carbonate, an organic foaming agent that generates a gas of an organic compound such as polycarboxylic acid or azo compound, or the like may be used. it can.

  Here, when a nucleating agent is used in combination with an inert gas, the nucleating agent becomes an appropriate nucleating material, and bubbles are formed moderately densely and uniformly, and as an interior material while maintaining higher sound absorption A resin foam molded article having good tactile sensation can be formed. The addition ratio of the nucleating agent with respect to the resin molding material not containing the nucleating agent may be a blending ratio that functions as a nucleus for foaming the physical foaming agent. For example, 100 parts by weight of the resin molding material not containing the nucleating agent On the other hand, it can be in the range of 1 to 50 parts by weight (more preferably 1 to 20 parts by weight). Moreover, when using a chemical foaming agent as a nucleating agent, a chemical foaming agent has the function to assist foaming of an inert gas. In addition, by adjusting the blending ratio of the nucleating agent, the density of the foamed cells can be adjusted and the sound absorption can be adjusted. Further, the pressure of the inert gas injected into the resin molding material is preferably 0.5 to 20 MPa. 1.5 to 7.0 MPa is more preferable. When the pressure of the inert gas is set to the above lower limit or more, the amount of the inert gas dissolved in the resin molding material is sufficient, which is preferable in that a resin foam molded body having a high expansion ratio can be obtained. On the other hand, it is preferable to set the pressure of the inert gas below the upper limit because the inert gas is not wasted and a general-purpose product can be used for the gas injection device and the mold, resulting in a low cost.

The resin molding material M1 may be composed of only a resin and a foaming agent, but an additive may be included in the resin molding material M1. As additives, fillers such as talc, nucleating agents, pigments, lubricants, antioxidants, heat stabilizers, ultraviolet absorbers, antistatic agents, combinations thereof, and the like can be used. The blending ratio of each material in the resin molding material is 50% by weight (preferably 65% by weight or more) of resin and less than 50% by weight of additive (preferably 35% by weight) from the viewpoint of sufficiently retaining the properties of the resin. %)).
When talc is included in the resin molding material, the foam cell can be made smaller, and the foam cell can be made smaller as the blending amount of talc is increased. Therefore, by adjusting the weight ratio of talc contained in the resin molding material, the size of the foam cell can be adjusted to mold the resin foam molded body. Therefore, by adjusting the amount of talc, the sound absorption property of the resin foam molded article can be adjusted.

As an injection molding machine suitable for molding the resin foam molded body, a known in-line screw type injection molding machine can be used, and its form (solid type, horizontal type) and drive system (hydraulic type, electric type) Etc.) does not matter.
FIG. 2 shows an example of a foam injection molding machine for molding the resin foam molding. The foam injection molding machine 10 includes a male mold 11, a female mold 12, a molding material charging hopper 13, a gas storage tank 14, a cylindrical outer cylinder member 15 centering on the extrusion direction of the resin molding material, and inserted into the outer cylinder member. The members 11 to 16 are made of metal, including a screw 16, a gas injection device 17 attached in the middle of the outer cylinder member 15, a motor (not shown) that rotationally drives the screw 16, and the like. The L / D ratio of the screw 16 can be set to about 20, for example. The molds 11 and 12 attached to the tip of the outer cylinder member 15 are male and female molds, and form a required cavity C1 sealed in a clamped state. For example, the gas injection device 17 controls the injection pressure of the inert gas to a constant pressure.
The foam injection molding machine 10 injects a liquid (including a molten state) resin molding material from the injection port 15a into the cavity C1, and separates the male mold 11 from the female mold 12 to a predetermined separation position, thereby resin in the cavity C1. By foaming the molding material and solidifying or curing the resin molding material, the resin foam injection molded body M10 is formed. Then, by opening the molds 11 and 12 and taking out the molded body M10, one cycle of manufacturing the resin foam injection molded body is completed.
A mold using a slide core may be used as the mold 11.

Next, with reference to FIG. 1 and FIG. 5, each step of the manufacturing method of this resin foam molding is demonstrated with the change of the state of the resin molding material in a cavity. Note that a thermoplastic resin is used as the resin constituting the resin molding material.
When molding the resin foam molded body M10, particularly important are the timing of mold separation, the core back speed during core back, and the viscosity of the molding resin during core back. In foam injection molding, the timing and speed of the core back of the mold are important, and it is known that the thickness of the skin layer to be formed, the magnification and shape of the cells of the foam layer change variously. .

  First, as shown in the upper part of FIG. 1, the male and female molds 11 and 12 in the mold open state are closed to form the cavity C1 (timing t1 to t2 in FIG. 5). At this time, the mold 11 is at a predetermined proximity position L1, and the distance between the molds 11 and 12 is d1. Moreover, the resin molding material M1 containing a foaming agent is a high-temperature liquid, and the molds 11 and 12 are set to 30 to 80 ° C. In addition, if a resin molding material is heated more than melting | fusing point and it is made into a molten state, it can be made a high temperature liquid state. For example, when polypropylene having a melting point of 160 ° C. is used as the thermoplastic resin, the resin molding material is heated to about 170 to 230 ° C. to melt the polypropylene. Next, as shown in the middle part of FIG. 1, the molten resin molding material M1 is injected into the cavity C1 with an injection pressure of 100 to 200 MPa and a filling time of 0.5 to 5 seconds. (Timing t2 to t3 in FIG. 5). The injection pressure and the filling time vary mainly depending on the amount of the resin molding material to be injected, that is, the size of the resin foam molded body. Here, since the temperature of the molds 11 and 12 is low, the resin molding material in the portion in contact with the molding surface of the molds 11 and 12 is cooled and solidified first, and is less than half of the distance d1 between the molds 11 and 12. In the range of 0.1 to 1.0 mm as a non-foamed skin layer. On the other hand, the resin molding material inside the skin layer maintains a molten state.

When the resin molding material is injected, a plurality of micro bubbles start to be generated. When a nucleating agent is included in the resin molding material, the nucleating agent becomes a nucleating material, and in the molten resin molding material, inert gas gathers around the nucleating agent to form an isotropic spherical shape. A large number of micro bubbles having a diameter of less than 0.1 mm begin to form. This stage is the initial foaming stage.
The time T1 (timing t3 to t4 in FIG. 5) for holding the molds 11 and 12 at the proximity position L1 is preferably 1 to 10 seconds, and more preferably 3 to 7 seconds. When the holding time T1 is set to 3 seconds or more, the viscosity of the resin molding material is moderately high, and the foamed cells are not easily cut in the separation direction D1, and when the holding time T1 is set to the upper limit or less, insufficient foaming due to solidification does not occur. . When the temperature of the resin molding material or the temperature of the mold is low, or when the speed at which the mold 11 is separated (separation speed) is slowed, the holding time T1 can be shortened so that the resin viscosity does not increase too much. Good. When the mold is held in the proximity position, a skin layer is formed between them, the temperature of the resin molding material inside the skin layer is lowered, and the shear viscosity is increased.

After the timing t4, as shown in the lower part of FIG. 1, the male and female molds 11 and 12 are separated from each other to a predetermined separation position L2, and the volume of the cavity C1 is expanded (timing t4 to t5 in FIG. 5). Then, the plurality of micro cells formed in the resin molding material in the initial foaming stage are expanded only in the separation direction D1 with the separation of the molding die, and communicate with other bubbles that are substantially adjacent in the separation direction. A part of the air bubbles communicates with other adjacent bubbles in the direction D2 perpendicular to the separation direction. As a result, a foam layer having frost column-like foam cells M13 extending in the separation direction D1 is formed between the skin layers on the surface so that the foam layer has air permeability in a direction D2 perpendicular to the separation direction. It is formed.
In the separation step, the separation speed V1 of the mold 11 is preferably 1 to 80 mm / second, and more preferably 10 to 60 mm / second. This is because when the separation speed V1 is equal to or higher than the lower limit, a phenomenon in which foaming does not occur does not occur, and when the separation speed V1 is equal to or lower than the upper limit, a phenomenon that the structure of the frosted columnar foam cell does not collapse occurs. This is because an inexpensive injection molding machine can be used. The time for separating from the proximity position L1 to the separation position L2 is about 0.02 to 3 seconds.
In the separation step (when the molds 11 and 12 are spaced apart), the resin molding material in which the temperature of the resin molding material inside the skin layer in the cavity (for example, the temperature at the center of the cavity) is used as the test temperature The melt tension of is preferably from 0.1 to 30 gf, more preferably from 0.2 to 1.0 gf. However, the melt tension of the molding resin material was determined by using a capillary rheometer “Capillograph 1C type” manufactured by Toyo Seiki Seisakusho Co., Ltd. in accordance with JIS K7199 and attaching a capillary with a diameter of 1.0 mm to the lower end of the cylinder. The cylinder is filled with the resin molding material at a temperature, the piston of the capillary rheometer is lowered at a descending speed of 10 mm / min, and the resin molding material in the cylinder is extruded from the capillary into a thread shape. At the same time, the extruded resin molding material is 5 The melt tension measured when the sheet is drawn at a take-up speed of 0.0 m / min. When the resin molding material is a thermoplastic material, the resin molding material is heated and melted, and the molten resin molding material is injected into the cavity when the molding dies 11 and 12 are in the proximity position L1. The highest temperature among the resin molding materials in the cavity when separating 11 and 12 is set as the test temperature, the resin molding material in a molten state at the test temperature is filled into the cylinder, and the piston is lowered to form the resin molding. What is necessary is just to measure melt tension, when material is extruded and taken out in the shape of a thread. If the melt tension of the molding resin material is as small as less than 0.1 gf, the foamed cell wall is cut when the mold is separated and the foamed cell is not formed in the form of frost columns. If the melt tension of the resin material is too large (greater than 30 gf), even if the mold is separated, the foamed cells are not formed in the form of frost columns, and the air permeability is hardly present and the sound absorption is low.

Further, the mold separation distance d2 is determined by the expansion ratio of the resin foam molding to be obtained, and is 1 to 9 times the distance d1 between the molds 11 and 12 when in the proximity position L1 ( The foaming ratio of the resin foam molding is preferably 2 to 10 times, and more preferably 2 to 5 times the distance d1 (the foaming ratio of the resin foam molding is 3 to 6 times). In other words, the volume ratio of the cavity C1 when the molds 11 and 12 are separated from the proximity position L1 to the separation position L2 is preferably 2 to 10, and more preferably 3 to 6. When the volume ratio of the cavities (separation distance d2) is greater than or equal to the lower limit, the foamed cells are frost columns in the separation direction D1 and become sufficiently long and the air permeability is increased. This is because the foamed cells are not cut in the middle of (separation distance D1), so that good elasticity and good tactile sensation can be obtained as an interior material.
In this manufacturing method, the distance d1 between the two molds at the close position is set to 1.0 to 10.0 mm, and the separation distance d2 is set to 1.0 to 50.0 mm. D1 is formed in a frost column shape in which bubbles are continuously extended by 1.0 mm or more at a separation distance d2 or less.

  In addition, the speed at the position reaching the separation position L2 is made larger than the speed at the position where the pair of molds 11 and 12 are separated from the proximity position L1 at the speed V1, and the resin foam molded body is obtained. When molded, the foam cell can be stably formed in a frost column shape, so that the elasticity and tactile sensation as the interior material can be further improved while maintaining high sound absorption. For example, as shown in the upper part of FIG. 6, by gradually increasing the separation speed V1 of the mold 11 at timings t4 to t5, the speed reaches the separation position L2 rather than the speed at the position where the separation mold 11 starts to separate from the proximity position L1. Increase the speed at the position. Further, as shown in the lower part of FIG. 6, by increasing the separation speed V1 of the mold 11 stepwise at timings t4 to t5, the separation position L2 is reached rather than the speed at the position where the separation position L1 starts to separate. Increase the speed at the position where you want to go.

When the separation step is completed, the mold 11 is held at the separation position L2 for a predetermined time (timing t5 to t6 in FIG. 5). The time T2 for holding the mold in the spaced position is sufficient if the internal foamed layer is cooled and solidified, for example, about 30 seconds.
Finally, the molds 11 and 12 in the clamped state are opened at the separation position L2, the cavity is opened (timing t6 to t7 in FIG. 5), and the resin foam molded body M10 is taken out to complete a series of manufacturing cycles. To do.

  The formed resin foam molded body M10 has a thin and widened shape, and has a non-foamed skin layer M16 formed on the surface thereof, and has frost columnar foam cells 13 that are elongated by 1 mm or more of open cells in the separating direction. A breathable foam layer M12 is formed. Even if the volume of each foam cell is large and the structure of the resin foam molding is low density, the distance between the foam cell walls in the direction perpendicular to the separation direction is small, so it is lightweight and buckles against compressive force in the thickness direction. It is difficult to obtain good elasticity and good tactile sensation as an automobile interior material. In addition, since the foam cell is formed in the shape of a very elongated open-cell frost column, a resin foam molded body having air permeability is formed inside, and high sound absorption is obtained.

  When using this resin foam molded article as a sound absorbing material, it suffices to process the internal foam layer on the surface. For example, the resin foam molded article is cut in parallel with the surface in the middle of the thickness direction to remove the foam layer. The sound absorbing material may be formed by being exposed, or the sound absorbing material may be formed by cutting the resin foam molded body in the thickness direction to expose the foam layer.

(2) Modification:
As shown in FIGS. 7 to 9, by separating the pair of molds by making the temperature distribution in the separation direction different in the direction D2 perpendicular to the separation direction D1 in the resin molding material filled in the cavity, While forming a non-foamed skin layer (M26a, b) on the surface, a cavity (M25) corresponding to the difference in the temperature distribution may be formed inside to mold the resin foam molded article.

In the example shown in FIGS. 7 and 8, the separation D1 is perpendicular to the separation direction D1 in the resin molding material M1 filled in the cavity so as to form the projections (dimples) M27 and the depressions M28 on the surface. By varying the temperature distribution in the direction, the cavity M25 corresponding to the difference in the temperature distribution is formed inside, and the resin foam molded body M20 is molded.
This resin foam molded body M20 has a shape in which a large number of convex portions M27 are bulged from the concave portion M28 on one surface in the thickness direction (separating direction D1), and is a vertical cross-sectional view as viewed from the position A1-A1 in FIG. As shown in the lower part of FIG. 7, the skin layer M26a along the shape of the convex portion M27 and the concave portion M28, the skin layer M26b on the surface side having no irregularities, and the foam layer M22 sandwiched between both skin layers M26a, b It is set as the structure which has. In the foam layer M22, foam cells M23 are formed in which bubbles are continuously extended in a frost column shape so as to be 1.0 mm or more with a separation distance d2 or less in the separation direction D1 corresponding to the position of the recess M28. Corresponding to the position of M27, the foam cell is cut halfway to form a cavity M25.

FIG. 8 is a cross-sectional view showing the structure of the pair of molds 21 and 22 and the temperature distribution of the resin molding material M1 filled in the cavity C2 formed between the molds 21 and 22.
On the molding surface of the mold 21 on the side where the irregularities are formed, a concave portion 21a having a shape corresponding to the convex portion M27 of the resin foam molded body is formed, and a shape corresponding to the concave portion M28 of the resin foam molded body is formed. Convex part 21b is formed. The other molds 21 and 22 have the same configuration as the molds 11 and 12 described above. It is assumed that the distance d1 between the molds 21 and 22 at the close position is a distance between the convex portion 21b of the mold 21 and the molding surface of the mold 22.
The height of the convex portion M27 from the concave portion M28 (depth of the concave portion 21a from the convex portion 21b) can be set to, for example, 0.2 to 2.0 mm from the viewpoint of reliably forming the cavity M25. When forming each convex part M27 so that the cross section along the surface is circular, the diameter of the convex part M27 (diameter of the concave part 21a) is, for example, 2.0 to 10 from the viewpoint of reliably forming the cavity M25. .0 mm.
In addition, the convex part M27 can be made into various shapes, such as a cross-sectional polygon. Further, the surface of the resin foam molded body may have a concavo-convex pattern in which a large number of concave portions are formed on the convex portions. The unevenness of the resin foam molded body may be formed not only on one side but also on both sides.
By forming irregularities on the surface of the resin foam molded article, a cavity is formed even when the mold separation distance d2 is shortened compared to the case where irregularities are not formed, and high air permeability is obtained, and good sound absorption is obtained. can get. Therefore, it is possible to reduce the weight, improve the sound absorption, or make the resin foam molded body thinner than a resin foam molded body having no irregularities on the surface.

  For the resin molding material M1 filled in the cavity C2, for convenience, the low temperature regions R1, R2 below a predetermined temperature (for example, the temperature at which the resin molding material solidifies) and the high temperature region R3 (FIG. 8) higher than the predetermined temperature. The area is divided into areas with dots. The temperature distribution of the resin molding material is such that in any position in the direction D2 perpendicular to the separation direction (excluding the edge of the resin foam molding that has spread thinly), the high temperature region R3 is in the low temperature region R1, R2 on the surface side. The distribution is sandwiched between. Here, the low temperature regions R1 and R2 have a substantially constant thickness, and the high temperature region R3 is expanded in the separation direction D1 at the position corresponding to the convex portion M27 than at the position corresponding to the concave portion M28. When the molds 21 and 22 are separated to a predetermined separation position in this state, a frost column-shaped foam cell M23 is formed at a position corresponding to the recess M28, while a high temperature region R3 is wide at a position corresponding to the protrusion M27. As a result, the foam cell is cut in the middle to form a cavity M25.

  As described above, since the air permeability inside the resin foam molded article is increased, it is possible to obtain light weight and high sound absorption. Moreover, when using this resin foam molding as an impact-absorbing material, since a cavity is formed inside, it can be made thin as a result of weight reduction. Moreover, when using this resin foam molded object as a sound-absorbing material, sound-absorbing property can be improved.

If the temperature distribution in the separation direction can be varied in the direction D2 perpendicular to the separation direction in the resin molding material in the cavity, the void can be formed in the foamed layer in the same manner.
FIG. 9 is a cross-sectional view showing the structure of the pair of molds 31 and 32 and the temperature distribution of the resin molding material M1 filled in the cavity C3 formed between the molds 31 and 32. As shown in FIG.
In this modification, no irregularities are formed on the surface of the resin foam molded article. Instead, the insulating material 31a is embedded in the molding surface of the molding die 31 for generating a temperature difference in accordance with the position of the cavity formed in the resin foam molded body. The insulating material is a heat insulating material such as a porous inorganic material, and is a material that reduces the amount of heat absorbed from the resin molding material to a molding die at a lower temperature than the resin molding material. The other molds 31 and 32 have the same configuration as the molds 11 and 12 described above.

The temperature distribution of the resin molding material M1 is a high temperature region in the low temperature regions R11 and R12 on the surface side at any position in the direction D2 perpendicular to the separation direction (in practice, excluding the edge of the resin foam molding that has spread thinly). R13 is sandwiched. Here, the low temperature region R11a in contact with the molding die 31 except for the insulating material 31a and the low temperature region R12 in contact with the molding die 32 have a substantially constant thickness, and the low temperature region R11b in contact with the insulating material 31a is smaller than the low temperature region R11a. getting thin. As a result, in the resin molding material M1 filled in the cavity C3, the high temperature region R3 is expanded in the separation direction D1 at the position corresponding to the insulating material 31a than at the other positions. When the molds 31 and 32 are separated to a predetermined separation position in this state, a frost column-shaped foam cell is formed at a position corresponding to a portion excluding the insulating material 31a, while a high temperature region is formed at a position corresponding to the insulating material 31a. As a result of the wide R13, the foamed cell is cut in the middle to form a cavity.
As described above, a resin foam molded body that is lightweight and capable of obtaining high sound absorption is formed.

  In addition, in the example shown in FIG. 9, since the surface becomes smooth compared with the case where unevenness is formed on the surface of the resin foam molded article, the surface needs to be smoothed to obtain a good appearance. Useful resin foam moldings are obtained. On the other hand, when forming irregularities on the surface, the structure of the mold is simple compared to the case where an insulating material is buried in the mold, and it is useful when it is required to reduce the cost of the mold. .

(3) Example:
EXAMPLES Hereinafter, although an Example is shown and this invention is demonstrated concretely, this invention is not limited by an Example.
In all of the following examples and comparative examples, an injection molding machine MD350SIV manufactured by Ube Industries Co., Ltd. (maximum clamping force 3430 kN, L / D = 20) was used as the injection molding machine, and the injection pressure of the resin molding material was set to 100 MPa. . The shape of the cavity formed between the molds at close positions was a flat plate of 200 × 400 × 2 mm, and the cavity volume was 160 cm ³ . Therefore, the distance d1 between the molds in the close position is 2 mm. In addition, the moving speed of the mold during mold clamping was set to 10 mm / second. The cavity was filled with a molten resin molding material in a full shot. The filling time of the molten resin molding material was 1 second. The moving speed for separating the mold from the proximity position to the separation position was 53 mm / second.
Further, as the inert gas, using CO ₂ gas.
Furthermore, as a capillary rheometer for measuring melt tension, a capillary rheometer “Capillograph 1C type” manufactured by Toyo Seiki Seisakusho Co., Ltd. compliant with JIS K7199 was used, and a capillary having a diameter of 1.0 mm was attached to the lower end of the cylinder. Test the temperature at the center of the cavity (the highest temperature among the resin molding materials in the cavity) when injecting molten resin molding material into the cavities between the molds in close proximity to separate the molds As the temperature, the resin molding material heated and melted to the test temperature is filled in the cylinder, the piston of the capillary rheometer is lowered at a descending speed of 10 mm / min, and the resin molding material in the cylinder is extruded from the capillary into a thread shape, At the same time, the melt tension when the extruded resin molding material was drawn at a take-up speed of 5.0 m / min was measured. When the mold is in the proximity position, the resin molding material at 210 ° C. is injected into the cavity, and the mold is held in the proximity position for 4 to 7 seconds. Then, the mold is moved to the separation position in the cavity. Since the temperature inside the skin layer (the portion that becomes the foam layer) is about 190 ° C., the test temperature was set to 190 ° C. in Examples 1 to 4 and Comparative Example 2. On the other hand, when the mold is in the proximity position, the resin molding material at 210 ° C. is injected into the cavity and the time for holding the mold in the proximity position is set to less than 1 second, and the mold is moved to the separation position. Since the temperature inside the skin layer is about 210 ° C., the test temperature was 210 ° C. in Comparative Example 1.

[Example 1]
A propylene-ethylene copolymer (Sun Allomer (trademark) polypropylene resin, grade PM970W, density 0.90 g / cm ³ , MI = 30, block copolymer) manufactured by Sun Allomer Co., Ltd. was used as the thermoplastic resin constituting the resin molding material. .
Polyslene EE207 (chemical foaming agent) manufactured by Eiwa Chemical Industry Co., Ltd. was used as a nucleating agent.
For each test section, the mixing ratio of each material is set as follows, the injection pressure of the inert gas is set as follows, the separation distance d2, the foaming magnification of the molded body, the clamping pressure, and the mold at the close positions. The holding time T1 and the moving speed V1 for separating the mold from the proximity position to the separation position were as follows. The addition amount of the nucleating agent is shown by the weight per 100 parts by weight of the resin molding material excluding the nucleating agent. The same applies to the following. Then, the resin molding material containing the nucleating agent was heated to 210 ° C., injected with an inert gas, injected into the cavity, demolded after molding, and a sample of a resin foam molding was produced as a prototype. At this time, the temperature of the mold was 30 to 60 ° C. Moreover, when the melt tension was measured for the thermoplastic resin under the conditions described above except that the test temperature was 190 ° C., it was 0.2 gf.

Test Zone 1 Test Zone 2
Thermoplastic resin 100% by weight 100% by weight
Nucleating agent 10 parts by weight 0 parts by weight Gas injection pressure (MPa) 4.0 4.0
Separation distance d2 (mm) 7.0 5.0
Foaming ratio of molded body 4.5 3.5
Clamping pressure (kN) 2000 2000
Proximity position holding time T1 6 seconds 6 seconds

[Example 2]
As a thermoplastic resin constituting the resin molding material, a propylene-ethylene copolymer (Sun Allomer (trademark) polypropylene resin, grade PMA80X, density 0.90 g / cm ³ , MI = 43, manufactured by Sun Allomer Co., Ltd., described as PE copolymer). ) And ethylene propylene rubber (described as EP rubber).
Further, talc (MICRO ACE manufactured by Nippon Talc Co., Ltd.) was used as a filler.
As the nucleating agent, Polyslene EE207 manufactured by Eiwa Kasei Kogyo Co., Ltd. as in Example 1 was used.
The blending ratio of each material is as follows, the inert gas injection pressure is as follows, the separation distance d2, the foaming magnification of the molded body, the clamping pressure, the time T1 for holding the mold in the proximity position, The moving speed V1 for separating the mold from the proximity position to the separation position was as follows. Then, the resin molding material containing the nucleating agent was heated to 210 ° C., injected with an inert gas, injected into the cavity, demolded after molding, and a sample of a resin foam molding was produced as a prototype. At this time, the temperature of the mold was 30 to 60 ° C. The melt tension of the molding resin material composed of PE copolymer, EP rubber, and talc was measured at 190 ° C. and the conditions other than the test temperature described above were 0.5 gf.

PE copolymer 60% by weight
EP rubber 30% by weight
Talc 10% by weight
Nucleating agent 10 parts by weight Gas injection pressure (MPa) 4.0
Separation distance d2 (mm) 7.0
Foaming ratio of molded body 4.5
Clamping pressure (kN) 2000
Proximity position holding time T1 5 seconds

[Example 3]
As the thermoplastic resin constituting the resin molding material, the same propylene-ethylene copolymer and EP rubber as in Example 2 were used.
Polyslene EE275F manufactured by Eiwa Chemical Industry Co., Ltd. was used as a nucleating agent.
For each test section, the mixing ratio of each material is set as follows, the injection pressure of the inert gas is set as follows, the separation distance d2, the foaming magnification of the molded body, the clamping pressure, and the mold at the close positions. The holding time T1 and the moving speed V1 for separating the mold from the proximity position to the separation position were as follows. In test group 3, a large number of cylindrical convex portions having a diameter of 3.5 mm and a height of 0.5 mm were formed on one surface in the thickness direction of the resin foam molded body sample. Here, the pitch of the protrusions is 8 mm, and the area ratio of the protrusions (the projected area of the protrusions relative to the projection area of the formed body sample when projected onto the horizontal plane perpendicular to the direction of the thickness of the formed body sample) The ratio of the total area) was 15%. Then, the resin molding material containing the nucleating agent was heated to 210 ° C., injected with an inert gas, injected into the cavity, demolded after molding, and a sample of a resin foam molding was produced as a prototype. At this time, the temperature of the mold was 30 to 60 ° C. Further, regarding the molding resin material composed of PE copolymer and EP rubber, the melt tension was 0.2 gf when the test temperature was 190 ° C. and the melt tension was measured under the conditions other than the test temperature described above.

Test Zone 1 Test Zone 2 Test Zone 3
PE copolymer 70% by weight 70% by weight 70% by weight
EP rubber 30% by weight 30% by weight 30% by weight
Nucleating agent 10 parts by weight 10 parts by weight 10 parts by weight Gas injection pressure (MPa) 3.0 3.0 3.0
Separation distance d2 (mm) 6.5 4.0 4.0
Foaming ratio of molded product 4.3 3.0 3.0
Clamping pressure (kN) 1000 1000 1000
Proximity position holding time T1 7 seconds 7 seconds 7 seconds

[Example 4]
As the thermoplastic resin constituting the resin molding material, in addition to the resin (PE copolymer and EP rubber) used in Example 2, an olefin-based thermoplastic elastomer resin (crystal pseudo-crosslinked TPO EXCELLINK 3400 manufactured by JSR Corporation. Elastomer resin). Was used).
As the nucleating agent, Polyslene EE207 manufactured by Eiwa Kasei Kogyo Co., Ltd. as in Example 1 was used.
The blending ratio of each material is as follows, the inert gas injection pressure is as follows, the separation distance d2, the foaming magnification of the molded body, the clamping pressure, the time T1 for holding the mold in the proximity position, The moving speed V1 for separating the mold from the proximity position to the separation position was as follows. Then, the resin molding material containing the nucleating agent was heated to 210 ° C., injected with an inert gas, injected into the cavity, demolded after molding, and a sample of a resin foam molding was produced as a prototype. At this time, the temperature of the mold was 30 to 60 ° C. Further, when the melt tension of the molding resin material composed of the PE copolymer, EP rubber and elastomer resin was measured at 190 ° C. and the conditions other than the test temperature described above, it was 0.6 gf.

PE copolymer 35% by weight
EP rubber 15% by weight
50% by weight of elastomer resin
Nucleating agent 10 parts by weight Gas injection pressure (MPa) 4.0
Separation distance d2 (mm) 6.5
Foaming ratio of molded product 4.3
Clamping pressure (kN) 2000
Proximity position holding time T1 7 seconds

[Comparative Example 1]
The same thing as Example 2 was used as a thermoplastic resin, a talc, and a nucleating agent which comprise a resin molding material.
The blending ratio of each material, the inert gas injection pressure, the separation distance d2, the foaming magnification of the molded body, the mold clamping pressure, and the moving speed V1 for separating the mold from the proximity position to the separation position were also the same as in Example 2. However, the time T1 for holding the mold in the proximity position was shortened to less than 1 second. Then, the resin molding material containing the nucleating agent was heated to 210 ° C., injected with an inert gas, injected into the cavity, demolded after molding, and a sample of a resin foam molding was produced as a prototype. The highest temperature among the resin molding materials in the cavity when the mold was separated to the separation position was about 210 ° C. The temperature of the mold was 30 to 60 ° C. Further, for a molding resin material composed of PE copolymer, EP rubber, and talc, when the test temperature was 210 ° C. and the melt tension was measured under the above-mentioned conditions other than the test temperature, the molding resin was less than 0.1 gf and taken up. The material was often cut out, and the molded resin material could not be continuously taken up, making it difficult to measure the melt tension.

[Comparative Example 2]
As the thermoplastic resin constituting the resin molding material, an olefin-based thermoplastic elastomer resin (crystal pseudo-crosslinked TPO EXCELLINK 3700N manufactured by JSR Corporation, described as an elastomer resin) was used.
As the nucleating agent, Polyslene EE207 manufactured by Eiwa Kasei Kogyo Co., Ltd. as in Example 1 was used.
The blending ratio of each material is as follows, the inert gas injection pressure is as follows, the separation distance d2, the foaming magnification of the molded body, the clamping pressure, the time T1 for holding the mold in the proximity position, The moving speed V1 for separating the mold from the proximity position to the separation position was as follows. Then, the resin molding material containing the nucleating agent was heated to 210 ° C., injected with an inert gas, injected into the cavity, demolded after molding, and a sample of a resin foam molding was produced as a prototype. At this time, the temperature of the mold was 30 to 60 ° C. In addition, for the elastomer resin, when the test temperature was set to 190 ° C. and the melt tension was measured under the conditions described above except for the test temperature, the resin was cut when the resin extruded into a string was taken out, and the melt tension could be measured. could not. As a reference, when the test temperature was raised to 210 ° C. and the take-up speed of the resin was lowered to 1.0 m / min and the melt tension was measured, it was 18.8 gf. Therefore, if the capillary tension is increased and the melt tension is measured at a test temperature of 190 ° C. and a take-off speed of 5.0 m / min, it is estimated that the melt tension is greater than 30 gf.

100% by weight of elastomer resin
Nucleating agent 10 parts by weight Gas injection pressure (MPa) 4.0
Separation distance d2 (mm) 5.0
Foaming ratio of molded product 3.0
Clamping pressure (kN) 1000
Proximity position holding time T1 4 seconds

[Test method]
Each resin foam molded body sample of Examples and Comparative Examples is cut in parallel with the thickness direction (separation direction D1), and the cross-sectional structure, the shape of the foam cell, and the foam state are observed, and the frost columnar foam cell in the thickness direction. The length of was measured. In addition, the average of the length of the foam cell in the range of 30 mm in the direction perpendicular to the thickness direction in the sample cross section was obtained and used as the length of the foam cell.
In addition, as shown in FIG. 3, a test piece was prepared by cutting in parallel with the thickness direction so that the thickness d11 was 5.0 mm in the direction D2 perpendicular to the separation direction D1, and the fragile shape defined in JIS L1096. The air permeability in the vertical direction D2 (unit: cc / cm ² / sec) was measured according to the air permeability measurement method by the method. In addition, when the test piece alone did not satisfy the prescribed test area, a plurality of test pieces were arranged to match the test area. And the atmospheric | air pressure difference before and behind a test piece was measured, and it converted into air permeability from the conversion table.
Further, as shown in FIG. 10, a plurality of vent holes M16a penetrating the skin layer M16 from one side in the thickness direction to the foamed layer M12 are formed by piercing a needle having a required diameter for each resin foam molded body sample. In accordance with the normal incidence method specified in ISO 10534-2, sound is incident from the skin layer side where the air vent is formed, and the normal incident sound absorption coefficient (unit:%) for each 1/3 octave band in the range of 1000 to 6300 Hz. ) Was measured. Here, each ventilation hole M16a was formed so that the vertical cross section with respect to the thickness direction of the molded body sample was circular, and had a diameter of 2.0 mm and a depth of 2.0 mm. In addition, the air holes are arranged in a staggered manner, the space between the air holes is 3.0 to 5.0 mm, the air hole opening rate (perpendicular to the direction of the thickness of the molded product sample). The ratio of the total area of the projected area of the vent holes to the projected area of the molded body sample when projected onto the horizontal plane was 18%. In the test group 3 of Example 3, air holes were formed in the skin layer on the side having no uneven pattern.

[Test results]
The results are shown in Table 1. In the column of the sound absorption coefficient, the maximum normal incident sound absorption coefficient (unit:%) is shown in the measurement frequency range (1000 to 6300 Hz).
Moreover, the photograph of the cross section of the resin foam molded object sample of Example 1 test section 1, Example 3 test section 3, and Comparative Examples 1 and 2 is shown in FIGS.

As shown in FIG. 13, in the resin foam molded article sample of Comparative Example 1 in which the melt tension of the molded resin material was less than 0.1 gf, a large crack occurred in the middle of the thickness direction, and a frost column-shaped foam cell was formed. Therefore, it became a resin foam molded body that was easily buckled against the compressive force in the thickness direction. Note that, in the sample of Comparative Example 1, when the cross section is cut out, it is split into two due to continuous cracks, so the end of the sample is temporarily fixed with a tape. Therefore, in FIG. 13, the tape is also imaged.
As shown in FIG. 14, in the resin foam molded body sample of Comparative Example 2 in which the melt tension of the molded resin material was large (greater than estimated 30 gf), frost column-shaped foam cells were not formed, and the foam cells in the thickness direction The length was less than 1 mm, the air permeability was not more than 0.33 cc / cm ² / sec, and the air permeability was low, and the normal incident sound absorption coefficient was 28%, and good sound absorption was not obtained.
On the other hand, for example, as shown in FIGS. 11 and 12, in the resin foam molded body sample of the example in which the melt tension of the molded resin material was 0.2 to 0.6 gf, the frost column-shaped foam cell having a thickness of 1 mm or more in the thickness direction. The air permeability is 0.4 cc / cm ² / sec or more and air permeability is obtained inside the sample, and the normal incident sound absorption coefficient is 45 to 97%, which is better than the comparative example. Obtained. Moreover, when the resin foam molded object sample of the Example was pushed in the thickness direction, the elasticity was better and the tactile sensation was better than the comparative example.
From the above, when the resin foam molded body is formed by extending the foamed cells in the form of frost columns so as to be 1.0 mm or more in the separation direction of the mold, the air permeability is 0.4 cc / cm. Air permeability of ² / sec or more is obtained in the interior, it is lightweight and is not easily buckled against compressive force in the thickness direction, and it has good elasticity and good tactile sensation as an automobile interior material, and high sound absorption is obtained. It was confirmed.
Also, if the molding resin material has a low melt tension of less than 0.1 gf, the foam cell walls are cut when the mold is separated, and the foam cell does not form a frost columnar structure. It was found that even when the mold was separated from the large (greater than estimated 30 gf), the foamed cells did not have a frost columnar structure and there was almost no air permeability. If the melt tension is less than 0.1 gf, the foamed cell is presumed to be cut in the middle of the thickness direction because the viscosity of the molding resin material is small. If the melt tension is too large, the foam cell does not communicate in the thickness direction. It is speculated that it will not be.

  Comparing test group 1 and test group 2 of Example 1, in test group 2 in which no nucleating agent was used, frost columnar foam cells had a rough structure, whereas in test group 2 in which nucleating agent was used, In No. 1, the frost columnar foam cells were formed more densely and uniformly, and when the resin foam molded body sample was pushed in the thickness direction, the tactile sensation was better than in the test section 2. Therefore, when a nucleating agent is used, the nucleating agent becomes an appropriate nucleating material, bubbles are formed in an appropriately dense and uniform manner, and the tactile sensation as an interior material is improved while maintaining high sound absorption. confirmed.

A comparison between test group 2 and test group 3 in Example 3 shows that although air permeability was 0.4 cc / cm ² / sec and normal incidence sound absorption coefficient was 45% in test group 2 where the surface was not uneven. On the other hand, in the test section 3 having a rough surface, the air permeability was 18.0 cc / cm ² / sec and the air permeability was improved, and the normal incident sound absorption rate was 80% and the sound absorption was improved.
From the above, it was confirmed that a high sound-absorbing property can be obtained by forming a cavity in the interior so as to form irregularities on the surface and molding a resin foam molded article.

  As described above, according to the present invention, various aspects make it possible to obtain a good elasticity and good tactile sensation as an automobile interior material that is lightweight but hardly buckled against a compressive force in the thickness direction. It is possible to provide a resin foam molded article capable of obtaining sound absorption and a method for producing the same.

The figure which shows typically the manufacturing method of a resin foaming molding. The figure which shows a foam injection molding machine typically. The vertical sectional view which shows the structure of a resin foaming molding. The vertical sectional view which shows the structure of another resin foaming molding. The timing chart which shows the movement amount of a shaping | molding die. The timing chart which shows the movement amount of a shaping | molding die in a modification. The perspective view which shows the external appearance of the resin foaming molding concerning a modification, and sectional drawing which shows a structure. Sectional drawing which shows the temperature distribution of the resin molding material with which the structure of the shaping | molding die and the cavity were filled. Sectional drawing which shows the temperature distribution of the resin molding material with which the structure of the shaping | molding die and the cavity were filled. The schematic diagram for demonstrating the measurement conditions of a normal incidence sound absorption coefficient. Example 1 A photograph of a cross section of a resin foam molded article sample in Test Section 1. The photograph of the cross section of the resin foaming molding sample of Example 3 test section 3 which formed the unevenness | corrugation in the surface. The photograph of the section of the resin foam molding object sample of comparative example 1. The photograph of the section of the resin foam molding object sample of comparative example 2.

Explanation of symbols

10: Foam injection molding machine,
11, 12 ... a pair of molds,
C1-C3 ... cavity,
D1 ... separation direction, D2 ... direction perpendicular to the separation direction,
L1: a predetermined proximity position, L2: a predetermined separation position,
M1 ... resin molding material,
M10, M20 ... resin foam molding,
M12, M22 ... foam layer, M13, M23 ... foam cell,
M14: middle layer,
M16, M26a, M26b ... skin layer,
M25 ... hollow, M27 ... convex, M28 ... concave,

Claims (12)

A cavity formed when a pair of molds that can approach and separate from each other is brought close to a predetermined proximity position, and a resin molding material containing a foaming agent is filled in the cavity, and then the pair of molds are separated to a predetermined separation position. A resin foam molded body formed by forming foam cells in the resin molding material in the cavity by expanding the cavity,
The distance between the pair of molds when in the proximity position is 1.0 to 10.0 mm, and the separation distance from the proximity position to the separation position is 1.0 to 50.0 mm. Resin foam molding, in which foam cells are stretched in the form of frost columns to form a foamed skin layer, and the foam is continuously formed so that the distance between the pair of molds is 1.0 mm or more in the separation direction of the pair of molds. body.   2. The resin foam molded article according to claim 1, wherein the resin molding material in the cavity contains a nucleating agent and is injected with an inert gas at 0.5 to 20 MPa.   The resin foam molding according to claim 1 or 2, wherein a volume ratio of the cavities when the pair of molding dies are separated from the proximity position to the separation position is 2 to 10.   The speed at which the pair of molds are separated from each other is formed by increasing the speed at a position reaching the separation position rather than a speed at a position at which the pair of molds are separated from the proximity position. The resin foam molded article according to any one of the above. 2. The JIS L1096 fragile method has a gas permeability of 0.4 cc / cm ² / sec or more when cut to a thickness of 5.0 mm in a direction perpendicular to the separation direction. The resin foam molded article according to any one of claims 4 to 5.   In the resin molding material filled in the cavity, the temperature distribution in the separation direction is varied in a direction perpendicular to the separation direction, and the pair of molds are separated to form a cavity corresponding to the difference in the temperature distribution. The resin foam molded article according to any one of claims 1 to 5, which is formed and molded inside.   A cavity corresponding to the difference in the temperature distribution is formed by making the temperature distribution in the separation direction different in the direction perpendicular to the separation direction in the resin molding material filled in the cavity so as to form irregularities on the surface. The resin foam molded article according to claim 6, which is formed and molded inside. The melt tension of the resin molding material is 0.1 to 30 gf with the temperature of the resin molding material inside the skin layer in the cavity when the pair of molding dies are spaced apart as the test temperature. The resin foam molded article according to any one of claims 1 to 7, which is molded as described above.
However, for the melt tension, a capillary rheometer compliant with JIS K7199 was used, a capillary having a diameter of 1.0 mm was attached to the lower end of the cylinder, and the resin molding material at the test temperature was filled into the cylinder. The rheometer piston is lowered at a descending speed of 10 mm / min to obtain a melt tension measured when the resin molding material in the cylinder is pushed out from the capillary into a thread shape and taken out at a take-up speed of 5.0 m / min. A cavity formed when a pair of molds that can approach and separate from each other is brought close to a predetermined proximity position, and a resin molding material containing a foaming agent is filled in the cavity, and then the pair of molds are separated to a predetermined separation position. A resin foam molded body formed by forming foam cells in the resin molding material in the cavity by expanding the cavity,
A non-foamed skin layer is formed on the surface by separating the pair of molds by differentiating the temperature distribution in the separation direction in a direction perpendicular to the separation direction in the resin molding material filled in the cavity. However, a resin foam molded article formed by forming a cavity corresponding to the difference in temperature distribution inside. A cavity formed when a pair of molds that can approach and separate from each other is brought close to a predetermined proximity position, and a resin molding material containing a foaming agent is filled in the cavity, and then the pair of molds are separated to a predetermined separation position. And expanding the cavity to form a foamed cell in the resin molding material in the cavity to mold a resin foam molded article,
The distance between the pair of molds when in the proximity position is 1.0 to 10.0 mm, and the separation distance from the proximity position to the separation position is 1.0 to 50.0 mm. While forming the foam skin layer, the foamed cells are elongated in the form of frost columns by continuing the bubbles in the separation direction of the pair of molds so that the distance is equal to or less than 1.0 mm. A method for producing a resin foam molded article, comprising molding. A cavity formed when a pair of molds that can approach and separate from each other is brought close to a predetermined proximity position, and a resin molding material containing a foaming agent is filled in the cavity, and then the pair of molds are separated to a predetermined separation position. And expanding the cavity to form a foamed cell in the resin molding material in the cavity to mold a resin foam molded article,
A non-foamed skin layer is formed on the surface by separating the pair of molds by differentiating the temperature distribution in the separation direction in a direction perpendicular to the separation direction in the resin molding material filled in the cavity. However, a method for producing a resin foam molded article, wherein the resin foam molded article is formed by forming a cavity corresponding to the difference in temperature distribution inside. The resin foam is made by using a material containing talc as the resin molding material to make the foam cell small, and by adjusting the weight ratio of the talc contained in the resin molding material to adjust the size of the foam cell. The method for producing a resin foam molded article according to claim 9 or 10, wherein the molded article is molded.