JP2013095070A - Injection mold of three-piece structure, injection molding apparatus, and injection molding method - Google Patents

Abstract

A three-sheet injection mold that can obtain a high-quality single-layer and multi-layer molded article in a three-sheet injection mold, injection molding apparatus, and injection molding method using a rack and pinion mechanism. An injection molding apparatus and an injection molding method are provided.
An injection mold having a three-piece structure including a fixed mold 12, a movable mold 14, a rotating mold 16, and a rack and pinion mechanism 20, and the rack and pinion mechanism 20 includes a pinion. 22 is supported so as to be movable in the mold opening / closing direction with respect to the rotating mold 16, and the pinion 22 is pressed against at least one side of the fixed mold 12 and the movable mold 14, so that the pinion 22 is a tooth 25 of the racks 24 and 26. , 27 is further provided, and in the state where the pinion 22 is pressed against the teeth 25, 27 of the racks 24, 26 by the pinion moving mechanism 30, the rotary mold 16 is opened and closed by the rack and pinion mechanism 20. It is configured to be movable in the direction.
[Selection] Figure 1

Description

  The present invention relates to a three-sheet injection mold and an injection molding apparatus for moving a rotary mold in a mold opening and closing direction by a rack and pinion mechanism, and an injection molding method using the same.

  Conventionally, a fixed mold (fixed mold) attached to the fixed platen, a movable mold (movable mold) attached to the movable platen, and a rotation provided between the fixed mold and the movable mold. A multicolor molding die (a three-sheet injection molding die) including a side die (rotating die) is known (see Patent Document 1). A multi-color molding die disclosed in Patent Document 1 is provided with a rack and pinion mechanism including a pair of racks and pinions on its side surface, and this rack and pinion mechanism supports movement of the movable mold in the mold opening and closing direction. Thus, the rotating side mold is configured to move in the mold opening / closing direction. The configuration in parentheses in the description relating to Patent Document 1 shows the configuration of the present invention that is considered to correspond to the configuration of the prior art immediately before the parenthesis for convenience of explanation, It does not imply that the configuration is the same or similar.

  A conventional rack and pinion mechanism such as that used in the multicolor molding die of Patent Document 1 is shown in FIG. 17A in order to smoothly mesh the rack and the pinion and rotate the pinion without hindrance. Thus, backlash α and β are provided between the teeth 111 and 113 of the pair of racks 110 and 112 and the teeth 115a and 115b of the pinion 114, respectively, and the teeth 115a of the pinion 114 with respect to the teeth 111 and 113 of the racks 110 and 112 are provided. It is formed so as to avoid biting of 115b.

  On the other hand, foam molding for molding foam molded products from foamable molten resin has been conventionally performed for the purpose of weight reduction and deformation suppression of products, functionalization such as heat insulation characteristics and sound absorption characteristics, and cost reduction by reducing material consumption. It is done. As such foam molding, after injecting and filling foamable molten resin into the mold cavity, the mold is micro-opened to expand the volume of the mold cavity and expandable molten resin in the mold cavity. The expanded foam molding method that forms foamed molded products with foamed cells inside covered with an unfoamed skin layer by foaming and expanding is a molding with high foaming efficiency such as foam controllability and stabilization of foam quality. It is known as a law (see Patent Document 2).

  Conventionally, as an injection molding method for molding, for example, a glass resin molded product, a molten resin is injected and filled into a mold cavity whose volume has been expanded in advance by a predetermined amount, and then the volume of the mold cavity is reduced. By applying a clamping press force to the molten resin in the mold cavity, an injection press molding method that suppresses deformation of the molded product, and for the same purpose, by the molten resin pressure in the injection-filled mold cavity There is known a molding method such as an injection compression molding method in which the mold cavity volume is expanded by a predetermined amount, and then the mold cavity volume is reduced to apply a clamping compression force to the molten resin in the mold cavity. These injection press molding method and injection compression molding method are called compression molding methods.

JP 2010-064278 A JP 2000-351142 A

  However, when an expansion foam molding method, an injection press molding method, or an injection compression molding method is performed with an injection mold having a three-sheet structure using a rack and pinion mechanism such as the multi-color molding die of Patent Document 1, backlash is performed. Therefore, there is a problem that high-precision mold opening and closing operations cannot be performed due to the influence of the above, and a high-quality foam molded product, injection press molded product, or injection compression molded product cannot be obtained.

  That is, in the multicolor molding die (three-sheet injection molding die) of Patent Document 1, the movable side die (movable die) and the rotary side die (rotary die) are closed from the mold open state. In the process of moving in the direction and clamping, it is considered that the rack and pinion of the rack and pinion mechanism are in the state shown in FIG. Assuming this, in the movement of the movable side mold and the rotation side mold in the mold opening direction, from the time when the movable side mold starts to move in the mold opening direction until the rotation side mold starts to move in the mold opening direction. First, from the state of FIG. 17 (a), as shown in FIG. 17 (b), the teeth 111 of the lower rack 110 on the movable side come into contact with the teeth 115a on the lower side of the pinion 114 (that is, 17 (a), the lower rack 110 moves in the mold opening direction (in FIG. 17B, the white arrow indicates the movement direction of the lower rack 110, and the black arrow indicates , Showing contact points). After that, as shown in FIG. 17C, the teeth 111 of the lower rack 110 on the movable side push the teeth 115a on the lower side of the pinion 114 in the mold opening direction, so that the teeth 115b on the upper side of the pinion 114 become The pinion 114 rotates clockwise and the lower rack 110 moves in the mold opening direction until it comes into contact with the teeth 113 of the upper rack 112 on the fixed side (ie, by the backlash β in FIG. 17B). . After such an operation, the upper teeth 115b of the pinion 114 push the teeth 113 of the fixed upper rack 112 that is fixed and does not move in the direction of the fixed mold, thereby rotating the pinion 114 clockwise. , And the rotation-side mold on which the pinion 114 is rotatably arranged starts moving in the direction of the movable mold (the mold opening direction) (in FIG. 17C, the white arrow indicates the lower side The moving direction of the rack 110 and the rotating / moving direction of the pinion 114 are shown, and the black arrow indicates the contact point). As described above, the multicolor molding die disclosed in Patent Document 1 causes a difference in the mold opening amount of both mold cavities by a maximum α + β due to the backlash of the rack and pinion mechanism (FIG. 17 (c). )) And during mold opening from the mold closed state or during mold closing from the mold open state, pressure in both mold cavities (for example, injection-filled molten resin pressure or foaming melting in the expanded foam molding method) When there is a difference in the resin foaming pressure, etc., a force in the mold opening / closing direction corresponding to the difference acts on the rotation side mold, and there is no restriction in the mold opening / closing direction other than the engagement of the rack and pinion. However, it suddenly moves in the mold opening and closing direction by the amount of backlash between the rack and pinion, the mold opening amount of both mold cavities is different, the mold opening speed and mold closing speed become unstable, etc. High precision There is a problem that the mold opening operation and the mold closing operation cannot be performed. The backlash problem of such a rack and pinion mechanism is particularly an expansion that requires accurate micro mold opening amount and micro mold opening position holding, and stable mold opening speed and mold closing speed control. This is a problem in foam molding, injection press molding, and injection compression molding.

  Therefore, the present invention provides a three-sheet injection capable of obtaining a high-quality single-layer and multi-layer molded product in a three-sheet injection mold, injection molding apparatus, and injection molding method using a rack and pinion mechanism. An object is to provide a molding die, an injection molding apparatus, and an injection molding method.

  To achieve the above object, a three-piece injection mold according to the present invention includes a fixed mold, a movable mold that faces the fixed mold and is movable in the mold opening and closing direction, It is movable between the fixed mold and the movable mold in the mold opening / closing direction and is rotatable about a rotation axis perpendicular to the mold opening / closing direction, and faces the fixed mold at one rotational position, A mold cavity can be formed between the fixed mold and the movable mold facing the movable mold at another rotational position rotated about the rotation axis from the one rotational position. A rotating mold having at least two mold dividing surfaces capable of forming a mold cavity, a pinion provided in the rotating mold, and a pinion provided in the fixed mold and the movable mold, respectively. Has teeth that can mesh with A rack and pinion mechanism that moves the rotating mold in the mold opening / closing direction in response to the movement of the movable mold in the mold opening / closing direction, and a three-sheet injection mold, The rack and pinion mechanism supports the pinion so as to be movable in a mold opening / closing direction with respect to the rotating mold, and presses the pinion to at least one side of the fixed mold and the movable mold, And a pinion moving mechanism that can press against the teeth of the rack. When the pinion is pressed against the teeth of the rack by the pinion moving mechanism, the rotating mold is moved in the mold opening / closing direction by the rack and pinion mechanism. It is configured to be possible.

  In the three-piece injection mold according to the present invention, the pinion moving mechanism is configured such that when the fixed mold, the movable mold and the rotating mold are opened, the pinion is moved to the fixed mold side or the movable mold. It is preferable that the pinion is pressed to the movable mold side when the fixed mold, the movable mold, and the rotating mold are closed.

  Further, in the three-sheet injection mold according to the present invention, the rotary mold is provided with a rotary mold support portion to which the pinion is attached and which is provided so as to be movable in the mold opening and closing direction by the rack and pinion mechanism. The rotating mold support portion is supported so as to be rotatable about a rotation axis orthogonal to the mold opening / closing direction, and is opposed to the fixed mold at one rotational position, and between the fixed mold and the mold cavity A mold division that can form a mold cavity between the movable mold and the movable mold at another rotational position rotated about the rotational axis from the one rotational position. A rotating mold part having at least two surfaces and a rotating mechanism for rotating the rotating mold part around the rotation axis may be provided.

  An injection molding apparatus according to a first example of the present invention is an injection molding apparatus including the above-described three-sheet injection mold, and a fixed platen to which the fixed mold can be attached, and the fixed platen. A movable plate capable of moving in the mold opening / closing direction with respect to the fixed plate and capable of attaching the movable mold, and a mold clamping device for moving the movable plate in the mold opening / closing direction and clamping the mold. It is characterized by providing.

  An injection molding apparatus according to a second example of the present invention includes a fixed part including a fixed mold and a movable mold facing the fixed mold, and is movable in a mold opening / closing direction with respect to the fixed part. And a movable part provided on the rotation axis orthogonal to the mold opening and closing direction.The movable part is opposed to the fixed mold at one rotational position, and a mold cavity is formed between the movable mold and the fixed mold. A mold dividing surface that can be formed and is opposed to the movable mold at another rotational position rotated about the rotational axis from the one rotational position and can form a mold cavity with the movable mold. A rotating mold having at least two rotating molds, a rotating part provided between the fixed part and the movable part so as to be movable in the mold opening / closing direction, and a mold for clamping the mold by moving the movable part in the mold opening / closing direction. The fastening device and the pin provided on the rotating part ON, and provided with racks that are respectively provided on the fixed part and the movable part and have teeth that can mesh with the pinion, and in response to the movement of the movable part in the mold opening and closing direction, the rotating part in the mold opening and closing direction. A rack-and-pinion mechanism for moving the rack-and-pinion mechanism, wherein the rack-and-pinion mechanism supports the pinion so as to be movable in a mold opening / closing direction with respect to the rotating part, and also fixes the pinion to the fixed part. And a pinion moving mechanism that can be pressed against at least one side of the movable part and press the pinion against the teeth of the rack, and in the state where the pinion is pressed against the teeth of the rack by the pinion moving mechanism The rotating part can be moved in the mold opening / closing direction by an and pinion mechanism. In the injection molding apparatus according to the second example of the present invention, the fixed part includes the fixed mold and a fixed plate to which the fixed mold can be attached, and the movable part includes the movable mold, The movable mold may be provided with a movable platen, and the rack may be provided on the fixed platen and the movable platen, respectively.

  An injection molding method according to a first example of the present invention is an injection molding method in which expansion foam molding is performed using the above-described injection molding apparatus, wherein the fixing is performed after mold clamping at a first rotational position of the rotary mold. A primary molding step of molding a primary molded body by injection-filling molten resin into a first mold cavity formed between the mold and the rotating mold, and after the primary molding step, the primary molded body is The movable mold and the rotating mold are opened in a state of being held in a fixed mold, the rotating mold is rotated to the second rotation position, and the other mold dividing surface of the rotating mold is moved. In a rotation step for facing the fixed mold and a second rotation position of the rotary mold, a molten resin is formed in a third mold cavity formed between the fixed mold and the rotary mold after clamping. Injection-filled into at least a part of the primary molded body A laminated molding step of laminating a secondary molded body, and at least one of the primary molding step and the secondary molding step is a step of molding a foam molded body from a foamable molten resin, and injection of the foamable molten resin A mold clamping releasing step for releasing the mold clamping state after filling, and a mold opening correction pressing step for pressing the pinion toward the fixed mold by the pinion moving mechanism in parallel with or after the mold clamping releasing step; In a state where the pinion is pressed to the fixed mold side by the mold opening correction pressing step, the movable mold and the rotating mold are opened by a predetermined amount in the mold opening / closing direction with respect to the fixed mold, A foaming mold opening step of foaming and expanding the foamed resin injected and filled in the mold cavity.

  An injection molding method according to a second example of the present invention is an injection molding method in which expansion foam molding is performed using the above-described injection molding apparatus, wherein the fixing is performed after mold clamping at a first rotational position of the rotary mold. A primary molding step of molding a primary molded body by injection-filling molten resin into a first mold cavity formed between the mold and the rotating mold, and after the primary molding step, the primary molded body is The movable mold and the rotating mold are opened in a state where the rotating mold is held, and the rotating mold is rotated to the second rotation position to hold the primary molded body. And a fourth rotation step formed between the movable mold and the rotating mold after clamping at a second rotation position of the rotating mold at a second rotation position where the mold dividing surface is opposed to the movable mold. The mold cavity is filled with molten resin by injection filling. A laminate molding step of laminating a secondary molded body on at least a part of the body, and at least one of the primary molding step and the secondary molding step is a step of molding a foam molded body from a foamable molten resin. A mold clamping release step for releasing the mold clamping state after injection filling of the foamable molten resin, and in parallel with or after the mold clamping release step, the pinion is pressed to the fixed mold side by the pinion moving mechanism. In the mold opening correction pressing step and the state where the pinion is pressed to the fixed mold side by the mold opening correction pressing step, the movable mold and the rotating mold are placed in the mold opening / closing direction with respect to the fixed mold. And a foaming mold opening step of opening the foamed resin by a predetermined amount and foaming and expanding the foamed resin injected and filled in the mold cavity.

  An injection molding method according to a third example of the present invention is an injection molding method in which expansion foam molding is performed using the above-described injection molding apparatus, and a mold dividing surface of one of the fixed mold and the rotary mold, A mold clamping step of forming a second mold cavity by clamping the mold to form a first mold cavity, and clamping the movable mold and another mold dividing surface of the rotary mold; After the mold clamping step, a foamable resin injection filling step of injecting and filling foamable molten resin into at least one of the first mold cavity and the second mold cavity, and after the foamable resin injection filling step, the mold clamping is performed. A mold clamping releasing step for releasing the state, a mold opening correction pressing step for pressing the pinion toward the fixed mold by the pinion moving mechanism in parallel with or after the mold clamping releasing step, and the mold opening correction The pressing step In a state where ON is pressed to the fixed mold side, the movable mold and the rotating mold are opened by a predetermined amount in the mold opening / closing direction with respect to the fixed mold, and in the foamable resin injection filling step A foaming mold opening step of foaming and expanding the foamed molten resin injected and filled in the mold cavity. In the injection molding method according to the third example of the present invention, in the foamable resin injection filling step, after the mold clamping step, the foamable molten resin is applied to both the first mold cavity and the second mold cavity. The step of injection filling is preferable.

  An injection molding method according to a fourth example of the present invention is an injection molding method in which injection press molding is performed using the above injection molding apparatus, wherein the fixing is performed after mold clamping at a first rotational position of the rotary mold. A primary molding step of molding a primary molded body by injection-filling molten resin into a first mold cavity formed between the mold and the rotating mold, and after the primary molding step, the primary molded body is The movable mold and the rotating mold are opened in a state of being held in a fixed mold, the rotating mold is rotated to the second rotation position, and the other mold dividing surface of the rotating mold is moved. In a rotation step for facing the fixed mold and a second rotation position of the rotary mold, a molten resin is formed in a third mold cavity formed between the fixed mold and the rotary mold after clamping. Injection-filling at least part of the primary molded body A laminate molding step of laminating a secondary molded body, and at least one of the primary molding step and the secondary molding step is a step of molding an injection press molded body, and the pinion is moved by the pinion moving mechanism. A mold closing correction pressing step for pressing the movable mold side and a state in which the pinion is pressed to the movable mold side by the mold closing correction pressing step is a predetermined amount between the fixed mold and the rotating mold. The fixed mold, the movable mold, and the rotary mold are closed to a position where the micro mold is opened, and a mold closing process for forming the mold cavity, and after the mold closing process, Injecting and filling molten resin with injection filling process, in conjunction with the injection filling process or after the injection filling process, the fixed mold, the movable mold and the rotating mold are connected to a predetermined mold clamping plate. And clamping a force, characterized in that it comprises a injection press step of applying the clamping pressing force to the molten resin within the mold cavity.

  An injection molding method according to a fifth example of the present invention is an injection molding method in which injection press molding is performed using the above injection molding apparatus, wherein the fixing is performed after mold clamping at a first rotational position of the rotary mold. A primary molding step of molding a primary molded body by injection-filling molten resin into a first mold cavity formed between the mold and the rotating mold, and after the primary molding step, the primary molded body is The movable mold and the rotating mold are opened in a state where the rotating mold is held, and the rotating mold is rotated to the second rotation position to hold the primary molded body. And a fourth rotation step formed between the movable mold and the rotating mold after clamping at a second rotation position of the rotating mold at a second rotation position where the mold dividing surface is opposed to the movable mold. The mold cavity is filled with molten resin by injection filling. A molding step of laminating a secondary molded body on at least a part of the shape, and at least one of the primary molding step and the secondary molding step is a step of molding an injection press molded body, and the pinion movement A mold closing correction pressing step for pressing the pinion to the movable mold side by a mechanism, and a state in which the pinion is pressed to the movable mold side by the mold closing correction pressing step, the fixed mold and the rotating mold A mold closing process for closing the fixed mold, the movable mold and the rotating mold to a position where a space between the molds is opened by a predetermined amount to form the mold cavity, and after the mold closing process Injecting and filling the mold cavity with molten resin, and in conjunction with the injection filling process or after the injection filling process, the fixed mold, the movable mold and the rotation Mold and mold clamping in a predetermined mold clamping press force, characterized in that it comprises a injection press step of applying the clamping pressing force to the molten resin within the mold cavity.

  An injection molding method according to a sixth example of the present invention is an injection molding method in which injection press molding is performed using the above-described injection molding apparatus, and a mold that presses the pinion toward the movable mold by the pinion moving mechanism. In the state where the pinion is pressed toward the movable mold by the closing correction pressing step and the mold closing correction pressing step, between the fixed mold and the rotating mold and between the movable mold and the rotating mold. The fixed mold, the movable mold, and the rotating mold are closed until a position where the micro mold is opened by a predetermined amount, and a first mold cavity is formed between the fixed mold and the rotating mold. And a mold closing process for forming a second mold cavity between the movable mold and the rotating mold, and at least one of the first mold cavity and the second mold cavity after the mold closing process. Injecting and filling the molten resin with injection filling process, in conjunction with the injection filling process or after the injection filling process, the fixed mold, the movable mold and the rotating mold are clamped with a predetermined clamping pressure. And an injection pressing step of applying the mold clamping press force to at least one of the molten resin in the first mold cavity and the second mold cavity. In the injection molding method according to the sixth example of the present invention, the injection filling step is a step of injecting molten resin into both the first mold cavity and the second mold cavity after the mold closing step. Preferably there is.

  An injection molding method according to a seventh example of the present invention is an injection molding method for performing injection compression molding using the above-described injection molding apparatus, wherein the fixing is performed after mold clamping at a first rotational position of the rotary mold. A primary molding step of molding a primary molded body by injection-filling molten resin into a first mold cavity formed between the mold and the rotating mold, and after the primary molding step, the primary molded body is The movable mold and the rotating mold are opened in a state of being held in a fixed mold, the rotating mold is rotated to the second rotation position, and the other mold dividing surface of the rotating mold is moved. In a rotation step for facing the fixed mold and a second rotation position of the rotary mold, a molten resin is formed in a third mold cavity formed between the fixed mold and the rotary mold after clamping. Injection-filled into at least a part of the primary molded body A molding process for laminating a secondary molded body, wherein at least one of the primary molding process and the secondary molding process is a process of molding an injection compression molded body, and the fixed mold, the movable mold, A mold closing process for closing the rotating mold to form the mold cavity, and a mold for pressing the pinion toward the movable mold by the pinion moving mechanism in parallel with or after the mold closing process. A closing correction pressing step, an injection filling step of injecting and filling molten resin into the mold cavity in a state where the pinion is pressed to the movable mold side by the mold closing correction pressing step, and injection filling into the mold cavity A micro mold opening step of opening the movable mold and the rotary mold by a predetermined amount in the mold opening and closing direction with respect to the fixed mold by the molten resin pressure; After the process, an injection compression process in which the fixed mold, the movable mold, and the rotary mold are clamped with a predetermined clamping compression force, and the clamping compression force is applied to the molten resin in the mold cavity. It is characterized by providing.

  An injection molding method according to an eighth example of the present invention is an injection molding method for performing injection compression molding using the above-described injection molding apparatus, wherein the fixing is performed after mold clamping at a first rotational position of the rotary mold. A primary molding step of molding a primary molded body by injection-filling molten resin into a first mold cavity formed between the mold and the rotating mold, and after the primary molding step, the primary molded body is The movable mold and the rotary mold are opened in a state of being held in the rotary mold, the rotary mold is rotated to the second rotational position, and the rotary mold to which the primary molded body is attached is formed. A fourth step formed between the movable mold and the rotating mold after clamping at a rotating step of making the mold dividing surface face the movable mold and at a second rotational position of the rotating mold; Injection molding of molten resin into mold cavity and primary molding A molding step of laminating a secondary molded body on at least a part thereof, and at least one of the primary molding step and the secondary molding step is a step of molding an injection compression molded body, and the fixed mold The movable mold and the rotary mold are closed to form a mold cavity, and in parallel with or after the mold closing process, the pinion is moved by the pinion moving mechanism. A mold opening correction pressing step for pressing the mold side, an injection filling step for injecting and filling molten resin into the mold cavity in the state where the pinion is pressed to the movable mold side by the mold opening correction pressing step, Micro mold opening for opening the movable mold and the rotating mold by a predetermined amount in the mold opening and closing direction with respect to the fixed mold by the molten resin pressure injected and filled in the mold cavity After the micro mold opening process, the fixed mold, the movable mold, and the rotary mold are clamped with a predetermined clamping force, and the clamped compression is performed on the molten resin in the mold cavity. And an injection compression process for applying a force.

  An injection molding method according to a ninth example of the present invention is an injection molding method for performing injection compression molding using the above injection molding apparatus, wherein the stationary mold, the movable mold, and the rotary mold are closed. A mold closing step of forming a first mold cavity between the stationary mold and the rotating mold, and forming a second mold cavity between the movable mold and the rotating mold; In parallel with or after the mold closing process, a mold closing correction pressing process for pressing the pinion toward the movable mold by the pinion moving mechanism and a mold opening correction pressing process for pressing the pinion toward the fixed mold. During any one of the correction pressing step and any one of the mold closing correction pressing step and the mold opening correction pressing step, a molten resin is applied to at least one of the first mold cavity and the second mold cavity. A micro mold that opens the movable mold and the rotary mold by a predetermined amount in the mold opening / closing direction with respect to the fixed mold by an injection filling process for injection filling and a molten resin pressure injected and filled in the mold cavity. After the opening step and the micro-die opening step, the fixed die, the movable die, and the rotating die are clamped with a predetermined clamping force, and the inside of the first die cavity and the second die are clamped. An injection compression step of applying the mold-clamping compression force to at least one of the molten resins in the cavity. In the injection molding method according to the ninth example of the present invention, the injection filling step is a step of injecting and filling molten resin into both the first mold cavity and the second mold cavity after the mold closing step. Preferably there is.

  According to the present invention, in a three-sheet injection mold, an injection molding apparatus, and an injection molding method using a rack and pinion mechanism, a three-sheet injection capable of obtaining a high-quality single layer and laminated molded product. A molding die, an injection molding apparatus, and an injection molding method can be provided.

It is a front view which shows schematic structure of the injection molding apparatus which concerns on one Embodiment of this invention. It is a schematic sectional drawing in alignment with the AA 'line of FIG. It is a front view which shows schematic structure of the pinion movement mechanism of the injection molding apparatus which concerns on this embodiment. It is a schematic sectional drawing in alignment with the BB 'line of FIG. FIG. 4 is a schematic cross-sectional view taken along the line CC ′ of FIG. 3. It is a front view which shows schematic structure of the alternative example of the injection molding apparatus which concerns on one Embodiment of this invention. It is explanatory drawing for demonstrating the process of the 1st shaping | molding example of the expansion foam molding method which concerns on this embodiment. It is explanatory drawing for demonstrating operation | movement of the rack and pinion at the time of the mold opening in the injection molding apparatus which concerns on this embodiment. It is explanatory drawing for demonstrating the process of the 2nd shaping | molding example of the expansion foam molding method which concerns on this embodiment. It is explanatory drawing for demonstrating the process of the 3rd shaping | molding example of the expansion foam molding method which concerns on this embodiment. It is explanatory drawing for demonstrating the process of the 1st shaping | molding example of the injection press molding method which concerns on this embodiment. It is explanatory drawing for demonstrating the process of the 2nd shaping | molding example of the injection press molding method which concerns on this embodiment. It is explanatory drawing for demonstrating the process of the 3rd shaping | molding example of the injection press molding method which concerns on this embodiment. It is explanatory drawing for demonstrating the process of the 1st shaping | molding example of the injection compression molding method which concerns on this embodiment. It is explanatory drawing for demonstrating the process of the 2nd shaping | molding example of the injection compression molding method which concerns on this embodiment. It is explanatory drawing for demonstrating the process of the 3rd shaping | molding example of the injection compression molding method which concerns on this embodiment. It is explanatory drawing for demonstrating operation | movement of the rack and pinion at the time of the mold opening in the conventional rack and pinion mechanism.

  Next, the best mode for carrying out the present invention will be described in detail with reference to the accompanying drawings. 1 and 2 are a front view and a sectional view showing a schematic configuration of the injection molding apparatus according to the present embodiment. 3 to 5 are a front view and a cross-sectional view showing a schematic configuration of the pinion moving mechanism in the present embodiment. FIG. 6 is a front view showing a schematic configuration of an alternative example of an injection molding apparatus according to an embodiment of the present invention. The injection molding apparatus 1 according to the present embodiment schematically includes a stationary part 100 including a stationary platen 3 and a stationary mold 12 fixed to the base 2, and is movable in the mold opening / closing direction with respect to the stationary part 100. A movable part 102 having a movable platen 4 and a movable mold 14 provided, a rotating part 104 having a rotating mold 16 provided to be movable in the mold opening / closing direction between the fixed part 100 and the movable part 102, and movable. The mold of the movable part 102 is moved in a state in which the backlash generated between the mold clamping device 6, the pinion 22, and the teeth 25 and 27 of the racks 24 and 26 is moved in the mold opening and closing direction to zero. The rack and pinion mechanism 20 moves the rotating unit 104 in the mold opening / closing direction in response to (in conjunction with) movement in the opening / closing direction. Hereinafter, a specific configuration of the injection molding apparatus 1 according to the present embodiment will be described with reference to FIGS. 1 to 6.

  As shown in FIG. 1, the injection molding apparatus 1 according to the present embodiment is provided with a fixed platen 3 fixed to a base 2 and facing the fixed platen 3, and moves in a mold opening / closing direction with respect to the fixed platen 3. A movable platen 4 that can be configured, a tie bar 5 that protrudes from the four corners of the fixed platen 3 so as to pass through the four corners of the movable platen 4 and guides the movement of the movable platen 4 in the mold opening / closing direction, and the movable platen 4 Is moved in the mold opening / closing direction along the tie bar 5 and can be clamped, and a three-piece injection mold 10 provided between the fixed plate 3 and the movable plate 4 and fixed. An injection unit 7 (hereinafter also referred to as “first injection unit 7”) that is provided on the back side of the panel 3 and injects a molten resin into a mold cavity formed by an injection mold 10 having a three-sheet structure; It has. In the injection molding apparatus 1 according to the present embodiment, the mold opening / closing direction is a direction in which the three-layer injection mold 10 is opened and closed, that is, a fixed mold 12, a movable mold 14, and a rotation described later. A direction in which the molds 16 face each other.

  The fixed platen 3 has a through-hole (not shown) through which a nozzle (not shown) of the injection unit 7 can be inserted from the back side (the side opposite to the surface facing the movable platen 4) to the front side (the surface facing the movable platen 4). (Not shown) is formed. The injection unit 7 is detachably provided on the back side of the fixed platen 3, and a nozzle for injecting the molten resin is provided on the back side of the fixed die 12, which will be described later, through the through hole of the fixed platen 3. The molten resin is injected and filled into the mold cavity of the three-sheet injection mold 10 via the resin flow path of the three-sheet injection mold 10. .

  As shown in FIGS. 1 and 2, the three-piece injection mold 10 includes a fixed mold 12, a movable mold 14 that is opposed to the fixed mold 12 and is movable in the mold opening and closing direction. A rotary mold 16 provided between the fixed mold 12 and the movable mold 14, movable in the mold opening / closing direction and rotatable about a rotation axis 16 c perpendicular to the mold opening / closing direction, and the movable mold 14. A rack and pinion mechanism 20 that moves the rotating mold 16 in the mold opening / closing direction is provided corresponding to (in conjunction with) movement in the mold opening / closing direction. The three-mold injection mold 10 is configured such that the fixed mold 12 and the movable mold 14 are detachably attached to the fixed plate 3 and the movable plate 4, respectively, so that the fixed plate 3 and the movable plate 4 are mounted. It is attached so that it can be removed and replaced. In the rack and pinion mechanism 20 according to the present embodiment, the fact that the rotating mold 16 is moved in the mold opening / closing direction in response to the movement of the movable mold 14 in the mold opening / closing direction will be described later. By movement of the rack 26 in the mold opening / closing direction, a pinion 22 described later provided in the rotating mold 16 rotates, and meshes with teeth 25 of a rack 24 described later provided in the fixed mold 12 while the pinion 22 rotates. However, it means that the rotary mold 16 is moved in the mold opening / closing direction by linearly moving in the mold opening / closing direction.

  The rotary mold 16 is provided with a pinion 22 which will be described later, and is centered on a frame-shaped rotary mold support portion 16a that can be moved in the mold opening / closing direction by a rack and pinion mechanism 20 and a rotation shaft 16c orthogonal to the mold opening / closing direction. A rotating mold part 16b rotatably supported by the rotating mold support part 16a, and a rotating mechanism 16d for rotating the rotating mold part 16b around a rotation axis 16c around a vertical axis line are provided. In addition, the rotation mold part 16b may be rotated around the horizontal axis in addition to the rotation around the vertical axis. The rotating mold part 16b includes at least two molds, that is, a rotating plate 17a having at least two mold mounting surfaces facing at least one of the fixed mold 12 and the movable mold 14 at different rotational positions, and the rotating plate 17a. A first mold 17b and a second mold each having one mold dividing surface which are respectively mounted on the mounting surface and can be molded with the fixed mold 12 and the movable mold 14 to form a mold cavity. 17c. Here, the rotating disk having at least two mold mounting surfaces facing each of at least one of the fixed mold 12 and the movable mold 14 at different rotational positions is such that one surface is a fixed mold at the first rotational position. 12, the other surface is opposed to the movable mold 14, the other surface is the stationary mold 12 in the second rotational position, and the one surface is the rotating disk opposed to the movable mold 14. It is meant to include not only a flat plate shape having two mold mounting surfaces but also a rotating disk having a polyhedral shape having four or more even number of mold mounting surfaces. The turntable 17a has substantially the same thickness as the rotary mold support portion 16a, and is rotatably supported by the rotary mold support portion 16a about a rotation shaft 16c orthogonal to the mold opening / closing direction. The first mold 17b and the second mold 17c are configured to be rotated or reversed to the rotation positions facing the fixed mold 12 and the movable mold 14, respectively, by the rotation mechanism 16d provided in the portion 16a. .

  A member (not shown) that rotatably supports the rotating disk 17a on the rotating mold support 16a via the rotating shaft 16c includes a rotating disk 17a, a first mold 17b, a thrust bearing, an oilless bushing, and the like. A suitable one can be used depending on the size, load, support structure, and the like with the second mold 17c. The rotating mechanism 16d for rotating the rotating disk 17a has a structure in which a rotation driving means such as an electric or hydraulic motor and a rotating shaft 16c are directly connected via a joint, a gear, a gear, a chain, a belt, a pulley, and the like. A suitable structure can be used depending on the size, load, support structure, and the like of the rotating disk 17a, the first mold 17b, and the second mold 17c, such as a structure coupled through a power transmission mechanism. In each of the first and second rotational positions, the first mold 17b and the second mold 17c to be matched, and the fixed mold 12 and the movable mold 14 are positioned on a general mold dividing surface. Similarly, positioning is performed with a suitable one such as a positioning pin provided on one of the mold dividing surfaces and an inlay structure (not shown) of a positioning pin hole provided on the other. Here, at the time of mold matching or mold clamping, in order to reduce the load applied to the rotary shaft 16c and its support structure and to protect these parts, the turntable 17a with respect to the rotary mold support 16a positioned by the rotary mechanism 16d is used. It is preferable that a rotational positioning means 17d for mechanically holding the rotational position is provided appropriately. Specifically, an actuator in which the tip shape of the sliding portion of an actuator such as a hydraulic cylinder is adapted to the shape of a positioning hole provided in one of the rotating die support portion 16a and the rotating disk 17a is a rotating die. It was positioned on the other of the support portion 16a and the turntable 17a, and after positioning by the rotation mechanism 16d, the sliding portion was advanced and the tip was inserted into the positioning hole positioned at the opposite position. The rotational position of the turntable 17a with respect to the rotating mold support 16a may be mechanically held. Or it is good also as a structure by which the rotation position of the turntable 17a with respect to the rotation mold support part 16a is positioned by this rotation positioning means 17d. As the specifications of the structure, position and quantity of the rotational positioning means 17d, a suitable one can be used as appropriate according to the load applied to the rotary shaft 16c and its support structure during mold matching and mold clamping. .

  The three-piece injection mold 10 includes a fixed mold 12 and a rotary mold part 16b (one of the first mold 17b and the second mold 17c), and a movable mold 14 and a rotary mold part. 16b (a first mold 17b or a second mold 17c) is provided with a mold dividing surface between each other. The three-sheet injection mold 10 is aligned between the fixed mold 12 and the first mold 17b when the molds are aligned at the first rotational position of the rotary mold 16, respectively. And a second mold cavity C2 is formed between the movable mold 14 and the second mold 17c. In addition, the injection mold 10 having a three-sheet structure is aligned with the fixed mold 12 and the second mold 17c when the molds are aligned at the second rotational position of the rotary mold 16 where the rotary disk 17a is inverted. A third mold cavity C3 is formed between them, and a fourth mold cavity C4 is formed between the movable mold 14 and the first mold 17b. Further, these mold dividing surfaces have a shear edge structure in which the resin injected and filled in the first mold cavity C1 to the fourth mold cavity C4 does not leak when each of the mold dividing surfaces is opened. ing. This shear edge structure is called a squeezing structure, an inlay structure, or the like, and is a structure generally known as a structure of a fitting portion that forms a mold dividing surface. This shear edge structure is filled in the mold cavity by forming a fitting part that extends in the mold opening and closing direction and can be inserted and removed while sliding with each other between the mold dividing surfaces. The resin can be prevented from leaking out of the mold even when the mold is opened by a predetermined amount. In the three-sheet injection mold 10 according to the present embodiment, each mold dividing surface has a shear edge structure, but is not limited thereto. Further, in the three-piece injection mold 10 according to this embodiment, the molds 12, 14, and 16 are illustrated as single molds in FIG. 1 and the like, but are not limited thereto. Instead, for example, each of the molds 12, 14, 16 may be divided into a product cavity mold part including a product cavity part and a mold base part to which the product cavity mold part is attached, A rotating mold part 16b composed of the rotating disk 17a, the first mold 17b, and the second mold 17c is configured as one mold having two mold dividing surfaces, and is attached to the rotating mold support part 16a. It may be supported so as to be rotatable.

  Guide pins 18a to 18d for guiding the movement of the rotary mold 16 in the mold opening / closing direction (between the fixed mold 12 and the rotary mold 16 and between the movable mold 14 and the rotary mold 16). Guide pins 18c and 18d are provided). That is, a pair of guide pins that protrude toward the movable mold 14 and the rotating mold 16 at two diagonal corners of the four corners of the fixed mold 12 and pass through the rotating mold support 16 a of the rotating mold 16. 18a and 18d are provided. In addition, a pair of guide pins 18b and 18c protruding from the movable mold 14 are housed in two positions on the diagonal opposite to the side where the pair of guide pins 18a and 18d are provided, among the four corners of the fixed mold 12. Possible storage holes 19a (in FIG. 1, the rear-side storage holes 19a are not shown) are formed. Of the four corners of the movable mold 14, two diagonal positions that do not face the guide pins 18 a and 18 d protruding from the fixed mold 12 protrude toward the fixed mold 12 and the rotating mold 16, and the rotating mold 16. A pair of guide pins 18b and 18c penetrating through the rotary mold support 16a is provided. Also, a pair of guide pins 18a and 18d protruding from the fixed mold 12 are housed in two locations on the diagonal opposite to the side where the pair of guide pins 18b and 18c are provided, among the four corners of the movable mold 14. Possible storage holes 19b (in FIG. 1, the rear side storage hole 19b is not shown) are formed.

  The guide pins 18a to 18d have a mold opening limit position of the three-mold injection mold 10, that is, a mold opening amount between the molds 12, 14, and 16 constituting the three-mold injection mold 10. The rotary mold support portion 16a of the rotary mold 16 can be supported and guided to the maximum position, and when the three-layer injection mold 10 is clamped, the tip thereof is a fixed mold 12 and a movable mold. 14 is accommodated in the accommodation holes 19a and 19b, and has a length that does not protrude to the back side of the fixed mold 12 and the movable mold 14. In order to prevent the rotary mold 16 from falling off, each of the guide pins 18a to 18d is released when the molds are separated when the molds are removed from the injection molding apparatus and maintenance of the molds is performed. At the time of coupling in which injection molding is performed by attaching to the injection molding apparatus in a combined state, a mechanical or electrical stopper (not shown) for preventing mold opening beyond the mold opening limit position is provided. Here, in the three-piece injection mold 10 according to the present embodiment, the guide pins 18a to 18d are provided at two locations on the diagonal line of the fixed mold 12 and the movable mold 14, respectively. For example, various modes such as a mode in which a guide pin is provided at one of the four corners of the fixed mold 12 and the movable mold 14 and a storage hole capable of storing the guide pin is provided at the other four corners are adopted. be able to.

  The fixed mold 12 is formed with a hot runner (not shown) that causes the molten resin injected from the injection unit 7 to flow and flows the molten resin from the fixed mold 12 side into the mold cavity. Here, the hot runner refers to one in which a heat retaining mechanism or a heating mechanism is arranged in a resin flow path (runner) in a mold, and the resin is retained and flowed in a constantly molten state. When the resin flow path itself in the mold is formed as a hot runner like the three-piece injection mold 10 according to the present embodiment, a sprue bar or an offset sprue bar that is a separate member is used as the hot runner. Compared to the case, the degree of freedom of arrangement of the resin flow path is high, and a large effective volume that can be used as a mold cavity can be secured. Therefore, molding is performed without restriction even for parts with a large projected area such as a door trim. be able to. In the three-piece injection mold 10 according to the present embodiment, each mold for flowing molten resin employs, for example, a sprue bar or an offset sprue bar in addition to forming a hot runner in the fixed mold 12. For example, a well-known configuration can be adopted. In the three-piece injection mold 10 according to this embodiment, the resin flow path in the mold allows the molten resin injected from the injection unit 7 to flow into the mold cavity from the fixed mold 12 side. However, the present invention is not limited to this. For example, as shown in FIG. 10, a resin flow path (hot runner) is formed in the stationary mold 12 and the rotating mold 16, and the molten resin injected from the injection unit 7 is rotated. It is possible to adopt various modes such as flowing to the mold 16 and flowing molten resin into at least one of the first mold cavity C1 to the fourth mold cavity C4 from the rotating mold 16 side. Further, in the three-piece injection mold 10 according to the present embodiment, a resin shut-off switching valve or the like that can open and close the resin flow path may be provided in the resin flow path in the mold. . In particular, when the resin flow path penetrates the mold dividing surface, it is necessary to provide a resin cutoff opening switching valve or the like at each resin flow path end of the mold dividing surface divided by the mold opening. These switching valves and the like may be either electrical control or mechanical control, but those that are automatically switched to open / close of the molten resin in conjunction with mold opening / closing are preferable. In the injection molding apparatus 1 according to the present embodiment, the molten resin injected from the injection unit 7 is caused to flow into the mold cavity. However, the present invention is not limited to this, for example, as shown in FIG. 9, FIG. 12, FIG. As described above, another injection unit (second injection unit 8) is provided on the movable mold 14 side, a resin flow path is formed in the movable mold 14, and the first mold cavity C1 and the first mold cavity C1 and The molten resin is injected into at least one of the third mold cavities C3, and the molten resin is injected from the second injection unit 8 into at least one of the second mold cavity C2 and the fourth mold cavity C4. good.

  As shown in FIGS. 1 to 3, the rack and pinion mechanism 20 includes a pinion 22 provided on the side surface of the rotating mold support 16a, an upper rack 24 provided on the side surface of the fixed mold 12, and a movable A lower rack 26 provided on the side surface of the mold 14 and a pinion moving mechanism 30 capable of supporting the pinion 22 so as to be movable in the mold opening / closing direction and pressing the pinion 22 in the mold opening / closing direction are provided. The rack and pinion mechanism 20 is attached to both side surfaces of the fixed mold 12, the movable mold 14, and the rotating mold support 16a.

  The upper rack 24 is formed in a long prismatic shape whose longitudinal direction is the mold opening / closing direction, and teeth 25 that can mesh with the pinion 22 are formed continuously on the lower surface thereof in the mold opening / closing direction. The upper end of the upper rack 24 is fixed to the side surface of the fixed mold 12 in a state parallel to the mold opening / closing direction so that the teeth 25 mesh with the upper side of the pinion 22. The lower rack 26 is formed in a long prismatic shape whose longitudinal direction is the mold opening / closing direction, and teeth 27 that can mesh with the pinion 22 are formed continuously on the upper surface thereof in the mold opening / closing direction. . The base of the lower rack 26 is fixed to the side surface of the movable mold 14 in a state parallel to the mold opening / closing direction so that the teeth 27 mesh with the lower side of the pinion 22. The upper rack 24 and the lower rack 26 are guided by rack holders 28 and 29 that are vertically erected on a base portion 32 to be described later of the pinion moving mechanism 30 on the opposite sides of the teeth 25 and 27, respectively. Left and right shaking is prevented. The rack holder 28 that guides the upper rack 24 is formed in a substantially U-shaped cross section that extends in the mold opening / closing direction and opens downward, and guides the upper rack 24 inside the substantially U-shaped cross section. (See FIG. 5). A rack holder 29 that guides the lower rack 26 is formed in a substantially U-shaped cross section that extends in the mold opening and closing direction and opens upward, and the lower rack 26 is installed inside the substantially U-shaped cross section. It is formed so as to guide (see FIG. 5). The pinion 22, the upper rack 24, and the lower rack 26 have the same tooth tip shape, and suitable ones may be used as appropriate depending on the size, load, moving stroke, and the like of the rotating mold 16 to be moved. it can.

  As shown in FIGS. 3 to 5, the pinion moving mechanism 30 includes a flat base portion 32 attached to the side surface of the rotary mold support portion 16 a, a pinion holder 34 that holds the pinion 22, and the pinion holder 34 as a base. A linear motion guide 36 that supports the part 32 so as to be movable in the mold opening / closing direction, and an actuator 38 that presses the pinion holder 34 against the base part 32 in the mold opening / closing direction.

  The base portion 32 is formed in a slightly horizontally long rectangular plate whose longitudinal direction is the mold opening / closing direction, and the rotating die support portion 16a is in surface contact with the side surface of the rotating die support portion 16a. Installed on the side of the. Hereinafter, one surface of the base portion 32 that is in surface contact with the side surface of the rotating mold support portion 16a is referred to as an attachment surface, and the other surface is referred to as a mounting surface.

  The pinion holder 34 is formed in a rectangular tube shape whose upper surface and lower surface are opened and slightly extends in the mold opening / closing direction. When the pinion 22 is arranged inside the pinion holder 34, And it has a shape that the lower side is exposed. Inside the pinion holder 34, the pinion 22 is rotatably mounted via bearings 35 and 35.

  The linear motion guide 36 includes a linear motion guide rail 36a attached to the mounting surface of the base portion 32, and a pair of linear motion guide blocks 36b and 36b attached to the pinion holder 34 and slidable on the linear motion guide rail 36a. It is composed of The linear motion guide rail 36 a is formed in an I-shaped cross section, extends in the mold opening / closing direction, and stands upright with respect to the mounting surface of the base portion 32. Each of the pair of linear motion guide blocks 36b and 36b is formed in a substantially U-shaped cross section that opens toward the linear motion guide rail 36a, and slidably engages with the linear motion guide rail 36a on the opening side. The surface opposite to the opening is fixed to the back surface of the pinion holder 34.

  The actuator 38 is a reciprocating cylinder (that is, a hydraulic cylinder) driven by hydraulic pressure, and is mounted on the mounting surface of the base portion 32 via an actuator support 40 fixed to the mounting surface of the base portion 32. Yes. The actuator 38 reciprocates the rod 42 in the mold opening / closing direction by a pressure fluid supplied from a pressure source (not shown), thereby pressing the pinion holder 34 in the mold opening / closing direction, thereby causing the pinion 22 attached to the pinion holder 34 to move. It is configured to move in the mold opening / closing direction with respect to the rotating mold 16. The tip of the rod 42 and the pinion holder 34 are connected by a joint 44 that allows (absorbs) some degree of eccentricity and inclination. By connecting the tip of the rod 42 and the pinion holder 34 with the joint 44 in this way, it is possible to suppress an increase in movement resistance and galling of the pinion holder 34 due to manufacturing of related components and assembly tolerances. The pinion holder 34 can be moved smoothly. Here, the actuator 38 is not limited to a hydraulic cylinder, and various actuators such as a reciprocating cylinder driven by pneumatic pressure, an electrically driven reciprocating ball screw mechanism, a spring, a pneumatic damper, or a hydraulic damper may be adopted. it can.

  In the injection molding apparatus 1 according to the present embodiment, the rack and pinion mechanism 20 can be any mode as long as it can move the rotary mold 16 in the mold opening / closing direction in response to the movement of the movable mold 14 in the mold opening / closing direction. It may be. That is, in the injection molding apparatus 1 according to the present embodiment, the rack and pinion mechanism 20 is attached to both side surfaces of the fixed mold 12, the movable mold 14, and the rotating mold support portion 16a. It is not limited. For example, it is attached to only one side of the fixed mold 12, the movable mold 14 and the rotating mold support 16a, or on the upper surface and / or the lower surface of the fixed mold 12, the movable mold 14 and the rotating mold support 16a. Various modes such as a mode of mounting can be adopted.

  In the injection molding apparatus 1 according to the present embodiment, the upper rack 24 is attached to both side surfaces of the fixed mold 12 and the lower rack 26 is attached to both side surfaces of the movable mold 14. It is not limited to. For example, the vertical arrangement of the racks 24, 26 is reversed (that is, the lower rack 26 is attached to both side surfaces of the fixed mold 12, and the upper rack 24 is attached to both side surfaces of the movable mold 14). Alternatively, the vertical arrangement of the racks 24 and 26 is reversed between one side surface of the molds 12 and 14 and the other side surface (that is, for example, the upper rack 24 on one side surface of the fixed mold 12 and the other side surface Various modes can be employed, such as a mode in which the lower rack 26 is attached and the lower rack 26 is attached to one side of the movable mold 14 and the upper rack 24 is attached to the other side. In this case, the racks 24 and 26 are preferably provided so that the vertical positions of the guide pins 18a to 18d are aligned, so that a large open area on the side surface of the mold when the mold is opened can be secured. The product can be easily taken out.

  Furthermore, in the injection molding apparatus 1 according to the present embodiment, the racks 24 and 26 are provided in the fixed mold 12 and the movable mold 14, but the present invention is not limited to this, and as shown in FIG. , 26 may be provided on the fixed platen 3 and the movable platen 4. In this case, it is preferable that the rotary mold support 16a of the injection molding apparatus 1 according to the present embodiment has substantially the same dimensions as the dimensions of the stationary platen 3 and the movable platen 4 in the direction perpendicular to the mold opening / closing direction. Alternatively, the guide pins 18a to 18d may be eliminated, and the rotary mold support 16a, the fixed plate 3 and the movable plate 4 may be directly connected by the tie bar 5.

  Furthermore, in the injection molding apparatus 1 according to the present embodiment, the pinion moving mechanism 30 is capable of pressing the pinion 22 to both the fixed mold 12 side and the movable mold 14 side, but is not limited thereto. As long as the pinion 22 can be pressed at least toward the fixed mold 12 (mold opening correction pressing process), or the pinion 22 can be pressed at least toward the movable mold 14 (mold closing correction pressing process). Specifically, the former is a molding method that requires the accuracy of a micro mold opening amount by which the movable mold 14 and the rotary mold 16 are micro-opened from the mold closed state by the mold clamping device 6 as in the expansion foam molding method. The latter is suitable for a molding method that requires the accuracy of a micro mold opening amount for closing the mold from the mold opening state to the micro mold opening state, such as an injection press molding method. Further, as long as the pinion 22 can be pressed to both the fixed mold 12 side and the movable mold 14 side, not only any of these molding methods, but also an injection compression molding method that requires switching of the mold opening / closing operation during the molding process. It is suitable for etc.

  The injection molding apparatus 1 according to the present embodiment includes a single-layer molding mold or a multilayer molding mold used in a general-purpose injection molding apparatus, and a three-sheet injection molding mold according to the present embodiment. It can be obtained by exchanging with 10 and minor modifications related thereto.

  Next, an expanded foam molding method, an injection press molding method, and an injection compression molding method performed using the injection molding apparatus 1 according to the present embodiment will be described with reference to FIGS. 7, 9 and 10 are explanatory views for explaining the steps of the first to third molding examples of the expanded foam molding method according to the present embodiment, and FIG. 8 is the rack when the mold is opened. FIG. 11, FIG. 12 and FIG. 13 are diagrams for explaining the steps of the first to third molding examples of the injection press molding method according to the present embodiment. FIG. 14, FIG. 15 and FIG. 16 are explanatory views for explaining steps of the first to third molding examples of the injection compression molding method according to the present embodiment. 7 to 16, each component is schematically shown. In FIGS. 7 and 9 to 16, for example, the rack and pinion mechanism 20, the guide pins 18 a to 18 d, and the rotary mold 16 are arranged. The rotary mold support 16a and the like are omitted. Moreover, the shape of each metal mold | die 12,14,16, the aspect of a resin flow path, etc. are an example to the last, and are not limited to the shape etc. which were illustrated.

  Examples of the thermoplastic resin used in the expanded foam molding method, injection press molding method, and injection compression molding method according to this embodiment include polyethylene (PE), polypropylene (PP), polystyrene (PS), and acrylonitrile butadiene. -General-purpose resins such as styrene copolymer synthetic resin (ABS) and polyethylene terephthalate (PET), engineering resins such as polyamide (PA), polyacetal (POM), polycarbonate (PC), polybutylene terephthalate (PBT), and polyethersulfone (PES), polyphenylene sulfide (PPS), superether resins such as polyetheretherketone (PEEK), thermoplastic elastomer (TPO), styrene elastomer (SBC), urethane elastomer TPU) elastomer resins, and the like, and these recycled resin can be used. These thermoplastic resins are not only used alone, but can also be used in a mixture of two or more, and if necessary, plasticizers, heat stabilizers, antioxidants, lubricants, electrification It can also be used in the state where various additives such as an inhibitor, a colorant, a flame retardant, and an extender are added. Moreover, it can also be used in the state which added reinforcing agents, such as glass fiber, carbon fiber, and natural fiber, for the intensity | strength and rigidity improvement of a molded article. For example, an inorganic chemical foaming agent mainly composed of sodium bicarbonate or an organic chemical foaming agent mainly composed of an azo compound is mixed with these thermoplastic resins (chemical foaming method), air, carbon dioxide gas, A foamable molten resin obtained by injecting nitrogen gas or the like (physical foam molding method) or obtained by a well-known method can be used not only in the expanded foam molding method but also in the injection press molding method and the injection compression molding method. .

[First molding example of expanded foam molding]
A first molding example of the expanded foam molding method according to the present embodiment will be described with reference to FIGS. The first molding example of the expanded foam molding method according to the present embodiment is a mold during the molding process in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16. A fixed mold 12 and a rotating mold which are formed by molding a non-foamed primary molded body by a general injection molding method (hereinafter referred to as “general injection molding method”) that does not change the cavity volume, and holding the unfoamed primary molded body In the third mold cavity C3 formed between the second molds 17c of the mold 16, the foamed secondary molded body molded by the expanded foam molding method is laminated and formed on at least a part of the unfoamed primary molded body. Is the method. That is, the primary molded body molded between the fixed mold and the rotating mold is not moved from the fixed mold side, but the rotating mold is rotated when the mold is opened, and a laminated molded product is obtained every two mold opening / closing operations. It is characterized by molding. Hereinafter, the first molding example of the expanded foam molding method according to the present embodiment will be specifically described in order.

  First, as shown in FIG. 7 (a), the movable mold 14 and the rotary mold 16 are moved in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20, and the fixed mold 12, the movable mold 14 and The rotary mold 16 is clamped (primary mold clamping step). Specifically, the movable platen 4 and the movable mold 14 attached thereto are moved to the mold closing position by the mold clamping device 6, and the movable mold 14 is moved in the mold closing direction by the rack and pinion mechanism 20. Corresponding to the above, the rotary mold 16 is moved to the mold closing position, and all the molds are matched. Then, after all the mold alignment is completed, the fixed mold 12, the movable mold 14, and the rotary mold 16 are clamped by the mold clamping device 6. As a result, a first mold cavity C1 is formed between the fixed mold 12 and the first mold 17b, and a second mold cavity C2 is formed between the movable mold 14 and the second mold 17c. The second mold cavity C2 is not used for molding. Further, as described above, at the time of mold clamping, the rotational position of the rotational mold 16 (the rotational mold part 16b) is mechanically held by the rotational positioning means 17d with respect to the rotational mold support part 16a. The clamping force applied to the rotating shaft 16c and its supporting structure is reduced to protect these parts, but these are not shown.

  After the primary mold clamping step, the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16 is injected through the resin flow path 50a formed in the fixed mold 12. A molten resin as a primary material is injected and filled from the unit 7 (primary injection filling step) to form an unfoamed primary molded body 52a (primary molding step). In addition, since this 1st shaping | molding example is the aspect which uses one injection | pouring unit 7, the primary material in a primary injection filling process is the same foamable molten resin as the secondary material in the secondary injection filling process mentioned later. In the primary molding step, the unfoamed primary molded body 52a is molded by a general injection molding method.

  After the elapse of a predetermined cooling and solidification time, as shown in FIG. The movable mold 14 and the rotary mold 16 are moved in the mold opening direction to a position where the rotary mold portion 16b of the mold 16 can rotate (primary mold opening process).

  After the primary mold opening process, as shown in FIG. 7C, the rotating mold portion 16b of the rotating mold 16 is rotated 180 degrees by the rotating mechanism 16d, and the second mold 17c of the rotating mold 16 is fixed to the fixed mold. The position is switched to a position facing 12 (rotation process).

  After the rotation process, as shown in FIG. 7D, the movable mold 14 and the rotary mold 16 are moved again in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20, and the fixed mold 12 is moved. The mold 14 and the rotating mold 16 are clamped (secondary clamping process). As a result, a third mold cavity C3 is formed between the fixed mold 12 holding the unfoamed primary molded body 52a and the second mold 17c of the rotary mold 16, and the movable mold 14 and the rotary mold 16 are connected to each other. A fourth mold cavity C4 is formed between the first molds 17b. The fourth mold cavity C4 is not used for molding.

  Further, in this secondary mold clamping process, the pinion 22 is pressed against the movable mold 14 by the pinion moving mechanism 30 with a predetermined pressure 1, and the teeth of the pinion 22 among the plurality of teeth 25, 27 of the racks 24, 26 are The pinion 22 is pressed against the surfaces A and B of the teeth 25 and 27 facing on the movable mold 14 side (hereinafter referred to as “surface A on the movable mold 14 side” and “surface B on the movable mold 14 side” respectively). (Mold closing correction pressing step). The state of the pinion 22 and the racks 24 and 26 at this time is shown in FIG. 8A (in FIG. 8A, the white arrow indicates the pressing direction to the pinion 22 and the black arrow indicates the contact location). . This mold closing correction pressing step is not performed for the purpose (to make backlash zero), which will be described later, but to match the axial position of the pinion 22 perpendicular to the mold opening / closing direction in the mold clamping state. The reason is that the pinion 22 is movable in the mold opening / closing direction, and therefore the pinion 22 attached to both side surfaces of the rotary mold 16 does not coincide with the axis position orthogonal to the mold opening / closing direction, that is, the pinion 22. When the respective rotating shafts are not coaxial but orthogonal to the mold opening / closing direction, depending on the degree of the eccentricity, the pinions on both side surfaces of the rotating mold 16 are moved by the movement of the movable rack 26 in the mold opening / closing direction. This is because the balance of the forces in the mold opening / closing direction acting on the rotary mold 16 via the respective rotation shafts 22 is lost, and an unnecessary load may be applied to the rack and pinion mechanism 20. By this mold closing correction pressing step, among the plurality of teeth 25 and 27 of the pinion 22 and the racks 24 and 26, the surfaces C and D (hereinafter referred to as teeth 25 and 27) facing the teeth of the pinion 22 on the fixed mold 12 side. The backlashes α and β generated between “the surface C on the fixed mold 12 side” and “the surface D on the fixed mold 12 side” are maximized. In the secondary mold clamping process, when the axial position of the pinion 22 that is orthogonal to the mold opening / closing direction is substantially coincided with the primary mold opening process or the like already performed, or when the degree of eccentricity is small, The mold closing correction pressing step is not necessarily performed. Further, the predetermined pressure 1 of the pinion moving mechanism 30 in this mold closing correction pressing step only needs to be such that the pinion 22 can be moved in the mold opening / closing direction, and is the same as the predetermined pressure 2 in the mold opening correction pressing step described later. May be.

  When the mold closing correction pressing step is performed after the secondary mold clamping step, the unfoamed primary molded body 52a is appropriately timed when the mold closing correction pressing step is not performed while the mold closing correction pressing step is not performed. A secondary material is injected from the injection unit 7 through the resin flow path 50b formed in the fixed mold 12 into the third mold cavity C3 formed between the fixed mold 12 and the second mold 17c. A foamable molten resin is injected and filled (secondary injection filling process). In the secondary injection filling process, the resin flow path switching from the primary injection filling process (switching from the resin flow path 50a to the resin flow path 50b) is, for example, a resin capable of opening and closing the resin flow path in the resin flow path. This can be done by providing a shut-off switching valve or the like. As described above, when the foamable molten resin is injected and filled in the secondary injection filling process, the third mold cavity C3 and the fourth mold are maintained by maintaining the mold clamping state until the secondary injection filling process is completed. Do not expand the cavity C4 by keeping the volume constant, or before the secondary resin injection filling process is completed, start the foaming mold opening process through the mold clamping release process and the mold opening correction pressing process, which will be described later. Whether to expand the volume of the mold cavity may be appropriately selected according to the combination of the resin and foaming agent used, the product shape, the required quality of the product, and the like.

  After the secondary injection filling process, the mold clamping force by the mold clamping device 6 is reduced to release the mold clamping state (mold clamping releasing process). By this mold clamping release step, the resin pressure of the foamable molten resin in the third mold cavity C3 is lowered, and foaming nuclei that form the base point of the foam cell gap are formed. In this foam nucleation, how much the clamping force is reduced per unit time (decrease rate of clamping force) depends on the combination with the resin and foaming agent used, the product shape and the required quality of the product, etc. What is necessary is just to select suitably. In parallel with this mold clamping release process, the pressing direction of the pinion 22 by the pinion moving mechanism 30 is switched from the movable mold 14 side to the fixed mold 12 side, and the pinion 22 is clamped to the fixed mold 12 side. Pressing with a predetermined pressure 2 weaker than the force (mold opening correction pressing step). The state of the pinion 22 and the racks 24 and 26 at this time is shown in FIG. 8B (in FIG. 8B, the white arrow indicates the pressing direction to the pinion 22 and the black arrow indicates the contact location). . At this stage, since the pressing force (predetermined pressure 2) to the pinion 22 is smaller than the mold clamping force, the pinion 22 does not move to the fixed mold 12 side. Thereafter, the mold clamping force by the mold clamping device 6 gradually decreases, and when the predetermined pressure 2 by the pinion moving mechanism 30 becomes larger than the mold clamping force, the pinion 22 moves backlash α, β to the fixed mold 12 side. The pinion 22 is pressed by a predetermined pressure 2 against the surfaces C and D on the fixed mold 12 side of the teeth 25 and 27 of the racks 24 and 26, and switching from the mold closing correction pressing process to the mold opening correction pressing process. Is completed. The state of the pinion 22 and the racks 24 and 26 at this time is shown in FIG. 8C (in FIG. 8C, the white arrows indicate the pressing direction to the pinion 22 and the moving direction of the lower rack 26, Black arrows indicate contact points). This mold opening correction pressing step is intended to reduce the backlash generated between the pinion 22 and the surfaces C and D on the fixed mold 12 side of the teeth 25 and 27 of the racks 24 and 26, which is the original purpose. It is done. As shown in FIG. 8D, the backlash generated between the pinion 22 and the surfaces C and D on the fixed mold 12 side of the teeth 25 and 27 of the racks 24 and 26 is zero (die opening correction pressing In the step), if the lower rack 26 is moved in the mold opening direction, the same tooth 27 is placed on the lower teeth of the pinion 22 on the surface D of the teeth 27 of the rack 27 on the fixed mold 12 side. The pinion 22 rotates in the clockwise direction. The clockwise rotation of the pinion 22 causes the upper teeth of the pinion 22 to be fixed in the mold opening direction from the teeth 25 of the rack on the surface C on the fixed mold 12 side of the teeth 25 of the upper rack 24 that does not move. Receive reaction force. Due to this reaction force, a force in the mold opening direction acts on the pinion 22, and the rotary mold 16 having the pinion 22 attached to the side surface via the pinion moving mechanism 30 is moved in the mold opening direction. Since these operations are performed at the same time, the rotary mold 16 can be moved in the mold opening direction without delaying the movement of the lower rack 26 in the mold opening direction. Further, as described above, it goes without saying that this mold opening correction pressing step is for matching the axial position of the pinion 22 orthogonal to the mold opening / closing direction. In the mold closing correction pressing step, which will be described later, the pinion 22 is pressed to the movable mold 14 side, and backlash generated between the teeth 25, 27 of the racks 24, 26 and the surfaces A, B on the movable mold 14 side is generated. In the state of zero, the lower rack 26 is moved in the mold closing direction, and the rotary mold 16 is moved in the mold closing direction. Regarding the movement operation of the rotary mold 16 in the mold closing direction during the mold closing correction pressing process, the mold opening operation of the rotary mold 16 during the mold opening correction pressing process described above is reversed. Therefore, the explanation is omitted. Further, this mold opening correction pressing step may be performed after the mold clamping release step is completed, and in this case, the step shown in FIG. 8B is omitted.

  Next, during the continuation of the mold opening correction pressing step, the movable mold 14 and the rotary mold 16 are placed in the mold opening direction by the mold clamping device 6 and the rack and pinion mechanism 20 as shown in FIG. The micro mold is opened by a fixed amount a (foaming mold opening process). The state of the pinion 22 and the racks 24 and 26 at this time is shown in FIG. 8D (in FIG. 8D, the white arrows indicate the pressing direction to the pinion 22, the moving direction of the lower rack 26, and the pinion 22). The black arrow indicates the contact location). Since the volume of the third mold cavity C3 and the fourth mold cavity C4 is expanded by this foaming mold opening process, the third mold cavity C3 is first injected and filled in the mold clamping release process. Foaming nuclei formed in the foamable molten resin are expanded (grown) into the foam cell voids, the foamable molten resin is expanded and expanded, and the foamed secondary molded body 52b is molded. In this way, foaming having foamed cells inside at least a part of the unfoamed primary molded body 52a held by the fixed mold 12 forming the third mold cavity C3 covered with the unfoamed skin layer. The secondary molded body 52b is laminated and molded (laminate molding process). In the expansion (growth) of the foam nuclei into the foam cell gap, how to perform the micro mold opening operation of the foam mold opening process (mold opening speed, mold opening operation divided into multiple times, etc.) is used. What is necessary is just to select suitably according to the combination with resin, a foaming agent, a product shape, the required quality of a product (dispersibility of a foaming cell space | gap), etc. Further, like the injection press molding method and the injection compression molding method described later, after the foaming mold opening process, the volume of these mold cavities expanded by the minute mold opening is reduced by a predetermined amount, and the foamed secondary molded body is obtained. In some cases, it is possible to ensure the final transferability and molding accuracy of the design.

  It is preferable to continue the mold opening correction pressing process even during and after the foam mold opening process. During the mold opening correction pressing process, during the foaming mold opening process, the rotating mold 16 is moved in the mold opening direction (movable mold 14 side) by the foaming pressure of the foamable molten resin in the third mold cavity C3. Force acts. This force in the mold opening direction acts in a direction opposite to the predetermined pressure 2 that presses the pinion 22 toward the fixed mold 12 (mold closing direction) by the pinion moving mechanism 30 in the continued mold opening correction pressing process. For example, when the force in the mold opening direction is larger than the predetermined pressure 2, the pinion moving mechanism 30 is fixed to the side surface of the rotating mold 16, so that the rotating mold 16 includes the pinion 22 and the racks 24, 26. Move to the mold opening direction (movable mold 14 side) by the amount corresponding to the backlash α and β between the teeth 25 and 27 and the surfaces A and B on the movable mold 14 side (FIG. 8C). reference). Therefore, a predetermined pressure 2 is set against the force in the mold opening direction acting on the rotating mold 16, that is, the foaming pressure of the foamable molten resin in the mold cavity, and the maximum foaming of the assumed foamable molten resin. If the pressure is equal to or higher than the pressure (preferably greater than the maximum foaming pressure), the rotary mold 16 is held in position on the surfaces C and D side of the teeth 25 and 27 of the racks 24 and 26 on the fixed mold 12 side. During the opening process, it moves more than the amount of movement in the mold opening direction by the rack and pinion mechanism, and after the foaming mold opening process is completed, it moves in the mold opening direction beyond the set small mold opening amount. There is nothing.

  After the elapse of a predetermined cooling and solidifying time, as shown in FIG. 7F, the movable mold 14 and the rotating mold 16 are moved in the mold opening direction to the product removal position by the mold clamping device 6 and the rack and pinion mechanism 20 ( Secondary mold opening process). Thereafter, the laminated molded product 52 molded between the second mold 17c (third mold cavity C3) of the stationary mold 12 and the rotating mold 16 is taken out by a product take-out device (not shown) (product take-out process). In this way, thereafter, by repeating the molding cycle from the state of FIG. 7 (a) to the state of FIG. 7 (f), a laminated molded product comprising the unfoamed primary molded body 52a and the foamed secondary molded body 52b. 52 is continuously formed. In these secondary mold opening process and product taking-out process, since the accuracy of mold opening is not required, it is not necessary to press the pinion 22 toward the fixed mold 12 by the pinion moving mechanism 30 (mold opening correction pressing process). However, in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction, it is preferable to press the pinion 22 by the pinion moving mechanism 30 until the mold closing operation for the next cycle. The direction of pressing the pinion 22 by the pinion moving mechanism 30 is preferably the fixed mold 12 side (mold opening correction pressing step) when the mold is opened, but in the mold open state, the movable mold 14 side and Any of the fixed mold 12 side may be sufficient.

  In the first molding example of the expanded foam molding method according to the present embodiment, when the molten resin is a soft resin such as an elastomer, a re-clamping process is performed following the foam mold opening process or the secondary mold opening process. It is preferable to do so. This re-clamping step is for ensuring the final transferability of the design, molding accuracy, and the like by applying a predetermined clamping force again after the foam layer is formed. In the re-clamping process, the pressing direction of the pinion 22 by the pinion moving mechanism 30 is switched to the movable mold 14 side (mold closing correction pressing process), and the pinion 22 is moved to the movable molds of the teeth 25 and 27 of the racks 24 and 26. It is preferable to carry out in a state where it is pressed against the surfaces A and B on the 14th side. In this way, in the mold closing operation, the pinion 22 is pressed again against the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26 (mold closing correction pressing process). The influence of backlash can be completely eliminated, thereby improving the accuracy of the clamping amount and clamping speed of the clamping operation, and quickly applying the re-clamping force to the foam molded body in the third mold cavity C3. And can be given evenly. In addition, even during re-clamping, the state in which the pinion 22 is pressed against the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26 (the mold closing correction pressing process) can be maintained. preferable. In the mold opening process and the product removing process performed after the re-clamping process, it is preferable to press the pinion 22 by the pinion moving mechanism 30 in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction. In these mold opening process and product take-out process, the precision of mold opening is not required, so the direction of pressing the pinion 22 by the pinion moving mechanism 30 is either the movable mold 14 side or the fixed mold 12 side. Also good.

  A first molding example of the expanded foam molding method according to the present embodiment is a general injection molding method in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16. In the third mold cavity C3 formed between the fixed mold 12 holding the unfoamed primary molded body and the second mold 17c of the rotary mold 16, the expanded foam is formed. The foamed secondary molded body molded by the molding method is an aspect in which at least a part of the unfoamed primary molded body is laminated and molded (unfoamed molding-expanded foam molding aspect), but is not limited thereto, What is necessary is just to shape | mold a foaming molding by an extended foaming molding method in at least one of the 1st metal mold | die cavity C1 and the 3rd metal mold cavity C3. That is, in the first molding example of the expanded foam molding method according to the present embodiment, for example, in the first mold cavity C1, the foam primary molded body is molded by the expanded foam molding method, and in the third mold cavity C3, The foamed secondary molded body molded by the expanded foam molding method may be formed by laminating and molding at least a part of the foamed primary molded body (expanded foam molding-expanded foam molding aspect). In the mold cavity C1, the foamed primary molded body is molded by the expanded foam molding method, and in the third mold cavity C3, the unfoamed secondary molded body molded by the general injection molding method is used as the foamed primary molded body. It is good also as a mode (a mode of expansion foam molding-non-foam molding) which carries out lamination molding at least partially. Furthermore, in the first molding example of the expanded foam molding method according to this embodiment, at least one of the primary molded body and the secondary molded body is foam-molded in the first mold cavity C1 and the third mold cavity C3. Although it is an aspect in which a laminated molded article made of a body is molded, that is, an aspect in which a laminated molded article is molded between the fixed mold 12 and the rotating mold 16, as another aspect, the second mold cavity C2 is used. In the fourth mold cavity C4, that is, a mode in which a laminated molded product is molded between the movable mold 14 and the rotary mold 16 may be employed.

  In the first molding example of the expanded foam molding method according to the present embodiment, both the primary injection filling process and the secondary injection filling process are injection-filled with foamable molten resin from one injection unit 7. In addition to the injection unit (first injection unit) 7, there is another injection unit (second injection unit) connected to the movable mold 14, the rotating mold 16, or the fixed mold 12. The non-foamable molten resin is foamed from the different injection units in the injection filling process in which the general injection molding method is performed in the primary injection filling process and the secondary injection filling process in the injection filling process in which the expanded foam molding method is performed. Alternatively, the molten resin may be injected and filled. The second injection unit is provided on the fixed platen 3 side so as to be connected to a stationary mold 12 that does not move, not a movable mold or a rotating mold that moves in the mold opening / closing direction. It is preferable to inject and fill the molten resin into a mold cavity formed by clamping the first mold 17b or the second mold 17c of the mold 16. The second injection unit may be detachably provided on the front side of the stationary platen 3 so that the nozzle for injecting the molten resin is connected to the side surface of the fixed mold 12, or the nozzle for injecting the molten resin The first injection unit 7 may be provided side by side so as to be connected to the back surface of the fixed mold 12.

  Furthermore, in the first molding example of the expanded foam molding method according to the present embodiment, the mold closing correction pressing process is performed in the secondary mold clamping process, and the mold opening correction pressing process is performed in the foaming mold opening process. It is not limited to. For example, the mold closing correction pressing process may be performed in the primary mold clamping process, and the primary injection filling process and the primary molding process may be performed while the mold closing correction pressing process is continued. Alternatively, the mold opening correction pressing process may be performed in the primary mold opening process, and the rotation process may be performed while the mold opening correction pressing process is continued. Furthermore, a mold opening correction pressing process may be performed in the secondary mold opening process, and a product takeout process may be performed during the mold opening correction pressing process. The mold closing correction pressing process in the primary mold clamping process and the secondary mold clamping process and the mold opening correction pressing process in the primary mold opening process and the secondary mold opening process are the original purposes of the mold opening correction pressing process in the foaming mold opening process. Since it is performed not for the purpose of making the backlash at the time of mold opening / closing operation zero, but to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction, it is not necessary to do so. Just as you did. However, the mold closing correction pressing process or the mold opening correction pressing process is appropriately performed even in a process that does not require the accuracy of the mold opening / closing operation so that an unnecessary load is not applied to the rack and pinion mechanism 20. It is preferable.

[Second example of expanded foam molding]
Next, a second molding example of the expanded foam molding method according to this embodiment will be described with reference to FIG. A second molding example of the expanded foam molding method according to the present embodiment is a general injection molding method in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16. In the fourth mold cavity C4 formed between the first mold 17b of the rotating mold 16 and the movable mold 14 that holds the unfoamed primary molded body by molding the unfoamed primary molded body. In this method, the foamed secondary molded body molded by the molding method is laminated and formed on at least a part of the unfoamed primary molded body. That is, the primary molded body formed between the fixed mold and the rotating mold is held on the rotating mold side, the rotating mold is rotated when the mold is opened, and the primary molded body is moved to the movable mold side by the rotation. The laminated molded product and the primary molded body are formed for each second and subsequent mold opening / closing operations except for the first mold opening / closing operation. In the second molding example, in addition to the first injection unit 7 provided on the fixed mold 12 side, the nozzle provided on the back side of the movable platen 4 is detachable, and a nozzle for injecting molten resin is provided on the movable platen 4 The second injection unit 8 that can be connected to the back surface of the movable mold 14 (the surface opposite to the mold dividing surface) through a through hole (not shown) will be described, but the present invention is not limited to this. Absent. Hereinafter, the description of the same steps and molding conditions as those of the first molding example of the expanded foam molding method will be omitted.

  First, in the first mold cavity C1 formed between the first mold 17b of the rotating mold 16 and the fixed mold 12 by the same process as the first molding example of the expanded foam molding method, general injection molding is performed. The unfoamed primary molded body 53a is molded by the method (clamping process or primary molding process). In the mold clamping process, the primary injection filling process, and the primary molding process, it is preferable to perform the mold closing correction pressing process in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction. In the second molding example, since two injection units are used, the primary material in the primary injection filling process is either an unfoamed molten resin or a foamable molten resin. Any unmolded primary molded body 53a may be formed by a typical injection molding method.

  After the elapse of a predetermined cooling and solidifying time, the mold clamping device 6 and the rack and pinion are held in a state where the unfoamed primary molded body 53a is held by the first mold 17b of the rotary mold 16 as shown in FIG. The movable mold 14 and the rotary mold 16 are moved in the mold opening direction by the mechanism 20 to a position where the rotary mold portion 16b of the rotary mold 16 can rotate (mold opening process). In this mold opening process, the pressing direction to the pinion 22 by the pinion moving mechanism 30 is switched from the movable mold 14 side to the fixed mold 12 side, and the mold opening is performed in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction. It is preferable to perform a correction pressing process. In addition, after the predetermined cooling and solidifying time has elapsed, before the mold opening process is performed, a second mold cavity C2 formed between the movable mold 14 and the second mold 17c of the rotary mold 16 will be described later. Such secondary injection filling process or lamination molding process is performed, but the description thereof is omitted here.

  When the mold opening correction pressing process is performed after the mold opening process, the mold opening correction pressing process is continued, and when the mold opening correction pressing process is not performed, the timing is suitably changed as shown in FIG. 9B. In addition, in a state where the unfoamed primary molded body 53a is held by the first mold 17b of the rotating mold 16, the first mold 17b of the rotating mold 16 is opposed to the movable mold 14, and the rotating mold 16 The rotating mold portion 16b of the rotating mold 16 is rotated 180 degrees by the rotating mechanism 16d at a position where the second mold 17c faces the fixed mold 12 (rotating process). As will be described later, the laminated molded product molded between the movable mold 14 and the second mold 17c (third mold cavity C3) of the movable mold 14 and the rotary mold 16 in the previous molding cycle is subjected to the mold opening process. Before the rotation process is started, since it has already been taken out from between these molds in the product removal process, it is movable except for the first mold 17b of the rotary mold 16 holding the unfoamed primary molded body 53a. Nothing is held by the mold 14, the second mold 17 c of the rotating mold 16, and the fixed mold 12.

  After the rotation step, as shown in FIG. 9C, the movable mold 14 and the rotary mold 16 are moved again in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20, and the fixed mold 12 and the movable mold 12 are moved. The mold 14 and the rotating mold 16 are clamped (clamping process). Thereby, a third mold cavity C3 is formed between the fixed mold 12 and the second mold 17c of the rotary mold 16, and the rotary mold 16 holding the movable mold 14 and the unfoamed primary molded body 53a is formed. A fourth mold cavity C4 is formed between the first molds 17b. In this mold clamping process, the pressing direction to the pinion 22 by the pinion moving mechanism 30 is switched to the movable mold 14 side, and the mold closing correction pressing process is performed in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction. Is preferred.

  After the mold clamping process, when the mold closing correction pressing process is performed, during the continuation of the mold closing correction pressing process, when the mold closing correction pressing process is not performed, the fixed mold 12 and the rotating mold are appropriately timed. The third mold cavity C3 formed between the 16 second molds 17c is injected and filled with the molten resin, which is the primary material, from the first injection unit 7 through the resin flow path 50c formed in the fixed mold 12. (Primary injection filling process) to form a new unfoamed primary molded body 53a (primary molding process). While these steps are performed, injection filling or the like is not performed on the fourth mold cavity C4.

  When the mold closing correction pressing step is performed after the predetermined cooling and solidifying time has elapsed, the mold closing correction pressing step is continued. As shown in FIG. 3, the movable mold 14 is formed in the fourth mold cavity C4 formed between the movable mold 14 and the first mold 17b of the rotating mold 16 holding the unfoamed primary molded body 53a. The foamable molten resin as the secondary material is injected and filled from the second injection unit 8 through the resin flow path 50d (secondary injection filling step). As described above, when the foamable molten resin is injected and filled in the secondary injection filling process, the third mold cavity C3 and the fourth mold are maintained by maintaining the mold clamping state until the secondary injection filling process is completed. Do not expand the cavity C4 by keeping the volume constant, or before the secondary resin injection filling process is completed, start the foaming mold opening process through the mold clamping release process and the mold opening correction pressing process, which will be described later. Whether to expand the volume of the mold cavity may be appropriately selected according to the combination of the resin and foaming agent used, the product shape, the required quality of the product, and the like.

  After the secondary injection filling process, as in the first molding example of the expanded foam molding method, the mold clamping force by the mold clamping device 6 is reduced, the mold clamping state is released (the mold clamping releasing process), and the pinion moving mechanism 30 Is switched from the movable mold 14 side to the fixed mold 12 side, and between the pinion 22 and the surfaces C and D of the teeth 25 and 27 of the racks 24 and 26 on the fixed mold 12 side. A mold opening correction pressing step is performed in order to reduce the generated backlash to zero. Next, during the mold opening correction pressing process, as shown in FIG. 9E, the movable mold 14 and the rotating mold 16 are moved by a predetermined amount in the mold opening direction by the mold clamping device 6 and the rack and pinion mechanism 20. Open only a small mold (foaming mold opening process). By this foaming mold opening process, the foamable molten resin injected and filled in the fourth mold cavity C4 is foamed and expanded, and the foamed secondary molded body 53b is molded. In this way, at least a part of the unfoamed primary molded body 53a held by the first mold 17b of the rotary mold 16 forming the fourth mold cavity C4 is covered with the unfoamed skin layer. The foamed secondary molded body 53b having foamed cells is laminated and molded (laminate molding process). It is preferable to continue the mold opening correction pressing process even during and after the foam mold opening process. During the mold opening correction pressing process, during the foaming mold opening process, the rotating mold 16 is closed in the mold closing direction (on the fixed mold 12 side) by the foaming pressure of the foamable molten resin in the fourth mold cavity C4. Force acts. This force in the mold closing direction acts in the same direction as the predetermined pressure 2 that presses the pinion 22 toward the fixed mold 12 (mold closing direction) by the pinion moving mechanism 30 in the continued mold opening correction pressing process. For example, when the force in the mold closing direction is larger than the predetermined pressure 2, the pinion 22 is pressed toward the fixed mold 12 by the force in the mold closing direction, and the force in the mold closing direction is smaller than the predetermined pressure 2. In this case, the pinion 22 is pressed toward the fixed mold 12 with a predetermined pressure 2, and the mold opening correction pressing process is maintained in any case. Unlike the first molding example of the expanded foam molding method, the predetermined pressure 2 does not need to be higher than the maximum foaming pressure of the foamable molten resin, but the foaming pressure of the foamable molten resin during the foam expansion is constant. Therefore, in order to reliably continue the mold opening correction pressing step under apparatus control, the predetermined pressure 2 is preferably set to be equal to or higher than the assumed maximum foaming pressure of the foamable molten resin. Thus, by this mold opening correction pressing process, the rotary mold 16 is held on the surfaces C and D sides of the teeth 25 and 27 of the racks 24 and 26 on the fixed mold 12 side, and the foam mold opening process is continued. In the middle, there is no movement in the mold opening direction beyond the amount of movement in the mold opening direction by the rack and pinion mechanism, and after the foaming mold opening process is completed, more than the set minute mold opening amount.

  When the mold opening correction pressing step is performed after a predetermined cooling and solidifying time has elapsed, the mold opening correction pressing step is continued. As shown in FIG. 4, the movable mold 14 and the rotating mold are moved by the mold clamping device 6 and the rack and pinion mechanism 20 in a state where the new unfoamed primary molded body 53a is held by the second mold 17c of the rotating mold 16. 16 is moved to the product removal position in the mold opening direction (mold opening process). Thereafter, the laminated molded product 53 molded between the movable mold 14 and the first mold 17b of the rotating mold 16 (fourth mold cavity C4) is taken out by a product take-out device (not shown) (product take-out process). The second mold 17c of the rotating mold 16 holds a new unfoamed primary molded body 53a molded in the previous primary molding process. In this way, thereafter, by repeating the molding cycle from the state of FIG. 9 (a) to the state of FIG. 9 (f), a laminated molded product composed of the unfoamed primary molded body 53a and the foamed secondary molded body 53b. 53 is continuously formed.

  In the second molding example of the expanded foam molding method according to the present embodiment, when the molten resin is a soft resin such as an elastomer, it is preferable to perform the re-clamping step as in the first molding example.

  The second molding example of the expanded foam molding method according to the present embodiment is a first mold cavity C1 (or a third mold cavity C3) formed between the first mold 17b of the fixed mold 12 and the rotary mold 16. ), An unfoamed primary molded body is molded by a general injection molding method, and the first mold 17b of the rotary mold 16 holding the movable mold 14 and the unfoamed primary molded body is formed. In the four mold cavity C4 (or the second mold cavity C2), the foamed secondary molded body molded by the expanded foam molding method is laminated and molded on at least a part of the unfoamed primary molded body (unfoamed molding— However, the present invention is not limited to this, and at least one of the first mold cavity C1 and the fourth mold cavity C4 (or the third mold cavity C3 and the second mold cavity C2) is used. In There Enhanced foam molding method as long as molding the expanded molded article. That is, in the second molding example of the expanded foam molding method according to the present embodiment, for example, in the first mold cavity C1, the foam primary molded body is molded by the expanded foam molding method, and in the fourth mold cavity C4, The foamed secondary molded body molded by the expanded foam molding method may be formed by laminating and molding at least a part of the foamed primary molded body (expanded foam molding-expanded foam molding aspect). In the mold cavity C1, a foamed primary molded body is molded by an expanded foam molding method. In the fourth mold cavity C4, an unfoamed secondary molded body molded by a general injection molding method is used. It is good also as a mode (a mode of expansion foam molding-non-foam molding) which carries out lamination molding at least partially. Furthermore, in the second molding example of the expanded foam molding method according to the present embodiment, a laminated molded product including a primary molded body in the first mold cavity and a secondary molded body in the fourth mold cavity is molded. However, as another mode, a mode in which a primary molded body is formed in the fourth mold cavity and a laminated molded product including the secondary molded body in the first mold cavity may be molded.

[Third molding example of expanded foam molding]
Next, a third molding example of the expanded foam molding method according to this embodiment will be described with reference to FIG. A third molding example of the expanded foam molding method according to the present embodiment includes a first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16, and the movable mold 14 and the rotary mold. In the second mold cavity C2 formed between the second molds 17c of the mold 16, a single-layer foam molded product is simultaneously molded by the expanded foam molding method. That is, unlike the first molding example and the second molding example of the expanded foam molding method, the rotating mold is not rotated, and a single-layer molded product is formed instead of a laminated molded product for each mold opening / closing operation. Features. In the third molding example, the foamable molten resin injected from the injection unit 7 is caused to flow to the rotary mold 16 and foamed from the rotary mold 16 side to the first mold cavity C1 and the second mold cavity C2, respectively. Although the aspect of the resin flow path into which a molten resin flows in is demonstrated, it is not limited to this. Hereinafter, the description of the same steps and molding conditions as those of the first molding example and the second molding example of the expanded foam molding method will be omitted.

  First, as shown in FIG. 10A, the fixed mold 12, the movable mold 14 and the rotating mold 16 are clamped by a process similar to the first molding example of the expanded foam molding method (clamping process). . As a result, a first mold cavity C1 is formed between the fixed mold 12 and the first mold 17b of the rotating mold 16, and the second mold is interposed between the movable mold 14 and the second mold 17c of the rotating mold 16. A mold cavity C2 is formed. In this mold clamping process, it is preferable to perform a mold closing correction pressing process in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction.

  As shown in FIG. 10B, when the mold closing correction pressing process is performed after the mold clamping process, the mold closing correction pressing process is continued, and when the mold closing correction pressing process is not performed, at a suitable timing. Next, the first mold cavity C1 and the second mold cavity C2 are injected and filled with the foamable molten resin from the injection unit 7 through the resin flow path 50e formed in the fixed mold 12 and the rotary mold 16 ( Foaming resin injection filling process). In this foaming resin injection filling process, until the foaming resin injection filling process is completed, the mold clamping state is maintained, and the volumes of the first mold cavity C1 and the second mold cavity C2 are kept constant and expanded. Whether or not to expand the volume of these mold cavities by starting a foaming mold opening process through a mold clamping release process and a mold opening correction pressing process, which will be described later, before the foamable resin injection filling process is completed, What is necessary is just to select suitably according to the combination with resin to be used, a foaming agent, a product shape, the required quality of a product, etc.

  After the foaming resin injection filling process, the mold clamping force by the mold clamping device 6 is reduced and the mold clamping state is released (the mold clamping releasing process) as in the first molding example and the second molding example of the expanded foam molding method. ) The direction of pressing the pinion 22 by the pinion moving mechanism 30 is switched from the movable mold 14 side to the fixed mold 12 side, and the surface C of the pinion 22 and the teeth 25 and 27 of the racks 24 and 26 on the fixed mold 12 side. , D is performed in order to make the backlash generated between D and D zero. Next, during the mold opening correction pressing process, as shown in FIG. 10 (c), the mold clamping device 6 and the rack and pinion mechanism 20 move the movable mold 14 and the rotating mold 16 by a predetermined amount in the mold opening direction. Open only a small mold (foaming mold opening process). By this foaming mold opening process, the foamable molten resin injected and filled in the first mold cavity C1 and the second mold cavity C2 is expanded by foaming, and a single-layer foam molded product 54 is molded. It is preferable to continue the mold opening correction pressing process even during and after the foam mold opening process. For example, during the mold opening correction pressing process, at the time of the foaming mold opening process, inadequate arrangement of resin flow paths and setting of inappropriate molding conditions in the first mold cavity C1 or the second mold cavity C2 Due to the sudden rise and fall of the foaming pressure of the foamable molten resin due to the above, there is a possibility that a difference occurs in the foaming pressure of both mold cavities. Therefore, when the foaming pressure of the first mold cavity C1 is higher than the foaming pressure of the second mold cavity C2, the force in the mold opening direction (the movable mold 14 side) is applied to the rotary mold 16 by the difference. Works. Since this is the same state as the first molding example of the expanded foam molding method, the mold opening correction pressing step (see FIG. 8C) is continued during and after the foam mold opening step, and the predetermined pressure 2 May be set to be equal to or higher than the maximum foaming pressure of the expandable molten resin (preferably larger than the maximum foaming pressure). On the contrary, when the foaming pressure of the second mold cavity C2 is higher than the foaming pressure of the first mold cavity C1, the force in the mold closing direction (on the fixed mold 12 side) is applied to the rotary mold 16 by the difference. ) Acts. Since this is the same state as in the second molding example of the expanded foam molding method, it is only necessary to continue the mold opening correction pressing process during and after the foam mold opening process, and a predetermined pressure 2 is assumed. It is not necessary to exceed the maximum foaming pressure of the foamable molten resin. That is, even when there is a difference in the foaming pressure between both mold cavities, the predetermined pressure 2 is equal to or higher than the assumed maximum foaming pressure of the foamable molten resin (preferably, as in the first molding example of the expanded foam molding method). By making the pressure larger than the maximum foaming pressure, the rotary mold 16 is held in position on the surfaces C and D side of the teeth 25 and 27 of the racks 24 and 26 on the fixed mold 12 side, and the foaming mold opening process is continuing. In this case, there is no movement in the mold opening direction beyond the amount of movement in the mold opening direction by the rack and pinion mechanism and after the foaming mold opening process is completed.

  When the mold opening correction pressing step is performed after the predetermined cooling and solidifying time has elapsed, the mold opening correction pressing step is continued. As shown in FIG. 2, the movable mold 14 and the rotating mold 16 are moved in the mold opening direction to the product removal position by the mold clamping device 6 and the rack and pinion mechanism 20 (mold opening process). Thereafter, the foam molded products 54 and 54 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16 and between the movable mold 14 and the second mold 17c of the rotary mold 16 are not shown. The product is taken out by the product take-out device (product take-out process). In the third molding example, the rotating mold 16 is not rotated, and a single-layer molded product is formed instead of a laminated molded product. Therefore, during this mold opening process, the foam molded product 54 is fixed to the fixed mold 12 and the rotating mold. Either of 16 and the movable mold 14 may be held. In this way, thereafter, by repeating the molding cycle from the state of FIG. 10A to the state of FIG. 10D, the single-layer foam molded articles 54 and 54 are simultaneously and continuously molded.

  In the third molding example of the expanded foam molding method according to the present embodiment, when the molten resin is a soft resin such as an elastomer, a re-clamping step is performed as in the first molding example and the second molding example. It is preferable.

  In the third molding example of the expanded foam molding method according to the present embodiment, both the first mold cavity C1 and the second mold cavity C2 are of the same type by the expanded foam molding method at the same time under the same molding conditions. Although the single-layer foam molded products 54 and 54 are formed, the present invention is not limited to this. That is, in the third molding example of the expanded foam molding method according to the present embodiment, for example, different types of foam molded products are molded from different molten resins in each of the first mold cavity C1 and the second mold cavity C2. It is also good. Specifically, an injection mold 10 having a three-piece structure in which the first mold cavity C1 and the second mold cavity C2 have different cavity shapes is used, and the movable mold 14 side in addition to the first injection unit 7 is used. A second injection unit capable of injection filling is provided in the second mold cavity C2, and the first mold cavity C1 and the second mold cavity C2 are respectively injected and filled with foamable molten resin from the two injection units. be able to. Thus, when molding different foamed molded products in the first mold cavity C1 and the second mold cavity C2, the projected areas of both molded products are different, and the difference in foaming pressure and foaming state becomes significant. According to the third molding example, even when there is a difference in foaming pressure between the mold cavities on both sides of the rotating mold 16, the rotating mold 16 when the micro mold is opened becomes the teeth 25, 27 of the racks 24, 26. Since the position is reliably held on the surfaces C and D on the fixed mold 12 side, a high-quality foam molded product can be molded without any problem.

  Further, the third molding example of the expanded foam molding method according to the present embodiment is a mode in which a single-layer foam molded product is molded by the expanded foam molding method simultaneously in both the first and second mold cavities C1 and C2. (Expanded Foam Molding-Aspect of Expanded Foam Molding) However, the present invention is not limited to this, and a single-layer foam molded product is molded by the expanded foam molding method in at least one of the first mold cavity C1 and the second mold cavity C2. Anything to do. That is, for example, a foam molded product is molded by the expanded foam molding method only on one side of the first mold cavity C1 and the second mold cavity C2, and a general injection molding method is used for the mold cavity on the other side. A mode in which an unfoamed molded product is molded by (expanded foam molding-non-foamed molding mode), or a foam molded product by an expanded foam molding method only on one side of the first mold cavity C1 and the second mold cavity C2. The mold cavity on the other side may not be molded (expanded foam molding-molding-free aspect). Specifically, in the former expanded-foamed-unfoamed mode, first, foamable melting is performed only on one side of the first mold cavity C1 and the second mold cavity C2, for example, only the first mold cavity C1. Resin is injected and filled and cooled and solidified. As will be described later, when a second injection unit connected to the fixed mold 12 is provided, only the first mold cavity C1 may be injected and filled with non-foamable molten resin. After that, the other side of the first mold cavity C1 and the second mold cavity C2, that is, the second mold cavity C2, is injected and filled with a foamable molten resin and cooled and solidified before the first mold cavity C1 and the second mold cavity C2. The mold cavity C2 is expanded, and only the foamable molten resin in the second mold cavity C2 is expanded and foamed. Thus, after the foamable molten resin or non-foamable molten resin initially injected and filled in the first mold cavity C1 is cooled and solidified, the first mold is expanded in order to expand the volumes of both mold cavities. In the mold cavity C1, not only the non-foaming molten resin but also the foaming molten resin does not expand and expand, and an unfoamed molded product can be molded. In order to separately inject and fill the molten resin into the first mold cavity C1 and the second mold cavity C2, in addition to the first injection unit 7, the movable mold 14, the rotary mold 16, or the fixed mold is used. It is preferable to provide a second injection unit connected to the mold 12 or to provide a resin flow path with a resin cutoff opening switching valve or the like capable of opening and closing the resin flow path, but it is not limited thereto. . In addition, since the latter expansion foam molding-the aspect without molding can be easily understood from the first to third molding examples of the conventional expanded foam molding method, the description thereof is omitted.

  Thus, according to the first molding example, the second molding example, and the third molding example of the expanded foam molding method according to this embodiment, the state in which the pinion 22 is pressed against the teeth 25, 27 of the racks 24, 26, that is, In the state where the backlash generated between the pinion 22 and the surfaces C and D on the fixed mold 12 side of the teeth 25 and 27 of the racks 24 and 26 is zero (mold opening correction pressing process), the foaming mold opening process ( Therefore, the influence of backlash is completely eliminated, and the first mold cavity C1 and the second mold cavity C2 are microscopically maintained during and after the foaming mold opening process. The small opening amount and the small mold opening amount of the third mold cavity C3 and the fourth mold cavity C4 can be made uniform, and the backlash is made zero even if there is a disturbance factor such as foaming pressure. It is possible to maintain the condition, it is possible to stabilize the very small type opening speed in step open position holding and foam-type micro-type open position, obtaining a foam molded article of high quality single-layer and multilayer.

  Further, according to the first molding example and the second molding example of the expanded foam molding method according to the present embodiment, the rigidity of the laminated molded product can be ensured by molding the primary molded body with the non-foamable molten resin. It is possible to reduce the weight of the laminated molded product by molding with a foamable molten resin. Further, by molding the secondary molded body with the foamable molten resin, it is possible to give a soft feeling to the design surface of the product, and to reduce the weight of the laminated molded product and improve the heat insulation and sound insulation. Further, according to the first molding example and the second molding example, for example, automotive interior parts such as instrument panels, door trims, glove box covers, housing equipment such as flooring, miscellaneous goods and toys, etc. It is possible to form a laminated molded product that requires the production of On the other hand, the third molding example of the expanded foam molding method according to the present embodiment is a foam molded product in which the molding conditions in the first mold cavity C1 and the second mold cavity C2 need to be the same, such as a symmetrical door trim. It is particularly suitable for molding such as. That is, the door trim and the like need to be molded under the same molding conditions in the first mold cavity C1 and the second mold cavity C2, and because the projected area of the product is large, in order to shorten the molding cycle, It is necessary to use a large mold capable of molding both the left and right door trims and to perform expansion foam molding with a large molding apparatus. However, according to the third molding example, since the injection mold 10 having a three-sheet structure is used, a large molding device and a large clamping force are not required, and backlash can be eliminated from the rack and pinion mechanism 20. Since the pinion moving mechanism 30 is provided, the molding conditions including the minute mold opening amount and the minute mold opening speed of the first mold cavity C1 and the second mold cavity C2 can be made exactly the same.

  The first molding example, the second molding example, and the third molding example of the expanded foam molding method according to the present embodiment have a mold dividing surface that is not a shear edge structure and is configured only by a plane orthogonal to the mold opening / closing direction. Even a mold having a general structure can be implemented. Specifically, the movable part such as a movable core placed inside the mold is moved to expand the volume of the mold cavity, or the molten resin does not leak out the amount of micro mold opening in the foaming mold opening process The skin layer formed by cooling and solidifying the molten resin at the contact portion between the molten resin injected and filled in the mold cavity and the inner surface of the mold cavity is adjusted by adjusting the temperature of the mold. The foamed molded article may be formed by a known method such as forming the mold so thick that the molten resin does not leak even if the mold is opened.

[First example of injection press molding]
Next, a first molding example of the injection press molding method according to the present embodiment will be described with reference to FIG. The first molding example of the injection press molding method according to the present embodiment is a general injection molding method in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16. In the third mold cavity C3 formed between the fixed mold 12 holding the unpressed primary molded body and the second mold 17c of the rotating mold 16, the injection press In this method, the pressed secondary molded body formed by the forming method is laminated and formed on at least a part of the unpressed primary molded body. That is, the primary molded body molded between the fixed mold and the rotating mold is not moved from the fixed mold side, but the rotating mold is rotated when the mold is opened, and a laminated molded product is obtained every two mold opening / closing operations. It is characterized by molding. Here, the injection press molding method simply means that the movable mold 14 is held in a micro mold open state with a mold clamping force stronger than the mold opening force by the molten resin pressure to be injected and filled in the mold cavity in advance. By opening the micro mold, molten resin is injected and filled into a mold cavity whose volume is expanded from the time of mold clamping, and the movable mold 14 is clamped with a predetermined mold clamping press force during or after the injection filling. In this method, the volume of the mold cavity is reduced to the time of mold clamping (injection press process) to cool and solidify the molten resin in the mold cavity in a state where a predetermined mold clamping press force is applied. This injection press molding method is particularly suitable for molding molded products that need to suppress distortion and deformation, such as optical disks such as CDs and DVDs, and resin glass products such as automobiles as glass substitutes. In the injection press molding method according to the present embodiment, the operations of the racks 24 and 26 and the pinion 22 can be easily understood from FIG. 8 showing the operations of the racks 24 and 26 and the pinion 22 in the expanded foam molding method. The explanation drawing is omitted.

  First, general injection molding is performed in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16 by the same process as the first molding example of the expanded foam molding method. The unpressed primary molded body 55a is molded by the method (primary mold clamping step or primary molding step). The second mold cavity C2 is not used for molding. Next, in a state where the unpressed primary molded body 55a is held by the fixed mold 12, the mold clamping device 6 and the rack and pinion mechanism 20 can be moved to a position where the rotary mold portion 16b of the rotary mold 16 can rotate. The mold 14 and the rotating mold 16 are moved in the mold opening direction (primary mold opening process), and the rotating mold portion 16b of the rotating mold 16 is rotated by 180 degrees so that the second mold 17c of the rotating mold 16 is rotated. Is switched to a position facing the fixed mold 12 (rotation process). FIG. 11A shows a state where this rotation process is completed. Also in the primary mold clamping process and the rotation process, as in the first molding example of the expanded foam molding method, the mold opening correction pressing process and the mold closing correction pressing are performed in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction. It is preferable to perform a process.

  After the rotation process, in the mold open state of the fixed mold 12, the movable mold 14, and the rotary mold 16, the pressing direction to the pinion 22 by the pinion moving mechanism 30 is switched from the fixed mold 12 side to the movable mold 14 side. A mold closing correction pressing step is performed in order to make backlash generated between the pinion 22 and the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26 zero. In this mold closing correction pressing step, the predetermined pressure 1 that presses the pinion 22 toward the movable mold 14 by the pinion moving mechanism 30 is sufficient if it can move the pinion 22 in the mold opening / closing direction.

  Next, during the continuation of the mold closing correction pressing process, as shown in FIG. 11B, the mold clamping device 6 and the rack and pinion mechanism 20 are used to fix the fixed mold 12 and the second mold 17c of the rotating mold 16 to each other. In addition, the movable mold 14 and the rotary mold 16 are moved to a position where a predetermined amount b is opened between the first mold 17b of the movable mold 14 and the rotary mold 16 (that is, until the mold is not completely aligned). 16 is moved in the mold closing direction, and the movable mold 14 and the rotary mold 16 are held in a minute mold open state (secondary mold clamping step). As a result, the third mold is expanded between the fixed mold 12 holding the unpressed primary molded body 55a and the second mold 17c of the rotary mold 16 in the mold opening / closing direction by a predetermined amount b as compared with the time of mold clamping. A mold cavity C3 is formed, and a fourth mold cavity C4 is formed between the movable mold 14 and the first mold 17b of the rotary mold 16 and is expanded in the mold opening / closing direction by a predetermined amount b from the time of mold clamping. The The fourth mold cavity C4 is not used for molding.

  After the secondary clamping process, during the continuation of the mold closing correction pressing process, as shown in FIG. 11C, the second mold of the stationary mold 12 and the rotating mold 16 holding the unpressed primary molded body 55a. From the injection unit 7 to the third mold cavity C3 formed between the molds 17c and expanded in the mold opening / closing direction by a predetermined amount b from the time of mold clamping, through the resin flow path 50f formed in the fixed mold 12. Molten resin is injected and filled (secondary injection filling step). Even during and after the completion of the secondary injection filling process, it is preferable to continue the mold closing correction pressing process. For example, while the mold closing correction pressing process is being continued, during the secondary injection filling process, the molten resin pressure injected and filled into the third mold cavity C3 expanded in the mold opening / closing direction by a predetermined amount b than during mold clamping is used. A force in the mold opening direction (movable mold 14 side) acts on the rotary mold 16. This force in the mold opening direction acts in the same direction as the predetermined pressure 1 that presses the pinion 22 toward the movable mold 14 (mold opening direction) by the pinion moving mechanism 30 in the continuing mold closing correction pressing process. When the force in the mold opening direction is larger than the predetermined pressure 1, the pinion 22 is pressed toward the movable mold 14 by the force in the mold opening direction, and when the force in the mold opening direction is smaller than the predetermined pressure 1, The pinion 22 is pressed toward the movable mold 14 with a predetermined pressure 1, and in any case, the mold closing correction pressing process is maintained. Unlike the second molding example of the injection press molding method, which will be described later, the predetermined pressure 1 does not need to be equal to or higher than the molten resin pressure for injecting and filling the third mold cavity C3. In order to ensure that the mold closing correction pressing step is continued under the control of the apparatus, it is preferable that the predetermined pressure 1 is equal to or higher than the molten resin pressure to be injected and filled into the third mold cavity C3. . Thus, by this mold closing correction pressing step, the rotating mold 16 is held on the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26, and the mold is opened in a minute mold state. After the clamping process is completed, the amount of mold opening is less than the set minute mold opening amount, and in the mold pressing direction by the rack and pinion mechanism during the later-described injection press process (movement operation in the mold closing direction). It does not move in the mold closing direction beyond the amount of movement.

  Further, as shown in FIG. 11 (d), the mold clamping device 6 and the rack and pinion mechanism are interlocked with this secondary injection filling process or during the mold closing correction pressing process after the secondary injection filling process. The movable mold 14 and the rotary mold 16 are moved in the mold closing direction by 20 and the fixed mold 12, the movable mold 14 and the rotary mold 16 are clamped with a predetermined mold clamping press force (injection press process). By this injection press step, a mold clamping press force is applied to the molten resin in the third mold cavity C3, and the press secondary molded body 55b is molded. In this way, a secondary press formed by applying a predetermined clamping force to at least a part of the unpressed primary molded body 55a held by the fixed mold 12 forming the third mold cavity C3. The molded body 55b is laminated and formed (lamination forming step). Note that the fourth mold cavity C4 expanded in the mold opening / closing direction by a predetermined amount b from the time of mold clamping is also reduced in mold cavity volume by the injection pressing process until the mold clamping, as described above. It is not used for molding. In the mold clamping state, it is not necessary to press the pinion 22 by the pinion moving mechanism 30 (mold closing correction pressing process). However, in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction, It is preferable to continue.

  After the elapse of a predetermined cooling and solidifying time, as shown in FIG. 11 (e), as in the first molding example of the expanded foam molding method, the fixed mold 12 and the rotating mold are obtained by the secondary mold opening process and the product removing process. The laminated molded product 55 molded between the 16 second molds 17c (third mold cavity C3) is taken out by a product take-out device (not shown). In this way, thereafter, by repeating the molding cycle from the state of FIG. 11 (a) to the state of FIG. 11 (e), a laminated molded product comprising the unpressed primary molded body 55a and the pressed secondary molded body 55b. 55 is formed continuously.

  A first molding example of the injection press molding method according to the present embodiment is a general injection molding method in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16. An unpressed primary molded body is molded, and a press secondary molded body molded by an injection press molding method in a third mold cavity C3 formed between the second mold 17c of the fixed mold 12 and the rotary mold 16 is formed. Although it is an aspect (non-injection press molding-injection press molding aspect) in which at least a part of the unpressed primary molded body is laminated, the present invention is not limited to this and is the same as the first embodiment of the expanded foam molding method. Furthermore, it may be an aspect of injection press molding-injection press molding or an aspect of injection press molding-non-injection press molding.

  Further, in the first molding example of the injection press molding method according to the present embodiment, the molten resin is injected and filled from one injection unit 7 in both the primary injection filling process and the secondary injection filling process. As in the second molding example of the expanded foam molding method, the second injection unit is provided, and the molten resin is injected and filled from different injection units in the primary injection filling process and the secondary injection filling process. May be.

[Second example of injection press molding]
Next, a second molding example of the injection press molding method according to the present embodiment will be described with reference to FIG. The second molding example of the injection press molding method according to the present embodiment is a general injection molding method in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16. In the fourth mold cavity C4 formed between the first mold 17b and the movable mold 14 of the rotary mold 16 formed by pressing the unpressed primary molded body and holding the unpressed primary molded body, injection press molding is performed. In this method, the pressed secondary molded body formed by the method is laminated and formed on at least a part of the unpressed primary molded body. That is, the primary molded body formed between the fixed mold and the rotating mold is held on the rotating mold side, the rotating mold is rotated when the mold is opened, and the primary molded body is moved to the movable mold side by the rotation. The laminated molded product and the primary molded body are formed for each second and subsequent mold opening / closing operations except for the first mold opening / closing operation. In the second molding example of the injection press molding method according to the present embodiment, in addition to the first injection unit 7 provided on the fixed mold 12 side, the mold is provided on the movable mold 14 side in parallel with the mold opening / closing direction. Although it demonstrates using the 2nd injection | emission unit 8, it is not limited to this. Hereinafter, the description of the same steps and molding conditions as those of the first molding example of the injection press molding method will be omitted.

  First, general injection molding is performed in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16 by the same process as the first molding example of the expanded foam molding method. The unpressed primary molded body 56a is molded by the method (primary mold clamping step or primary molding step). After a predetermined cooling and solidifying time has elapsed, as shown in FIG. 12A, the unpressed primary molded body 56a is held by the first mold 17b of the rotating mold 16, and the mold clamping device 6 and the rack and pinion The movable mold 14 and the rotary mold 16 are moved in the mold opening direction by the mechanism 20 to a position where the rotary mold portion 16b of the rotary mold 16 can rotate (mold opening process). After the predetermined cooling and solidifying time has elapsed, before the mold opening process is performed, in the second mold cavity C2 formed between the movable mold 14 and the second mold 17c of the rotary mold 16, as described later. A secondary injection filling process or a lamination molding process is performed, but the description thereof is omitted here.

  After the mold opening process, as shown in FIG. 12B, the first mold 17b of the rotary mold 16 is held in a state where the unpressed primary molded body 56a is held by the first mold 17b of the rotary mold 16. The rotating mold portion 16b of the rotating mold 16 is rotated 180 degrees by the rotating mechanism 16d at a position facing the movable mold 14 and the second mold 17c of the rotating mold 16 facing the fixed mold 12 (rotation). Process). Also in the mold clamping process and the rotation process, as in the first molding example of the injection press molding method, the mold opening correction pressing process and the mold closing correction pressing process are performed in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction. It is preferable to carry out. As will be described later, the laminated molded product molded between the movable mold 14 and the second mold 17c (third mold cavity C3) of the movable mold 14 and the rotary mold 16 in the previous molding cycle is subjected to the mold opening process. Before the rotation process is started, since it has already been taken out between these dies in the product take-out process, it is movable except for the first mold 17b of the rotary mold 16 holding the unpressed primary molded body 56a. Nothing is held by the mold 14, the second mold 17 c of the rotating mold 16, and the fixed mold 12.

  After the rotation process, in the mold open state of the fixed mold 12, the movable mold 14, and the rotary mold 16, the pressing direction to the pinion 22 by the pinion moving mechanism 30 is switched from the fixed mold 12 side to the movable mold 14 side. A mold closing correction pressing step is performed in order to make backlash generated between the pinion 22 and the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26 zero. Next, during the continuation of the mold closing correction pressing process, as shown in FIG. 12C, the mold clamping device 6 and the rack and pinion mechanism 20 are used to fix the fixed mold 12 and the second mold 17 c of the rotating mold 16. In addition, the movable mold 14 and the rotary mold 16 are moved to a position where the distance between the first mold 17b of the movable mold 14 and the rotary mold 16 is slightly opened by a predetermined amount b (that is, to a position where the molds are not completely aligned). 16 is moved in the mold closing direction, and the movable mold 14 and the rotary mold 16 are held at the minute mold opening position (mold clamping step). As a result, the fourth mold is expanded between the first mold 17b of the rotating mold 16 holding the movable mold 14 and the unpressed primary molded body 56a by a predetermined amount b in the mold opening / closing direction than when the mold is clamped. A mold cavity C4 is formed.

  After the mold clamping process and during the mold closing correction pressing process, as shown in FIG. 12D, the first mold 17b and the movable mold 14 of the rotary mold 16 holding the unpressed primary molded body 56a are held. The second injection unit 8 is inserted into a fourth mold cavity C4 formed in the mold opening / closing direction by a predetermined amount b from the time of mold clamping through a resin flow path 50g formed in the movable mold 14. The molten resin is injected and filled from (secondary injection filling step). It is preferable to continue the mold closing correction pressing correction step even during and after the secondary injection filling step. For example, during the mold closing correction pressing correction process, during this secondary injection filling process, the molten resin pressure injected and filled into the fourth mold cavity C4 expanded in the mold opening / closing direction by a predetermined amount b than at the time of mold clamping. Thus, a force in the mold closing direction (on the fixed mold 12 side) acts on the rotary mold 16. This force in the mold closing direction acts in a direction opposite to the predetermined pressure 1 that presses the pinion 22 toward the movable mold 14 (mold opening direction) by the pinion moving mechanism 30 in the continuing mold closing correction process. When the force in the mold closing direction is larger than the predetermined pressure 1, the pinion moving mechanism 30 is fixed to the side surface of the rotating mold 16, and therefore the rotating mold 16 is connected to the pinion 22 and the teeth 25 of the racks 24 and 26, Accordingly, it moves in the mold closing direction (fixed mold 12 side) by an amount corresponding to the backlashes α and β between the surfaces C and D on the fixed mold 12 side (see FIG. 8A). Therefore, a predetermined pressure 1 is applied from the beginning of the mold closing correction pressing step against the force in the mold closing direction acting on the rotary mold 16, that is, the molten resin pressure to be injected and filled into the fourth mold cavity C4. Alternatively, if the molten resin pressure is set to be equal to or higher than this molten resin pressure (preferably larger than the molten resin pressure) before the secondary injection filling step, the rotary mold 16 is movable molds of the teeth 25 and 27 of the racks 24 and 26. After completion of the mold clamping process in which the molds are held in the surfaces A and B on the 14th side and opened in a minute mold, the injection press process (in the mold closing direction to be described later) is performed below the set minute mold opening amount. During the continuation of the movement operation, the movement in the mold closing direction does not exceed the amount of movement in the mold closing direction by the rack and pinion mechanism.

  Also, in conjunction with this secondary injection filling process or after the secondary injection filling process, as in the first molding example of the injection press molding method, during the continuation of the mold closing correction pressing process, FIG. As shown, the movable mold 14 and the rotary mold 16 are moved in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20, and the fixed mold 12, the movable mold 14 and the rotary mold 16 are moved to a predetermined mold. The mold is clamped with a clamping press force (injection press process). By this injection press step, a mold clamping press force is applied to the molten resin in the fourth mold cavity C4, and the press secondary molded body 56b is molded. In this manner, a predetermined clamping press force is applied to at least a part of the unpressed primary molded body 56a held by the first mold 17b of the rotary mold 16 forming the fourth mold cavity C4. The formed press secondary molded body 56b is laminated and molded (laminate molding process). The third mold cavity C3 expanded in the mold opening / closing direction by a predetermined amount b from the time of mold clamping is also reduced in mold cavity volume by the injection press process until the mold clamping, but these processes are performed. Meanwhile, injection filling or the like is not performed in the third mold cavity C3. In the mold clamping state, it is not necessary to press the pinion 22 by the pinion moving mechanism 30 (mold closing correction pressing process). However, in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction, It is preferable to continue.

  Further, in conjunction with the injection press process or after the injection press process, the resin mold 50h is provided in the third mold cavity C3 formed between the fixed mold 12 and the second mold 17c of the rotary mold 16. Then, the molten resin is injected and filled from the first injection unit 7 (primary injection filling step), and a new unpressed primary molded body 56a is formed by a general injection molding method (primary molding step).

  After the elapse of a predetermined cooling and solidifying time, as shown in FIG. 12 (f), the movable mold 14 and the rotating mold 16 are removed by the mold opening process and the product removing process as in the second molding example of the expanded foam molding method. The laminated molded product 56 molded between the first molds 17b (fourth mold cavity C4) is taken out by a product take-out device (not shown). Further, a new unpressed primary molded body 56a formed in the previous primary molding step is held in the second mold 17c of the rotary mold 16. In this way, thereafter, by repeating the molding cycle from the state of FIG. 12 (a) to the state of FIG. 12 (f), a laminated molded product composed of the unpressed primary molded body 56a and the pressed secondary molded body 56b. 56 and a new unpressed primary compact 56a are continuously molded.

  In the second molding example of the injection press molding method according to the present embodiment, the first mold cavity C1 (or the third mold cavity C3) formed between the fixed mold 12 and the first mold 17b of the rotary mold 16 is used. 4) formed between the movable mold 14 and the first mold 17b of the rotating mold 16 holding the unpressed primary molded body by a general injection molding method. In the mold cavity C4 (or the second mold cavity C2), a press secondary molded body molded by the injection press molding method is laminated and formed on at least a part of the unpressed primary molded body (non-injection press molding— The embodiment of the injection press molding is not limited to this, but, as in the second molding example of the expanded foam molding method, the injection press molding-injection press molding mode, or the injection press molding-non-injection press It may be an aspect of the shape.

[Third example of injection press molding]
Next, a third molding example of the injection press molding method according to the present embodiment will be described with reference to FIG. The third molding example of the injection press molding method according to the present embodiment is a first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16, the movable mold 14 and the rotary mold. In the second mold cavity C2 formed between the second molds 17c of the mold 16, a single-layer injection press molded product is simultaneously molded by the injection press molding method. That is, unlike the first molding example and the second molding example of the injection press molding method, the rotating mold is not rotated, and a single-layer molded product is formed instead of a laminated molded product for each mold opening / closing operation. Features. In the third molding example, the second injection unit 8 provided on the movable mold 14 side will be described in addition to the first injection unit 7 provided on the fixed mold 12 side, but the present invention is not limited thereto. Is not to be done. Hereinafter, the description of the same steps and molding conditions as those of the first molding example and the second molding example of the injection press molding method will be omitted.

  First, in a state where the pinion 22 is pressed against the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26 (mold closing correction pressing step), as shown in FIG. The movable mold 14 and the rotary mold 16 are moved in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20 to a position where they cannot be completely aligned, and the movable mold 14 and the rotary mold 16 are opened in a minute mold state. Hold the position (clamping process). As a result, a first mold cavity C1 is formed between the fixed mold 12 and the first mold 17b of the rotary mold 16 and is expanded in the mold opening and closing direction by a predetermined amount b from the time of mold clamping, and the movable mold is formed. 14 and the second mold 17c of the rotating mold 16 are formed with a second mold cavity C2 that is expanded in the mold opening and closing direction by a predetermined amount b from the time of mold clamping.

  After the mold closing process, during the mold closing correction pressing process, as shown in FIG. 13B, the first mold cavity C1 and the second mold cavity C2 are moved to the fixed mold 12 and the movable mold 14. Molten resin is injected and filled from the first injection unit 7 and the second injection unit 8 through the formed resin flow paths 50i and 50j (injection filling step). It is preferable to continue the mold closing correction pressing process even during and after the injection filling process. For example, during the continuation of the mold closing correction pressing process, during this injection filling process, in the first mold cavity C1 and the second mold cavity C2, due to inappropriate resin flow path arrangement, inappropriate injection conditions, etc. There may be a difference in the molten resin pressure in both mold cavities. Therefore, when the molten resin pressure in the first mold cavity C1 is higher than the molten resin pressure in the second mold cavity C2, the mold opening direction (movable mold 14 side) is set in the rotating mold 16 by the difference. The force of acts. Since this is the same state as the first embodiment of the injection press molding method, it is only necessary to continue the mold closing correction pressing process (see FIG. 8A) during and after the injection filling process. The predetermined pressure 1 need not be equal to or higher than the molten resin pressure for injecting and filling the first mold cavity C1 and the second mold cavity C2. Conversely, when the molten resin pressure in the second mold cavity C2 is higher than the molten resin pressure in the first mold cavity C1, the rotational mold 16 is closed in the mold closing direction (on the fixed mold 12 side) by the difference. ) Acts. Since this is the same state as in the second embodiment of the injection press molding method, the mold closing correction pressing process is continued during and after the injection filling process, and the predetermined pressure 1 is applied to the first mold cavity C1 and What is necessary is just to make it more than the molten resin pressure (preferably larger than a molten resin pressure) which injects and fills the 2nd metal mold cavity C2. That is, even when there is a difference in the molten resin pressure between both mold cavities, the predetermined pressure 1 is applied to the first mold cavity C1 and the second mold cavity C2 as in the first embodiment of the injection press molding method. By setting the pressure to be equal to or higher than the molten resin pressure to be injected and filled (preferably larger than the molten resin pressure), the rotary mold 16 is moved to the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26. After completion of the mold clamping process with the position held and in a minute mold open state, it is below the set small mold opening amount, and during the injection press process (moving operation in the mold closing direction), the rack and It does not move in the mold closing direction beyond the amount of movement in the mold closing direction by the pinion mechanism.

  Further, in conjunction with this injection filling process or after the injection filling process, as in the first molding example and the second molding example of the injection press molding method, during the continuation of the mold closing correction pressing process, FIG. As shown in FIG. 2, the movable mold 14 and the rotary mold 16 are moved in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20, and the fixed mold 12, the movable mold 14 and the rotary mold 16 are predetermined. The mold is clamped by the mold clamping press force (injection press process). By this injection press step, a predetermined mold clamping press force is applied to the molten resin in the first mold cavity C1 and the second mold cavity C2, and a single-layer injection press molded product 57 is formed. In the mold clamping state, it is not necessary to press the pinion 22 by the pinion moving mechanism 30 (mold closing correction pressing process), but the pressing is continued in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction. It is preferable to do.

  After elapse of a predetermined cooling and solidifying time, as shown in FIG. 13 (d), a fixed mold 12 and a rotating mold are obtained by performing a mold opening process and a product removing process in the same manner as in the third molding example of the expanded foam molding method. Injection press-molded products 57 and 57 molded between the first mold 17b of the mold 16 and between the second mold 17c of the movable mold 14 and the rotary mold 16 are taken out by a product take-out device (not shown). In the third molding example, the rotary mold 16 is not rotated, and a single-layer molded product is formed instead of a laminated molded product. Therefore, during this mold opening process, the injection press-molded product 57 is fixed to the fixed mold 12 and the rotary mold. You may hold | maintain in any metal mold | die 16 and the movable metal mold | die 14. In this way, thereafter, by repeating the molding cycle from the state of FIG. 13 (a) to the state of FIG. 13 (d), single-layer injection press molded products 57 and 57 are simultaneously and continuously molded. .

  In the third molding example of the injection press molding method according to the present embodiment, both the first mold cavity C1 and the second mold cavity C2 are of the same type by the injection press molding method at the same time under the same molding conditions. Although single-layer injection press-molded articles 57 and 57 are formed, the present invention is not limited to this. That is, the third molding example of the injection press molding method according to the present embodiment is similar to the third molding example of the expanded foam molding method, for example, in each of the first mold cavity C1 and the second mold cavity C2. Different types of injection press molded products may be molded from different molten resins.

  Further, in the third molding example of the injection press molding method according to this embodiment, a single layer injection press molded product is molded by the injection press molding method simultaneously in both the first and second mold cavities C1 and C2. Although the mode (injection press molding-injection press molding mode) is used, the present invention is not limited to this, and as in the third molding example of the expanded foam molding method, the mode of injection press molding-non-injection press molding or injection press molding is used. -It may be an embodiment without molding. Specifically, in the former injection press molding-non-injection press molding, first, molten resin is applied only to one side of the first mold cavity C1 and the second mold cavity C2 in the micro mold open state. After injection filling, an injection press process is performed by the method described above. Thereafter, the molten resin is injected and filled into the other side of the first mold cavity C1 and the second mold cavity C2 in the clamped state, and the molten resin in both the first mold cavity C1 and the second mold cavity C2 is cooled. Solidify. Thereby, an injection press-molded product can be molded on one side of the first mold cavity C1 and the second mold cavity C2, and a non-injection press-molded product can be molded on the other side. In addition, since the latter aspect of injection press molding-no molding can be easily understood from the first to third molding examples of the conventional injection press molding method, description thereof will be omitted.

  Furthermore, in the third molding example of the injection press molding method according to the present embodiment, the first mold cavity C1 is injected and filled with molten resin by the first injection unit 7 provided on the back side of the fixed mold 12, Although the molten resin is injected and filled into the second mold cavity C2 by the second injection unit 8 provided on the movable mold 14 side, the present invention is not limited to this. That is, in the third molding example, for example, similarly to the third molding example of the expanded foam molding method, the second injection unit 8 on the movable mold 14 side is not provided, and the melt injected only from the first injection unit 7 is used. The resin may flow to the rotating mold 16 and the molten resin may flow into the first mold cavity C1 and the second mold cavity C2 from the rotating mold 16 side. In this case, the resin flow path may be provided with a resin shut-off switching valve or the like that can open and close the resin flow path.

  Thus, according to the first molding example, the second molding example, and the third molding example of the injection press molding method according to the present embodiment, the pinion 22 is pressed against the teeth of the racks 24 and 26, that is, the pinion 22 And the secondary injection filling process or injection filling in a state where the backlash generated between the teeth 25 and 27 of the racks 24 and 26 and the surfaces A and B on the movable mold 14 side is zero (mold closing correction pressing process). Process and injection press process (mold closing / clamping operation from micro mold open state) completely eliminates the effect of backlash and during and after the secondary injection filling process or injection filling process When the micro mold opening amount of the first mold cavity C1 and the second mold cavity C2 and the micro mold opening amount of the third mold cavity C3 and the fourth mold cavity C4 can be made uniform. In addition, even if there is a disturbance factor such as molten resin pressure, it is possible to maintain a state in which the backlash is zero, so that the position of the minute mold opening position is maintained and the mold clamping speed in the injection press process is stabilized, resulting in high quality. Single-layer and multi-layer injection press molded products can be obtained.

[First molding example of injection compression molding]
Next, a first molding example of the injection compression molding method according to the present embodiment will be described with reference to FIG. The first molding example of the injection compression molding method according to the present embodiment is a general injection molding method in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16. In the third mold cavity C3 formed between the fixed mold 12 holding the uncompressed primary molded body and the second mold 17c of the rotating mold 16, the injection compression is performed. In this method, the compressed secondary molded body molded by the molding method is laminated and formed on at least a part of the uncompressed primary molded body. That is, the primary form formed between the fixed mold and the rotating mold is not moved from the fixed mold side, and the rotating mold is rotated when the mold is opened, so that a laminated molded product is produced every two mold opening / closing operations. It is characterized by molding. Here, the injection compression molding method simply means that the movable mold 14 is clamped in advance with a mold clamping force that is weaker than the mold opening force due to the molten resin pressure that is injected and filled into the mold cavity. The movable mold 14 is micro-opened by the molten resin pressure injected and filled into the mold cavity, and the micro mold is opened and the molten resin is injected and filled into the mold cavity whose volume has been expanded from the time of clamping. In the middle or after completion of injection filling, the movable mold 14 is clamped with a predetermined clamping compression force, and the mold cavity volume is reduced to the clamping time (injection compression process), whereby the molten resin in the mold cavity is predetermined. This is a method of cooling and solidifying in a state where the mold clamping compression force is applied. This injection compression molding method, like the injection press molding method, is a molded product that needs to particularly suppress distortion and deformation, such as optical disks such as CD and DVD, resin glass products such as automobiles as glass substitutes, etc. Particularly suitable for molding. In the injection compression molding method according to the present embodiment, the operations of the racks 24 and 26 and the pinion 22 can be easily understood from FIG. 8 showing the operations of the racks 24 and 26 and the pinion 22 in the expanded foam molding method. The explanation drawing is omitted.

  First, general injection molding is performed in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16 by the same process as the first molding example of the expanded foam molding method. The uncompressed primary molded body 58a is molded by the method (primary mold clamping step or primary molding step). The second mold cavity C2 is not used for molding. Next, in a state where the uncompressed primary molded body 58a is held in the fixed mold 12, the mold clamping device 6 and the rack and pinion mechanism 20 can be moved to a position where the rotary mold portion 16b of the rotary mold 16 can rotate. The mold 14 and the rotating mold 16 are moved in the mold opening direction (primary mold opening process), and the rotating mold portion 16b of the rotating mold 16 is rotated by 180 degrees so that the second mold 17c of the rotating mold 16 is rotated. Is switched to a position facing the fixed mold 12 (rotation process). FIG. 14A shows a state in which this rotation process is completed. Also in the primary mold clamping process and the rotation process, as in the first molding example of the expanded foam molding method, the mold opening correction pressing process and the mold closing correction pressing are performed in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction. It is preferable to perform a process.

  After the rotation process, in the mold open state of the fixed mold 12, the movable mold 14, and the rotary mold 16, the pressing direction to the pinion 22 by the pinion moving mechanism 30 is switched from the fixed mold 12 side to the movable mold 14 side. A mold closing correction pressing step is performed in order to make backlash generated between the pinion 22 and the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26 zero. The mold closing correction pressing process is not necessarily performed at this stage, and may be performed from the secondary mold clamping process described later to the start of the secondary injection filling process. Next, while the mold closing correction pressing process is continued, the movable mold 14 and the rotating mold 16 are moved in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20 as shown in FIG. 14B. The fixed mold 12, the movable mold 14 and the rotary mold 16 are clamped (secondary mold clamping step). As a result, a third mold cavity C3 is formed between the fixed mold 12 holding the uncompressed primary molded body 58a and the second mold 17c of the rotary mold 16, and the movable mold 14 and the rotary mold 16 are formed. A fourth mold cavity C4 is formed between the first molds 17b. Here, the clamping force of the clamping device 6 in the secondary clamping process is set to be smaller than the molten resin pressure injected and filled into the third mold cavity C3. The fourth mold cavity C4 is not used for molding.

  After the secondary mold clamping process, during the continuation of the mold closing correction pressing process, as shown in FIG. 14C, the second mold of the stationary mold 12 and the rotating mold 16 holding the uncompressed primary molded body 58a. The third mold cavity C3 formed between the molds 17c is injected and filled with molten resin from the injection unit 7 through the resin flow path 50k formed in the fixed mold 12 (secondary injection filling process).

  In this secondary injection filling step, the movable mold 14 and the rotary mold 16 are moved relative to the fixed mold 12 by the molten resin pressure injected and filled into the third mold cavity C3 as shown in FIG. The mold is opened by a predetermined amount c in the mold opening direction (micro mold opening process). Specifically, the mold clamping force of the mold clamping device 6 in the secondary mold clamping process is set to be smaller than the molten resin pressure for injecting and filling the third mold cavity C3 as described above. Therefore, the force in the mold opening direction acts on the rotary mold 16 by the difference between the mold clamping force of the mold clamping device 6 and the force in the mold opening direction due to the molten resin pressure to be injected and filled, and the rotary mold 16 is fixed. A small mold is opened from the mold 12. In the initial stage of the micro mold opening process, since the movable mold 14 and the rotary mold 16 are in the mold-matching state, the force in the mold opening direction also acts on the movable mold 14 via the rotary mold 16 and is movable. This is an opportunity for the mold 14 to be slightly opened from the rotating mold 16. After the movable mold 14 is separated from the rotating mold 16 in the mold opening direction, the force in the mold opening direction acting on the rotating mold 16 also acts on the movable mold 14 via the rack and pinion mechanism 20 and rotates. In conjunction with the micro mold opening operation of the mold 16, the movable mold 14 is micro opened. That is, instead of the mold opening correction pressing process performed in the expansion mold opening process of the expanded foam molding method, the mold closing correction pressing process is reversed, that is, the pinion 22 is a movable mold of the teeth 25 and 27 of the racks 24 and 26. In a state of being pressed against the surfaces A and B on the 14 side, the pinion 22 also moves in the mold opening direction as the rotating mold 16 moves in the mold opening direction, and the movable mold of the teeth 27 of the lower rack 26 is moved. On the surface B on the 14th side, a force in the mold opening direction is applied to the teeth 27 of the same rack by the lower teeth of the pinion 22. At this time, the pinion 22 receives a counterclockwise reaction force (in the mold closing direction) via the lower teeth, but at the same time, the upper teeth of the pinion 22 are fixed and do not move. Since the surface A on the movable mold 14 side receives a counterclockwise reaction force (the mold opening direction), the pinion 22 does not rotate counterclockwise, and as the rotary mold 16 moves in the mold opening direction, While rotating clockwise, the lower rack 26 is moved in the mold opening direction, and the movable mold 14 is moved in the mold opening direction (see FIG. 8A). At this time, the mold clamping device 6 opposes the force in the mold opening direction due to the molten resin pressure acting on the movable mold 14 from the rotary mold 16 via the rack and pinion mechanism 20, and the micro mold of the movable mold 14. A mold clamping force is applied so as to control the opening amount and the minute mold opening speed, but a force in the mold opening direction is not applied to the movable mold 14. Here, not the mold closing correction pressing process, but the mold opening correction pressing process, that is, the state in which the pinion 22 is pressed against the surfaces C and D on the fixed mold 12 side of the teeth 25 and 27 of the racks 24 and 26 (FIG. 8 (c)), when this micro mold opening process is performed, as described above, in the initial stage of the micro mold opening process in which the movable mold 14 and the rotary mold 16 are in a mold-matching state, The movable mold 14 is moved together with the rotating mold in the mold opening direction. After the movable mold 14 is separated from the rotating mold 16 in the mold opening direction, only the rotating mold 16 has teeth of the racks 24 and 26. The surfaces 25 and 27 move to the surfaces A and B on the movable mold 14 side by backlash α and β, and the difference in the micro mold opening amounts of the first mold cavity C1 and the second mold cavity C2 occurs.

  Even during and after the completion of the secondary injection filling process, it is preferable to continue the mold closing correction pressing process. For example, during the mold closing correction pressing process, during the secondary injection filling process, due to the molten resin pressure injected and filled into the third mold cavity C3, the rotating mold 16 has a mold opening direction (on the movable mold 14 side). ) Acts. This force in the mold opening direction acts in the same direction as the predetermined pressure 1 that presses the pinion 22 toward the movable mold 14 (mold opening direction) by the pinion moving mechanism 30 in the continuing mold closing correction pressing process. When the force in the mold opening direction is larger than the predetermined pressure 1, the pinion 22 is pressed toward the movable mold 14 by the force in the mold opening direction, and when the force in the mold opening direction is smaller than the predetermined pressure 1, The pinion 22 is pressed toward the movable mold 14 with a predetermined pressure 1, and in any case, the mold closing correction pressing process is maintained. As in the second molding example of the injection press molding method described above, the predetermined pressure 1 does not need to be equal to or higher than the molten resin pressure for injection filling the third mold cavity C3. Since the pressure is not constant but fluctuates, the predetermined pressure 1 is set to be equal to or higher than the molten resin pressure for injecting and filling the third mold cavity C3 in order to reliably continue the mold closing correction pressing process under the control of the apparatus. Is preferred. As described above, by this mold closing correction pressing process, the rotary mold 16 is held at the movable mold side surfaces A and B of the teeth 25 and 27 of the racks 24 and 26, and the micro mold opening process is continuing. In this case, there is no movement in the mold opening direction beyond the amount of movement in the mold opening direction by the rack and pinion mechanism, and after the micro mold opening process is completed, the amount of movement is more than the set micro mold opening amount. Further, in the injection compression process described later, if the mold closing correction pressing process is continued as it is, the backlash during the movement operation in the mold closing direction from the set minute mold opening position can be made zero.

In the first molding example of the injection compression molding method according to the present embodiment, in order to control the micro mold opening amount and micro mold opening speed with high accuracy, the movable mold 14 and the rotation are interlocked with the secondary injection filling process. It is preferable to further include a feedback step of monitoring the amount of mold opening of the mold 16 and feedback controlling the clamping force by the clamping device 6. Specifically, this feedback step monitors the minute mold opening amounts of the movable mold 14 and the rotary mold 16 in a state where the molten resin is injected and filled into the third mold cavity C3, and the movable mold 14 And a mold that increases the clamping force of the clamping device 6 so that the positions of the movable mold 14 and the rotating mold 16 are maintained when the minute mold opening amount of the rotating mold 16 reaches a predetermined amount c. It can be performed by tightening control. In the first molding example of the injection compression molding method according to the present embodiment, this feedback step is not necessarily performed. Instead of the feedback step, for example, micro mold opening of the movable mold 14 and the rotary mold 16 is performed. When the amount reaches the predetermined amount c or after that (after the micro mold opening step), it may be transferred to an injection compression step described later.

  After the micro mold opening process, during the mold closing correction pressing process, as shown in FIG. 14E, the movable mold 14 and the rotating mold 16 are moved in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20. The fixed mold 12, the movable mold 14 and the rotary mold 16 are clamped with a predetermined clamping compression force (injection compression process). Through this injection compression process, a compression clamping force is applied to the molten resin in the third mold cavity C3 to form the compression secondary molded body 58b. Thus, the compressed secondary molded by applying a predetermined clamping force to at least a part of the uncompressed primary molded body 58a held by the fixed mold 12 forming the third mold cavity C3. The molded body 58b is laminated and molded (laminate molding process). The fourth mold cavity C4 is also micro-molded by a predetermined amount c in the mold opening direction in the secondary injection filling process (micro-mold opening process), and the mold cavity volume is reduced by the injection compression process until the mold is clamped. Although reduced, it is not used for molding as described above. In addition, this injection compression process may be performed in conjunction with the secondary injection filling process, or may be performed after the secondary injection filling process. In the mold clamping state, it is not necessary to press the pinion 22 by the pinion moving mechanism 30 (mold closing correction pressing process), but the pressing is continued in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction. It is preferable to do.

  After the elapse of a predetermined cooling and solidifying time, as shown in FIG. 14 (f), as in the first molding example of the expanded foam molding method, the fixed mold 12 and the rotating mold are obtained by the secondary mold opening process and the product taking-out process. The laminated molded product 58 molded between the 16 second molds 17c (third mold cavity C3) is taken out by a product take-out device (not shown). In this way, thereafter, by repeating the molding cycle from the state of FIG. 14 (a) to the state of FIG. 14 (f), a laminated molded product comprising the uncompressed primary molded body 58a and the compressed secondary molded body 58b. 58 is continuously formed.

  The first molding example of the injection compression molding method according to the present embodiment is a general injection molding method in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16. An uncompressed primary molded body is molded by the above, and a compressed secondary molded body is molded by an injection compression molding method in a third mold cavity C3 formed between the fixed mold 12 and the second mold 17c of the rotating mold 16. Is formed in at least a part of the uncompressed primary molded body (non-injection compression molding-injection compression molding aspect), but is not limited thereto, and the first molding example of the expanded foam molding method and Similarly, it may be an aspect of injection compression molding-injection compression molding or an aspect of injection compression molding-non-injection compression molding.

  In the first molding example of the injection compression molding method according to the present embodiment, the molten resin is injected and filled from one injection unit 7 in both the primary injection filling process and the secondary injection filling process. As in the second molding example of the expanded foam molding method, the second injection unit is provided, and the molten resin is injected and filled from different injection units in the primary injection filling process and the secondary injection filling process. Anyway.

[Second example of injection compression molding]
Next, a second molding example of the injection compression molding method according to the present embodiment will be described with reference to FIG. The second molding example of the injection compression molding method according to the present embodiment is a general injection molding method in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16. In the fourth mold cavity C4 formed between the first mold 17b and the movable mold 14 of the rotary mold 16 formed by molding the uncompressed primary molded body and holding the uncompressed primary molded body, injection compression molding is performed. In this method, the compressed secondary molded body formed by the method is laminated and formed on at least a part of the uncompressed primary molded body. That is, the primary molded body formed between the fixed mold and the rotating mold is held on the rotating mold side, the rotating mold is rotated when the mold is opened, and the primary molded body is moved to the movable mold side by the rotation. The laminated molded product and the primary molded body are formed for each second and subsequent mold opening / closing operations except for the first mold opening / closing operation. In the second molding example, in addition to the first injection unit 7 provided on the fixed mold 12 side, the second injection unit 8 provided in parallel with the mold opening / closing direction on the movable mold 14 side will be described. However, the present invention is not limited to this. Hereinafter, the description of the same steps and molding conditions as those of the first molding example of the injection compression molding method will be omitted.

  First, general injection molding is performed in the first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16 by the same process as the first molding example of the expanded foam molding method. The uncompressed primary molded body 59a is molded by the method (primary mold clamping step or primary molding step). After a predetermined cooling and solidifying time has elapsed, the rotary mold 16 is rotated by the mold clamping device 6 and the rack and pinion mechanism 20 while the uncompressed primary molded body 59a is held by the first mold 17b of the rotary mold 16. The movable mold 14 and the rotating mold 16 are moved in the mold opening direction to a position where the mold portion 16b can rotate (mold opening process). After the predetermined cooling and solidifying time has elapsed, before the mold opening process is performed, in the second mold cavity C2 formed between the movable mold 14 and the second mold 17c of the rotary mold 16, as described later. A secondary injection filling process or a lamination molding process is performed, but the description thereof is omitted here.

After the mold opening process, as shown in FIG. 15A, the first mold 17b of the rotary mold 16 is held in a state where the uncompressed primary molded body 59a is held by the first mold 17b of the rotary mold 16. The rotating mold portion 16b of the rotating mold 16 is rotated 180 degrees by the rotating mechanism 16d at a position facing the movable mold 14 and the second mold 17c of the rotating mold 16 facing the fixed mold 12 (rotation). Process). In the mold clamping process and the rotation process, as in the first molding example of the injection compression molding method, the mold opening correction pressing process and the mold closing correction pressing process are performed in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction. It is preferable to carry out. As will be described later, the laminated molded product molded in the previous molding cycle has already been taken out from between these dies in the product take-out step after the mold opening step and before the rotation step is started. Therefore, nothing is held in the movable mold 14, the second mold 17c of the rotary mold 16, and the fixed mold 12 other than the first mold 17b of the rotary mold 16 holding the uncompressed primary molded body 59a. Not.

  After the rotation process, in the mold open state of the fixed mold 12, the movable mold 14, and the rotary mold 16, the pressing direction to the pinion 22 by the pinion moving mechanism 30 is switched from the fixed mold 12 side to the movable mold 14 side. A mold closing correction pressing step is performed in order to make backlash generated between the pinion 22 and the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26 zero. Next, during the mold closing correction pressing process, as shown in FIG. 15B, the movable mold 14 and the rotating mold 16 are moved in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20. The fixed mold 12, the movable mold 14 and the rotating mold 16 are clamped (clamping process). As a result, a fourth mold cavity C4 is formed between the first mold 17b of the rotary mold 16 holding the movable mold 14 and the uncompressed primary molded body 59a. The mold clamping force of the mold clamping device 6 in this mold clamping process is set to be smaller than the molten resin pressure injected and filled in the fourth mold cavity C4.

  In parallel with or after the mold clamping process, the pinion moving mechanism is used to reduce backlash generated between the pinion 22 and the surfaces C and D on the fixed mold 12 side of the teeth 25 and 27 of the racks 24 and 26. The mold opening correction pressing step is performed by switching the pressing direction to the pinion 22 by 30. During the continuation of the mold opening correction pressing process, as shown in FIG. 15C, the mold is formed between the first mold 17b of the rotating mold 16 holding the uncompressed primary molded body 59a and the movable mold 14. The fourth mold cavity C4 is injected and filled with molten resin from the first injection unit 7 through the resin flow path 50l formed in the movable mold 14 (secondary injection filling process).

  In this secondary injection filling process, the movable mold 14 and the rotary mold 16 are moved relative to the fixed mold 12 by the molten resin pressure injected and filled into the fourth mold cavity C4 as shown in FIG. The mold is opened by a predetermined amount c in the mold opening direction (micro mold opening process). Here, the micro mold opening process of the second molding example is slightly different from the micro mold opening process of the first molding example of the injection compression molding method in terms of the movement mechanism in the mold opening direction. As described above, in the first molding example of the injection compression molding method, during the continuation of the mold closing correction pressing process, the rotary mold 16 is applied to the rotary mold 16 by the molten resin pressure injected and filled in the third mold cavity C3. A force in the direct mold opening direction acts to cause the rotating mold 16 to slightly open from the fixed mold 12, and this force in the mold opening direction also acts on the movable mold 14 via the rack and pinion mechanism 20. In conjunction with the micro mold opening operation of the rotary mold 16, the movable mold 14 is micro opened. Therefore, not the mold opening correction pressing process, but the mold closing correction pressing process for pressing the pinion 22 against the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 16 is performed. On the other hand, in the second molding example, a force in the mold closing direction acts on the rotary mold 16 and the mold is applied to the movable mold 14 by the pressure of the molten resin injected and filled in the fourth mold cavity C4. A force in the opening direction acts. That is, it is not the force in the mold closing direction that acts on the rotating mold 16 but the force in the mold opening direction that acts on the movable mold 14 that moves the rotating mold 16 in the mold opening direction with respect to the fixed mold 12. It is. This is a foam mold opening step of an expanded foam molding method in which the movable platen 4 and the movable mold 14 are moved in the mold opening direction by the mold clamping device 6 and the rotary mold 16 is moved in the mold opening direction by the rack and pinion mechanism 20. Is the same state. Therefore, in the secondary injection filling process of the second molding example, it is preferable to continue the mold opening correction pressing process, unlike the first molding example of the injection compression molding method. Specifically, a force in the mold closing direction acts on the rotary mold 16 by the molten resin pressure injected and filled in the fourth mold cavity C4 during the secondary injection filling process. This force in the mold closing direction acts in the same direction as the predetermined pressure 2 for pressing the pinion 22 toward the fixed mold 12 (mold closing direction) by the pinion moving mechanism 30 in the continued mold opening correction process. When the force in the mold closing direction is larger than the predetermined pressure 2, the pinion 22 is pressed toward the fixed mold 12 by the force in the mold closing direction, and when the force in the mold closing direction is smaller than the predetermined pressure 2, the pinion No. 22 is pressed to the fixed mold 12 side with a predetermined pressure 2, and the mold opening correction pressing process is maintained in any case. Unlike the above-described second molding example of the injection press molding method, the predetermined pressure 2 need not be equal to or higher than the molten resin pressure for injecting and filling the fourth mold cavity C4. Therefore, in order to ensure that the mold opening correction pressing process is continued under the control of the apparatus, the predetermined pressure 2 may be set to be equal to or higher than the molten resin pressure for injecting and filling the fourth mold cavity C4. preferable. As described above, the mold opening correction pressing process keeps the rotating mold 16 positioned on the surfaces C and D side of the teeth 25 and 27 of the racks 24 and 26 on the fixed mold 12 side, and the micro mold opening process is continuing. In this case, there is no movement in the mold opening direction beyond the amount of movement in the mold opening direction by the rack and pinion mechanism, and after the micro mold opening process is completed, the amount of movement is more than the set micro mold opening amount. Further, as in the first molding example of the injection compression molding method, a feedback process for controlling the micro mold opening amount and micro mold opening speed with high accuracy may be performed.

  After the micro mold opening process, the pinion 22 by the pinion moving mechanism 30 is set to zero backlash generated between the pinion 22 and the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26. It is preferable to perform the mold closing correction pressing process by switching the pressing direction from the fixed mold 12 side to the movable mold 14 side. Next, during the mold closing correction pressing process, the movable mold 14 and the rotating mold 16 are moved in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20 as shown in FIG. Then, the fixed mold 12, the movable mold 14, and the rotary mold 16 are clamped with a predetermined clamping force (injection compression process). By this injection compression process, a mold compression force is applied to the molten resin in the fourth mold cavity C4, and the compression secondary molded body 59b is molded. In this way, a predetermined clamping compression force is applied to at least a part of the uncompressed primary molded body 59a held in the second mold 17b of the rotary mold 16 forming the fourth mold cavity C4. The formed compression secondary molded body 59b is laminated and molded (laminate molding process). Note that the third mold cavity C3 expanded in the mold opening / closing direction by a predetermined amount c from the time of mold clamping is also reduced in mold cavity volume by the injection compression process until the mold clamping, but these processes are performed. Meanwhile, injection filling or the like is not performed in the third mold cavity C3. In addition, this injection compression process may be performed in conjunction with the secondary injection filling process, or may be performed after the secondary injection filling process. In the mold clamping state, it is not necessary to press the pinion 22 by the pinion moving mechanism 30 (mold closing correction pressing process), but the pressing is continued in order to match the axial position of the pinion 22 orthogonal to the mold opening / closing direction. It is preferable to do.

  Further, in conjunction with the injection compression process or after the injection compression process, the fixed mold 12 is formed in the third mold cavity C3 formed between the fixed mold 12 and the second mold 17c of the rotary mold 16. The molten resin is injected and filled from the first injection unit 7 through the resin flow path 50m (primary injection filling process) to form a new uncompressed primary molded body 59a (primary molding process).

  After the elapse of a predetermined cooling and solidifying time, as shown in FIG. 15 (f), the movable mold 14 and the rotating mold 16 are removed by the mold opening process and the product removing process as in the second molding example of the expanded foam molding method. The laminated molded product 59 molded between the first molds 17b (fourth mold cavity C4) is taken out. In this way, thereafter, by repeating the molding cycle from the state of FIG. 15 (a) to the state of FIG. 15 (f), a laminated molded product composed of the uncompressed primary molded body 59a and the compressed secondary molded body 59b. 59 is continuously formed.

  In the second molding example of the injection compression molding method according to the present embodiment, the first mold cavity C1 (or the third mold cavity C3) formed between the fixed mold 12 and the first mold 17b of the rotary mold 16 is used. 4) formed between the movable mold 14 and the first mold 17b of the rotating mold holding the uncompressed primary molded body by a general injection molding method. A mode in which the compression secondary molded body molded by the injection compression molding method in the mold cavity C4 (or the second mold cavity C2) is laminated on the uncompressed primary molded body (non-injection compression molding-injection compression molding). However, the present invention is not limited to this, and it is an aspect of injection compression molding-injection compression molding or an aspect of injection compression molding-non-injection compression molding, as in the second molding example of the expanded foam molding method. It is also good.

[Third molding example of injection compression molding]
Next, a third molding example of the injection compression molding method according to the present embodiment will be described with reference to FIG. The third molding example of the injection compression molding method according to the present embodiment is a first mold cavity C1 formed between the fixed mold 12 and the first mold 17b of the rotary mold 16, and the movable mold 14 and the rotary mold. In the second mold cavity C2 formed between the second molds 17c of the mold 16, a single-layer injection compression molded product is simultaneously molded by an injection compression molding method. That is, unlike the first molding example and the second molding example of the injection compression molding method according to the present embodiment, the rotating mold is not rotated, and a single-layer molded product is used instead of a laminated molded product for each mold opening / closing operation. Is formed. In the third molding example, the second injection unit 8 provided on the movable mold 14 side will be described in addition to the first injection unit 7 provided on the fixed mold 12 side, but the present invention is not limited thereto. Is not to be done. Hereinafter, the description of the same steps and molding conditions as those of the first molding example and the second molding example of the injection compression molding method according to the present embodiment will be omitted.

  First, in a state where the pinion 22 is pressed against the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26 (mold closing correction pressing step), as shown in FIG. The movable mold 14 and the rotary mold 16 are moved in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20, and the fixed mold 12, the movable mold 14 and the rotary mold 16 are clamped (a mold clamping step). ). As a result, a first mold cavity C1 is formed between the fixed mold 12 and the first mold 17b of the rotating mold 16, and the second mold is interposed between the movable mold 14 and the second mold 17c of the rotating mold 16. A mold cavity C2 is formed. In the third molding example, the mold clamping force of the mold clamping device 6 in the mold closing process is set to be smaller than the molten resin pressure injected and filled into the first mold cavity C1 and the second mold cavity C2. ing.

  After the mold closing process, during the mold closing correction pressing process, as shown in FIG. 16B, the first mold cavity C1 and the second mold cavity C2 are moved to the fixed mold 12 and the movable mold 14. The molten resin is injected and filled from the first injection unit 7 and the second injection unit 8 through the formed resin flow paths 50n and 50o (injection filling step).

  As in the first and second molding examples of the injection compression molding method, injection molding of the molten resin into the first mold cavity C1 and the second mold cavity C2 in this injection filling step is performed as shown in FIG. As shown in FIG. 2, the movable mold 14 and the rotating mold 16 are micro-opened by a predetermined amount c in the mold opening direction with respect to the fixed mold 12 (micro-die opening process). Here, as in the third molding example of the injection press molding method, a difference occurs in the pressure of the molten resin injected and filled in the first mold cavity C1 and the second mold cavity C2 during the injection filling process. Suppose. First, when the molten resin pressure in the first mold cavity C1 is higher than the molten resin pressure in the second mold cavity C2, the difference in the mold opening direction (movable mold 14 side) is applied to the rotary mold 16. Force acts. Further, a force in the mold opening direction acts on the movable mold 14 by the difference between the mold clamping force of the mold clamping device 6 and the mold opening direction due to the pressure of the molten resin injected and filled in the second mold cavity C2. The force in the mold opening direction is smaller than the force in the mold opening direction that acts on the rotary mold 16. That is, in this case, the movable mold 14 is slightly opened through the rack and pinion mechanism 20 by the force in the mold opening direction that acts on the rotating mold 16. Since this is the same state as the first molding example of the injection compression molding method, the mold closing correction pressing step (FIG. 5) presses the pinion 22 against the surfaces A and B of the teeth 25 and 17 of the racks 24 and 26 on the movable mold 14 side. 8 (a)) is continued, and this mold closing correction pressing step is preferably continued even in the injection compression step performed subsequent to the injection filling step (micro mold opening step). Next, when the molten resin pressure in the second mold cavity C2 is higher than the molten resin pressure in the first mold cavity C1, the mold closing direction (on the fixed mold 12 side) is set to the rotating mold 16 by the difference. The force of acts. Further, a force in the mold opening direction acts on the movable mold 14 by the difference between the mold clamping force of the mold clamping device 6 and the mold opening direction due to the pressure of the molten resin injected and filled in the second mold cavity C2. The force in the mold opening direction is larger than the force in the mold closing direction that acts on the rotary mold 16. That is, in this case, the rotating mold 16 is slightly opened through the rack and pinion mechanism 20 by the force in the mold opening direction acting on the movable mold 14. Since this is the same state as in the second molding example of the injection compression molding method, if the mold closing correction pressing process is in progress, the pinion 22 is connected to the teeth 25 and 17 of the racks 24 and 26 on the fixed mold 12 side. Switch to the mold opening correction pressing process (see FIG. 8 (c)) to be pressed against the surfaces C and D, and after the injection filling process (micro mold opening process) is completed, this mold opening correction pressing process is performed again at an appropriate timing. It is preferable to switch to the mold closing correction pressing process and to perform the injection compression process during the continuation of the mold closing correction pressing process. As described above, in the third molding example, a pinion moving mechanism is provided as necessary due to the difference in the pressure of the molten resin injected and filled into the first mold cavity C1 and the second mold cavity C2 during the injection filling process. By rotating the pressing direction of the pinion 22 by 30 and performing an appropriate mold opening / mold closing correction pressing process, the rotary mold 16 can move the surface A of the movable mold 14 of the teeth 25, 17 of the racks 24, 26, The position is held on the B side or on the appropriate side of the surface C or D side of the fixed mold 12, and during the minute mold opening process, it is more than the amount of movement in the mold opening direction by the rack and pinion mechanism. In addition, after the micro mold opening process is completed, the micro mold does not move in the mold opening direction beyond the set micro mold opening amount. Also in the third molding example, as in the first molding example and the second molding example of the injection compression molding method, a feedback process or the like for controlling the minute mold opening amount with high accuracy may be performed.

  After the micro mold opening process, the backlash generated between the pinion 22 and the surfaces A and B on the movable mold 14 side of the teeth 25 and 27 of the racks 24 and 26 is the same as in the second molding example of the injection compression molding method. In order to make it zero, it is preferable to perform the mold closing correction pressing step by switching the pressing direction to the pinion 22 by the pinion moving mechanism 30. Similarly to the first molding example of the injection compression molding method, if the process has already been switched to the mold closing correction pressing process at this time, the mold closing correction pressing process may be continued as it is. Next, while the mold closing correction pressing process is continued, the movable mold 14 and the rotating mold 16 are moved in the mold closing direction by the mold clamping device 6 and the rack and pinion mechanism 20 as shown in FIG. Then, the fixed mold 12, the movable mold 14, and the rotary mold 16 are clamped (injection compression process). Through this injection compression process, a single layer injection compression molded product 60 is formed by applying a clamping force to the molten resin in the first mold cavity C1 and the second mold cavity C2. This injection compression process may be performed in conjunction with the injection filling process, or may be performed after the injection filling process. In the mold clamping state, it is not necessary to press the pinion 22 by the pinion moving mechanism 30 (mold closing correction pressing step), but it is preferable to continue the pressing in order to keep the pinion 22 axial position.

  After elapse of a predetermined cooling and solidifying time, as shown in FIG. 16 (e), the fixed mold 12 and the rotating mold 16 are formed by the mold opening process and the product removing process as in the third molding example of the expanded foam molding method. The injection compression molded products 60 and 60 molded between the first mold 17b and between the movable mold 14 and the second mold 17c of the rotary mold 16 are taken out by a product take-out device (not shown). In this way, thereafter, by repeating the molding cycle from the state of FIG. 16A to the state of FIG. 16E, single-layer injection compression molded products 60, 60 are simultaneously and continuously molded. .

  In the third molding example of the injection compression molding method according to the present embodiment, both the first mold cavity C1 and the second mold cavity C2 are of the same type under the same molding conditions and simultaneously by the injection compression molding method. Although the single-layer injection compression molded products 60 and 60 are formed, the present invention is not limited to this. For example, the first mold cavity C1 and the second mold cavity C2 are similar to the third molding example of the expanded foam molding method. In each of the above, different types of injection compression molded products may be molded from different molten resins.

  Moreover, the third molding example of the injection compression molding method according to the present embodiment is a mode in which a single-layer injection compression molding product is molded simultaneously by the injection compression molding method in both the first and second mold cavities C1 and C2. Injection compression molding-injection compression molding aspect), but is not limited to this, as in the third molding example of the expanded foam molding method, injection compression molding-non-injection compression molding aspect, or injection compression molding-molding. There may be no aspect.

  Furthermore, in the third molding example of the injection compression molding method according to the present embodiment, the first mold cavity C1 is injected and filled with molten resin by the first injection unit 7 provided on the back side of the fixed mold 12, Although the molten resin is injected and filled into the second mold cavity C2 by the second injection unit 8 provided on the side surface of the movable mold 14, the present invention is not limited to this. Similarly, the second injection unit 8 on the movable mold 14 side is not provided, but the molten resin injected only from the first injection unit 7 is caused to flow to the rotary mold 16, and the first mold cavity from the rotary mold 16 side. A configuration may be adopted in which molten resin flows into C1 and the second mold cavity C2, respectively. In this case, the resin flow path may be provided with a resin shut-off switching valve or the like that can open and close the resin flow path.

  Thus, according to the first molding example, the second molding example, and the third molding example of the injection compression molding method according to the present embodiment, the state in which the pinion 22 is pressed against the teeth of the racks 24 and 26, that is, the pinion 22 And the state where the backlash generated between the teeth 25 and 27 of the racks 24 and 26 and the surfaces A and B on the movable mold 14 side is zero (mold closing correction pressing step), or the pinion 22 and the racks 24 and 26 In the state where the backlash generated between the surfaces 25 and 27 of the teeth 25 and 27 on the fixed mold 12 side is zero (mold opening correction pressing process), the secondary injection filling process or the injection filling process is performed, The movable mold 14 and the rotary mold 16 are micro-opened by the pressure of the molten resin injected and filled into the cavity, and the surfaces A and B of the pinion 22 and the teeth 25 and 27 of the racks 24 and 26 on the movable mold 14 side. Occurs between In the state where the backlash is zero (mold closing correction pressing process), the injection compression process (mold closing / clamping operation from the minute mold open state) is performed, so the influence of backlash is completely eliminated and the secondary injection filling process Alternatively, during and after the injection filling process, the micro mold opening amount and the mold closing amount of the first mold cavity C1 and the second mold cavity C2 can be made uniform, and disturbance factors such as molten resin pressure can be obtained. Even if there is a backlash, it is possible to maintain a state where the backlash is zero, so that the position of the micro mold opening position is maintained, the mold opening speed in the micro mold opening process and the mold clamping speed in the injection compression process are stabilized, and high quality Single-layer and multi-layer injection compression molded articles can be obtained.

  In the conventional multi-color molding mold, due to the mechanical tolerance of the rack and pinion mechanism, the mold opening amount of the mold cavity formed by the movable mold and the rotating mold is determined by the rotating mold and the stationary mold. The backlash α + β is larger than the mold opening amount of the mold cavity to be formed, and there is a difference in the thickness, foaming magnification, bubble diameter, etc. of the foam molded product molded in both mold cavities by the expanded foam molding method. There is a problem. In addition, the difference in mold opening between both mold cavities occurs not only during the mold opening operation from the mold clamping state, but also during the mold closing / clamping operation from the mold opening state. Similarly, in the injection compression molding method, there is a problem that the quality of the molded product molded by both mold cavities is different. Furthermore, in these molding methods, it is difficult to envisage, and due to the difference in the foaming pressure of the foamable molten resin in both mold cavities and the molten resin pressure at the time of injection filling, the rotary mold has a mold opening / closing direction. Force acts. The force in the mold opening / closing direction is equal to or greater than the amount of movement in the mold opening / closing direction by the rack and pinion mechanism by the amount of such backlash for the rotating mold that does not have the means for restricting the mold opening / closing direction other than the engagement of the rack and pinion. Alternatively, it is moved in the mold opening / closing direction below the movement amount. Due to the movement in the mold opening / closing direction of the rotating mold that cannot be controlled by this rack and pinion mechanism, not only the difference in mold opening between both mold cavities, but also the mold opening speed and mold closing / molding of both mold cavities. There is a problem that the fastening speed becomes unstable, and the quality of the molded product formed by both mold cavities is different. In contrast, in the three-piece injection mold, injection molding apparatus, and injection molding method according to this embodiment, the pinion 22 is moved by the pinion moving mechanism 30 in the direction opposite to the mold opening / closing operation, that is, the movable platen (mold clamping). When the mold is opened by the apparatus, the pinion 22 is pressed against the fixed mold 12 side (the mold opening correction pressing process) with a predetermined pressure 2, and when the mold is closed by the movable platen (the mold clamping apparatus), the pinion 22 is moved. When the mold is opened by the molten resin pressure that is pressed to the mold 14 side (mold closing correction pressing step) with a predetermined pressure 1 and injected and filled into the mold cavity, such as an injection compression molding method, Due to the difference, if necessary, the pressing direction of the pinion 22 by the pinion moving mechanism 30 is switched and an appropriate mold opening / closing correction pressing step is performed, so that the mold opening / closing operation and the movable mold 14 can be performed. Since the influence of the backlash α, β in the rack and pinion mechanism 20 that performs the mold opening / closing operation of the rotary mold 16 by the molten resin pressure injected into the mold cavity can be completely eliminated, a high-quality single layer and Laminated foam molded products, injection press molded products and injection compression molded products can be obtained.

  DESCRIPTION OF SYMBOLS 1 Injection molding apparatus, 3 Fixed board, 4 Movable board, 6 Clamping apparatus, 10 Three-piece injection mold, 12 Fixed mold, 14 Movable mold, 16 Rotating mold, 16a Rotating mold support part, 16b Rotating mold part, 16c Rotating shaft, 16d Rotating mechanism, 17a Rotating disc, 17b 1st mold, 17c 2nd mold, 20 Rack and pinion mechanism, 22 Pinion, 24, 26 Rack, 25, 27 Rack teeth , 30 Pinion moving mechanism

Claims (17)

A fixed mold,
A movable mold facing the fixed mold and movable in the mold opening and closing direction;
It is movable between the fixed mold and the movable mold in the mold opening / closing direction and is rotatable about a rotation axis perpendicular to the mold opening / closing direction, and faces the fixed mold at one rotational position, A mold cavity can be formed between the fixed mold and the movable mold facing the movable mold at another rotational position rotated about the rotation axis from the one rotational position. A rotating mold having at least two mold dividing surfaces capable of forming a mold cavity in FIG.
A pinion provided on the rotating mold, and a rack provided on each of the fixed mold and the movable mold and having teeth that can be meshed with the pinion are provided for moving the movable mold in the mold opening / closing direction. Correspondingly, a rack and pinion mechanism for moving the rotating mold in the mold opening and closing direction,
A three-sheet injection mold comprising:
The rack and pinion mechanism supports the pinion so as to be movable in a mold opening / closing direction with respect to the rotating mold, and presses the pinion to at least one side of the fixed mold and the movable mold, Further comprising a pinion moving mechanism capable of pressing the teeth on the rack teeth,
A three-sheet injection characterized in that, in a state where the pinion is pressed against the teeth of the rack by the pinion moving mechanism, the rotating mold is movable in the mold opening / closing direction by the rack and pinion mechanism. Molding mold. The pinion moving mechanism is configured to press the pinion toward the fixed mold side or the movable mold side when the fixed mold, the movable mold, and the rotating mold are opened, so that the fixed mold and the movable mold are moved. The three-sheet injection mold according to claim 1, wherein the pinion is pressed against the movable mold side when the mold and the rotary mold are closed. The rotating mold is
A rotating mold support provided with the pinion attached thereto and movable in the mold opening and closing direction by the rack and pinion mechanism;
The rotating mold support portion is supported so as to be rotatable about a rotation axis orthogonal to the mold opening / closing direction, and is opposed to the fixed mold at one rotational position, and a mold cavity is formed between the rotating mold support section and the fixed mold. A mold dividing surface that can be formed and is opposed to the movable mold at another rotational position rotated about the rotational axis from the one rotational position and can form a mold cavity with the movable mold. A rotating mold part having at least two,
The three-piece injection mold according to claim 1, further comprising: a rotating mechanism that rotates the rotating mold part about the rotation axis. An injection molding apparatus comprising the three-sheet injection mold according to any one of claims 1 to 3,
A stationary platen to which the stationary mold can be attached;
A movable plate provided opposite to the fixed plate, movable in a mold opening / closing direction with respect to the fixed plate, and capable of attaching the movable mold;
A mold clamping device for moving the movable plate in the mold opening and closing direction and clamping the mold;
An injection molding apparatus comprising: A fixed part including a fixed mold,
A movable part including a movable mold facing the fixed mold, the movable part being movable in a mold opening / closing direction with respect to the fixed part;
Provided to be rotatable about a rotation axis orthogonal to the mold opening / closing direction, facing the fixed mold at one rotational position, and forming a mold cavity between the fixed mold and the one rotation Rotating mold having at least two mold dividing surfaces facing the movable mold at another rotational position rotated about the rotational axis from the position and capable of forming a mold cavity with the movable mold A rotating part provided to be movable in a mold opening / closing direction between the fixed part and the movable part,
A mold clamping device for moving the movable part in the mold opening and closing direction and clamping the mold;
A pinion provided in the rotating part, and a rack having teeth that can be meshed with the pinion provided in the fixed part and the movable part, respectively, corresponding to the movement of the movable part in the mold opening and closing direction A rack and pinion mechanism that moves the rotating part in the mold opening and closing direction;
An injection molding apparatus comprising:
The rack-and-pinion mechanism supports the pinion so as to be movable in the mold opening / closing direction with respect to the rotating unit, and presses the pinion toward at least one of the fixed unit and the movable unit, thereby causing the pinion to move to the rack. A pinion moving mechanism that can be pressed against the teeth of
An injection molding apparatus, wherein the rotating part can be moved in the mold opening / closing direction by the rack and pinion mechanism in a state where the pinion is pressed against the teeth of the rack by the pinion moving mechanism. The fixed portion includes the fixed mold and a fixed plate to which the fixed mold can be attached,
The movable portion includes the movable mold and a movable plate to which the movable mold can be attached,
The injection molding apparatus according to claim 5, wherein the rack is provided on each of the fixed platen and the movable platen. An injection molding method for performing expanded foam molding using the injection molding apparatus according to any one of claims 4 to 6,
At the first rotational position of the rotating mold, a primary molded body is formed by injecting and filling molten resin into a first mold cavity formed between the fixed mold and the rotating mold after clamping. A primary molding process;
After the primary molding step, the movable mold and the rotary mold are opened in a state where the primary molded body is held in the fixed mold, and the rotary mold is rotated to a second rotational position. A rotating step in which another mold dividing surface of the rotating mold is opposed to the fixed mold;
At a second rotational position of the rotary mold, a molten resin is injected and filled into a third mold cavity formed between the fixed mold and the rotary mold after clamping, and at least the primary molded body With a part forming process of forming a secondary molded body in part,
At least one of the primary molding step and the secondary molding step is a step of molding a foam molded body from a foamable molten resin, and a mold clamping release step of releasing the mold clamping state after injection filling of the foamable molten resin; In parallel with or after the mold clamping release process, a mold opening correction pressing process for pressing the pinion toward the fixed mold by the pinion moving mechanism, and the pinion is fixed by the mold opening correction pressing process. The movable mold and the rotating mold are opened by a predetermined amount in the mold opening / closing direction with respect to the fixed mold, and the injection-filled foamable resin is placed in the mold cavity. An injection molding method comprising: a foaming mold opening step of foaming and expanding. An injection molding method for performing expanded foam molding using the injection molding apparatus according to any one of claims 4 to 6,
At the first rotational position of the rotating mold, a primary molded body is formed by injecting and filling molten resin into a first mold cavity formed between the fixed mold and the rotating mold after clamping. A primary molding process;
After the primary molding step, the movable mold and the rotary mold are opened in a state where the primary molded body is held in the rotary mold, and the rotary mold is rotated to a second rotational position, A rotating step in which a mold dividing surface of the rotating mold holding the primary molded body is opposed to the movable mold;
At a second rotational position of the rotary mold, after the mold is clamped, a molten resin is injected and filled into a fourth mold cavity formed between the movable mold and the rotary mold, and at least the primary molded body With a part forming process of forming a secondary molded body in part,
At least one of the primary molding step and the secondary molding step is a step of molding a foam molded body from a foamable molten resin, and a mold clamping release step of releasing the mold clamping state after injection filling of the foamable molten resin; In parallel with or after the mold clamping release process, a mold opening correction pressing process for pressing the pinion toward the fixed mold by the pinion moving mechanism, and the pinion is fixed by the mold opening correction pressing process. The movable mold and the rotating mold are opened by a predetermined amount in the mold opening / closing direction with respect to the fixed mold, and the injection-filled foamable resin is placed in the mold cavity. An injection molding method comprising: a foaming mold opening step of foaming and expanding. An injection molding method for performing expanded foam molding using the injection molding apparatus according to any one of claims 4 to 6,
The fixed mold and one mold dividing surface of the rotating mold are clamped to form a first mold cavity, and the movable mold and another mold dividing surface of the rotating mold are formed. A mold clamping step of clamping to form a second mold cavity;
A foamable resin injection filling step of injecting and filling foamable molten resin into at least one of the first mold cavity and the second mold cavity after the mold clamping step;
After the foaming resin injection filling step, a mold clamping release step for releasing the mold clamping state,
In parallel with or after the mold-clamping release process, a mold opening correction pressing process for pressing the pinion toward the fixed mold by the pinion moving mechanism,
In a state where the pinion is pressed to the fixed mold side by the mold opening correction pressing step, the movable mold and the rotating mold are opened by a predetermined amount in the mold opening / closing direction with respect to the fixed mold, An injection molding method comprising: a foaming mold opening step of foaming and expanding the foamable molten resin injected and filled in the foamable resin injection and filling step in the mold cavity. The foamable resin injection filling step is a step of injecting and filling foamable molten resin into both the first mold cavity and the second mold cavity after the mold clamping step. The injection molding method described. An injection molding method for performing injection press molding using the injection molding apparatus according to any one of claims 4 to 6,
At the first rotational position of the rotating mold, a primary molded body is formed by injecting and filling molten resin into a first mold cavity formed between the fixed mold and the rotating mold after clamping. A primary molding process;
After the primary molding step, the movable mold and the rotary mold are opened in a state where the primary molded body is held in the fixed mold, and the rotary mold is rotated to a second rotational position. A rotating step in which another mold dividing surface of the rotating mold is opposed to the fixed mold;
At a second rotational position of the rotary mold, a molten resin is injected and filled into a third mold cavity formed between the fixed mold and the rotary mold after clamping, and at least the primary molded body With a part forming process of forming a secondary molded body in part,
At least one of the primary molding step and the secondary molding step is a step of molding an injection press molded body, and a mold closing correction pressing step of pressing the pinion toward the movable mold by the pinion moving mechanism, In a state where the pinion is pressed toward the movable mold by the mold closing correction pressing step, the fixed mold and the movable mold are moved to a position where a predetermined amount is opened between the fixed mold and the rotary mold. A mold closing process for closing the mold and the rotating mold to form the mold cavity, an injection filling process for injecting and filling molten resin into the mold cavity after the mold closing process, and the injection filling process In conjunction with or after the injection filling step, the fixed mold, the movable mold, and the rotating mold are clamped with a predetermined clamping press force, and the molten tree in the mold cavity is clamped. Injection molding method characterized by comprising the injection press step of applying the clamping pressing force. An injection molding method for performing injection press molding using the injection molding apparatus according to any one of claims 4 to 6,
At the first rotational position of the rotating mold, a primary molded body is formed by injecting and filling molten resin into a first mold cavity formed between the fixed mold and the rotating mold after clamping. A primary molding process;
After the primary molding step, the movable mold and the rotary mold are opened in a state where the primary molded body is held in the rotary mold, and the rotary mold is rotated to a second rotational position, A rotating step in which a mold dividing surface of the rotating mold holding the primary molded body is opposed to the movable mold;
At a second rotational position of the rotary mold, after the mold is clamped, a molten resin is injected and filled into a fourth mold cavity formed between the movable mold and the rotary mold, and at least the primary molded body With a part forming process of forming a secondary molded body in part,
At least one of the primary molding step and the secondary molding step is a step of molding an injection press molded body, and a mold closing correction pressing step of pressing the pinion toward the movable mold by the pinion moving mechanism, In a state where the pinion is pressed toward the movable mold by the mold closing correction pressing step, the fixed mold and the movable mold are moved to a position where a predetermined amount is opened between the fixed mold and the rotary mold. A mold closing process for closing the mold and the rotating mold to form the mold cavity, an injection filling process for injecting and filling molten resin into the mold cavity after the mold closing process, and the injection filling process In conjunction with or after the injection filling step, the fixed mold, the movable mold, and the rotating mold are clamped with a predetermined clamping press force, and the molten tree in the mold cavity is clamped. Injection molding method characterized by comprising the injection press step of applying the clamping pressing force. An injection molding method for performing injection press molding using the injection molding apparatus according to any one of claims 4 to 6,
A mold closing correction pressing step of pressing the pinion toward the movable mold by the pinion moving mechanism;
In a state where the pinion is pressed to the movable mold side by the mold closing correction pressing step, a minute mold is formed between the fixed mold and the rotating mold and between the movable mold and the rotating mold by a predetermined amount. The fixed mold, the movable mold, and the rotating mold are closed to a position where the mold is opened, and a first mold cavity is formed between the fixed mold and the rotating mold, and the movable mold is formed. A mold closing step of forming a second mold cavity between the mold and the rotating mold;
An injection filling step of injecting and filling molten resin into at least one of the first mold cavity and the second mold cavity after the mold closing step;
In conjunction with the injection filling process or after the injection filling process, the fixed mold, the movable mold, and the rotating mold are clamped with a predetermined clamping force, and the first mold cavity and the An injection press step of applying the mold clamping press force to at least one of the molten resins in the second mold cavity. An injection molding method for performing injection compression molding using the injection molding apparatus according to any one of claims 4 to 6,
At the first rotational position of the rotating mold, a primary molded body is formed by injecting and filling molten resin into a first mold cavity formed between the fixed mold and the rotating mold after clamping. A primary molding process;
After the primary molding step, the movable mold and the rotary mold are opened in a state where the primary molded body is held in the fixed mold, and the rotary mold is rotated to a second rotational position. A rotating step in which another mold dividing surface of the rotating mold is opposed to the fixed mold;
At a second rotational position of the rotary mold, a molten resin is injected and filled into a third mold cavity formed between the fixed mold and the rotary mold after clamping, and at least the primary molded body With a part forming process of forming a secondary molded body in part,
At least one of the primary molding step and the secondary molding step is a step of molding an injection compression molded body, the fixed mold, the movable mold and the rotary mold are closed, and the mold cavity is formed. The mold closing step to be formed, in parallel with or after the mold closing step, the mold closing correction pressing step for pressing the pinion toward the movable mold by the pinion moving mechanism, and the mold closing correction pressing step. In the state where the pinion is pressed to the movable mold side, the movable mold and the rotating mold are formed by an injection filling process of injecting and filling molten resin into the mold cavity, and a pressure of the molten resin injected and filled into the mold cavity. A micro mold opening step of opening a predetermined amount in the mold opening and closing direction with respect to the fixed mold, and after the micro mold opening step, the fixed mold, the movable mold, and the The Tenkin type and clamping at a predetermined clamping compressive force, injection molding method, characterized in that it comprises an exit compression step of applying the clamping compressive force to the molten resin within the mold cavity. An injection molding method for performing injection compression molding using the injection molding apparatus according to any one of claims 4 to 6,
At the first rotational position of the rotating mold, a primary molded body is formed by injecting and filling molten resin into a first mold cavity formed between the fixed mold and the rotating mold after clamping. A primary molding process;
After the primary molding step, in the state where the primary molded body is held by the rotary mold, the rotary mold is rotated to the second rotational position to hold the primary molded body. A rotation step of making the mold dividing surface face the movable mold;
At a second rotational position of the rotary mold, after the mold is clamped, a molten resin is injected and filled into a fourth mold cavity formed between the movable mold and the rotary mold, and at least the primary molded body With a part forming process of forming a secondary molded body in part,
At least one of the primary molding step and the secondary molding step is a step of molding an injection compression molded body, the fixed mold, the movable mold and the rotary mold are closed, and the mold cavity is formed. The mold closing step to be formed, in parallel with or after the mold closing step, the mold opening correction pressing step for pressing the pinion toward the fixed mold by the pinion moving mechanism, and the mold opening correction pressing step. In the state where the pinion is pressed to the fixed mold side, the movable mold and the rotating mold are formed by an injection filling process of injecting and filling molten resin into the mold cavity, and a pressure of the molten resin injected and filled into the mold cavity. A micro mold opening step of opening a predetermined amount in the mold opening and closing direction with respect to the fixed mold, and after the micro mold opening step, the fixed mold, the movable mold, and the The Tenkin type and clamping at a predetermined clamping compressive force, injection molding method, characterized in that it comprises an exit compression step of applying the clamping compressive force to the molten resin within the mold cavity. An injection molding method for performing injection compression molding using the injection molding apparatus according to any one of claims 4 to 6,
The fixed mold, the movable mold and the rotating mold are closed, and a first mold cavity is formed between the fixed mold and the rotating mold, and the movable mold and the rotating mold are formed. A mold closing step of forming a second mold cavity between
In parallel with or after the mold closing process, a mold closing correction pressing process for pressing the pinion toward the movable mold by the pinion moving mechanism and a mold opening correction pressing process for pressing the pinion toward the fixed mold. Any one of the correction pressing step,
An injection filling step of injecting and filling molten resin into at least one of the first mold cavity and the second mold cavity during one of the mold closing correction pressing step and the mold opening correction pressing step;
A micro mold opening step of opening the movable mold and the rotary mold by a predetermined amount in a mold opening / closing direction with respect to the fixed mold by a molten resin pressure injected and filled in the mold cavity;
After the micro mold opening step, the fixed mold, the movable mold, and the rotary mold are clamped with a predetermined clamping compression force, and at least in the first mold cavity and the second mold cavity. An injection compression step of applying the mold clamping compression force to one of the molten resins. The injection filling step is a step of injecting and filling molten resin into both the first mold cavity and the second mold cavity after the mold closing step. Injection molding method.

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