Method for producing resin molded body and method for producing foam molded body

Abstract

Provided is a method for producing a foam-molded body, whereby foam molding can be performed without using an SCF device. According to the present invention, provided is a method for producing a foam molded body, the method comprising a step for forming a foam parison by extruding a melt-kneaded resin from an extruder, the melt-kneaded resin being obtained by melt-kneading a resin and a physical foaming agent in the extruder, and molding the foam parison to obtain a foam molded body, the physical foaming agent is a liquid at 25 DEG C and 1 atmospheric pressure, and if the length from the base end of the inner space of the cylinder of the extruder in the longitudinal direction to the tip of the screw of the extruder is L, the physical foaming agent is injected into the cylinder of the extruder from a position 0.2 L or less from the base end.

Description

Technical Field

[0001] The present invention relates to a method for producing a resin molded body and a method for producing a foamed molded body. Background Art

[0002] (First point of view) Patent Document 1 discloses a method for producing a foamed molded body. In this method, a foaming agent injection port is provided near the center of a cylinder in the longitudinal direction, and a physical foaming agent such as nitrogen or carbon dioxide is injected into the resin in the cylinder through the foaming agent injection port.

[0003] (Second point of view) Patent document 2 discloses a resin molded body having a processed portion as a mounting piece and a main body portion as a catheter body. In Patent document 2, an opening portion is formed at a predetermined position in the processed portion. The opening portion can be formed, for example, by a processing device for opening a hole after the resin molded body is molded.

[0004] Prior art literature Patent Literature Patent Document 1: Japanese Patent Application Publication No. 2017-39812 Patent Document 2: Japanese Patent Application Publication No. 2012-176604 Summary of the invention (Problem that the invention aims to solve) (First point of view) However, near the center of the long side of the cylinder, the pressure of the resin in the cylinder (hereinafter referred to as "resin pressure") is very high, and the pressure of the physical foaming agent needs to be increased in order to inject the physical foaming agent. The physical foaming agent is usually raised to a supercritical state using a device called an SCF (supercritical) device, but this device is very expensive, so a technology for foaming without using an SCF device is needed.

[0005] The present invention has been made in view of such circumstances, and provides a method for producing a foamed molded product that can be foam-molded without using an SCF device.

[0006] (Second point of view) When processing the processed part (a processing device for forming an opening in the example of Patent Document 2), a reference position can be set on the main body, and the position of the processing device can be determined based on the reference position. On the other hand, since the resin molded body undergoes deformation such as shrinkage after molding, dimensional deviation (error relative to the design dimension) may occur. If the resin molded body has not only a main body but also a processed part as a component part, each component part may deform in a complex manner depending on the shape of each component part. In this case, even if the processing position of the processing device (the position for forming the opening in the example of Patent Document 2) is a position determined based on the reference position of the main body, the processing position of the processing device may deviate from the predetermined position on the processed part (the center position of the processed part as the mounting piece in the example of Patent Document 2), resulting in the manufacture of defective products.

[0007] The present invention has been made in view of the above circumstances, and an object of the present invention is to suppress the production of defective products when a resin molded body is produced using a processing device.

[0008] (Technical solution to the problem) (First point of view) According to the present invention, the following inventions are provided.

[0009] (1) A method for producing a foamed molded article, comprising the steps of extruding a molten kneaded resin from an extruder to form a foamed parison, and molding the foamed parison to obtain a foamed molded article, wherein the molten kneaded resin is obtained by melt-kneading a resin and a physical foaming agent in an extruder, the physical foaming agent being liquid at 25° C. and 1 atmosphere, and wherein if the length from the base end of the inner space of the cylinder of the extruder in the long side direction to the front end of the screw of the extruder is L, the physical foaming agent is injected into the cylinder of the extruder from a position less than 0.2L from the base end.

[0010] (2) According to the method described in (1), the physical foaming agent is injected into the internal space of the cylinder through an opening provided with a hopper.

[0011] (3) In the method according to (2), a discharge end of the pipe for injecting the physical foaming agent is arranged at a position closer to the internal space of the cylinder than to the outer surface of the cylinder.

[0012] (4) In the method according to (1), the physical foaming agent is injected into the internal space of the cylinder through an opening different from the opening where the hopper is provided.

[0013] (5) The method according to any one of (1) to (4), wherein the physical foaming agent is supplied using a diaphragm pump.

[0014] The inventors of the present invention have conducted careful research and proposed to inject a physical foaming agent that is liquid at 25°C and 1 atmosphere into the cylinder from a position close to the base end of the cylinder. First, since the pressure of the resin in the cylinder is lower as it approaches the base end of the cylinder, it is not necessary to apply high pressure to the physical foaming agent when injecting the physical foaming agent from a position close to the root of the screw. In addition, since the physical foaming agent is liquid at 25°C and 1 atmosphere, it is not necessary to make the physical foaming agent liquid or supercritical in advance when implementing the present invention at room temperature and pressure. Therefore, according to the present invention, foam molding can be performed without using an SCF device.

[0015] (Second point of view) According to the present invention, there is provided a method for manufacturing a resin molded body using a processing device, wherein the resin molded body has a main body and a processed part, the processing device has a movable moving part and a monitoring part, the moving part has a processing part for processing the processed part, the monitoring part can detect whether the position of the processing part is within a tolerance range based on the main body, and the manufacturing method has a moving step, in which the position of the processing part is moved closer to the processed part based on the processed part, and the monitoring part monitors whether the position of the processing part in the moving step is within the tolerance range.

[0016] In the present invention, during the moving process, the position of the processing part of the processing device is monitored to see whether it is within the tolerance range with the main body as the reference. Therefore, it is not only possible to ensure that the position processed by the processing part is within the tolerance range with the main body as the reference, but also the position of the processing part of the processing device is brought close to the processed part with the processed part as the reference. Therefore, the position of the processing part of the processing device is determined in consideration of the dimensional deviation of the processed part itself, thereby suppressing the situation of manufacturing defective products.

[0017] Various embodiments of the present invention are described below. The embodiments described below can be combined with each other.

[0018] [1] A method for manufacturing a resin molded body using a processing device, wherein the resin molded body has a main body and a processed part, the processing device has a movable moving part and a monitoring part, the moving part has a processing part that processes the processed part, and the monitoring part can detect whether the position of the processing part is within a tolerance range based on the main body, and the manufacturing method has a moving step, in which the position of the processing part is moved closer to the processed part based on the processed part, and the monitoring part monitors whether the position of the processing part in the moving step is within the tolerance range.

[0019] [2] According to the method described in [1], the manufacturing method further includes a processing step, in which if the position of the processing part in the moving step is within the tolerance range, the processing part is operated at the position of the processing part to process the processed part.

[0020] [3] The method according to [2], wherein during the moving step, if the monitoring unit detects that the position of the processing unit is outside the tolerance range, the monitoring unit reports the situation.

[0021] [4] According to any one of the methods [1] to [3], the moving part has an abutment part arranged on the processing part, and during the moving process, the abutment part approaches the processed part and abuts against the processed part, so that the processed part is guided by the abutment part to position the processing part.

[0022] [5] According to the method described in [4], the moving part also has a base part, a pedestal moving part, a moving mechanism part, and a holding part, the base part is fixedly provided with the moving mechanism part, the pedestal moving part can move the base part so that the base part is close to the processed part, the moving mechanism part is provided with the holding part, and the moving mechanism part can make the holding part move on a plane parallel to the direction of movement of the base part, and the holding part holds the abutment part and the processing part.

[0023] [6] The method according to any one of [1] to [5], wherein the resin molded body is a foamed resin molded body. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 In (Viewpoint 1), Figure 1 A is a cross-sectional view showing a molding device 101 that can be used in the method for producing a foamed molded product according to one embodiment of the present invention. Figure 1 B is Figure 1 Magnified view of area B in A.

[0025] Figure 2 Another embodiment of the physical foaming agent injection unit 48 is shown in FIG. Figure 1 B corresponds to the figure.

[0026] Figure 3 In (Viewpoint 2), Figure 3 A is a perspective view of a resin molded body 20A processed by the manufacturing method of the first embodiment of the present invention, Figure 3 B is from Figure 3 A is a perspective view of the resin molded body 20A viewed from a different direction.

[0027] Figure 41 is a perspective view showing a state where a resin molded body 20 before being processed by the manufacturing method according to the first embodiment of the present invention is set in a processing device 100. Figure 4 , the moving parts 1 and 2 of the processing device 100 are respectively located at the initial positions.

[0028] Figure 5 yes Figure 4 The resin molded body 20 and the processing device 100 are shown in a top view.

[0029] Figure 6 Yes means Figure 5 The illustrated plan view is a state in which the moving parts 1 and 2 of the processing apparatus 100 are moved from the initial position to the processing position and approach the resin molded body 20.

[0030] Figure 7 It is a perspective view of the moving part 1.

[0031] Figure 8 yes Figure 7 A top view of the mobile part 1 is shown.

[0032] Fig. 9 It is a perspective view of the moving part 2.

[0033] Fig.10 yes Fig. 9 A top view of the moving part 2 is shown.

[0034] Fig.11 Indicates that Figure 6 The state where the first holding portion 1D1 of the moving portion 1 is removed is shown. Fig.11 In FIG. 1 , the dotted circle c schematically represents the first cutting part 1F1. Fig.11 The schematic diagram shows a situation in which the contact portion 1E is not in contact with the mounting piece 22 when the moving portion 1 moves forward.

[0035] Fig.12 In, with Fig.11 different, Fig.12 A and Fig.12 B schematically shows the situation when the contact portion 1E contacts the mounting piece 22 when the moving portion 1 moves forward. Fig.12 A represents the situation before the contact portion 1E contacts the mounting piece 22. Fig.12 B shows a state where the contact portion 1E contacts the mounting piece 22 and the moving portion 1 (base portion 1A) completes a predetermined process.

[0036] Fig.13 yes Fig.12 B is an enlarged view of the mounting piece 22 and the like.

[0037] Fig.14 middle, Fig.14A is a cross-sectional view showing a state where the contact portion 2E (the first contact portion 2E1 and the second contact portion 2E2) is opposed to the base portion 21A of the main body portion 21 in the vertical direction. Fig.14 A is a cross-sectional view of the center portion of the abutment portion 2E in the width direction in the x2 direction. Fig.14 B means from Fig.14 A is a cross-sectional view showing a state in which the opposing interval between the abutting portions 2E is narrowed. Fig.14 In B, the contact portion 2E does not contact the base portion 21A.

[0038] Fig.15 middle, Fig.15 A is from Fig.14 The state shown in B is a cross-sectional view of a state in which the contact portion 2E moves in the x2 direction and hits the enlarged diameter portion 23A of the bag body 23. Fig.15 B means from Fig.15 In the state shown in A, the opposing intervals between the contact portions 2E are further narrowed so that the contact portions 2E press against the base portion 21A, and the cutting member 2F1 of the processing portion 2F descends to cut the bag body 23 .

[0039] Fig.16 It is a perspective view showing a resin molded body 20 before being processed by the manufacturing method according to the second embodiment of the present invention.

[0040] Fig.17 middle, Fig.17 A is a perspective view of a processing device 100 according to a second embodiment of the present invention. Fig.17 B is Fig.17 Enlarged view of area B in A.

[0041] Fig.18 middle, Fig.18 A is a perspective view showing a state where the resin molded body 20 is set in the processing device 100. Fig.18 B is Fig.18 Enlarged view of area B in A.

[0042] Fig.19 middle, Fig.19 A is a front view showing a state before the resin molded body 20 is set in the processing device 100, as viewed from the processing portion 32e side. Fig.19 B is Fig.19 An enlarged view of area B in A. Figure 19-20 In the figure, the support frame 32f is omitted, and the front end portion of the processed portion 32e is simplified by ○.

[0043] Fig. 20 middle, Fig. 20 A means from Fig.19 State B is the state immediately after the processed portion 24 abuts against the support block 32d. Fig. 20 B means from Fig. 20 The state A is a state in which the workpiece 24 is pressed downward to move the support block 32d and the moving base 32a. DETAILED DESCRIPTION

[0044] Hereinafter, embodiments of the present invention will be described. Various features shown in the embodiments described below can be combined with each other.

[0045] (First point of view) 1. Molding device In one example, the method for producing a foamed molded article according to one embodiment of the present invention can be performed using a method comprising: Figure 1 The molding device 101 shown in the figure includes an extruder 41, an extrusion head 52, and a die 54. The extruder 41 includes a cylinder 43, a hopper 45, a screw 47, a physical foaming agent injection unit 48, a temperature control unit 49, a resin extrusion port 51, and an extrusion head 52.

[0046] Hereinafter, each component will be described in detail.

[0047] <Hopper 45> The hopper 45 is connected to the internal space 43b of the cylinder 43 through an opening 43a provided on the side of the cylinder 43, and the resin 42 is put into the internal space 43b by the hopper 45. The form of the resin 42 is not particularly limited, and is usually in the state of particles 42a. The resin 42 is heated in the internal space 43b to melt and become a molten state. In addition, by the rotation of the screw 47 disposed in the internal space 43b, the molten resin is transported to the resin extrusion port 51 provided at the front end 43b2 of the internal space 43b.

[0048] The resin 42 is, for example, a thermoplastic resin such as polyolefin. Examples of polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-propylene copolymers, and mixtures thereof. Any of these thermoplastic resins can be used in the embodiment.

[0049] <Screw 47> The screw 47 is disposed in the internal space 43b of the cylinder 43, and by rotating, the molten resin can be kneaded while being transported to the resin extrusion port 51. A motor 44 is provided at one end of the screw 47. The motor 44 can control the rotation speed while rotating the screw 47. The screw 47 is preferably a full-thread screw.

[0050] <Physical foaming agent injection unit 48> The extruder 41 is provided with a physical foaming agent injection part 48 for injecting a physical foaming agent P. The physical foaming agent injection part 48 includes a pipe 48a and a pump 48b. The physical foaming agent P delivered by the action of the pump 48b is discharged from the discharge end 48c of the pipe 48a and injected into the internal space 43b of the cylinder 43. The physical foaming agent P is a substance that is liquid at 25°C and 1 atmosphere, such as water. The physical foaming agent P is injected from the physical foaming agent injection part 48, and the resin and the physical foaming agent P are melt-kneaded by the screw 47 to obtain a foaming agent-containing resin. Usually, the temperature of the foaming agent-containing resin in the extruder 41 rises to a temperature exceeding the boiling point of the physical foaming agent P at 1 atmosphere (100°C when the physical foaming agent P is water), but since a high pressure is applied to the foaming agent-containing resin in the extruder 41, the physical foaming agent P is still in a liquid state.

[0051] If the length from the base end 43b1 in the longitudinal direction of the internal space 43b to the front end 47a of the screw 47 is L, the discharge end 48c is preferably arranged at a position less than 0.2L from the base end 43b1. Thus, the physical foaming agent P can be injected into the internal space 43b from a position less than 0.2L from the base end 43b1.

[0052] Since the pressure of the molten resin in the internal space 43b decreases as it approaches the base end 43b1, when the physical foaming agent P is injected from a position close to the base end 43b1, it is not necessary to apply a high pressure to the physical foaming agent P. In addition, since the physical foaming agent P is a liquid at 25°C and 1 atmosphere, when the present invention is implemented at room temperature and pressure, it is not necessary to make the physical foaming agent P liquid or supercritical in advance. Therefore, according to this embodiment, foam molding can be performed without using an SCF device.

[0053] The length from the base end 43b1 to the position where the discharge end 48c is configured or the position where the physical foaming agent P is injected is, for example, 0, 0.01L, 0.05L, 0.1L, 0.15L, 0.20L, and may be within the range between any two values ​​exemplified here or below any value.

[0054] Preferably, the pipe 48a is arranged to pass through the hopper 45, and the physical foaming agent P is injected into the internal space 43b through the opening 43a provided with the hopper 45. In this way, it is not necessary to provide an additional opening in the cylinder 43, and the physical foaming agent P can be injected from a position close to the base end 43b1. In addition, the discharge end 48c is preferably arranged at a position closer to the internal space 43b than the outer surface 43c of the cylinder 43, and more preferably arranged at a position further inside than the peripheral surface 43b3 of the internal space 43b. If the discharge end 48c is arranged at a position away from the internal space 43b, the physical foaming agent P will adhere to the particles 42a in the hopper 45 before being injected into the internal space 43b, so that the ratio of the physical foaming agent P to the resin 42 becomes uneven. By arranging the discharge end 48c at a position close to the internal space 43b, the uneven ratio of the physical foaming agent P to the resin 42 can be reduced, so that the foaming becomes stable. It should be noted that, instead of injecting the physical foaming agent P from the opening 43a provided with the hopper 45, Figure 2 As shown, an opening 43d different from the opening 43a is provided on the side of the cylinder 43, and then the physical foaming agent P is injected into the internal space 43b from the opening 43b. In this way, since the physical foaming agent P does not adhere to the particles 42a in the hopper 45, it is possible to suppress the unevenness of the ratio of the physical foaming agent P to the resin 42.

[0055] The type of pump 48b is not particularly limited, but a diaphragm pump suitable for quantitative and small amount liquid delivery is preferred. The diaphragm pump is configured to deliver a fluid by reciprocating a thin film called a diaphragm.

[0056] The ratio of the physical foaming agent P to the resin 42 is, for example, 0.01 to 2.0 mass %, preferably 0.1 to 0.5 mass %. Specifically, the ratio is, for example, 0.01, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.5, 2.0 mass %, and may be within the range between any two of the values ​​exemplified here.

[0057] The injection amount of the physical foaming agent P is preferably 2 to 8 ml / min. If it exceeds 8 ml / min, the moldability tends to deteriorate. The injection amount is specifically, for example, 2, 3, 4, 5, 6, 7, 8 ml / min, and may be within the range between any two values ​​exemplified here.

[0058] <Temperature control unit 49> The temperature control unit 49 is configured to control the temperature of each part by individually controlling a plurality of temperature control units provided in the cylinder 43 and the extrusion head 52. The temperature control unit 49 controls the temperature of each part so that the physical foaming agent P in the foaming agent-containing resin is vaporized immediately after being extruded from the extrusion head 52.

[0059] <Resin extrusion port 51 and extrusion head 52> The foaming agent-containing resin is extruded from the resin extrusion port 51 and then injected into the extrusion head 52. The extrusion head 52 has a slit, and the foaming agent-containing resin is extruded through the slit to form a foamed parison 53. The shape of the slit is not particularly limited, and may be, for example, annular or linear (e.g., linear). If the slit is annular, a cylindrical foamed parison can be obtained. If the slit is linear (e.g., when the extrusion head 52 is a T-die), a sheet-shaped foamed parison can be obtained.

[0060] When the foaming agent-containing resin is extruded from the slit and exposed to the atmosphere, the pressure applied to the foaming agent-containing resin decreases, causing the physical foaming agent P to gasify, thereby forming a foamed parison 53. When the foamed parison 53 is gradually cooled in the atmosphere, the temperature of the foamed parison 53 becomes lower than the boiling point of the physical foaming agent P, and the physical foaming agent P becomes a liquid state. Since the viscosity of the foamed parison 53 increases as the temperature decreases, even if the physical foaming agent P becomes a liquid state due to the temperature decrease, the foamed parison 53 can maintain a foamed state.

[0061] If the temperature of the foaming agent-containing resin in the extrusion head 52 is T1 and the boiling point of the physical foaming agent P is T2, T1 is, for example, 160 to 250°C. And, T1-T2 is, for example, 60 to 150°C. Specifically, T1 is, for example, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250°C, and may also be within the range between any two of the values ​​exemplified here. Specifically, T1-T2 is, for example, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150°C, and may also be within the range between any two of the values ​​exemplified here.

[0062] <Mold 54> The foamed parison 53 is molded by a mold 54. The mold 54 is preferably a combination mold 54a, 54b that can be opened and closed, and the foamed parison 53 is guided between the combination molds 54a, 54b. The foamed parison 53 is molded by using the mold 54 to obtain a foamed molded body. The molding method using the mold 54 is not particularly limited, and it can be blow molding in which air is blown into the cavity of the mold 54 for molding, or it can be vacuum molding in which the inside of the cavity is depressurized from the inner surface of the cavity of the mold 54 to mold the foamed parison 53, or it can be a combination of these. In blow molding or vacuum molding, since the foamed parison 53 is stretched during molding, the foaming moldability is easily deteriorated. Therefore, when the molding of the foamed parison 53 is blow molding or vacuum molding, it has significant technical significance to stabilize the foaming state of the foamed parison 53 by suppressing the fluctuation of the ratio of the physical foaming agent P relative to the resin 42. The blow molding pressure of the blow molding is preferably 0.001 to 0.05 MPa. If it exceeds 0.05 MPa, the foamability tends to be deteriorated. Specifically, the blow pressure is, for example, 0.001, 0.005, 0.01, 0.02, 0.03, 0.04, or 0.05 MPa, and may be within the range between any two of the values ​​exemplified here.

[0063] 2. Method for producing foamed molded article A method for manufacturing a foamed molded article according to an embodiment of the present invention is described. The method of this embodiment comprises the steps of extruding a melt-kneaded resin obtained by melt-kneading a resin 42 and a physical foaming agent P in the extruder 41 to form a foamed parison 53, and molding the foamed parison 53 to obtain a foamed molded article.

[0064] Unless it violates the intention of the present method, the contents described in “1. Molding device” are also applicable to the present method.

[0065] As an example of the foamed molded body obtained by the manufacturing method of this embodiment, a catheter can be cited. The foaming ratio of the foamed molded body is, for example, 1.1 to 3.0 times, specifically, for example, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.5, 3.0 times, and can also be within the range between any two values ​​exemplified here.

[0066] 3. Other Implementation Methods ・The above embodiment is a continuous extrusion foaming molding without using a hopper, but it is also possible to store a certain amount of foaming agent-containing resin in a hopper and then extrude the stored foaming agent-containing resin to form a foamed parison. In this case, compared with the case of continuous extrusion, since the extrusion speed of the foamed parison can be increased, there is an advantage that the foaming state of the foamed parison can be stabilized.

[0067] [Example] according to Figure 1 The apparatus shown and the method shown in the above embodiment are used to make a foamed molded body from a foamed parison 53. As a raw material resin, a polypropylene resin A (manufactured by Borealis AG, trade name "Daploy WB140"), a polypropylene resin B (manufactured by Polypro Co., Ltd., trade name "NOVATEC PP・BC4BSW"), and a polyethylene elastomer (manufactured by Mitsui Chemicals, Inc., trade name "TAFMER DF605") are mixed at a mass ratio of 80:10:10 (specific gravity 0.90). As an extrusion head 52, an extrusion head having an annular slit around a core with a diameter of 150 mm is used. The set temperature of the extrusion head 52 is 180°C. The width of the annular slit is 1.2 mm, and water is injected into the internal space 43b as a physical foaming agent P from the hopper 45 by a diaphragm pump so that it is 0.4% by mass relative to the raw material resin. The resin extrusion rate was 59.6 kg / h and the water injection rate was 4 ml / min. Water was injected through the pipe 48 a, and the pipe 48 a was configured so that the discharge end 48 c was arranged closer to the internal space 43 b than the outer surface of the cylinder 43 .

[0068] The cylindrical foamed parison 53 extruded from the extrusion head 52 is placed between the split molds 54a and 54b, and after the molds are closed, air is blown into the foamed parison 53 at a blow pressure of 0.01 MPa to perform blow molding. In this way, a foamed molded body serving as a duct is produced.

[0069] The specific gravity of the obtained foamed molded article was measured, and the expansion ratio was calculated by dividing the specific gravity of the resin composition itself by the specific gravity of the foamed molded article. The result was 1.5 times.

[0070] (Second point of view) 1 First Embodiment use Figure 3 to Figure 15 , describing the first embodiment of the present invention.

[0071] 1-1 Description of the structure of the resin molded body 20, 20A use Figures 4 to 6 The processing device 100 shown in the figure processes the resin molded body 20 to produce Figure 3 A and Figure 3 The resin molded body 20A shown in B. The resin molded body 20A is not particularly limited, but is constituted by a duct in the embodiment.

[0072] The resin molded body 20A is different in structure from the resin molded body 20 in that the mounting piece 22 is formed with an opening 22D and the bag body 23 is cut to form an opening 23t, but the other structures are the same. Figure 4 The mounting piece 22 of the resin molded body 20 shown is processed to form Figure 3 The opening 22D shown in FIG. Figure 4 and Fig.14 The bag body 23 of the resin molded body 20 shown in A is processed so that an opening 23t is formed in the bag body 23 which is closed in a bag shape. The attachment piece 22 and the bag body 23 are examples of processed portions of the resin molded body.

[0073] The resin molded body 20A is, for example, a foamed resin molded body manufactured by blow molding. In the embodiment, the case where the resin constituting the resin molded body 20A is a foamed resin is described, but it is not limited to the foamed resin. The resin constituting the resin molded body 20A (resin molded body 20) can be composed of, for example, a resin composition containing a thermoplastic resin such as polyolefin, and examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-propylene copolymers, and mixtures thereof.

[0074] The following describes the components of the resin molded body 20, which is a molded body before being processed by the processing device 100. Figure 4 As shown, the resin molded body 20 includes a main body 21 , a mounting piece 22 , and a bag body 23 .

[0075] The main body 21 includes a base portion 21A and a reference portion 21B. The base portion 21A is a tube portion of the catheter and is formed in a cylindrical shape. Figure 4 As shown, the base portion 21A extends upward from the reference portion 21B, then bends and extends in parallel to the y direction, and further bends and extends in parallel to the x direction. It should be noted that the x direction and the y direction refer to the directions of the xy coordinate system described later. The base portion 21A is provided with a reference portion 21B on one side, and a bag body 23 is provided on the other side. The reference portion 21B and the opening 23t of the bag body 23 have the function of serving as a connecting port (for example, an air intake port or an exhaust port) of a conduit. The reference portion 21B is a portion provided on the setting portion 3 of the processing device 100. By providing the reference portion 21B on the setting portion 3, the operator positions the resin molded body 20 relative to the processing device 100, and the resin molded body 20 becomes a processable state.

[0076] The mounting piece 22 has a plate-like portion 22A, an edge portion 22B, and a connecting portion 22C, and is integrally formed with the main body portion 21. The plate-like portion 22A is a solid plate-like portion formed by pressing molten resin against a blow molding mold. Figure 7 ), an opening 22D is formed on the plate-like portion 22A (refer to Figure 3A). The purpose of the opening 22D is not particularly limited, and it is used, for example, when the resin molded body 20 is mounted on a mounting target. In the embodiment, the edge 22B is formed to extend in an arc shape. The connecting portion 22C is a connecting portion between the mounting piece 22 and the main body 21 (base portion 21A).

[0077] The bag body 23 has an expanded diameter portion 23A and a closed portion 23B, and is formed integrally with the main body 21. The expanded diameter portion 23A is connected to the end of the base portion 21A. The expanded diameter portion 23A is formed to expand in the radial direction relative to the base portion 21A. In other words, the diameter of the expanded diameter portion 23A is larger than the diameter of the portion of the base portion 21A connected to the expanded diameter portion 23A. The closed portion 23B is formed by the processing unit 2F (refer to Fig. 9 ) Cut part (refer to Fig.15 B). In blow molding, air needs to be supplied to the molten resin to expand the molten resin, so a portion such as the sealing portion 23B that seals air is formed on the resin molded body 20. Therefore, in the manufacturing method of the embodiment, the sealing portion 23B is cut to form the opening 23t.

[0078] 1-2 Considerable Dimensions of Processing Device 100 The processing device 100 has a function of processing the resin molded body 20 . The dimensions that can be considered when the processing device 100 processes the resin molded body 20 can be divided into the following first and second aspects.

[0079] 1-2-1 Dimensions from the first point of view The first viewpoint is a dimension based on the main body 21 (more specifically, the reference portion 21B) of the resin molded body 20, which corresponds to the tolerance range described later. Hereinafter, an xy coordinate system is defined and described for the main body 21 (reference portion 21B). The xy coordinate system is a coordinate system based on the position of the setting portion 3 (the position of the reference portion 21B set in the setting portion 3), and the reference position O is determined based on the position of the setting portion 3 (the position of the reference portion 21B set in the setting portion 3). The xy coordinate system is a plane coordinate system parallel to the moving direction of the moving portions 1 and 2 (the base portion 1A and the base portion 2A described later).

[0080] 1-2-2 Dimensions of the Second Viewpoint The second viewpoint is a dimension based on an example of a processed part, namely, a mounting piece 22 or a bag body 23. That is, even if the dimensions in the xy coordinate system of the first viewpoint are satisfied, defective products may be produced, so in the embodiment, the dimensions of the second viewpoint are also considered during processing. For example, in a case where the condition for a good product is to form an opening 22D in the center of the mounting piece 22, even if the shape and size of the mounting piece 22 itself match, there will be a significant deviation in the position where the mounting piece 22 is connected to the main body 21. At this time, the position of the opening 22D will significantly deviate from the center of the mounting piece 22 even if it satisfies the dimensions in the xy coordinate system of the first viewpoint. Therefore, the processing device 100 is constructed so as to easily satisfy not only the dimensions of the first viewpoint, but also the dimensions of the second viewpoint.

[0081] Hereinafter, an x1-y1 coordinate system is defined and described for the mounting piece 22. The x1-y1 coordinate system is a coordinate system based on the moving part 1 (a dedicated coordinate system for machining the mounting piece 22), and the reference position O1 is determined based on the position (e.g., initial position) of the moving part 1. The x1-y1 coordinate system is a plane coordinate system parallel to the moving direction of the base part 1A.

[0082] In addition, the x2-y2 coordinate system is defined and described below for the mounting piece 22. The x2-y2 coordinate system is a coordinate system based on the moving part 2 (a dedicated coordinate system for processing the bag body 23), and the reference position O2 is determined based on the position (e.g., initial position) of the moving part 2. The x2-y2 coordinate system is a plane coordinate system parallel to the moving direction of the base part 2A.

[0083] It should be noted that in the embodiments, the xy coordinate system, the x1-y1 coordinate system, and the x2-y2 coordinate system are parallel to the horizontal plane, but may be inclined or parallel to the vertical plane.

[0084] Thus, the manufacturing method of the embodiment can satisfy the requirements that the dimension based on the origin (reference portion 21B) is within the tolerance range (first viewpoint) and the relative position in the mounting piece 22 or in the bag 23 is within the predetermined range (second viewpoint). The specific structure of the processing device 100 is described below.

[0085] 1-3 Specific structural description of the processing device 100 like Figure 4 As shown, the processing device 100 includes moving parts 1, 2, a setting part 3, and monitoring parts 11, 12. It should be noted that the processing device 100 includes a control device (not shown) that performs various controls such as controlling various driving mechanisms such as the moving parts 1, 2 and determining detection signals of the monitoring parts 11, 12.

[0086] 1-3-1 Moving section 1 (moving section for forming a hole in a plate-like portion) like Figure 7 as well as Figure 8 As shown, the moving portion 1 includes a base portion 1A, a pedestal moving portion 1B, a moving mechanism portion 1C, a holding portion 1D, a contact portion 1E, and a processing portion 1F.

[0087] 1-3-1-1 Base 1A The base 1A is fixed with a moving mechanism 1C, and the relative position between the base 1A and the moving mechanism 1C does not change. The base 1A is fixed with three monitoring units 11, and the relative position between the base 1A and each monitoring unit 11 does not change. In addition, the base 1A is equipped with a pedestal moving unit 1B, and the base 1A is configured to be movable in a direction parallel to the x1 direction in the x1-y1 coordinate system by the driving force of the pedestal moving unit 1B.

[0088] 1-3-1-2 Base moving part 1B The pedestal moving portion 1B is configured to be able to move the base portion 1A in the x1 direction, and may be configured by, for example, a hydraulic or pneumatic cylinder mechanism.

[0089] 1-3-1-3 Moving mechanism section 1C The moving mechanism 1C is configured to move the holding portion 1D relative to the base portion 1A in parallel to the x1 direction and in parallel to the y1 direction. It should be noted that the holding portion 1D is provided with the contact portion 1E and the processing portion 1F, so the holding portion 1D moves simultaneously with the contact portion 1E and the processing portion 1F. The moving mechanism 1C can be configured, for example, by a linear guide mechanism of two axes (the axis in the x1 direction and the axis in the y1 direction).

[0090] When the base portion 1A moves along the Figure 5 as well as Figure 6If the contact portion 1E of the moving part 1 moves in the x1 direction in the x1-y1 coordinate system shown in the figure, there is a possibility that the contact portion 1E of the moving part 1 will contact (interfere with) the mounting piece 22 of the resin molded body 20. For example, the more the formation position of the mounting piece 22 of the resin molded body 20 deviates from the desired position in the xy coordinate system, the more likely the contact portion 1E will interfere with the mounting piece 22. Even if the contact portion 1E contacts the mounting piece 22, when the driving force of the pedestal moving part 1B is applied to the base part 1A, the base part 1A will move forward, but since the contact portion 1E contacts the mounting piece 22, it is difficult for the contact portion 1E to move forward in the x1 direction, and the moving mechanism part 1C causes the contact portion 1E (holding part 1D) to perform an avoidance action so that the contact force between the contact portion 1E (holding part 1D) and the mounting piece 22 does not increase. Here, the avoidance action means, for example, that the contact portion 1E (holding part 1D) moves in a direction parallel to the y1 direction, or retreats in a direction parallel to the x1 direction. In this way, by performing the avoidance action, the relative positions of the holding portion 1D, the contact portion 1E, and the processing portion 1F and the base portion 1A change. It should be noted that, due to the driving force of the pedestal moving portion 1B, even if the contact portion 1E moves forward, it may not contact the mounting piece 22. In this case, the relative positions of the holding portion 1D, the contact portion 1E, and the processing portion 1F and the base portion 1A do not change.

[0091] The moving mechanism part 1C is configured to apply a driving force to the holding part 1D along the forward direction (i.e., the x1 direction). In other words, the moving mechanism part 1C is configured to be easier to move in the left-right direction (i.e., the direction parallel to the y1 direction) than in the backward direction (i.e., the -x1 direction). Therefore, even if the abutting part 1E abuts against the mounting piece 22, the abutting part 1E (holding part 1D) is not easily pushed back in the direction parallel to the x1 direction. That is, when the abutting part 1E (holding part 1D) performs an avoidance action parallel to the y1 direction, it will be forcibly pushed to the x1 direction to a certain extent, and it can be expected that the mounting piece 22 will be easily guided to the inside of the abutting part 1E. It should be noted that if the abutting force exceeds the above-mentioned driving force, the abutting part 1E will retreat.

[0092] 1-3-1-4 Holding section 1D The holding part 1D includes a first holding part 1D1, a second holding part 1D2, and a connecting part 1D3. The first cutting component 1F1 of the processing part 1F is fixed to the first holding part 1D1, and the second cutting component 1F2 of the processing part 1F is fixed to the second holding part 1D2. The first holding part 1D1 and the second holding part 1D2 are arranged to be opposite to each other. The holding part 1D is configured so that the opposing interval between the first holding part 1D1 and the second holding part 1D2 is narrowed by omitting the driving force of the driving mechanism not shown in the figure. It should be noted that the first holding part 1D1 can be moved upward, the second holding part 1D2 can be moved downward, and both of the above situations can be included at the same time. The first holding part 1D1 is formed with a discharge port Op, and the part of the mounting piece 22 cut by the processing part 1F is discharged from the discharge port Op through the internal space of the processing part 1F. In addition, in the embodiment, the second holding part 1D2 is monitored by three monitoring parts 11. The connecting portion 1D3 has a function of preventing the position of the first holding portion 1D1 and the position of the second holding portion 1D2 from deviating in the plane of the x1-y1 coordinate.

[0093] 1-3-1-5 Contact portion 1E The abutment portion 1E is provided on the processing portion 1F, for example, held on the holding portion 1D (the first holding portion 1D1 in the embodiment). Thus, in the x1-y1 coordinate system, the abutment portion 1E moves integrally with the holding portion 1D. If the dimensional deviation of the shape of the mounting piece 22 itself or the dimensional deviation of the mounting position of the main body 21 relative to the mounting piece 22 does not exist or is very small, the abutment portion 1E will not abut against the mounting piece 22, and the processing portion 1F will be arranged at the desired position. On the other hand, since there may be a certain degree of dimensional unevenness, the movable portion 1 has the abutment portion 1E, so that the resin molded body 20 can be processed more appropriately. In other words, the abutment portion 1E is configured to be close to the mounting piece 22 and abut against the mounting piece 22, so that the processing portion 1F is positioned. This positioning is used to position the size that satisfies the second viewpoint mentioned above. The positioning function by the abutment portion 1E is described in detail below.

[0094] The abutment portion 1E is configured so that the mounting piece 22 is guided by the abutment portion 1E when abutting against the mounting piece 22. In the embodiment, the abutment portion 1E has an abutment surface 1E1, and the abutment surface 1E1 is formed in a circular arc shape when viewed from above. In other words, the abutment surface 1E1 is curved in a convex manner relative to the retreat direction of the base portion 1A. As a result, it is easier to guide the mounting piece 22 to the inner side of the abutment portion 1E (closer to the center of the abutment portion 1E in the y1 direction), and in particular, in the direction parallel to the y1 direction, the position of the processing portion 1F can be corrected. It should be noted that in the embodiment, as Figure 7 As shown, the contact surface 1E1 is formed along the shape of the edge portion 22B of the mounting piece 22 .

[0095] For example, the shape and size of the mounting piece 22 itself match, but even if the connection position relative to the main body 21 deviates slightly in the y1 direction, when the abutment portion 1E abuts against the mounting piece 22, the abutment portion 1E (processing portion 1F) is relatively moved relative to the base portion 1A through the action of the moving mechanism portion 1C, and the mounting piece 22 is smoothly guided to the inner side of the abutment portion 1E, and the processing portion 1F is guided to the desired position.

[0096] 1-3-1-6 Processing Department 1F The processing portion 1F is configured to process the mounting piece 22. In the embodiment, the processing portion 1F forms an opening 22D in the mounting piece 22. It should be noted that the processing portion 1F may also form other cuts other than the opening, and various processing parts may be used. The processing portion 1F includes a first cutting part 1F1 and a second cutting part 1F2.

[0097] like Figure 7 As shown, the first cutting member 1F1 is held by the first holding portion 1D1. The first cutting member 1F1 is formed in a cylindrical shape, and a space is formed inside the first cutting member 1F1 to allow the second cutting member 1F2 to be inserted. The upper end of the first cutting member 1F1 is provided to communicate with the discharge port Op.

[0098] The second cutting member 1F2 is held on the second holding portion 1D2. The second cutting member 1F2 is opposed to the first cutting member 1F1 so that its central axis is aligned with the central axis of the first cutting member 1F1. The second cutting member 1F2 has a blade protruding toward the first cutting member 1F1, and when the relative positions of the first cutting member 1F1 and the second cutting member 1F2 are close to each other, the blade of the first cutting member 1F1 and the lower end of the second cutting member 1F2 clamp the mounting piece 22, and the blade of the first cutting member 1F1 is inserted into the second cutting member 1F2, so that a portion of the mounting piece 22 is cut and discharged from the discharge port Op.

[0099] 1-3-2 Moving part 2 (moving part for cutting the bag body) like Fig. 9 as well as Fig.10 As shown, the moving portion 2 includes a base portion 2A, a pedestal moving portion 2B, a moving mechanism portion 2C, a holding portion 2D, a contact portion 2E, and a processing portion 2F.

[0100] 1-3-2-1 Base 2A The structure of the base 2A is basically the same as that of the base 1A. A moving mechanism 2C is fixed to the base 2A, and the relative position between the base 2A and the moving mechanism 2C does not change. Three monitoring units 12 are fixed to the base 2A, and the relative position between the base 2A and each monitoring unit 12 does not change. In addition, a pedestal moving unit 2B is installed on the base 2A, and the base 2A is configured so that the driving force of the pedestal moving unit 2B can move the base 2A in parallel along the x2 direction of the x2-y2 coordinate system.

[0101] 1-3-2-2 Base moving part 2B The structure of the pedestal moving unit 2B is basically the same as that of the pedestal moving unit 1B. The pedestal moving unit 2B is configured to be able to move the base unit 2A in the x2 direction, and can be configured by, for example, a hydraulic or pneumatic cylinder mechanism.

[0102] 1-3-2-3 Moving mechanism section 2C The structure of the moving mechanism 2C is basically the same as that of the moving mechanism 1C, so the description thereof is appropriately omitted. The moving mechanism 2C is configured to move the holding portion 2D relative to the base portion 2A in parallel to the x2 direction and in parallel to the y2 direction. It should be noted that the holding portion 2D is provided with the abutment portion 2E and the processing portion 2F, so the moving mechanism 2C moves simultaneously with the abutment portion 2E and the processing portion 2F. The moving mechanism 2C can be configured, for example, by a linear guide mechanism of two axes (the axis in the x2 direction and the axis in the y2 direction).

[0103] Similar to the moving mechanism 1C, the moving mechanism 2C is also configured to perform an avoidance action with respect to the contact portion 2E. The avoidance action of the moving mechanism 2C means, for example, that the contact portion 2E (holding portion 2D) moves in a direction parallel to the y2 direction, or retreats in a direction parallel to the x2 direction. Thus, by performing the avoidance action, the relative positions of the holding portion 2D, the contact portion 2E, and the processing portion 2F and the base portion 2A change.

[0104] Furthermore, similar to the moving mechanism section 1C, the moving mechanism section 2C is also configured to apply a thrust to the holding section 2D in the advancing direction (ie, the x2 direction).

[0105] 1-3-2-4 Holding section 2D The processing portion 2F is fixed to the holding portion 2D. Figures 4 to 6 , Fig. 9 , Fig.10 In the figure, for the sake of convenience, the part where the processing part 2F is fixed to the holding part 2D is omitted. In addition, the holding part 2D has a function of sliding the contact part 2E, so that the contact part 2E can move in the up-down direction.

[0106] 1-3-2-5 Abutment portion 2E The contact portion 2E includes a first contact portion 2E1 and a second contact portion 2E2. The first contact portion 2E1 and the second contact portion 2E2 are each configured to be movable up and down and to be able to sandwich and press the resin molded body 20.

[0107] The contact portion 2E is provided on the processing portion 2F, for example, and is held on the holding portion 2D. Thus, in the x2-y2 coordinate system, the contact portion 2E and the holding portion 2D move together. Figure 5 as well as Figure 6 The moving part 2 moves in the x2 direction in the x2-y2 coordinate system shown in FIG. 1 , and the contact portion 2E of the moving part 2 contacts the bag 23 of the resin molded body 20, thereby positioning the moving part 2. In other words, the contact portion 1E of the moving part 1 does not necessarily contact the mounting piece 22, but the contact portion 2E of the moving part 2 contacts the bag 23 (see FIG. 1 ). Fig.15 A). Thus, the contact portion 2E can hold the root portion of the base portion 21A of the main body 21 connected to the bag body 23 (see Fig.15 B) The bag body 23 can be cut more reliably and accurately by using the processing part 2F. In the processing of the movable part 1, since the mounting piece 22 is clamped by the first cutting part 1F1 and the second cutting part 1F2 from the top and bottom directions for processing, it is easy to avoid the position deviation of the mounting part 22 during the processing. On the other hand, in the processing of the movable part 2, such as the processing part 2F described later, the cutting part 2F1 composed of a blade is lowered to perform cutting. At this time, in the processing of the bag body 23, there is a concern that the cutting position may deviate or the cutting part 2F1 may not be able to properly pass through the bag body 23, for example, due to the movement or bending of the bag body 23. Therefore, in the movable part 2, the abutment part 2E of the movable part 2 is abutted against the bag body 23 for positioning so as to more reliably maintain the appropriate part (the root of the bag body 23).

[0108] The contact portion 2E is configured so that when the bag body 23 contacts the contact portion 2E, the bag body 23 is guided by the contact portion 2E. In the embodiment, the first contact portion 2E1 and the second contact portion 2E2 respectively have a contact surface 2E3, and the contact surface 2E3 is formed to be an arc shape when viewed from above. In other words, the contact surface 2E3 is curved in a convex manner relative to the retreat direction of the base portion 2A. As a result, the central axis of the bag body 23 is more easily guided to the center of the contact portion 2E in the y2 direction, and the center of the cutting part 2F1 can be aligned with the central axis of the bag body 23 in a direction parallel to the y2 direction, so that the bag body 23 can be cut more reliably by the cutting part 2F1.

[0109] 1-3-2-6 Processing Department 2F The processing unit 2F is configured to process the bag body 23. In the embodiment, the processing unit 2F cuts the bag body 23 to form an opening 23t. The processing unit 2F includes a cutting member 2F1 and a guide 2F2.

[0110] The cutting member 2F1 is composed of a thin plate-shaped blade, and is configured to be movable in the up-down direction. The cutting member 2F1 is opposed to the contact portion 2E in a manner separated by a predetermined interval in the x2 direction. The cutting member 2F1 is guided by the guide portion 2F2. It should be noted that, although the guide portion 2F2 is omitted for ease of description, it is fixed to the holding portion 2D so that the processing portion 2F is held on the holding portion 2D.

[0111] 1-3-3 Setting section 3 The installation part 3 is configured to be able to install the reference part 21B of the resin molded body 20. By installing the reference part 21B in the installation part 3, the resin molded body 20 Figure 5 as well as Figure 6 The shape of the installation portion 3 can be set according to the shape of the reference portion 21B.

[0112] 1-3-4 Monitoring Unit 11 The monitoring unit 11 is configured to detect whether the position of the processing unit 1F is within a tolerance range based on the main body 21. The monitoring unit 11 includes a sensor support unit 11A and a sensor unit 11B. The sensor support unit 11A is fixed to the base unit 1A, and the sensor unit 11B is fixed to the sensor support unit 11A. The sensor unit 11B may be configured, for example, by a motor, and the sensor unit 11B detects whether the position of the processing unit 1F that moves integrally with the holding unit 1D is within a tolerance range by detecting whether it is in contact with the holding unit 1D (the second holding unit 1D2 in the embodiment). It should be noted that the sensor unit 11B is not limited to being configured by a contact sensor, and may be configured by a non-contact distance measuring sensor, for example.

[0113] like Figure 7 as well as Figure 8 As shown, the monitoring unit 11 is provided on the backward direction side (-x1 direction side) based on the moving mechanism unit 1C of the moving unit 1 and on the left and right directions orthogonal to the forward direction (y1 direction side and -y1 direction side).

[0114] Here, the tolerance range is a predetermined allowable range as a dimension based on the position of the reference portion 21B of the main body 21 (a dimension based on the xy coordinate system), and corresponds to the dimension of the first viewpoint. For example, when the position where the mounting piece 22 is connected to the main body 21 deviates from the desired range, the position of the mounting piece 22 deviates from the position of the reference portion 21B and is therefore outside the tolerance range.

[0115] Furthermore, when the contact portion 1E contacts the mounting piece 22, the holding portion 1D performs any relative movement relative to the base portion 1A, but the range of its relative movement is consistent with the above-mentioned tolerance range. In other words, when the contact portion 1E contacts the mounting piece 22, if the holding portion 1D does not contact the sensor portion 11B, it can be ensured to be within the tolerance range in the xy coordinate system. In other words, if the monitoring portion 11 does not contact the holding portion 1D, the position of the monitoring portion 11 is set so as to be ensured to be within the tolerance range in the xy coordinate system.

[0116] In the embodiment, the monitoring unit 11 is fixed to the base unit 1A of the x1-y1 coordinate system, but the initial position of the base unit 1A is determined based on the xy coordinate system, and the width of the base unit 1A moved forward by the pedestal moving unit 1B is predetermined. Therefore, the x1-y1 coordinate system and the xy coordinate system can be converted to each other, and the position of the monitoring unit 11 can be set to ensure that it is within the tolerance range in the xy coordinate system.

[0117] 1-3-5 Monitoring Unit 12 The structure of the monitoring unit 12 is basically the same as that of the monitoring unit 11, so the description is omitted. The monitoring unit 12 is configured to detect whether the position of the processing unit 2F is within the tolerance range based on the main body 21. Specifically, the monitoring unit 12 includes a sensor support portion 12A and a sensor portion 12B. The sensor support portion 12A is fixed to the base portion 2A, and the sensor portion 12B is fixed to the sensor support portion 12A. The sensor portion 12B can be composed of an electrode, for example, and the sensor portion 12B detects whether the position of the processing unit 1F that moves integrally with the holding portion 2D is within the tolerance range by detecting whether it is in contact with the holding portion 2D.

[0118] like Fig. 9 as well as Fig.10 As shown, the monitoring unit 12 is provided on the backward direction side (-x2 direction side) based on the moving mechanism unit 2C of the moving unit 2 and on the left and right direction sides (y2 direction side and -y2 direction side) perpendicular to the moving direction.

[0119] 1-4 Method for Manufacturing Resin Molded Body 20A This method includes a setting process, a moving process, a processing process, and a disassembly process. Each process is described below.

[0120] 1-4-1 Setting process like Figure 4As shown, in the setting process, the reference portion 21B of the resin molded body 20 is set on the setting portion 3, and the resin molded body 20 is positioned in the processing device 100. It should be noted that in the setting process, the movement of the resin molded body 20 can also be restricted by an arbitrary holding portion (not shown) so that it cannot move. In the setting process, the moving portions 1 and 2 are located at the initial position.

[0121] 1-4-2 Moving process 1-4-2-1 About Mobile Unit 1 In the moving process, the position of the moving part 1 (processing part 1F) is moved closer to the mounting piece 22 with reference to the mounting piece 22. In other words, the position of the moving part 1 is moved from Figure 5 The position shown (initial position) advances to Figure 6 The position (processing position) shown in the embodiment. Therefore, in the embodiment, the moving part 1 is configured to move in an x1-y1 coordinate system (a dedicated coordinate system for processing the mounting piece 22) that is different from the xy coordinate system. In other words, since the position of the processing part 1F is brought closer to the mounting piece 22 based on the mounting piece 22, it is easy to determine the position of the processing part 1F by assuming and considering the dimensional deviation of the mounting piece 22 itself in advance. Therefore, in the embodiment, it is easy to control the processing position of the processing part 1F within a predetermined range, in other words, it is easy to satisfy the size of the second viewpoint. Therefore, in the embodiment, it is possible to suppress the situation of manufacturing defective products.

[0122] like Fig.11 As shown, when the shape of the mounting piece 22 itself matches the size and the connection position of the main body 21 relative to the mounting piece 22 also matches the size, when the moving part 1 is moved, the abutment portion 1E will not abut the mounting piece 22 but will be on the inner side of the abutment portion 1E. Fig.11 The position p1 shown is the center position of the processed portion 1F, and in the processing steps described later, an opening portion centered at the position p1 is formed.

[0123] On the other hand, Fig.12 As shown in A, for example, the shape of the mounting piece 22 itself matches the size, and the connection position of the main body 21 relative to the mounting piece 22 is slightly deviated in the direction parallel to the y1 direction. Fig.12 When the contact portion 1E is further advanced and contacts the mounting piece 22 in the state shown, the contact portion 1E (processing portion 1F) moves relative to the base portion 1A by the action of the moving mechanism portion 1C. The relative movement amount corresponds to Fig.12 The interval d1 shown in A is Fig.12B. The interval d1 is the distance between the sensor portion 11B and the second holding portion 1D2 before the contact portion 1E contacts the mounting piece 22. The interval d2 is the distance between the sensor portion 11B and the second holding portion 1D2 after the contact portion 1E contacts the mounting piece 22 and guides the mounting piece 22 into the contact portion 1E. When the interval d2 is smaller than the interval d1, the holding portion 1D and the processing portion 1F move in the -y1 direction.

[0124] Here, in the dimension of the second viewpoint, the opening 22D needs to be Fig.13 The predetermined range Rg can be determined based on the shape of the edge portion 22B of the mounting piece 22, for example. If the moving part 1 does not have the abutment portion 1E, the processing part 1F can only move forward, so the center position of the processing part 1F will move to Fig.13 If processing is performed at this position p2, an opening as shown in the dotted circle c2 will be formed, and the opening 22D will exceed the predetermined range of the rectangle. However, the movable part 1 has the abutment part 1E, so the mounting piece 22 will be guided into the abutment part 1E, and the center position of the processing part 1F will move to Fig.13 Position p3 shown. If processing is performed at position p3, the opening 22D can be prevented from exceeding the predetermined range Rg. In this way, in the embodiment, by providing the moving part 1 with the contact part 1E, the dimension of the second viewpoint can be easily satisfied, and the manufacturing of defective products can be more effectively suppressed.

[0125] It should be noted that there is a conventional method in which the operator moves the moving part 1 each time to adjust the position of the processing part 1F, instead of the moving part 1 having the abutment part 1E, etc., but the adjustment work in this conventional method takes time and effort. In addition, since the shrinkage amount of the resin molded body 20 varies according to the molding conditions (wall thickness or ambient temperature, raw material batch), the deformation of the resin molded body 20 is not uniform. In addition, not only the molding conditions, but also the factors that make the state of the resin molded body 20 uneven due to the timing of processing the resin molded body 20, such as the time from taking the resin molded body out of the mold to processing it using the processing device 100, will also cause the shrinkage amount of the resin molded body 20 to change. In this way, the molding conditions of the resin molded body 20 and the factors that make the state of the resin molded body 20 uneven will cause the deformation of the resin molded body 20 to be uneven, but as in the embodiment, when the resin molded body 20 is composed of a foamed resin, the influence is significant. Therefore, in the conventional method, there is a concern that the processing accuracy will deviate depending on the operator's operating proficiency. In contrast, the present embodiment can suppress the time and effort required for adjustment work and the variation in processing accuracy.

[0126] As described above, when the resin molded body 20 is composed of a foamed resin, the influence of deformation due to shrinkage is significant, so the manufacturing method of the embodiment is preferably a case where the resin molded body 20 is composed of a foamed resin. It should be noted that when the resin molded body 20 is a foamed resin molded body, the foaming ratio of the resin constituting the resin molded body 20 is 1.1 to 8 times, preferably 1.2 to 4 times. Specifically, for example, it is 1.1, 1.2, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8 times, and may also be within the range between any two values ​​exemplified here.

[0127] Furthermore, even if the mounting piece 22 is guided by the contact portion 1E and the position of the processing portion 1F is relatively moved, the situation outside the tolerance range of the first viewpoint can be avoided. That is, during the moving process, the monitoring unit 11 monitors whether the position of the holding portion 1D (processing portion 1F) is within the tolerance range. Therefore, it is ensured that the processing position of the resin molded body 20A is within the tolerance range in the xy coordinate system. In other words, in the embodiment, the dimensions of the first viewpoint can be met, and the situation of manufacturing defective products can be suppressed.

[0128] If the monitoring unit 11 detects that the position of the processing unit 1F is outside the tolerance range, the control device notifies by voice or display, for example, to stop the operation of the moving units 1 and 2. This can avoid forced transition from the moving process to the processing process.

[0129] 1-4-2-2 About Mobile Unit 2 The position of the moving part 2 (processing part 2F) is moved closer to the mounting piece 22 based on the bag body 23. Figure 4 As shown, in a state where the opposing interval between the first contact portion 2E1 and the second contact portion 2E2 is larger than the upper and lower widths of the bag body 23, the position of the moving portion 2 is changed from Figure 5 The initial position shown in FIG. 1 is moved back a predetermined distance so that the bag body 23 passes between the first abutting portion 2E1 and the second abutting portion 2E2 (see FIG. 2A ). Fig.14 Next, the first contact portion 2E1 and the second contact portion 2E2 are advanced and contacted with the enlarged diameter portion 23A of the bag body 23 to perform positioning (see Fig.14 B and Fig.15 A).

[0130] like Fig.15 As shown, when the positioning of the contact portion 2E is completed, the opposing interval between the first contact portion 2E1 and the second contact portion 2E2 is narrowed, and the first contact portion 2E1 and the second contact portion 2E2 sandwich and press the main body 21 .

[0131] When the shape of the bag body 23 itself matches the size, and the connection position relative to the main body 21 of the bag body 23 also matches the size, when the moving part 2 moves forward, the abutment part 2E will just abut against the bag body 23.

[0132] On the other hand, for example, the following situation may occur: the formation position of the enlarged diameter portion 23A of the bag body 23 is too close (too biased to the Fig.14 A in the -x2 direction), so that the first contact portion 2E1 and the second contact portion 2E2 prematurely contact the enlarged diameter portion 23A. At this time, the holding portion 2D will move relatively along the -x2 direction.

[0133] On the contrary, the following situation may occur: if the position of the expanded diameter portion 23A of the bag body 23 is too far (too far to the Fig.14 In the x2 direction of A), even if the base portion 2A advances by a predetermined width, the contact portion 2E will not abut against the enlarged diameter portion 23A. In this case, the control device can be configured to detect that the contact portion 2E does not abut against the enlarged diameter portion 23A. In addition, if the control device detects this situation, the contact portion 2E is further advanced. When the advance amount exceeds a predetermined threshold, even if the contact detection of the monitoring unit 12 is not performed, it can be detected that the position of the processing portion 2F is outside the tolerance range.

[0134] If the monitoring unit 12 detects that the position of the processing unit 2F is outside the tolerance range, the control device notifies the monitoring unit 11 by voice or display, for example, and stops the operation of the moving units 1 and 2 .

[0135] Regarding the moving unit 2 , the contents of the dimensions from the first and second viewpoints are basically the same as those of the moving unit 1 described in the above 4-2-1, and thus are omitted.

[0136] 1-4-3 Processing steps In the moving process, the processing process is performed when the positions of the processing parts 1F and 2F are within the tolerance range. That is, in the moving process, when it is detected that the positions of the processing parts 1F and 2F are outside the tolerance range, the control device processes the resin molded body 20 at the positions of the processing parts 1F and 2F moved in the moving process. That is, for the mounting piece 22, the opening part 22D is formed by the processing part 1F, and for the bag body 23, the closing part 23B is cut by the processing part 2F to form the opening 23t.

[0137] 1-4-4 Disassembly process In the disassembly step, the moving parts 1 and 2 are operated in the reverse order of the operations in the moving step, and the moving parts 1 and 2 are returned to, for example, the initial positions. In addition, the manufactured resin molded body 20A is removed from the setting part 3 .

[0138] 1-5 Variations The manufacturing method of the above embodiment is suitable for processing a portion that is relatively far from the reference portion 21B. This is because the farther the portion is from the reference portion 21B, the greater the influence of deformation such as shrinkage of the resin molded body 20. The linear distance (cm) between the reference portion 21B and the processing target portion (mounting piece 22 or bag body 23) passing through the moving portion is specifically, for example, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 120, 140, 160, 180, 200, 220, 240, 260, 280, 300, 320, 340, 360, 380, 400, and may also be within the range between any two values ​​exemplified here.

[0139] In the above embodiment, the contact portion 1E of the movable part 1 does not contact the mounting piece 22, but the present invention is not limited thereto. Like the contact portion 2E, the contact portion 1E may contact the mounting piece 22 as the processing target portion for positioning.

[0140] 2. Second Embodiment use Figures 16 to 20 , the second embodiment of the present invention is described. This embodiment is similar to the first embodiment, and the description of the first embodiment is also applicable to this embodiment as long as it does not violate its purpose. The following description will focus on the differences.

[0141] 2-1. Resin molded body 20 like Fig.16 As shown, in this embodiment, the resin molded body 20 as the processing target has a main body 21 and a processed part 24. The resin molded body 20 is, for example, a hollow molded body such as a tank. In the state before processing, the processed part 24 is a columnar part (preferably a cylindrical part) without an opening. The processed part 24 can be solid or hollow. In any case, the processing part 32e (such as a drill) is used to cut the processed part 24. Fig.17 B), the processed portion 24 is processed by punching or the like. The resin molded body 20 can be manufactured by blow molding or the like using a resin composition containing a thermoplastic resin such as polyolefin. In addition, a second processed portion (not shown) is preferably provided on the reference surface 21a or at a position adjacent thereto.

[0142] 2-2. Processing device 100 like Figure 17-18 As shown, the processing device 100 of the present embodiment includes a fixing unit 31 , a moving unit 32 , a stage 33 , and a monitoring unit 34 .

[0143] The fixing portion 31 includes a main base 31a, a reference base 31b, a connecting portion 31c, a reference block 31da, and a reference block 31db. The reference base 31b is fixed to the main base 31a via the connecting portion 31c. The reference blocks 31da and 31db are fixed to the reference base 31b. The reference blocks 31da and 31db are used as positioning references for the main body 21. In the present embodiment, a pair of reference blocks 31da and 31db are provided for positioning in the x-direction and the y-direction, and the main body 21 can be positioned by making the two reference surfaces 21a and 21b of the main body 21 abut against the pair of reference blocks 31da and 31db, respectively. It should be noted that in the present embodiment, for the sake of convenience, Fig.18 As shown in A, the longitudinal direction of the main body 21 is the x direction, and the direction perpendicular to the x direction is the y direction.

[0144] The fixing portion 31 is preferably provided with a processing portion (not shown) for processing a second processed portion (not shown) provided on the reference surface 21a or at a position adjacent thereto. The processing portion is preferably provided so as to process the second processed portion with the main body 21 as a reference. According to this embodiment, when the resin molded body 20 has processed portions at a plurality of locations separated from each other, even if the resin molded body 20 undergoes molding shrinkage, deviation of the processing position on each processed portion can be suppressed.

[0145] The moving part 32 is fixed to the main base 31a via a platform 33. In the present embodiment, the platform 33 is a dual-axis platform that can move in the x-direction and the y-direction. Therefore, the moving part 32 can move in the x-direction and the y-direction relative to the fixed part 31. It should be noted that the platform 33 can also be a single-axis platform, and the moving part 32 can only move in the x-direction relative to the main base 31a.

[0146] The moving part 32 includes a moving base 32a, a supporting base 32b, a connecting part 32c, a supporting block 32d, a processing part 32e, a supporting frame 32f, and a linear slider 32g. The supporting base 32b is fixed to the moving base 32a via the connecting part 32c. The supporting block 32d is fixed to the supporting base 32b. The processing part 32e is supported by the supporting frame 32f, and the supporting frame 32f moves in the y direction via the linear slider 32g. The linear slider 32g is fixed to the moving base 32a.

[0147] The support block 32d is configured to support the processed portion 24. If the position of the processed portion 24 is designed based on the main body 21, the movable portion 32 will not move even if the processed portion 24 is supported by the support block 32d. Fig.19 As shown in FIG. 2B, due to the molding deviation of the resin molded body 20, the position of the processed portion 24 based on the main body 21 is shifted to the left from the designed position. Fig. 20 As shown in A, the processed portion 24 abuts against the tapered surface 32d1 of the support block 32d. In this state, if the processed portion 24 is pressed, Fig. 20 As shown in B, the support block 32d will move along Fig.10 A moves to the left side (-x direction), and the workpiece 24 is stably supported by the support portion 32d2 of the support block 32d. The support block 32d is connected to the moving base 32a through the support base 32b and the connecting portion 32c, so as the support block 32d moves, the moving base 32a also moves together (that is, the entire moving portion 32 moves together). It should be noted that if the position of the workpiece 24 deviates to the right side from the designed position, the support block 32d and the moving base 32a move to the right side (+x direction).

[0148] The processing portion 32e is fixed to the moving base 32a via the support frame 32f and the linear slider 32g, so even if the support block 32d moves, the relative position of the support block 32d and the processing portion 32e does not change. The processing portion 32e is provided at a position opposite to the support portion 32d2 of the support block 32d, and when the support portion 32d2 moves in a manner close to the processing portion 24 with respect to the processing portion 24 as a reference, the processing portion 32e also moves in a manner close to the processing portion 24.

[0149] Next, the linear slider 32 g advances the processing portion 32 e , and the processing portion 32 e can process (eg, punch a hole) the processed portion 24 .

[0150] Thus, in the present embodiment, when the resin molded body 20 is placed in the processing device 100, a moving process is performed to bring the position of the processing portion 32e closer to the processed portion 24. Furthermore, by this moving process, the deviation of the processing position passing through the processing portion 32e can be made smaller than the dimensional deviation of the resin molded body 20, thereby suppressing the production of defective products.

[0151] The monitoring unit 34 is fixed to the fixing unit 31 to monitor whether the position of the processing unit 32e is within the tolerance range based on the main body 21. This monitoring can be performed by the same method as the first embodiment. Thus, it is possible to suppress the occurrence of an unobjectionable process in which the resin molded body 20 with a processing dimension outside the allowable range is processed.

[0152] In this embodiment, for example, it is possible to monitor whether the moving base 32a is in contact with the monitoring unit 34. Preferably, the monitoring unit 34 is disposed on both sides of the moving base 32a in the x direction. In this case, even if the moving base 32a moves in the +x direction or the -x direction, it is possible to monitor whether the moving amount of the moving base 32a is within the tolerance range.

[0153] (Explanation of symbols) 100: Processing device, 1: Moving part, 1A: Base part, 1B: Stage moving part, 1C: Moving mechanism part, 1D: Holding part, 1D1: First holding part, 1D2: Second holding part, 1D3: Connecting part, 1E: Contact part, 1E1: Contact surface, 1F: Processing part, 1F1: First cutting member, 1F2: Second cutting member, 2: Moving part, 2A: Base part, 2B: Stage moving part, 2C: Moving mechanism part, 2D: Holding part, 2E: Contact part, 2E1: First contact part, 2E2: Second contact part, 2E3: Contact surface , 2F: Processing part, 2F1: Cutting member, 2F2: Guide part, 3: Setting part, 11: Monitoring part, 11A: Sensor support part, 11B: Sensor part, 12: Monitoring part, 12A: Sensor support part, 12B: Sensor part, 20: Resin molded body, 20A: Resin molded body, 21: Main body, 21A: Base part, 21B: Reference part, 21a: Reference surface, 21b: Reference surface, 22: Mounting piece, 22A: Plate-shaped part, 22B: Edge part, 22C: Connecting part, 22D: Opening part, 23: Bag body, 23A : Expanding portion, 23B: Closing portion, 23t: Opening, 24: Processed portion, 31: Fixing portion, 31a: Main base, 31b: Reference base, 31c: Connecting portion, 31da: Reference block, 31db: Reference block, 32: Moving portion, 32a: Moving base, 32b: Support base, 32c: Connecting portion, 32d: Support block, 32d1: Tapered surface, 32d2: Support portion, 32e: Processing portion, 32f: Support frame, 32g: Linear slider, 33: Platform, 34: Monitoring portion, 41: Extruder, 42a: Particles, 43: Cylinder, 43a: opening, 43b: internal space, 43b1: base end, 43b2: front end, 43b3: peripheral surface, 43c: outer surface, 43d: opening, 44: motor, 45: hopper, 47: screw, 47a: front end, 48: physical foaming agent injection part, 48a: pipeline, 48b: pump, 48c: discharge end, 49: temperature control part, 51: resin extrusion port, 52: extrusion head, 53: foaming parison, 54: mold, 54a: combination mold, 54b: combination mold, 101: molding device, P: physical foaming agent.

Claims

1. A method for producing a foamed molded article, The method comprises the steps of extruding a molten kneaded resin from an extruder to form a foamed parison, and molding the foamed parison to obtain a foamed molded article. The melt-mixed resin is prepared by melt-mixing resin and a physical foaming agent in an extruder. The physical foaming agent is liquid at 25°C and 1 atmosphere, If the length from the base end of the long side direction of the internal space of the cylinder of the extruder to the front end of the screw of the extruder is L, The physical foaming agent is injected into the cylinder of the extruder from a position less than 0.2L from the base end.

2. The method according to claim 1, wherein: The physical foaming agent is injected into the inner space of the cylinder through an opening provided with a hopper.

3. The method according to claim 2, wherein: The discharge end of the pipe for injecting the physical foaming agent is arranged at a position closer to the inner space of the cylinder than to the outer surface of the cylinder.

4. The method according to claim 1, wherein: The physical foaming agent is injected into the inner space of the cylinder through an opening different from the opening where the hopper is provided.

5. The method according to any one of claims 1 to 4, wherein: The physical foaming agent was supplied using a diaphragm pump.

6. A method for producing a resin molded body using a processing device, The resin molded body comprises a main body portion and a processed portion. The processing device comprises a movable moving part and a monitoring part, The moving part includes a processing part for processing the processed part. The monitoring unit is capable of detecting whether the position of the processing unit is within a tolerance range based on the main body. The manufacturing method comprises a moving step, In the moving step, the position of the processing portion is moved closer to the processing portion with the processing portion as a reference, and the monitoring portion monitors whether the position of the processing portion in the moving step is within the tolerance range.

7. The method according to claim 6, wherein: The manufacturing method further comprises a processing step, In the processing step, if the position of the processing portion in the moving step is within the tolerance range, the processing portion is operated at the position of the processing portion to process the processed portion.

8. The method according to claim 7, wherein: In the moving step, if the monitoring unit detects that the position of the processing unit is outside the tolerance range, the monitoring unit reports the situation.

9. The method according to any one of claims 6 to 8, wherein: The moving part has a contact part provided on the processing part, In the moving step, the contact portion approaches the processed portion and contacts the processed portion, so that the processed portion is guided by the contact portion to position the processed portion.

10. The method according to claim 9, wherein: The moving part further comprises a base part, a pedestal moving part, a moving mechanism part, and a holding part. The base portion is fixedly provided with the moving mechanism portion. The pedestal moving part can move the base part so that the base part is close to the processed part. The moving mechanism is provided with the holding portion, and the moving mechanism can move the holding portion on a plane parallel to a direction in which the base moves. The holding portion holds the contact portion and the processed portion.

11. The method according to any one of claims 6 to 8, wherein: The resin molded body is a foamed resin molded body.

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