Foam molding machine

Abstract

The present invention provides a foam molding apparatus that can prevent the upper mold from interfering with the lower mold when the upper frame is opened and closed. [Solution] The foam molding apparatus comprises a lower frame, a first airbag positioned on the lower frame, a support frame positioned on the first airbag, a second airbag positioned on the support frame, a lower mold positioned on the second airbag, an upper frame pivotally supported on the lower frame so as to be openable and closable, and an upper mold fixed to the upper frame. When the upper frame is closed relative to the lower frame, the upper mold closes relative to the lower mold, forming a foam molding cavity between the upper mold and the lower mold.

Description

Technical Field

[0003]

[0001] This disclosure relates to a foam molding apparatus.

Background Art

[0002] Patent Documents 1 to 3 disclose a foam molding apparatus for molding a urethane foam. This foam molding apparatus includes a lower frame and an upper frame pivotally supported on the lower frame by a hinge so as to be openable and closable. The lower mold is fixed to the lower frame via an air bag. The upper mold is fixed to the upper frame.

[0003] When closing the mold, the foam molding apparatus closes the upper frame with respect to the lower frame while keeping the air bag contracted, and opposes the upper mold to the lower mold. The foam molding apparatus then inflates the air bag to push up the lower mold and bring the lower mold into close contact with the upper mold.

[0004] When opening the mold, the foam molding apparatus contracts the air bag to pull down the lower mold and retract the lower mold from the upper mold. The foam molding apparatus opens the upper frame with respect to the lower frame while keeping the air bag contracted, and separates the upper mold from the lower mold.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0006] In foam molding apparatuses, it is desirable to prevent the upper mold from interfering with the lower mold when the upper frame is opened and closed. This disclosure provides a foam molding apparatus that can prevent the upper mold from interfering with the lower mold when the upper frame is opened and closed. [Means for solving the problem]

[0007] A foam molding apparatus according to one aspect of the present disclosure comprises a lower frame, a first airbag disposed on the lower frame, a support frame disposed on the first airbag, a second airbag disposed on the support frame, a lower mold disposed on the second airbag, an upper frame pivotally supported on the lower frame so as to be openable and closable, and an upper mold fixed to the upper frame. When the upper frame is closed relative to the lower frame, the upper mold closes relative to the lower mold, forming a foam molding cavity between the upper mold and the lower mold. [Effects of the Invention]

[0008] This disclosure describes a foam molding apparatus according to one aspect of this disclosure that can prevent the upper mold from interfering with the lower mold when the upper frame is opened or closed. [Brief explanation of the drawing]

[0009] [Figure 1] This is a right side view showing a foam molding apparatus according to an embodiment of the present disclosure, and in particular, it shows the upper frame in an open state. [Figure 2] This is a right side view showing a foam molding apparatus according to an embodiment of the present disclosure, and in particular, it shows a state in which the upper frame is closed and the first airbag and the second airbag are contracted. [Figure 3] This is a right side view showing a foam molding apparatus according to an embodiment of the present disclosure, and in particular, it shows a state in which the upper frame is closed and the first airbag and the second airbag are inflated. [Figure 4] This is a top view showing a second airbag according to an embodiment of the present disclosure. [Figure 5] This is a top view showing a second airbag according to another embodiment of the present disclosure. [Figure 6]This is a right side view of a foam molding apparatus relating to a comparative example, specifically showing the state where the upper frame is closed and the first airbag is contracted. [Figure 7] This is a right side view showing a foam molding apparatus according to an embodiment of the present disclosure, and in particular, it shows the lower mold unit detached from the lower frame. [Modes for carrying out the invention]

[0010] As shown in Figures 1 to 3, the foam molding apparatus 10 comprises a lower frame 20 and an upper frame 30 pivotally supported on the lower frame 20 by a hinge 32 so as to be openable and closable. In this embodiment, the lower frame 20 comprises a rear frame 21, a front frame 22 facing the rear frame 21, and a floor frame 23 positioned between the rear frame 21 and the front frame 22. In this embodiment, the upper frame 30 comprises a ceiling frame 31, a clamp 33 rotatably connected to the ceiling frame 31, and a handle 34 connected to the clamp 33.

[0011] The foam molding apparatus 10 further includes a first airbag 41 positioned on top of the lower frame 20. The first airbag 41 inflates by drawing in air and deflates by releasing air. The first airbag 41 is formed from, for example, a fire hose. In this embodiment, the first airbag 41 includes a plurality of straight hoses arranged in parallel. In the right side view of Figures 1 to 3, one straight hose is visible. The vertical stroke of the first airbag 41 is, for example, about 20 mm.

[0012] The foam molding apparatus 10 further includes a frame 50 positioned on the first airbag 41. In this embodiment, the frame 50 includes a substrate 51 and a base 52 positioned on the substrate 51. The frame 50 is formed from, for example, aluminum, steel, or other metal material.

[0013] The foam molding apparatus 10 further includes a second airbag 42 positioned on a frame 50. The second airbag 42 inflates by air intake and deflates by air discharge. The second airbag 42 is formed of, for example, a rubber tube. The vertical stroke of the second airbag 42 may be greater than the vertical stroke of the first airbag 41. For example, the vertical stroke of the second airbag 42 is about 70 mm. The capacity of the second airbag 42 may be greater than the capacity of the first airbag 41.

[0014] The foam molding apparatus 10 further comprises a lower mold 61 positioned above the second airbag 42 and an upper mold 62 fixed to the upper frame 30. As shown in Figure 3, when the upper frame 30 is closed relative to the lower frame 20, the upper mold 62 closes relative to the lower mold 61, forming a foam molding cavity 63 between the upper mold 62 and the lower mold 61. The lower mold 61 and the upper mold 62 form the foam molding cavity 63 between them. The lower mold 61 and the upper mold 62 are formed from, for example, aluminum or other metal materials.

[0015] The foam molding apparatus 10 may further include a first guide means 70 positioned between the lower frame 20 and the support base 50. The first guide means 70 guides the support base 50 to slide up and down relative to the lower frame 20. In this embodiment, the first guide means 70 includes a first support base 71 fixed to the floor frame 23, a first guide column 72 extending vertically from the first support base 71, and a first slide member 73 fixed to the substrate 51. The first slide member 73 has a through hole for receiving the first guide column 72 and is slidable up and down along the first guide column 72. The first guide means 70 prevents horizontal displacement of the support base 50 relative to the lower frame 20 when the support base 50 moves up and down due to the inflation and deflation of the first airbag 41. In this embodiment, the foam molding apparatus 10 includes four first guide means 70. Two first guide means 70 are visible in the right side views of Figures 1 to 3.

[0016] The foaming molding apparatus 10 may further include second guiding means 80 disposed between the lower mold 61 and the gantry 50 and outside the second airbag 42. The second guiding means 80 guides the lower mold 61 to slide vertically with respect to the gantry 50. In the present embodiment, the second guiding means 80 includes a second support base 81 fixed to the pedestal 52, a second guide post 82 extending vertically from the second support base 81, and a second slide member 83 fixed to the lower mold 61. The second slide member 83 has a through-hole for receiving the second guide post 82 and is slidable vertically along the second guide post 82. The second guiding means 80 prevents the lower mold 61 from shifting horizontally with respect to the gantry 50 when the lower mold 61 moves vertically due to the expansion and contraction of the second airbag 42. In the present embodiment, the foaming molding apparatus 10 includes four second guiding means 80. Two second guiding means 80 can be seen in the right side views of FIGS. 1 to 3.

[0017] When the mold is closed, the foaming molding apparatus 10 transitions in the order of the state shown in FIG. 1, the state shown in FIG. 2, and the state shown in FIG. 3. FIG. 1 shows a state in which the upper frame 30 is open with respect to the lower frame 20. FIG. 2 shows a state in which the upper frame 30 is closed with respect to the lower frame 20 and the first airbag 41 and the second airbag 42 are contracted. FIG. 3 shows a state in which the upper frame 30 is closed with respect to the lower frame 20 and the first airbag 41 and the second airbag 42 are expanded.

[0018] Conversely, when the mold is opened, the foaming molding apparatus 10 transitions in the order of the state shown in FIG. 3, the state shown in FIG. 2, and the state shown in FIG. 1.

[0019] As shown in FIG. 4, the second airbag 42 may be an annular airbag. In the embodiment of FIG. 4, a single second airbag 42 is provided on the pedestal 52. In the present embodiment, the displacement of the thickness of the second airbag 42 due to expansion and contraction is uniform in the circumferential direction. Such a second airbag 42 makes it easy to maintain the horizontal position of the lower mold 61 when the lower mold 61 moves vertically.

[0020] As shown in Figure 5, the second airbag 42 may be a linear airbag. In the embodiment shown in Figure 5, a plurality of second airbags 42 are arranged parallel to each other on a base 52. Each of the plurality of second airbags 42 may have the same characteristics (material, wall thickness, size, and other physical properties) so that they inflate and deflate uniformly. Also, the plurality of pipes connected to each of the plurality of second airbags 42 may have the same characteristics (impedance, and other physical properties).

[0021] As shown in Figure 4, the foam molding apparatus 10 may further include a controller 90 that controls the air to start inflating the second airbag 42 simultaneously with the first airbag 41. In this embodiment, the second airbag 42 has a vent 43. The vent 43 is connected to a compressor 93 via a first valve 91. The vent 43 is further connected to the atmosphere 94 via a second valve 92. The first airbag 41 is similarly connected.

[0022] As described above, in this embodiment, the second airbag 42 is connected to the same system as the first airbag 41. The controller 90 opens the first valve 91 and closes the second valve 92 to start inflating the second airbag 42 simultaneously with the first airbag 41. The controller 90 closes the first valve and opens the second valve 92 to start deflating the second airbag 42 simultaneously with the first airbag 41. However, the second airbag 42 may be connected to a different system from the first airbag 41.

[0023] As shown in Figure 6, the foam molding apparatus 10c according to the comparative example is equipped with a first airbag 41 but not a second airbag 42. When the upper frame 30 opens and closes relative to the lower frame 20, the inner surface 62a of the upper mold 62 rotates with a rotation radius R. Since the lower mold 61 is not pulled down sufficiently, the inner surface 62a of the upper mold 62 interferes with the inner surface 61a of the lower mold 61. On the other hand, as shown in Figure 2, in this embodiment, the foam molding apparatus 10 is equipped with a first airbag 41 and a second airbag 42. Since the lower mold 61 is pulled down sufficiently by the contraction of the first airbag 41 and the second airbag 42, it is possible to prevent the inner surface 62a of the upper mold 62 from interfering with the inner surface 61a of the lower mold 61.

[0024] As shown in Figure 7, the foam molding apparatus 10 may be classified into a frame apparatus 11 and a lower mold unit 12 that is detachably attached to the frame apparatus 11. The frame apparatus 11 comprises a lower frame 20, an upper frame 30, and a first airbag 41. The lower mold unit 12 comprises a support base 50, a second airbag 42, and a lower mold 61. In this embodiment, the lower mold unit 12 further comprises a second guide means 80.

[0025] A foam molding plant possesses a variety of mold units to accommodate a wide range of foam molding products. The plant can manufacture a variety of foam molding products by changing the mold units. In this embodiment, the mold unit comprises a lower mold unit 12 including a lower mold 61 and a frame 50, and an upper mold 62. In this embodiment, the first airbag 41 is provided in the frame equipment 11, and the second airbag 42 is provided in the lower mold unit 12.

[0026] The frame equipment 11 may be detachable from either a lower mold unit 12 equipped with a second airbag 42 or a lower mold unit 12 without a second airbag 42. The lower mold unit 12 equipped with a second airbag 42 allows for a relatively large vertical stroke of the lower mold 61, but requires a relatively long time to close the mold. Conversely, the lower mold unit 12 without a second airbag 42 allows for a relatively small vertical stroke of the lower mold 61, but allows for closing the mold in a relatively short time.

[0027] For example, as shown in Figure 7, in this embodiment, the lower mold 61 has a relatively deep foam molding cavity 63, and the upper mold 62 has a protruding shape that significantly protrudes into the cavity 63 of the lower mold 61. Such a lower mold 61 is preferably mounted in a lower mold unit 12 equipped with a second airbag 42 in order to prevent interference with the upper mold 62 when the upper frame 30 is opened and closed. On the other hand, if the lower mold 61 has a relatively shallow foam molding cavity 63, the problem of interference between the lower mold 61 and the upper mold 62 is less likely to occur, and it is more desirable to complete the mold closing in a short time in order to prevent the overflow of the expanding foam. Such a lower mold 61 is preferably mounted in a lower mold unit 12 that is not equipped with a second airbag 42. Since the first airbag 41 is provided in the frame equipment 11 and the second airbag 42 is provided in the lower mold unit 12, an appropriate lower mold unit 12 can be designed according to the cavity shapes of the lower mold 61 and the upper mold 62.

[0028] Although embodiments of the present disclosure have been described above, the present disclosure is not limited to the embodiments described above, and various modifications are possible without departing from the spirit of the invention. In particular, the various modifications described herein can be combined as needed. [Explanation of symbols]

[0029] 10: Foam molding apparatus, 11: Frame equipment, 12: Lower mold unit, 20: Lower frame, 30: Upper frame, 41: First airbag, 42: Second airbag, 50: Stand, 61: Lower mold, 62: Upper mold, 70: First guide means, 80: Second guide means, 90: Controller

Claims

1. The lower frame and A first airbag positioned on the lower frame, A support structure positioned above the first airbag, A second airbag positioned on the aforementioned mounting frame, The lower mold positioned above the second airbag, An upper frame pivotally supported to the lower frame so as to be able to open and close, The upper mold is fixed to the upper frame, When the upper frame closes relative to the lower frame, the upper mold closes relative to the lower mold, forming a foam molding cavity between the upper and lower molds. Foam molding machine.

2. The foam molding apparatus according to claim 1, wherein the second airbag is an annular airbag.

3. The foam molding apparatus according to claim 1, further comprising a second guide means positioned between the lower mold and the support frame and outside the second airbag, which guides the lower mold to slide up and down relative to the support frame.

4. The foam molding apparatus according to claim 1, further comprising a first guide means disposed between the lower frame and the support base, which guides the support base to slide up and down relative to the lower frame.

5. The foam molding apparatus according to any one of claims 1 to 4, further comprising a controller that controls air to cause the second airbag to begin inflating simultaneously with the first airbag.

6. A lower mold unit that is detachably attached to a frame equipment comprising a lower frame, an upper frame pivotally supported to the lower frame so as to be openable and closable, and a first airbag positioned on the lower frame, A support structure positioned above the first airbag, A second airbag positioned on the aforementioned mounting frame, A lower mold positioned above the second airbag, Lower mold unit.

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