US 12,459,173 B2
Mold device for resin molded article, molding apparatus, molding system, and method for manufacturing molded article
Yasuhiro Suzuki, Suzuka (JP)
Appl. No. 17/602,984
Filed by Yasuhiro Suzuki, Suzuka (JP)
PCT Filed Apr. 6, 2020, PCT No. PCT/JP2020/015536
§ 371(c)(1), (2) Date Oct. 11, 2021,
PCT Pub. No. WO2020/213457, PCT Pub. Date Oct. 22, 2020.
Claims priority of application No. 2019-080274 (JP), filed on Apr. 19, 2019.
Prior Publication US 2022/0219358 A1, Jul. 14, 2022
Int. Cl. B29C 44/58 (2006.01); B29C 33/00 (2006.01); B29C 33/44 (2006.01); B29C 44/04 (2006.01); B29C 44/10 (2006.01); C08J 3/22 (2006.01); C08J 9/10 (2006.01)
CPC B29C 44/588 (2013.01) [B29C 33/0038 (2013.01); B29C 33/442 (2013.01); B29C 44/0407 (2013.01); B29C 44/105 (2013.01); B29C 44/58 (2013.01); B29C 44/586 (2013.01); C08J 3/22 (2013.01); C08J 9/10 (2013.01); C08J 9/101 (2013.01); C08J 2323/12 (2013.01)] 5 Claims
OG exemplary drawing
 
1. A method for manufacturing a foam-molded article by performing a gas counter pressure (GCP) using a sealed mold, a mold clamping mechanism, a shaft body for ejecting the foam-molded article from the sealed mold, and at least one of: a loaded O-ring for sealing the shaft body; an O-ring having a U-shaped groove for sealing the shaft body; and a spacer block for sealing the shaft body, the method comprising:
a step of compressing a sealed space including a molding space inside the sealed mold by injecting a gas having a pressure of 0.6 MPa or more into the sealed space, the gas being selected from the group consisting of air, nitrogen gas, carbon dioxide, and a mixed gas of two or more thereof;
a step of filling a foamable resin into the molding space by 90 volume % or more in a state that the sealed space is compressed by the gas;
a step of discharging an amount of the gas injected into the sealed space to atmosphere by opening a discharge valve after the foamable resin is filled into the molding space by 90 volume % or more, wherein the step of discharging the gas is performed through a fixed side or a mobile side of the sealed mold, the fixed and mobile sides of the sealed mold defining the molding space;
a step of retreating a mobile side of the mold clamping mechanism by 0.1 mm to 2 mm at the same time as when the step of discharging the gas is started, during the step of discharging the gas, immediately after the step of discharging the gas, or when a specified delay time has elapsed after the step of discharging the gas is finished for performing at least one of a mold-back and a core-back so as to discharge an amount of the gas injected into the sealed space from a parting where the fixed side and the mobile side of the sealed mold are mated with each other and increase a foaming ratio of the foamable resin in a state that a cooling and a solidification of an inside of the foamable resin are not finished;
a step of cooling and solidifying the foamable resin, thereby forming the foam-molded article; and
a step of opening the sealed mold and taking the foam-molded article from the sealed mold.