JP2007130845A - Method for molding foamable resin and structure of mold - Google Patents

Method for molding foamable resin and structure of mold Download PDF

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JP2007130845A
JP2007130845A JP2005325158A JP2005325158A JP2007130845A JP 2007130845 A JP2007130845 A JP 2007130845A JP 2005325158 A JP2005325158 A JP 2005325158A JP 2005325158 A JP2005325158 A JP 2005325158A JP 2007130845 A JP2007130845 A JP 2007130845A
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mold
cavity
resin material
opposing surfaces
resin
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JP4706446B2 (en
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Yasuyuki Shimizu
康之 清水
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Toyota Boshoku Corp
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Toyota Boshoku Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for molding a foamable resin which can form a good-looking molding and the structure of a mold. <P>SOLUTION: Opposing surfaces 11a and 12a facing each other are formed by the fixed and movable molds 11 and 12 of a mold 10 which forms a porous door trim substrate 1 from a foamable resin material, and projections 11b and 12b are protruded from the opposing surfaces 11a and 12a to contact each other when the mold 10 is opened. The sides 11c and 12c of the projections 11b and 12b are tapered, and a cavity CV is formed by the opposing surfaces 11a and 12a and the sides 11c and 12c. The sum 2A of the lengths in the mold opening direction of the sides 11c and 12c is set to be the length of the distance t between the opposing surfaces 11a and 12a when the mold 10 is opened plus a mold opening amount α when the resin material is expanded. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

本発明は、発泡性樹脂成形方法および成形用型構造に関する。   The present invention relates to a foamable resin molding method and a mold structure for molding.

一対の成形型間に形成されたキャビティ内に、発泡性樹脂材料を射出して、内部が多孔質の樹脂成形品を形成する発泡樹脂成形方法に関する従来技術があった（例えば、特許文献１参照）。これは、キャビティ内に溶融した発泡性樹脂材料を供給し、所定時間後、成形型を所定量だけ開型して、キャビティの内圧を低下させることにより樹脂材料を発泡させ、多孔質の成形品を形成するものであった。図１３に基づいて、当該成形方法について詳述する。図１３Ａに示すように、固定型１００と可動型１１０とを互いに閉じることによって、その内部に形成されたキャビティ１２０内に、溶融した発泡性樹脂材料を射出する。この状態においては、キャビティ１２０内の樹脂材料の内圧が、発泡可能な圧力の上限値よりも高くされているため発泡は行われない。キャビティ１２０内の樹脂材料は、所定時間経過すると、型１００、１１０と接した表面１３０、１４０、１５０が、型１００、１１０によって冷却され、それぞれ固化してスキン層を形成するが、内部は溶融状態のままとなっている。   There has been a conventional technique related to a foamed resin molding method in which a foamable resin material is injected into a cavity formed between a pair of molds to form a porous resin molded product (see, for example, Patent Document 1). ). This is because a foamable resin material is supplied into the cavity, and after a predetermined time, the mold is opened by a predetermined amount, and the resin pressure is reduced by lowering the internal pressure of the cavity. Was formed. The molding method will be described in detail based on FIG. As shown in FIG. 13A, the fixed mold 100 and the movable mold 110 are closed to inject the molten foamable resin material into the cavity 120 formed therein. In this state, foaming is not performed because the internal pressure of the resin material in the cavity 120 is higher than the upper limit of the foamable pressure. When the resin material in the cavity 120 elapses for a predetermined time, the surfaces 130, 140, and 150 in contact with the molds 100 and 110 are cooled by the molds 100 and 110, and solidify to form a skin layer, respectively. It remains in the state.

その後、図１３Ｂに示すように、可動型１１０を固定型１００に対して離間（コアバック）させて、キャビティ１２０を拡張させることにより、キャビティ１２０内の樹脂材料の内圧を、発泡可能な圧力まで低下させる。これにより、キャビティ１２０内の樹脂材料が発泡しながら冷却され、内部が多孔質の樹脂成形品が形成される（図１３Ｃ示）。
特開平４−２１４３１１号公報（第１図） Thereafter, as shown in FIG. 13B, the movable mold 110 is separated (core back) from the fixed mold 100 and the cavity 120 is expanded, whereby the internal pressure of the resin material in the cavity 120 is increased to a pressure at which foaming is possible. Reduce. Thereby, the resin material in the cavity 120 is cooled while foaming, and a resin molded product having a porous inside is formed (shown in FIG. 13C).
JP-A-4-214311 (FIG. 1)

ここで、キャビティ１２０内の樹脂材料は、型１００、１１０のコアバックにより発泡しながら、図１３において左右に膨張するが、樹脂材料の表面１５０は発泡前に固化しているため延びることができず、図１３Ｃに示すように、表面１３０、１４０が、表面１５０の近傍においては段付形状となる。これは、特に、表面１３０、１４０が意匠面である場合、その見栄えが悪く、成形品の品質において重大な問題となる。本発明は上記のような事情に基づいて完成されたものであって、見栄えのよい成形品を形成することが可能な発泡性樹脂成形方法および成形用型構造を提供することを目的とする。   Here, the resin material in the cavity 120 expands to the left and right in FIG. 13 while being foamed by the core back of the molds 100 and 110, but the surface 150 of the resin material can be extended because it is solidified before foaming. First, as shown in FIG. 13C, the surfaces 130 and 140 are stepped in the vicinity of the surface 150. In particular, when the surfaces 130 and 140 are design surfaces, the appearance is poor, which is a serious problem in the quality of the molded product. This invention is completed based on the above situations, Comprising: It aims at providing the foaming resin molding method and the type | mold structure for shaping | molding which can form a good-looking molded article.

上記の目的を達成するための手段として、請求項１の発明は、開閉可能なように設けられた一対の成形型において、該成形型のそれぞれに形成され、その開き方向と交差するとともに、互いに対向する対向面と、閉型時に該対向面を互いに連結する連結面により内部にキャビティが形成され、該キャビティ内に溶融した発泡性樹脂材料を供給し、所定時間後、前記成形型を所定量だけ開型して、前記キャビティの内圧を低下させることにより前記樹脂材料を発泡させて、内部が多孔質の樹脂成形品を形成する発泡性樹脂成形方法において、前記連結面の型開き方向の長さは、前記連結面が接続している部位における、閉型時の前記対向面間の距離よりも長くなるように形成されていることを特徴とする発泡性樹脂成形方法とした。   As a means for achieving the above object, the invention of claim 1 is a pair of molding dies provided so as to be openable and closable, formed on each of the molding dies, intersecting the opening direction thereof, and mutually A cavity is formed in the interior by the facing surfaces facing each other and a connecting surface that connects the facing surfaces to each other when the mold is closed, and a molten foamable resin material is supplied into the cavity. In the foamable resin molding method in which the resin material is foamed by lowering the internal pressure of the cavity by reducing the internal pressure of the cavity to form a porous resin molded product, the length of the connecting surface in the mold opening direction The foaming resin molding method is characterized in that it is formed so as to be longer than the distance between the facing surfaces at the time of mold closing at the portion where the connecting surfaces are connected.

請求項２の発明は、前記連結面の型開き方向の長さは、前記連結面が接続している部位における、閉型時の前記対向面間の距離に、前記樹脂材料を発泡させる時の、型開き量を加えた長さであることを特徴とする請求項１記載の発泡性樹脂成形方法とした。   According to a second aspect of the present invention, the length of the connecting surface in the mold opening direction is such that the resin material is foamed at a distance between the opposing surfaces at the time of mold closing in a portion where the connecting surface is connected. The foaming resin molding method according to claim 1, wherein the mold opening length is added.

請求項３の発明は、前記連結面は、前記成形型の一側の前記対向面から突出して、相手側の前記対向面に当接する突起部の側面に形成されたことを特徴とする請求項１または請求項２記載の発泡性樹脂成形方法とした。   The invention according to claim 3 is characterized in that the connection surface is formed on a side surface of a protruding portion that protrudes from the facing surface on one side of the mold and contacts the facing surface on the other side. The foamable resin molding method according to claim 1 or claim 2.

請求項４の発明は、前記一対の成形型には、それぞれの前記対向面から突出して、互いに相手側に当接する一対の突起部が設けられ、前記突起部の側面は、各々テーパ状に形成されるとともに、前記連結面は前記突起部の前記側面に形成されたことを特徴とする請求項１または請求項２記載の発泡性樹脂成形方法とした。   According to a fourth aspect of the present invention, the pair of molds are provided with a pair of protrusions that protrude from the opposing surfaces and abut against each other, and the side surfaces of the protrusions are each tapered. In addition, the foaming resin molding method according to claim 1, wherein the connecting surface is formed on the side surface of the protruding portion.

請求項５の発明は、開閉可能なように設けられた一対の成形型を備え、該成形型のそれぞれには、その開き方向と交差するとともに、互いに対向する対向面が形成され、該対向面および閉型時にこれらを互いに連結する連結面により、前記成形型の内部にはキャビティが形成され、前記成形型の一側には、該キャビティ内に溶融した発泡性樹脂材料を供給するための樹脂供給装置が設けられ、前記キャビティ内に前記樹脂材料を供給し、所定時間後、前記成形型を所定量だけ開型して、前記キャビティの内圧を低下させることにより前記樹脂材料を発泡させて、内部が多孔質の樹脂成形品を形成するための成形用型構造において、前記連結面の型開き方向の長さは、前記連結面が接続している部位における、閉型時の前記対向面間の距離よりも長くなるように形成されていることを特徴とする成形用型構造とした。   The invention of claim 5 includes a pair of molding dies provided so as to be openable and closable, and each of the molding dies is provided with opposing surfaces that intersect with the opening direction and face each other. A cavity is formed inside the molding die by a connecting surface that connects them to each other when the mold is closed, and a resin for supplying a foamable resin material melted in the cavity to one side of the molding die A supply device is provided to supply the resin material into the cavity, and after a predetermined time, the mold is opened by a predetermined amount to foam the resin material by lowering the internal pressure of the cavity, In a mold structure for forming a resin molded product having a porous interior, the length of the connecting surface in the mold opening direction is between the opposing surfaces at the time of mold closing at a portion where the connecting surface is connected. Than the distance Was mold structure characterized in that it is formed to be longer.

＜請求項１の発明＞
連結面の型開き方向の長さは、連結面が接続している部位における、閉型時の対向面間の距離よりも長くなるように形成されている構成としたことにより、連結面の型開き方向の長さのうち、対向面間の距離よりも長い分だけ、発泡による樹脂材料の膨張に追従可能なため、対向面と接した樹脂材料の表面に段付が発生することを低減して、平坦面にすることができ、見栄えのよい成形品にすることが可能となる。また、膨張時にも、膨張した樹脂材料の表面が対向面に接しているため、表面が対向面に倣って、その形状どおりに成形され、いっそう見栄えよく形成できる。また、特に複雑な型構造にする必要がないため、低コストの成形方法にすることが可能となる。 <Invention of Claim 1>
The length of the connecting surface in the mold opening direction is such that the length of the connecting surface is longer than the distance between the opposing surfaces at the time of closing at the part to which the connecting surface is connected. The length of the opening direction can follow the expansion of the resin material due to foaming by an amount longer than the distance between the opposing surfaces, reducing the occurrence of stepping on the surface of the resin material in contact with the opposing surface. Therefore, it is possible to obtain a molded product having a flat surface and a good appearance. Further, since the surface of the expanded resin material is in contact with the opposing surface even during expansion, the surface is shaped according to the shape following the opposing surface, and can be formed more attractively. In addition, since it is not necessary to have a particularly complicated mold structure, a low-cost molding method can be achieved.

＜請求項２の発明＞
連結面の型開き方向の長さは、連結面が接続している部位における、閉型時の対向面間の距離に、樹脂材料を発泡させる時の、型開き量を加えた長さである構成としたことにより、連結面に接した樹脂材料の表面の長さが、樹脂材料が膨張した後の対向面間の距離と一致するため、樹脂材料の表面に段付が全く発生しないとともに、連結面も平坦となり、いっそう見栄えのよい成形品にすることが可能となる。 <Invention of Claim 2>
The length of the connecting surface in the mold opening direction is a length obtained by adding the amount of mold opening when the resin material is foamed to the distance between the opposing surfaces at the time of mold closing in the portion where the connecting surface is connected. By having the configuration, the length of the surface of the resin material in contact with the connecting surface matches the distance between the opposing surfaces after the resin material has expanded, so no stepping occurs on the surface of the resin material, The connecting surface is also flattened, and it becomes possible to make a molded article having a better appearance.

＜請求項３の発明＞
連結面は、成形型の一側の対向面から突出して、相手側の対向面に当接する突起部の側面に形成された構成としたことにより、突起部により成形品に貫通孔を形成でき、貫通孔周囲に段付が発生することを低減することができる。 <Invention of Claim 3>
The connecting surface protrudes from the facing surface on one side of the mold and is formed on the side surface of the protruding portion that comes into contact with the opposing surface on the other side, so that a through hole can be formed in the molded product by the protruding portion. Generation of a step around the through hole can be reduced.

＜請求項４の発明＞
一対の成形型には、それぞれの対向面から突出して、互いに相手側に当接する一対の突起部が設けられ、連結面である突起部の側面は、各々テーパ状に形成される構成としたことにより、連結面を対向面間の距離よりも容易に長くできるとともに、それぞれの突起部の型抜きも容易となる。 <Invention of Claim 4>
The pair of molds are provided with a pair of protrusions that protrude from the opposing surfaces and abut against each other, and the side surfaces of the protrusions that are the connecting surfaces are each formed in a tapered shape. Accordingly, the connecting surface can be easily made longer than the distance between the opposing surfaces, and the respective protrusions can be easily removed from the mold.

＜請求項５の発明＞
連結面の型開き方向の長さは、連結面が接続している部位における、閉型時の対向面間の距離よりも長くなるように形成されている構成としたことにより、連結面の型開き方向の長さのうち、対向面間の距離よりも長い分だけ、発泡による樹脂材料の膨張に追従可能なため、対向面と接した樹脂材料の表面に段付が発生することを低減して、平坦面にすることができ、見栄えのよい成形品を形成可能な型構造となる。 <Invention of Claim 5>
The length of the connecting surface in the mold opening direction is such that the length of the connecting surface is longer than the distance between the opposing surfaces at the time of closing at the part to which the connecting surface is connected. The length of the opening direction can follow the expansion of the resin material due to foaming by an amount longer than the distance between the opposing surfaces, reducing the occurrence of stepping on the surface of the resin material in contact with the opposing surface. Thus, the mold structure can be formed into a flat surface and capable of forming a molded article having a good appearance.

＜実施形態１＞
本発明の実施形態１を、図１乃至図１０によって説明する。本実施形態による発泡樹脂成形方法によって形成されるドアトリム基材１は、熱可塑性樹脂であるポリプロピレン、あるいはＡＢＳ樹脂による発泡材によって形成されており、内部は複数の気泡を含んだ多孔質状とされている（図２示）。ドアトリム基材１は、図示しないが表面を表皮材等により装飾し、スイッチ等の機能品を取り付けた後、車両用ドアのドアパネルに取り付けられるもので、図２に示すように、平板状の基板２の中央部にはアームレストとなる凸状部が設けられ、外周縁には周壁３が立設された形状を呈している。また、基板２には、スピーカ等を固定する図示しないパネル取付用の開口部４、インサイドハンドル固定用の取付孔５、およびオーナメント部材を嵌め込むための装着孔６が貫通している。また、基板２上には、複数の真空孔７が適当に並ぶように形成されている。真空孔７は、直径が１〜２ｍｍ程度の貫通孔で、ドアトリム基材１の表面に図示しない化粧用の表皮を貼着する際に、ドアトリム基材１の裏面（図２において上面）に加えられたバキュームを表面に伝えて、表皮を吸引する役割を果たす。 <Embodiment 1>
A first embodiment of the present invention will be described with reference to FIGS. The door trim base material 1 formed by the foamed resin molding method according to the present embodiment is formed of a foam material made of polypropylene, which is a thermoplastic resin, or ABS resin, and the inside thereof is a porous shape containing a plurality of bubbles. (Shown in FIG. 2). Although the door trim base material 1 is not shown, the surface is decorated with a skin material or the like, and after a functional product such as a switch is attached, the door trim base material 1 is attached to a door panel of a vehicle door. As shown in FIG. A convex portion serving as an armrest is provided at the central portion of 2, and a peripheral wall 3 is erected on the outer peripheral edge. Further, the board 2 has an opening 4 for attaching a panel (not shown) for fixing a speaker or the like, an attachment hole 5 for fixing an inside handle, and a mounting hole 6 for fitting an ornament member. A plurality of vacuum holes 7 are formed on the substrate 2 so as to be arranged appropriately. The vacuum hole 7 is a through hole having a diameter of about 1 to 2 mm. When a cosmetic skin (not shown) is pasted on the surface of the door trim base material 1, the vacuum hole 7 is added to the back surface (upper surface in FIG. 2) of the door trim base material 1. It plays the role of sucking the epidermis by transferring the vacuum to the surface.

次に、図３および図４に基づいて、ドアトリム基材１を成形する成形用型１０について説明する。成形用型１０は、一対の成形用金型である固定側成形型１１と可動側成形型１２を備えており、固定側成形型１１に対して可動側成形型１２が、図３において上下方向に移動することにより、双方は開閉可能とされている。ドアトリム基材１の基板２の平坦部を形成する固定側成形型１１の下端には、可動側成形型１２の移動方向に垂直な（成形型１１、１２の開き方向と交差する）対向面１１ａが形成されており、ドアトリム基材１の基板２の裏面を形成する面となる。対向面１１ａ上には、突起部１１ｂが形成されており、これは、対向面１１ａから可動側成形型１２に向けて下方へと突出している。突起部１１ｂの側面１１ｃは突起部１１ｂの先端に向かって先細りする形状、いわゆるテーパ状をしており、突起部１１ｂ全体は円錐台形状を呈している。   Next, based on FIG. 3 and FIG. 4, the shaping | molding die 10 which shape | molds the door trim base material 1 is demonstrated. The molding die 10 includes a fixed-side molding die 11 and a movable-side molding die 12 which are a pair of molding dies, and the movable-side molding die 12 is positioned in the vertical direction in FIG. Both can be opened and closed by moving to. At the lower end of the fixed mold 11 that forms the flat portion of the substrate 2 of the door trim base material 1, a facing surface 11 a perpendicular to the moving direction of the movable mold 12 (crossing the opening direction of the molds 11, 12). Is formed and becomes a surface forming the back surface of the substrate 2 of the door trim base material 1. A protrusion 11b is formed on the facing surface 11a, and protrudes downward from the facing surface 11a toward the movable mold 12. The side surface 11c of the protrusion 11b has a so-called taper shape that tapers toward the tip of the protrusion 11b, and the entire protrusion 11b has a truncated cone shape.

一方、ドアトリム基材１の基板２の平坦部を形成する可動側成形型１２の上端には、その移動方向に垂直な対向面１２ａが形成されており、これは、双方の成形型１１、１２が閉じられた時、固定側成形型１１の対向面１１ａに対して、所定間隔ｔを有して対向している（図４および図９示）。対向面１２ａは、ドアトリム基材１の基板２の表面を形成する面となり、本実施形態においては、固定側成形型１１の対向面１１ａに平行に形成されている。対向面１２ａ上には、固定側成形型１１と同様に、突起部１２ｂが形成されている。突起部１２ｂは、対向面１２ａから固定側成形型１１に向けて上方へと突出している。突起部１２ｂは、、固定側成形型１１の突起部１１ｂと同一の大きさ、および形状をしており、その側面１２ｃはテーパ状をし、突起部１２ｂ全体は円錐台形状を呈している。   On the other hand, on the upper end of the movable mold 12 that forms the flat portion of the substrate 2 of the door trim base material 1, a facing surface 12 a perpendicular to the moving direction is formed. When the is closed, it faces the facing surface 11a of the fixed mold 11 with a predetermined interval t (shown in FIGS. 4 and 9). The facing surface 12 a is a surface that forms the surface of the substrate 2 of the door trim base 1, and is formed in parallel with the facing surface 11 a of the stationary mold 11 in the present embodiment. Similar to the fixed-side mold 11, a protruding portion 12 b is formed on the facing surface 12 a. The protrusion 12b protrudes upward from the facing surface 12a toward the fixed-side mold 11. The protruding portion 12b has the same size and shape as the protruding portion 11b of the fixed mold 11, the side surface 12c is tapered, and the entire protruding portion 12b has a truncated cone shape.

図４に示すように、双方の成形型１１、１２に形成された一対の突起部１１ｂ、１２ｂは、成形型１１、１２が閉じられている時、互いに先端において当接し、それぞれの側面１１ｃ、１２ｃは、対向面１１ａ、１２ａを互いに連結しており、本発明による連結面に該当している。成形型１１、１２に形成された対向面１１ａ、１２ａおよび側面１１ｃ、１２ｃは、発泡樹脂材料が射出されるキャビティＣＶを形成している。図９に拡大して示したように、双方の突起部１１ｂ、１２ｂの側面１１ｃ、１２ｃの型開き方向の長さは、ともにＡとされ、双方の和２Ａは、成形型１１、１２を閉じた時の、双方の対向面１１ａ、１２ａ間の可動側成形型１２の移動方向の距離ｔよりも長く形成されている。   As shown in FIG. 4, the pair of protrusions 11 b and 12 b formed on both molds 11 and 12 abut each other at the tip when the molds 11 and 12 are closed, 12c connects the opposing surfaces 11a and 12a to each other and corresponds to the connecting surface according to the present invention. Opposing surfaces 11a and 12a and side surfaces 11c and 12c formed on the molds 11 and 12 form a cavity CV into which the foamed resin material is injected. As shown in an enlarged view in FIG. 9, the lengths of the side surfaces 11c and 12c of both protrusions 11b and 12b in the mold opening direction are both A, and the sum 2A of both closes the molds 11 and 12. In this case, the distance is longer than the distance t in the moving direction of the movable mold 12 between the opposing surfaces 11a and 12a.

本実施形態と異なり、対向面１１ａ、１２ａが互いに平行でない場合、あるいは、対向面１１ａ、１２ａが可動側成形型１２の移動方向に垂直でない場合は、側面１１ｃ、１２ｃの長さの和２Ａを、側面１１ｃ、１２ｃがそれぞれ接続している部位における、対向面１１ａ、１２ａの間の可動側成形型１２の移動方向の距離よりも長くすればよい。また、キャビティＣＶの周縁部には、上述した周壁３を形成するべく、固定側成形型１１には、上下方向に延びる内壁１１ｄと、その上端部を閉じるように水平壁１１ｅが形成され、可動側成形型１２には、内壁１１ｄと半径方向に対向するように、外壁１２ｄが形成されている。   Unlike this embodiment, when the opposing surfaces 11a and 12a are not parallel to each other, or when the opposing surfaces 11a and 12a are not perpendicular to the moving direction of the movable mold 12, the sum 2A of the lengths of the side surfaces 11c and 12c is set to 2A. What is necessary is just to make it longer than the distance of the moving direction of the movable side shaping | molding die 12 between the opposing surfaces 11a and 12a in the site | part to which the side surfaces 11c and 12c are connected, respectively. Further, in order to form the above-described peripheral wall 3 at the peripheral portion of the cavity CV, the fixed-side mold 11 is formed with an inner wall 11d extending in the vertical direction and a horizontal wall 11e so as to close the upper end thereof, and is movable. An outer wall 12d is formed on the side mold 12 so as to face the inner wall 11d in the radial direction.

固定側成形型１１の上端部には、キャビティＣＶ内に溶融した発泡性樹脂材料を射出するためのインジェクション装置１３（本発明の樹脂供給装置に該当する）が取り付けられている。インジェクション装置１３は、下端のノズル１３ａにおいて固定側成形型１１に当接し、固定側成形型１１内には、ノズル１３ａから射出された溶融樹脂を、キャビティＣＶ内に導くための樹脂通路１１ｆが上下方向に貫通している。また、可動側成形型１２には、電動モータおよび減速機を含み、可動側成形型１２を上下動させるための型移動装置（図示せず）が連結されている。   An injection device 13 (corresponding to the resin supply device of the present invention) for injecting a molten foamable resin material into the cavity CV is attached to the upper end portion of the fixed mold 11. The injection device 13 abuts the fixed side mold 11 at the nozzle 13a at the lower end, and the resin path 11f for guiding the molten resin injected from the nozzle 13a into the cavity CV is vertically arranged in the fixed side mold 11. It penetrates in the direction. The movable mold 12 includes an electric motor and a speed reducer, and is connected to a mold moving device (not shown) for moving the movable mold 12 up and down.

次に、図３乃至図１０に基づいて、成形用型１０を用いた、ドアトリム基材１の成形方法について説明する。図３に示した成形型１１、１２が開かれた状態（開型状態）から、型移動装置の作動により、可動側成形型１２を上方へと移動させて、成形型１１、１２を閉じた状態（閉型状態）とし、その内部にキャビティＣＶを形成させる（図４示）。この状態において、インジェクション装置１３のノズル１３ａから、加熱して溶融状態にある発泡性樹脂材料を射出し、樹脂通路１１ｆを介してキャビティＣＶ内に充填させる（図５示）。発泡性樹脂材料は、上述したポリプロピレン等の熱可塑性樹脂材料に、発泡剤を混ぜ合わせたものである。この状態においては、キャビティＣＶ内の樹脂圧（キャビティＣＶの内圧）が、発泡剤が発泡する圧力の上限値以上であるため発泡は行われない。しかしながら、キャビティＣＶ内の樹脂材料の表面は、成形型１１、１２の対向面１１ａ、１２ａ、突起部１１ｂ、１２ｂの側面１１ｃ、１２ｃ等に接することにより冷却されて固化し、スキン層ＳＫ（図９における斜線部）を形成する（図６および図９示）。   Next, based on FIG. 3 thru | or FIG. 10, the shaping | molding method of the door trim base material 1 using the shaping | molding die 10 is demonstrated. From the state in which the molds 11 and 12 shown in FIG. 3 are opened (open mold state), the movable mold 12 is moved upward by the operation of the mold moving device, and the molds 11 and 12 are closed. A state (closed mold state) is set, and a cavity CV is formed therein (shown in FIG. 4). In this state, the foamable resin material that is heated and melted is injected from the nozzle 13a of the injection device 13 and filled into the cavity CV through the resin passage 11f (shown in FIG. 5). The foamable resin material is obtained by mixing a foaming agent with the above-described thermoplastic resin material such as polypropylene. In this state, foaming is not performed because the resin pressure in the cavity CV (internal pressure in the cavity CV) is equal to or higher than the upper limit of the pressure at which the foaming agent foams. However, the surface of the resin material in the cavity CV is cooled and solidified by contacting the opposing surfaces 11a and 12a of the molds 11 and 12, the side surfaces 11c and 12c of the protrusions 11b and 12b, etc., and the skin layer SK (FIG. 9 (shown in FIG. 6 and FIG. 9).

所定時間経過後、型移動装置の作動により、可動側成形型１２を所定量αだけ下方へと移動させて、成形型１１、１２が僅かに開かれた状態（以下、コアバック状態と呼ぶ）にすると、キャビティＣＶが拡張するため、キャビティＣＶ内の樹脂圧が低下することにより、含有された発泡剤が発泡を開始し樹脂材料は膨張する。これにより、樹脂材料のうち、対向面１１ａ、１２ａと接したスキン層ＳＫは、対向面１１ａ、１２ａの形状に倣って、平坦面を維持しながら互いに上下方向に離れていき、対向面１１ａ、１２ａの間の間隔はｔ＋αとなる（図７及び図１０示）。突起部１１ｂ、１２ｂの側面１１ｃ、１２ｃと接しているスキン層ＳＫの長さ（それぞれ側面１１ｃ、１２ｃの長さと同じになる）の和２Ａは、閉型時の双方の対向面１１ａ、１２ａの、可動側成形型１２の移動方向の距離ｔよりも長く形成されているため、樹脂材の膨張を妨げることがなく、対向面１１ａ、１２ａと接したスキン層ＳＫの表面に段付が発生することはない。   After a predetermined time has elapsed, the movable side mold 12 is moved downward by a predetermined amount α by the operation of the mold moving device, and the molds 11 and 12 are slightly opened (hereinafter referred to as a core back state). Then, since the cavity CV expands, the resin pressure in the cavity CV decreases, so that the contained foaming agent starts to foam and the resin material expands. Thereby, among the resin materials, the skin layers SK in contact with the opposing surfaces 11a and 12a are separated from each other in the vertical direction while maintaining a flat surface following the shape of the opposing surfaces 11a and 12a. The interval between 12a is t + α (shown in FIGS. 7 and 10). The sum 2A of the lengths of the skin layers SK in contact with the side surfaces 11c and 12c of the protrusions 11b and 12b (which are the same as the lengths of the side surfaces 11c and 12c, respectively) Since the movable mold 12 is formed longer than the distance t in the moving direction, the surface of the skin layer SK in contact with the opposing surfaces 11a and 12a is stepped without hindering the expansion of the resin material. There is nothing.

樹脂材料の膨張により、側面１１ｃ、１２ｃと接しているスキン層ＳＫは、図９において上下方向に引っ張られて、やがて、同方向を向いて一直線状となり、突起部１１ｂ、１２ｂを取り巻く真空孔７が形成される。ここで、側面１１ｃ、１２ｃと接しているスキン層ＳＫの長さの和２Ａは、コアバック状態の対向面１１ａ、１２ａ間の距離ｔ＋α（閉型時の対向面１１ａ、１２ａ間の距離ｔに、樹脂材料を発泡させるコアバック状態における型開き量αを加えた長さ）と等しく設定してあるため、側面１１ｃ、１２ｃに接したスキン層ＳＫの長さが、樹脂材料の膨張後の、対向面１１ａ、１２ａ間の距離と一致するため、対向面１１ａ、１２ａと接したスキン層ＳＫの表面に、段付が全く発生しないとともに、真空孔７の内周面も平坦に形成される。その後、キャビティＣＶ内の樹脂材料が冷却され、内部が多孔質状のドアトリム基材１が形成されると、可動側成形型１２を更に下方に移動させて成形型１１、１２を開型状態とし（図８示）、成形されたドアトリム基材１を取り出す。   Due to the expansion of the resin material, the skin layer SK in contact with the side surfaces 11c and 12c is pulled in the vertical direction in FIG. 9 and eventually becomes a straight line in the same direction, and the vacuum hole 7 surrounding the projections 11b and 12b. Is formed. Here, the sum 2A of the lengths of the skin layers SK in contact with the side surfaces 11c and 12c is the distance t + α between the opposing surfaces 11a and 12a in the core back state (the distance t between the opposing surfaces 11a and 12a at the time of mold closing). , The length of the skin layer SK in contact with the side surfaces 11c and 12c is the length after expansion of the resin material. Since the distance coincides with the distance between the opposing surfaces 11a and 12a, no stepping occurs on the surface of the skin layer SK in contact with the opposing surfaces 11a and 12a, and the inner peripheral surface of the vacuum hole 7 is also formed flat. After that, when the resin material in the cavity CV is cooled and the interior of the door trim base 1 having a porous shape is formed, the movable mold 12 is moved further downward to open the molds 11 and 12. (FIG. 8 shows) and the molded door trim base material 1 is taken out.

本実施形態によれば、突起部１１ｂ、１２ｂの側面１１ｃ、１２ｃの型開き方向の長さの和２Ａは、閉型時の対向面１１ａ、１２ａ間の距離ｔよりも長くなるように形成されていることにより、側面１１ｃ、１２ｃの型開き方向の長さの和２Ａのうち、対向面１１ａ、１２ａ間の距離ｔよりも長い分だけ、発泡による樹脂材料の膨張に追従可能なため、対向面１１ａ、１２ａと接した樹脂材料の表面に段付が発生することを低減して、平坦面にすることができ、見栄えのよい成形品にすることが可能となる。また、膨張時にも、膨張した樹脂材料の表面が対向面１１ａ、１２ａに接しているため、表面が対向面１１ａ、１２ａに倣って、その形状どおりに平坦に成形され、いっそう見栄えよく形成できる。   According to the present embodiment, the sum 2A of the lengths in the mold opening direction of the side surfaces 11c and 12c of the protrusions 11b and 12b is formed to be longer than the distance t between the opposed surfaces 11a and 12a when the mold is closed. Therefore, it is possible to follow the expansion of the resin material due to foaming by an amount longer than the distance t between the opposing surfaces 11a and 12a in the sum 2A of the lengths of the side surfaces 11c and 12c in the mold opening direction. It is possible to reduce the occurrence of stepping on the surface of the resin material in contact with the surfaces 11a and 12a, to obtain a flat surface, and to obtain a molded product having a good appearance. In addition, since the surface of the expanded resin material is in contact with the opposing surfaces 11a and 12a even during expansion, the surface is formed flat according to the shape following the opposing surfaces 11a and 12a, and can be formed more attractively.

また、側面１１ｃ、１２ｃの型開き方向の長さ２Ａは、閉型時の対向面１１ａ、１２ａ間の型開き方向の距離ｔに、樹脂材料を発泡させる時の、コアバック状態における型開き量αを加えた長さである構成としたことにより、側面１１ｃ、１２ｃに接した樹脂材料の表面の長さ２Ａが、樹脂材料が膨張した後の対向面１１ａ、１２ａ間の距離ｔ＋αと一致するため、樹脂材料の表面に段付が全く発生しないとともに、真空孔７の内周面も平坦となり、いっそう見栄えのよい成形品にすることが可能となる。また、突起部１１ｂ、１２ｂは、成形型１１、１２の双方からそれぞれ突出して、互いに相手側に当接するように一対に設けられ、連結面である突起部１１ｂ、１２ｂの側面１１ｃ、１２ｃは、各々テーパ状に形成された構成としたことにより、連結面を対向面１１ａ、１２ａ間の距離よりも容易に長くできるとともに、それぞれの突起部１１ｂ、１２ｂの型抜きも容易となる。   Further, the length 2A in the mold opening direction of the side surfaces 11c and 12c is the mold opening amount in the core back state when the resin material is foamed at the distance t in the mold opening direction between the opposing surfaces 11a and 12a when the mold is closed. By adopting a configuration in which α is added, the length 2A of the surface of the resin material in contact with the side surfaces 11c and 12c matches the distance t + α between the opposing surfaces 11a and 12a after the resin material expands. Therefore, no stepping occurs on the surface of the resin material, and the inner peripheral surface of the vacuum hole 7 becomes flat, so that it is possible to obtain a molded product having a better appearance. Further, the protrusions 11b and 12b protrude from both the molds 11 and 12, respectively, and are provided in a pair so as to contact each other. The side surfaces 11c and 12c of the protrusions 11b and 12b, which are connecting surfaces, By adopting a configuration in which each is tapered, the connecting surface can be easily made longer than the distance between the opposing surfaces 11a and 12a, and the respective protrusions 11b and 12b can be easily removed from the mold.

＜実施形態２＞
本発明の実施形態２を図１１によって説明する。本実施形態においては、実施形態１と同様に、一対の成形型２１、２２の対向面２１ａ、２２ａから、それぞれ突起部２１ｂ、２２ｂが相手側に向けて突出しており、成形型２１、２２の閉型時において、突起部２１ｂ、２２ｂは、互いに当接している。突起部２１ｂ、２２ｂの側面２１ｃ、２２ｃは、互いに連続する弧によって形成されており、このため、側面２１ｃ、２２ｃによって形成されるキャビティＣＶの表面は、滑らかな曲線を呈している。本実施形態においても、側面２１ｃ、２２ｃの型開き方向の長さの和が、閉型時の対向面２１ａ、２２ａ間の距離よりも長く形成されている。本実施形態における、その他の構成および成形方法については、実施形態１のものと同様であるため、説明は省略する。 <Embodiment 2>
A second embodiment of the present invention will be described with reference to FIG. In the present embodiment, as in the first embodiment, the protruding portions 21b and 22b protrude from the opposing surfaces 21a and 22a of the pair of molds 21 and 22 toward the other side, respectively. When the mold is closed, the protrusions 21b and 22b are in contact with each other. The side surfaces 21c and 22c of the protruding portions 21b and 22b are formed by arcs that are continuous with each other, and therefore the surface of the cavity CV formed by the side surfaces 21c and 22c has a smooth curve. Also in the present embodiment, the sum of the lengths of the side surfaces 21c and 22c in the mold opening direction is formed to be longer than the distance between the opposing surfaces 21a and 22a when the mold is closed. Since other configurations and molding methods in the present embodiment are the same as those in the first embodiment, description thereof will be omitted.

＜実施形態３＞
本発明の実施形態３を図１２によって説明する。本実施形態においても、実施形態１と同様に、一対の成形型３１、３２の対向面３１ａ、３２ａから、それぞれ突起部３１ｂ、３２ｂが相手側に向けて突出しており、成形型３１、３２の閉型時において、突起部３１ｂ、３２ｂは、互いに当接している。突起部３１ｂ、３２ｂの側面３１ｃ、３２ｃは、互いに連続することにより、形成されるキャビティＣＶの表面は台形を呈している。本実施形態においても、側面３１ｃ、３２ｃの型開き方向の長さの和が、閉型時の対向面３１ａ、３２ａ間の距離よりも長いことは言うまでもない。本実施形態における、その他の構成および成形方法についても、実施形態１のものと同様であるため、説明は省略する。 <Embodiment 3>
A third embodiment of the present invention will be described with reference to FIG. Also in the present embodiment, as in the first embodiment, the protruding portions 31b and 32b protrude from the opposing surfaces 31a and 32a of the pair of molds 31 and 32 toward the other side, respectively. When the mold is closed, the protrusions 31b and 32b are in contact with each other. The side surfaces 31c and 32c of the protrusions 31b and 32b are continuous with each other, so that the surface of the formed cavity CV has a trapezoidal shape. Also in this embodiment, it goes without saying that the sum of the lengths of the side surfaces 31c and 32c in the mold opening direction is longer than the distance between the opposing surfaces 31a and 32a when the mold is closed. Since other configurations and molding methods in the present embodiment are the same as those in the first embodiment, description thereof will be omitted.

＜他の実施形態＞
本発明は上記記述及び図面によって説明した実施形態に限定されるものではなく、例えば次のような実施形態も本発明の技術的範囲に含まれ、さらに、下記以外にも要旨を逸脱しない範囲内で種々変更して実施することができる。
（１）本発明は、成形品の貫通孔の周囲だけでなく、成形品の端部に適用することも可能である。
（２）一対の成形型にそれぞれ形成された対向面は、互いに平行でなくともよい。あるいは、対向面が型開き方向に垂直でなくともよい。この場合、連結面の型開き方向の長さは、連結面が接続している部位における、閉型時の対向面間の型開き方向の距離よりも長くなるように形成されていればよい。
（３）側面がテーパ状の突起部を、一方の型の対向面からのみ突出させ、閉型時にその先端を相手型の対向面に当接させ、突起部の側面を連結面としてもよい。 <Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention, and further, within the scope not departing from the gist of the invention other than the following. Various modifications can be made.
(1) The present invention can be applied not only to the periphery of the through hole of the molded product but also to the end of the molded product.
(2) The opposing surfaces formed on the pair of molds may not be parallel to each other. Alternatively, the facing surface may not be perpendicular to the mold opening direction. In this case, the length of the connecting surface in the mold opening direction may be formed so as to be longer than the distance in the mold opening direction between the opposing surfaces at the time of mold closing at the portion where the connecting surface is connected.
(3) The protruding portion having a tapered side surface may be protruded only from the opposing surface of one mold, and the tip thereof may be brought into contact with the opposing surface of the counterpart mold when the mold is closed, and the side surface of the protruding portion may be used as a connecting surface.

本発明によって成形されるドアトリム基材の正面図である。It is a front view of the door trim base material shape | molded by this invention. 図１に示したドアトリム基材の断面図である。It is sectional drawing of the door trim base material shown in FIG. 実施形態１による成形用型の、成形前に可動側成形型を降下させた開型状態を示す一部断面図である。It is a partial cross section figure which shows the open mold state which lowered | hung the movable mold before shaping | molding of the shaping | molding die by Embodiment 1. FIG. 図３に示した成形用型の、成形型を閉型状態とし発泡性樹脂材料を射出する前の一部断面図である。FIG. 4 is a partial cross-sectional view of the molding die shown in FIG. 3 before the foaming resin material is injected with the molding die in a closed state. 図３に示した成形用型において、発泡性樹脂材料を射出したところを示す一部断面図である。FIG. 4 is a partial cross-sectional view showing a foamed resin material injected in the molding die shown in FIG. 3. 図３に示した成形用型において、発泡性樹脂材料の表面が固化したところを示す一部断面図である。FIG. 4 is a partial cross-sectional view showing the surface of the foamable resin material solidified in the molding die shown in FIG. 3. 図３に示した成形用型において、発泡性樹脂材料を発泡させたところを示す一部断面図である。FIG. 4 is a partial cross-sectional view showing a foamed resin material foamed in the molding die shown in FIG. 3. 図３に示した成形用型において、成形品を取り出すために可動側成形型を降下させた開型状態を示す一部断面図である。FIG. 4 is a partial cross-sectional view showing an opened state in which a movable mold is lowered in order to take out a molded product in the mold shown in FIG. 3. 図６の要部拡大図である。It is a principal part enlarged view of FIG. 図７の要部拡大図である。It is a principal part enlarged view of FIG. 実施形態２による成形用型による成形状態を示す要部拡大断面図である。FIG. 6 is an enlarged cross-sectional view showing a main part of a molding state according to a second embodiment. 実施形態３による成形用型による成形状態を示す要部拡大断面図である。FIG. 10 is an enlarged cross-sectional view showing a main part of a molding state according to a third embodiment. 従来技術による発泡性樹脂成形方法において、キャビティ内に溶融した樹脂材料を射出した状態を示す断面図である。It is sectional drawing which shows the state which injected the resin material fuse | melted in the cavity in the foaming resin molding method by a prior art. 図１３Ａに示した樹脂材料を発泡させた状態を示す断面図である。It is sectional drawing which shows the state which made the resin material shown to FIG. 13A foam. 図１３Ａに示した成形型内に成形品が完成した状態を示す断面図である。It is sectional drawing which shows the state which the molded article was completed in the shaping | molding die shown to FIG. 13A.

符号の説明Explanation of symbols

１…ドアトリム基材
１０…成形用型
１１、２１、３１…固定側成形型
１１ａ、１２ａ、２１ａ、２２ａ、３１ａ、３２ａ…対向面
１１ｂ、１２ｂ、２１ｂ、２２ｂ、３１ｂ、３２ｂ…突起部
１１ｃ、１２ｃ、２１ｃ、２２ｃ、３１ｃ、３２ｃ…側面
１２、２２、３２…可動側成形型
１３…インジェクション装置
ＣＶ…キャビティ
Ａ…突起部の側面の長さ
ｔ…閉型時の対向面間の距離
α…樹脂材料を発泡させる時の型開き量 DESCRIPTION OF SYMBOLS 1 ... Door trim base material 10 ... Molding die 11, 21, 31 ... Fixed side shaping | molding die 11a, 12a, 21a, 22a, 31a, 32a ... Opposing surface 11b, 12b, 21b, 22b, 31b, 32b ... Projection part 11c, 12c, 21c, 22c, 31c, 32c ... side surface 12, 22, 32 ... movable side mold 13 ... injection device CV ... cavity A ... length of side surface of protrusion t ... distance between opposing surfaces when closed mold α ... Mold opening when foaming resin material

Claims (5)

開閉可能なように設けられた一対の成形型において、該成形型のそれぞれに形成され、その開き方向と交差するとともに、互いに対向する対向面と、閉型時に該対向面を互いに連結する連結面により内部にキャビティが形成され、該キャビティ内に溶融した発泡性樹脂材料を供給し、所定時間後、前記成形型を所定量だけ開型して、前記キャビティの内圧を低下させることにより前記樹脂材料を発泡させて、内部が多孔質の樹脂成形品を形成する発泡性樹脂成形方法において、
前記連結面の型開き方向の長さは、前記連結面が接続している部位における、閉型時の前記対向面間の距離よりも長くなるように形成されていることを特徴とする発泡性樹脂成形方法。 In a pair of molding dies provided so as to be openable and closable, formed on each of the molding dies, intersecting the opening direction of the molding dies and facing each other and a coupling surface connecting the opposing surfaces to each other when the mold is closed A cavity is formed in the cavity, a foamable resin material melted in the cavity is supplied, and after a predetermined time, the mold is opened by a predetermined amount, and the internal pressure of the cavity is lowered to reduce the resin material. In a foamable resin molding method in which a resin molded product having a porous interior is formed.
The foaming property is characterized in that the length of the connecting surface in the mold opening direction is formed to be longer than the distance between the opposing surfaces at the time of mold closing at a portion where the connecting surface is connected. Resin molding method. 前記連結面の型開き方向の長さは、前記連結面が接続している部位における、閉型時の前記対向面間の距離に、前記樹脂材料を発泡させる時の、型開き量を加えた長さであることを特徴とする請求項１記載の発泡性樹脂成形方法。 The length of the connecting surface in the mold opening direction is obtained by adding the mold opening amount when foaming the resin material to the distance between the opposing surfaces at the time of mold closing in the portion where the connecting surface is connected. 2. The foamable resin molding method according to claim 1, wherein the foamable resin molding method has a length. 前記連結面は、前記成形型の一側の前記対向面から突出して、相手側の前記対向面に当接する突起部の側面に形成されたことを特徴とする請求項１または請求項２記載の発泡性樹脂成形方法。 The said connection surface protrudes from the said opposing surface of the one side of the said shaping | molding die, and was formed in the side surface of the projection part contact | abutted to the said opposing surface of the other party. Foaming resin molding method. 前記一対の成形型には、それぞれの前記対向面から突出して、互いに相手側に当接する一対の突起部が設けられ、前記突起部の側面は、各々テーパ状に形成されるとともに、前記連結面は前記突起部の前記側面に形成されたことを特徴とする請求項１または請求項２記載の発泡性樹脂成形方法。 The pair of molding dies are provided with a pair of protrusions that protrude from the opposing surfaces and abut against each other, and the side surfaces of the protrusions are each formed in a tapered shape, and the connection surface 3. The foamable resin molding method according to claim 1, wherein the foaming resin is formed on the side surface of the protrusion. 開閉可能なように設けられた一対の成形型を備え、該成形型のそれぞれには、その開き方向と交差するとともに、互いに対向する対向面が形成され、該対向面および閉型時にこれらを互いに連結する連結面により、前記成形型の内部にはキャビティが形成され、前記成形型の一側には、該キャビティ内に溶融した発泡性樹脂材料を供給するための樹脂供給装置が設けられ、前記キャビティ内に前記樹脂材料を供給し、所定時間後、前記成形型を所定量だけ開型して、前記キャビティの内圧を低下させることにより前記樹脂材料を発泡させて、内部が多孔質の樹脂成形品を形成するための成形用型構造において、
前記連結面の型開き方向の長さは、前記連結面が接続している部位における、閉型時の前記対向面間の距離よりも長くなるように形成されていることを特徴とする成形用型構造。 A pair of molds provided so as to be openable and closable are provided, and each of the molds has an opposing surface that intersects with the opening direction and opposes each other. A cavity is formed inside the mold by the connecting surface to be connected, and a resin supply device for supplying a foamable resin material melted in the cavity is provided on one side of the mold, The resin material is supplied into the cavity, and after a predetermined time, the mold is opened by a predetermined amount, and the resin material is foamed by reducing the internal pressure of the cavity. In a mold structure for forming a product,
The length of the connecting surface in the mold opening direction is formed so as to be longer than the distance between the facing surfaces at the time of mold closing at a portion where the connecting surface is connected. Type structure.
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010042516A (en) * 2008-08-08 2010-02-25 Toyota Boshoku Corp Mold
JP2010064268A (en) * 2008-09-08 2010-03-25 Toyota Boshoku Corp Resin foam molded body

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2005288745A (en) * 2004-03-31 2005-10-20 Toyoda Gosei Co Ltd Method for producing injection-molded article

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2005288745A (en) * 2004-03-31 2005-10-20 Toyoda Gosei Co Ltd Method for producing injection-molded article

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010042516A (en) * 2008-08-08 2010-02-25 Toyota Boshoku Corp Mold
JP2010064268A (en) * 2008-09-08 2010-03-25 Toyota Boshoku Corp Resin foam molded body

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