JP2009220387A - Method for molding foamed resin molding - Google Patents
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Abstract
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本発明は、発泡樹脂成形品の成形方法に関し、特に、可動型を固定型から成形品の厚み方向にコアバックするものに関するものである。 The present invention relates to a method for molding a foamed resin molded product, and more particularly to a method in which a movable die is core-backed from a fixed die in the thickness direction of the molded product.
従来、ＡＢＳ（アクリロニトリル・ブタジエン・スチレン）樹脂やＰＰ（ポリプロピレン）樹脂等を材料にして射出成形等により成形された樹脂成形品、例えばインパネコア、空調ダクト、バンパービーム、ドアステップ、クォータパネル及びエアクリーナケース等の自動車部品に採用されている。その場合に、断熱性、軽量性、防音性、衝撃吸収性等の観点から、樹脂成形品を、例えば二酸化炭素や窒素等の物理発泡剤或いは炭酸水素ナトリウム等の化学発泡剤を用いて樹脂中に気泡を生成させた多孔質構造の発泡樹脂成形品とすることがある。 Conventionally, resin molded products molded by injection molding etc. using ABS (acrylonitrile butadiene styrene) resin or PP (polypropylene) resin as materials, such as instrument panel core, air conditioning duct, bumper beam, door step, quarter panel and air cleaner It is used for automobile parts such as cases. In that case, from the viewpoint of heat insulation, lightness, soundproofing, shock absorption, etc., the resin molded product is used in the resin by using a physical foaming agent such as carbon dioxide or nitrogen or a chemical foaming agent such as sodium hydrogen carbonate. In some cases, the foamed resin molded article has a porous structure in which bubbles are generated.
このような発泡樹脂成形品は、特許文献１に記載されているように、成形品と同輪郭形状の成形品形状よりも厚みを小さくしたキャビティに溶融状態の発泡性樹脂（未発泡の発泡剤を含有させた発泡前の樹脂）を充填した後、キャビティの容積が増大する方向、より詳しくは、成形品の厚みが増大する方向に成形品をコアバックすることにより成形される。 As described in Patent Document 1, such a foamed resin molded product has a foamed resin (unfoamed foaming agent) in a molten state in a cavity whose thickness is smaller than that of the molded product having the same contour shape as the molded product. The resin is molded by core-backing the molded product in a direction in which the volume of the cavity increases, more specifically, in a direction in which the thickness of the molded product increases.
このようにして成形された発泡樹脂成形品は、コアバック方向から見たときの形状、所謂成形品形状の輪郭（以下、便宜上「平面形状」とする）がキャビティ形状を維持しつつ、コアバック方向と直交する方向から見たときの形状、所謂成形品形状の厚み（以下、便宜上「側面形状」とする）が成形型のコアバックと樹脂の発泡とによりコアバック前に比べて数倍に膨張したものとなっている。 The foamed resin molded product thus molded has a shape when viewed from the core back direction, that is, a so-called contour of the molded product shape (hereinafter referred to as “planar shape” for convenience) while maintaining the cavity shape. The shape when viewed from the direction orthogonal to the direction, the so-called molded product thickness (hereinafter referred to as “side shape” for convenience) is several times larger than before the core back due to the core back of the mold and the foaming of the resin. It has expanded.
ところが、成形型のコアバックによる発泡樹脂成形品の成形では、成形後の外周の縁部をはじめ、成形品の外側に部分的に設けられた切欠の縁部、或いは成形品の外周から切離して成形品の中に設けられた開口の周縁部等成形品形状の輪郭形成端部が成形品の肉のある内方へ縮退し、その結果、成形品の平面形状での全体の大きさが目標とする大きさよりも小さくなり、開口や切欠の大きさが目標とする大きさよりも大きくなるという問題が判明した。 However, in the molding of the foamed resin molded product by the core back of the molding die, it is separated from the outer peripheral edge after molding, the notch edge partially provided outside the molded product, or the outer periphery of the molded product. The contoured end of the molded product shape, such as the peripheral edge of the opening provided in the molded product, contracts inward with the meat of the molded product, and as a result, the overall size in the planar shape of the molded product is the target The problem that the size of the opening and the notch becomes larger than the target size has been found.
その結果、発泡樹脂成形品の平面形状での寸法精度が低下し、発泡樹脂成形品の形状不良が生じて、例えば、開口を利用して相手部材に嵌合しようとしても嵌合が外れたり、切欠を利用して相手部材に嵌合や位置決めしようとしてもガタが生じる。 As a result, the dimensional accuracy in the planar shape of the foamed resin molded product is reduced, resulting in a defective shape of the foamed resin molded product, for example, even if trying to fit the mating member using the opening, Even if an attempt is made to fit or position the mating member using the notch, backlash occurs.
図１３に示すように、前述した問題を解明するため、成形型をコアバックして発泡樹脂成形品５０を成形する場合について詳細検討を行った。 As shown in FIG. 13, in order to elucidate the above-described problem, a detailed study was conducted on the case where the foamed resin molded product 50 was molded by core-backing the mold.
図１３（ａ）に示すように、発泡樹脂成形品５０のロの字状の開口５１を形成するため、固定型３１におけるキャビティ形成面の所定の部位には凹部３１ａが形成され、可動型３２におけるキャビティ形成面の対応する所定の部位には凸部３２ａが形成され、凸部３２ａが凹部３１ａに突入している。このようにして、型締め状態の固定型３１と可動型３２とで形成されるキャビティ３３に発泡性樹脂が充填される。 As shown in FIG. 13 (a), in order to form a square-shaped opening 51 of the foamed resin molded product 50, a recess 31 a is formed at a predetermined portion of the cavity forming surface of the fixed mold 31, and the movable mold 32. A convex portion 32a is formed at a predetermined portion of the cavity forming surface corresponding to the convex portion 32a, and the convex portion 32a enters the concave portion 31a. In this way, the foamable resin is filled into the cavity 33 formed by the fixed mold 31 and the movable mold 32 in the clamped state.
その後、図１３（ｂ）に示すように、キャビティ３３の容積が増大する方向、より詳しくは、成形品５０の厚みが増大する方向に可動型３２がコアバックされる。この結果、コアバック方向（図例では上下方向）から見たときの形状がキャビティ形状を維持しつつ、コアバック方向と直交する方向（図例では紙面前後方向）から見たときの形状、所謂厚みがコアバック前に比べて数倍に膨張した発泡樹脂成形品５０が得られる。 Thereafter, as shown in FIG. 13B, the movable mold 32 is core-backed in the direction in which the volume of the cavity 33 increases, more specifically in the direction in which the thickness of the molded product 50 increases. As a result, the shape when viewed from the core back direction (vertical direction in the example) maintains the cavity shape, and the shape when viewed from the direction orthogonal to the core back direction (front and back direction in the figure), so-called A foamed resin molded product 50 having a thickness several times larger than that before the core back is obtained.
成形品５０は、固定型３１及び可動型３２のキャビティ形成面に接する表層部５０ａが、発泡セルが成長した発泡内部５０ｂを被覆した構造を有している。特に、図では可動型３２の凸部３２ａの側面（縦面）に接する樹脂部分が開口５１の周縁部の端面を形成することになる。 The molded product 50 has a structure in which a surface layer portion 50a in contact with the cavity forming surfaces of the fixed mold 31 and the movable mold 32 covers a foamed interior 50b in which foamed cells are grown. In particular, in the drawing, the resin portion in contact with the side surface (vertical surface) of the convex portion 32 a of the movable mold 32 forms the end surface of the peripheral portion of the opening 51.
ところが、現実には、コアバックを開始する際ないしコアバック中に、成形型のキャビティ形成面に接する発泡性合成樹脂の表層部５０ａが既に冷却されて伸張性が低下しており、内部からの発泡圧力を受けても膨張し難い状態になっている。その結果、コアバックに伴い容積が増大するキャビティ３３に表層部５０ａが十分に追従せず、内部からの発泡圧力の受圧面積が相対的に小さい面、つまり成形品の厚みを構成する外周縁部の端面や切欠縁部の端面或いは開口縁部の端面等成形品形状の輪郭形成端部がコアバック時に成形品の内方へ引き込まれるように移動して縮退するのである。 However, in reality, when the core back is started or during the core back, the surface layer portion 50a of the foamable synthetic resin in contact with the cavity forming surface of the mold is already cooled and the extensibility is lowered. Even when subjected to foaming pressure, it is difficult to expand. As a result, the surface layer portion 50a does not sufficiently follow the cavity 33 whose volume increases with the core back, and the surface area where the pressure receiving area of the foaming pressure from the inside is relatively small, that is, the outer peripheral edge portion constituting the thickness of the molded product The contoured end of the shape of the molded product such as the end surface, the end surface of the notch edge, or the end surface of the opening edge moves so as to be drawn inward of the molded product when the core is backed.
その結果、開口５１の縁部の端面と、可動型３２の凸部３２ａの側面との間に空間が発生し、開口５１の大きさが目標とする大きさよりも大きくなってしまい、開口５１を利用して成形品５０を相手部材に組み付けようとしても、大きさが合わずに外れてしまうという不具合が生じるのである。 As a result, a space is generated between the end face of the edge of the opening 51 and the side surface of the convex portion 32a of the movable mold 32, and the size of the opening 51 becomes larger than the target size. Even if it tries to assemble the molded product 50 to the mating member by using it, there arises a problem that the size does not match and the product 50 comes off.
図１３に示す例は、開口５１の縁部が縮退する場合を示したが、同様の問題は、成形品５０の平面形状の他の縁部、例えば、成形品５０の外周縁部や、成形品５０に部分的に設けられた切欠の縁部においても生じる。その結果、外周縁部が縮退した場合は、成形品５０の平面形状での大きさが目標とする大きさよりも小さくなってしまう。また、切欠縁部が縮退した場合は、開口５１と同様に、成形品５０の平面形状での切欠大きさが目標とする大きさより大きくなってしまう。 The example shown in FIG. 13 shows a case where the edge of the opening 51 is degenerated, but the same problem is caused by other edges of the planar shape of the molded product 50, for example, the outer peripheral edge of the molded product 50, or molding. It also occurs at the edge of the notch partially provided in the article 50. As a result, when the outer peripheral edge is degenerated, the size of the molded product 50 in the planar shape is smaller than the target size. In addition, when the cutout edge portion is contracted, the cutout size in the planar shape of the molded product 50 is larger than the target size, like the opening 51.
本発明の目的は、成形型をコアバックして発泡樹脂成形品を成形する場合に生じる前記問題に対処するもので、コアバックに伴う成形品形状の輪郭形成端部の成形品内方への縮退に起因する発泡樹脂成形品の平面形状での寸法精度の低下を抑制することを課題としている。 An object of the present invention is to cope with the above-mentioned problem that occurs when a foamed resin molded product is molded by core-backing a molding die. It is an object to suppress a decrease in dimensional accuracy in the planar shape of a foamed resin molded product due to degeneration.
請求項１の発泡樹脂成形品の成形方法は、固定型と、この固定型との間に成形品形状と同形状で成形品形状よりも厚みを小さくした充填用キャビティを形成すると共に固定型から成形品の厚み方向にコアバックすることで固定型との間に成形用キャビティを形成する可動型とを備え、発泡性樹脂を充填用キャビティに充填し、可動型のコアバックにより成形用キャビティ内で発泡性樹脂を発泡させて成形品を成形する成形方法であって、成形品形状の輪郭形成端部のうちの特定部位については成形品形状の輪郭形成端部を発泡部材にて形成して、この発泡部材を充填用キャビティに配置する工程と、発泡部材が配置された状態で充填用キャビティに発泡性樹脂を充填する充填工程と、可動型を固定型から成形品の厚み方向にコアバックして発泡性樹脂を発泡させる発泡工程とを備えることを特徴としている。 According to a first aspect of the present invention, there is provided a molding method for a foamed resin molded article, wherein a filling cavity is formed between the stationary mold and the stationary mold and has the same shape as the molded article and has a smaller thickness than the molded article shape. It has a movable mold that forms a molding cavity with the fixed mold by core-backing in the thickness direction of the molded product, and fills the filling cavity with a foamable resin, and the movable core back fills the molding cavity. In the molding method, the foamed resin is foamed to form a molded product, and the contour-shaped end portion of the molded product shape is formed with a foam member for a specific portion of the contour-shaped end portion of the molded product shape. The step of disposing the foam member in the filling cavity, the filling step of filling the filling cavity with the foamable resin in the state in which the foam member is disposed, and the core back from the fixed die in the thickness direction of the molded product. Depart It is characterized in that it comprises a foaming step of foaming the sexual resin.
請求項２の発泡樹脂成形品の成形方法は、請求項１の発明において、発泡部材は、反端部側に充填される発泡性樹脂と係合可能なアンダーカット部を有することを特徴としている。 The method for molding a foamed resin molded product according to claim 2 is characterized in that, in the invention according to claim 1, the foamed member has an undercut portion engageable with the foamable resin filled on the opposite end side. .
請求項３の発泡樹脂成形品の成形方法は、請求項１又は２の発明において、発泡部材は、コアバック前の型締め状態において、固定型と可動型とによって挟持されることを特徴としている。 The method for molding a foamed resin molded product according to claim 3 is characterized in that, in the invention according to claim 1 or 2, the foamed member is sandwiched between the fixed die and the movable die in the mold-clamped state before the core back. .
請求項４の発泡樹脂成形品の成形方法は、請求項１から請求項３の発明において、発泡性樹脂は物理発泡剤を含有することを特徴としている。 According to a fourth aspect of the present invention, there is provided a method for molding a foamed resin molded product, wherein the foamable resin contains a physical foaming agent.
請求項５の発泡樹脂成形品の成形方法は、請求項４の発明において、物理発泡剤は超臨界状態の流体であることを特徴としている。 According to a fifth aspect of the present invention, the physical foaming agent is a fluid in a supercritical state.
請求項１の発明によれば、成形品形状の輪郭形成端部のうちの特定部位については成形品形状の輪郭形成端部を発泡部材にて形成して、この発泡部材を充填用キャビティに配置する工程と、発泡部材が配置された状態で充填用キャビティに発泡性樹脂を充填する充填工程と、可動型を固定型から成形品の厚み方向にコアバックして発泡性樹脂を発泡させる発泡工程とを備えるため、コアバックに伴う成形品形状の輪郭形成端部の成形品内方への縮退に起因する発泡樹脂成形品の平面形状での寸法精度の低下を抑制することができる。つまり、発泡部材が対向する部分を有するため、コアバック工程で成形品形状の輪郭形成端部が成形品内方へ引き込まれる力、所謂縮退力を成形品形状の輪郭形成端部に配置した発泡部材により抑制することが可能となり、更に、この特定部位を利用して発泡部材を成形型に位置決め固定することが可能となる。しかも、成形品形状の輪郭形成端部を発泡部材で形成しているため、成形品全体が発泡部材で構成される全体発泡の樹脂成形品とすることができ、断熱性、軽量性、防音性、衝撃吸収性等に優れた成形品を得ることができる。 According to the first aspect of the present invention, the contour forming end of the molded product shape is formed by the foam member for the specific portion of the contour forming end portion of the molded product shape, and the foam member is disposed in the filling cavity. A filling step of filling the filling cavity with a foamable resin in a state where the foaming member is disposed, and a foaming step of foaming the foamable resin by core-backing the movable mold from the fixed mold in the thickness direction of the molded product. Therefore, it is possible to suppress a reduction in dimensional accuracy in the planar shape of the foamed resin molded product resulting from the inward shrinkage of the contoured end of the molded product shape accompanying the core back. In other words, since the foamed member has a facing portion, the foaming in which the contoured end of the molded product shape is drawn into the molded product in the core back process, that is, the so-called degeneration force is arranged at the contoured end of the molded product shape. It becomes possible to suppress by the member, and furthermore, it becomes possible to position and fix the foamed member to the mold using this specific part. In addition, since the contoured end of the molded product shape is formed of a foamed member, the entire molded product can be made into an overall foamed resin molded product composed of a foamed member, and is heat-insulating, lightweight, and soundproof. In addition, it is possible to obtain a molded article excellent in impact absorption and the like.
請求項２の発明によれば、発泡部材は、反端部側に充填される発泡性樹脂と係合可能なアンダーカット部を有するため、発泡部材と発泡性樹脂との結合が図れ、成形品形状の輪郭形成端部の成形品内方への縮退を確実に防止できる。 According to the invention of claim 2, since the foam member has the undercut portion that can be engaged with the foam resin filled on the opposite end side, the foam member and the foam resin can be joined, and the molded product can be obtained. It is possible to reliably prevent the contoured end portion of the shape from shrinking inward of the molded product.
請求項３の発明によれば、発泡部材は、コアバック前の型締め状態において、固定型と可動型とによって挟持されるため、発泡部材の位置決め保持を確実にできる。 According to the invention of claim 3, since the foam member is sandwiched between the fixed mold and the movable mold in the mold-clamped state before the core back, positioning and holding of the foam member can be ensured.
請求項４の発明によれば、充填工程で充填される発泡性樹脂は物理発泡剤を含有するため、発泡倍率の高い成形品を得ることができると共に、更に顕著となる縮退に起因する発泡樹脂成形品の平面形状での寸法精度の低下を抑制できる。また、化学発泡剤等に比べて、発泡樹脂成形品の内部の発泡セル径を相対的に小さな径に揃えることができ、発泡樹脂成形品の剛性等の物性を向上することができる。 According to invention of Claim 4, since the foamable resin with which a filling process is filled contains a physical foaming agent, while being able to obtain a molded article with a high expansion ratio, the foamed resin resulting from further conspicuous degeneration A decrease in dimensional accuracy in the planar shape of the molded product can be suppressed. Moreover, compared with a chemical foaming agent etc., the foam cell diameter inside a foamed resin molded product can be made into a relatively small diameter, and physical properties, such as rigidity of a foamed resin molded product, can be improved.
請求項５の発明によれば、物理発泡剤は超臨界状態の流体であるため、発泡倍率の高い成形品を得ることができると共に、更に顕著となる縮退に起因する発泡樹脂成形品の平面形状での寸法精度の低下を抑制できる。また、発泡樹脂成形品の内部の発泡セル径を一層微細な径に揃えることができ、発泡樹脂成形品の剛性等の物性を一層向上することができる。 According to the invention of claim 5, since the physical foaming agent is a fluid in a supercritical state, it is possible to obtain a molded product having a high expansion ratio, and further, the planar shape of the foamed resin molded product resulting from the remarkable degeneration. Decrease in dimensional accuracy can be suppressed. In addition, the foamed cell diameter inside the foamed resin molded product can be made even finer, and physical properties such as rigidity of the foamed resin molded product can be further improved.
以下、本発明を実施する為の最良の形態について実施例１に基づいて説明する。 Hereinafter, the best mode for carrying out the present invention will be described based on the first embodiment.
以下、本発明の実施例１について図面に基づいて説明する。尚、この発泡樹脂成形品の成形装置では既に説明した部材には同一の符号を付している。 Embodiment 1 of the present invention will be described below with reference to the drawings. In the foamed resin molded product molding apparatus, the members already described are given the same reference numerals.
図１は、本発明に係る発泡樹脂成形品５０（図２を参照）の成形装置１０の全体構成図であって、図１ａは充填工程を示す図、図１ｂはコアバック工程を示す図である。この成形装置１０は、充填手段としての射出機２０と、成形型３０とを備えている。この成形装置１０を用いて行う発泡樹脂成形品５０の成形動作は、本発明に係る発泡樹脂成形品５０の成形方法を構成する。 FIG. 1 is an overall configuration diagram of a molding apparatus 10 for a foamed resin molded product 50 (see FIG. 2) according to the present invention. FIG. 1a shows a filling process, and FIG. 1b shows a core back process. is there. The molding apparatus 10 includes an injection machine 20 as a filling unit and a molding die 30. The molding operation of the foamed resin molded product 50 performed using the molding apparatus 10 constitutes the molding method of the foamed resin molded product 50 according to the present invention.
図１ａに示すように、射出機２０は型締め状態の成形型３０のキャビティ３３に、物理発泡剤を含有させた溶融状態の発泡性樹脂４０を射出、充填するもので、シリンダ内に例えばＰＰ樹脂等の基材樹脂を投入するためのホッパ２１と、シリンダ内で混練された溶融状態の基材樹脂に対して物理発泡剤としての超臨界状態の流体を供給するためのノズル２４（発泡剤供給手段）とを備えている。超臨界状態の流体は、二酸化炭素又は窒素等の不活性ガスのボンベ２２から超臨界流体状態発生装置２３を介して生成される。これにより、基材樹脂に物理発泡剤を含有させた溶融状態の発泡性樹脂４０が得られる。この発泡性樹脂４０は、固定型３１に形成された供給通路を経て、型締め状態の成形型３０のキャビティ３３に射出、充填される。 As shown in FIG. 1a, the injection machine 20 injects and fills a molten foamable resin 40 containing a physical foaming agent into a cavity 33 of a mold 30 in a clamped state. A hopper 21 for introducing a base resin such as a resin, and a nozzle 24 (foaming agent) for supplying a supercritical fluid as a physical foaming agent to a molten base resin kneaded in a cylinder Supply means). A fluid in a supercritical state is generated from a cylinder 22 of an inert gas such as carbon dioxide or nitrogen through a supercritical fluid state generator 23. Thereby, the foamable resin 40 of the molten state which made the base resin contain the physical foaming agent is obtained. The foamable resin 40 is injected and filled into the cavity 33 of the mold 30 in a clamped state through a supply passage formed in the fixed mold 31.
ここで、超臨界状態の流体とは、気体と液体とが共存できる限界の温度（臨界温度）及び圧力（臨界圧力）を超えた状態にある流体のことで、前記臨界温度は、例えば二酸化炭素で３１℃、窒素でマイナス１４７℃であり、前記臨界圧力は、例えば二酸化炭素で７．４ＭＰａ、窒素で３．４ＭＰａである。超臨界状態にある流体は、密度が液体に近似し、流動性が気体に類似する。その結果、溶融状態の基材樹脂中を活発に移動して、樹脂分子の奥深くまで均一に拡散、浸透し、微細発泡の種または核になり得るものである。 Here, the fluid in a supercritical state is a fluid that exceeds a limit temperature (critical temperature) and pressure (critical pressure) at which gas and liquid can coexist, and the critical temperature is, for example, carbon dioxide The critical pressure is, for example, 7.4 MPa for carbon dioxide and 3.4 MPa for nitrogen. A fluid in a supercritical state has a density close to that of a liquid and has a fluidity similar to that of a gas. As a result, it actively moves in the molten base resin, and diffuses and penetrates even deeply into the resin molecules, which can become seeds or nuclei of fine foaming.
成形型３０は、相互に型締め及び型開きする固定型３１と可動型３２とで構成されている。可動型３２は型締め及び型開きのために移動する他、キャビティ３３の容積が増大する方向にコアバック可能に構成されており、この可動型３２を移動させる油圧装置９０が設置されている。また、この可動型３２は、発泡樹脂成形品５０の輪郭形成端部を含めた成形品５０の外周の輪郭形状を有するキャビティ３３を形成するように構成されている。
この可動型３２のコアバックにより、内部で発泡セルが成長し、断熱性、軽量性、防音性、衝撃吸収性等に優れた多孔質構造の発泡樹脂成形品が成形される。
The mold 30 is composed of a fixed mold 31 and a movable mold 32 that clamp and open each other. The movable mold 32 is configured to move for mold clamping and mold opening, and is configured to be core-backed in the direction in which the volume of the cavity 33 increases. A hydraulic device 90 for moving the movable mold 32 is installed. Further, the movable mold 32 is configured to form a cavity 33 having a contour shape on the outer periphery of the molded product 50 including the contour forming end of the foamed resin molded product 50.
Due to the core back of the movable mold 32, foam cells grow inside, and a foamed resin molded article having a porous structure excellent in heat insulation, light weight, sound insulation, shock absorption and the like is formed.
図２は、成形装置１０で成形された発泡樹脂成形品５０の使用例を示す斜視図である。本発泡樹脂成形品５０は自動車部品であって、相手部材６０であるインスツルメントパネルの裏面に組み付けられるベンチレーションダクトである。発泡樹脂成形品５０は、外周５０ｘから切離して成形品５０の中に設けられた開口５１を有している。その開口５１を利用して相手部材６０のクリップ爪６１に嵌合され組み付けられる。 FIG. 2 is a perspective view showing an example of use of the foamed resin molded product 50 molded by the molding apparatus 10. The foamed resin molded product 50 is an automotive part and is a ventilation duct that is assembled to the back surface of the instrument panel that is the mating member 60. The foamed resin molded product 50 has an opening 51 provided in the molded product 50 so as to be separated from the outer periphery 50x. The opening 51 is used to fit and assemble the clip claw 61 of the mating member 60.
図３及び図４に基づき、発泡樹脂成形品５０の開口５１端部を形成するスペーサ７０について説明する。図３はスペーサ７０の斜視図、図４は図３のIV-IV線断面図を示す。 The spacer 70 that forms the end of the opening 51 of the foamed resin molded product 50 will be described with reference to FIGS. 3 and 4. 3 is a perspective view of the spacer 70, and FIG. 4 is a sectional view taken along line IV-IV in FIG.
図３に示すように、本実施例のスペーサ７０は、開口５１と同形状の開口部７１と、成形品５０の厚さ方向側に位置する上下面部７２，７３と、スペーサ７０の成形品５０内方側の外周面を形成する外周部７４と、この外周部７４から延設され、断面略楔状の凹部を有するアンダーカット部７５とから構成される。このスペーサ７０の材質は成形品５０と同一の発泡性樹脂４０であり、図示しない成形型を用いて射出成形により予め発泡成形しておく。 As shown in FIG. 3, the spacer 70 of this embodiment includes an opening 71 having the same shape as the opening 51, upper and lower surface portions 72 and 73 positioned on the thickness direction side of the molded product 50, and the molded product 50 of the spacer 70. The outer peripheral part 74 which forms the outer peripheral surface of an inner side, and the undercut part 75 extended from this outer peripheral part 74 and having a substantially wedge-shaped recessed part in cross section are comprised. The material of the spacer 70 is the same foamable resin 40 as that of the molded product 50, and is previously foam-molded by injection molding using a molding die (not shown).
図５ａ、図５ｂは、本実施例１に係る成形型の要部断面拡大図であって、図５ａは充填工程、図５ｂはコアバック工程を示すものである。 5a and 5b are enlarged cross-sectional views of the main part of the mold according to the first embodiment, in which FIG. 5a shows a filling process and FIG. 5b shows a core back process.
固定型３１から可動型３２を開いた状態で、凹部３１ａとスペーサ７０の開口部７１とを対応させてスペーサ７０を固定型３１に配置した後、可動型３２を近接移動させて型締めを行う。この時、図に示すように、可動型３２の凸部３２ａは、スペーサ７０の開口部７１と凹部３１ａとに隙間なく突入しており、固定型３１、可動型３２及びスペーサ７０とで充填用キャビティ３３が形成される。また、この時、スペーサ７０の上下面部７２，７３は固定型３１と可動型３２とに所定の圧力で挟持されており、射出圧力が掛かっても位置決め精度は担保されている。 In a state where the movable mold 32 is opened from the fixed mold 31, after the spacer 70 is disposed on the fixed mold 31 with the recess 31 a corresponding to the opening 71 of the spacer 70, the movable mold 32 is moved close to perform mold clamping. . At this time, as shown in the figure, the convex portion 32a of the movable mold 32 protrudes into the opening 71 and the concave portion 31a of the spacer 70 without any gap, and is filled with the fixed mold 31, the movable mold 32, and the spacer 70. A cavity 33 is formed. At this time, the upper and lower surfaces 72 and 73 of the spacer 70 are sandwiched between the fixed mold 31 and the movable mold 32 at a predetermined pressure, and the positioning accuracy is ensured even when the injection pressure is applied.
次に、射出機２０から発泡性樹脂４０が充填用キャビティ３３内に射出される。この射出された発泡性樹脂４０は充填用キャビティ３３内に充填され、スペーサ７０のアンダーカット部７５の背面にも流入する。充填用キャビティ３３内に隙間なく発泡性樹脂４０が充填され、キャビティ内が所定圧力になった時点で射出を終了する。 Next, the foamable resin 40 is injected from the injection machine 20 into the filling cavity 33. The injected foamable resin 40 is filled in the filling cavity 33 and flows into the back surface of the undercut portion 75 of the spacer 70. The filling cavity 33 is filled with the foamable resin 40 without a gap, and the injection is terminated when the inside of the cavity reaches a predetermined pressure.
図５ｂに示すように、コアバックしたときに、成形用キャビティ３３が形成される。コアバック工程では、内部で発泡セルが成長する一方、成形品５０の表面には表層部５０ａが形成される。また、前述したように、成形品５０の縁部が成形品５０の内方に向かって縮退しようとする力、所謂縮退力が発生するが、成形品５０の縁部はスペーサ７０のアンダーカット部７５の背面に回り込んだ状態で発泡成形しているため、成形品５０の縁部は成形用キャビティ３３の形状を維持したまま縮退の発生はない。
このようにして、スペーサ７０を成形品形状の輪郭形成端部の一部とした成形品５０が形成される。
As shown in FIG. 5b, a molding cavity 33 is formed when the core is backed. In the core back process, foam cells grow inside, and a surface layer portion 50 a is formed on the surface of the molded product 50. Further, as described above, a force that causes the edge of the molded product 50 to contract toward the inside of the molded product 50, that is, a so-called degenerate force, is generated. Since the foam molding is performed in a state of wrapping around the back surface of 75, the edge of the molded product 50 is not degenerated while maintaining the shape of the molding cavity 33.
In this way, the molded product 50 is formed in which the spacer 70 is a part of the molded product-shaped contour forming end.
図６ａ、図６ｂは、本実施例２に係る成形型の要部断面拡大図であって、図６ａは充填工程、図６ｂはコアバック工程を示すものである。
実施例１との相違点は、スペーサ７０の形状である。尚、実施例１と同一の部材は同一符号を付す。
6a and 6b are enlarged cross-sectional views of the main part of the mold according to the second embodiment. FIG. 6a shows a filling process and FIG. 6b shows a core back process.
The difference from the first embodiment is the shape of the spacer 70. The same members as those in the first embodiment are denoted by the same reference numerals.
スペーサ７０の開口部７１は成形品形状の輪郭形成端部の端部全面を形成する、所謂スペーサ７０の厚さが成形品５０の厚さと同じものを用いる。スペーサ７０は断面が楔状凹部を有する台形状のアンダーカット部７５を備えた第１スペーサ部７６と第２スペーサ部７７とから構成されている。このスペーサ７０材質は、実施例１と同様に、成形品５０と同一の発泡性樹脂４０であり、図示しない成形型を用いて射出、発泡成形により予め成形されている。 As the opening 71 of the spacer 70, a so-called spacer 70 having the same thickness as that of the molded product 50, which forms the entire end portion of the contoured end of the molded product shape, is used. The spacer 70 includes a first spacer portion 76 and a second spacer portion 77 each having a trapezoidal undercut portion 75 having a wedge-shaped recess in cross section. The material of the spacer 70 is the same expandable resin 40 as that of the molded product 50 as in the first embodiment, and is preliminarily molded by injection and foam molding using a molding die (not shown).
図６ａに示すように、充填工程時は、固定型３１と可動型３２と第１スペーサ部７６とにより充填用キャビティ３３が形成されている。尚、第２スペーサ部７７は可動型３２に形成された収容部３２ｂ内に収容されている。
発泡性樹脂４０が射出されると、発泡性樹脂４０は充填用キャビティ３３内に充填され、スペーサ７０のアンダーカット部７５の背面にも流入し、充填が完了する。
As shown in FIG. 6a, the filling cavity 33 is formed by the fixed mold 31, the movable mold 32, and the first spacer portion 76 during the filling process. Note that the second spacer portion 77 is housed in a housing portion 32 b formed in the movable mold 32.
When the foamable resin 40 is injected, the foamable resin 40 is filled into the filling cavity 33 and also flows into the back surface of the undercut portion 75 of the spacer 70 to complete the filling.
コアバックしたときに、第２スペーサ部７７がキャビティ内に現れ、成形用キャビティ３３が形成される。このコアバック量は、スペーサ７０の厚さが成形品５０の厚さと同じになるように設定されている。コアバック工程で、成形品５０の縁部が成形品５０の内方に向かって縮退しようとする縮退力が発生するが、成形品５０の縁部はスペーサ７０のアンダーカット部７５の背面に回り込んだ状態で発泡しているため、成形品５０の縁部は成形用キャビティ３３の形状を維持したまま縮退の発生はない。また、スペーサ７０を成形品形状の輪郭形成端部の全面とすることができ、端部を一様で一体的な構造とすることができる。 When the core is backed, the second spacer 77 appears in the cavity, and the molding cavity 33 is formed. The core back amount is set so that the thickness of the spacer 70 is the same as the thickness of the molded product 50. In the core back process, a degeneration force is generated in which the edge of the molded product 50 tends to shrink toward the inside of the molded product 50, but the edge of the molded product 50 rotates around the back surface of the undercut portion 75 of the spacer 70. Since the foamed portion is foamed, the edge of the molded product 50 is not degenerated while the shape of the molding cavity 33 is maintained. Further, the spacer 70 can be the entire surface of the molded product-shaped contour forming end portion, and the end portion can have a uniform and integral structure.
図７ａ、図７ｂは、本実施例３に係る成形型の要部断面拡大図であって、図７ａは充填工程、図７ｂはコアバック工程を示すものである。
実施例１との相違点は、スペーサ７０の配置位置と形状である。尚、実施例１と同一の部材は同一符号を付す。
7a and 7b are enlarged cross-sectional views of the main part of the mold according to the third embodiment, in which FIG. 7a shows a filling process and FIG. 7b shows a core back process.
The difference from the first embodiment is the arrangement position and shape of the spacer 70. The same members as those in the first embodiment are denoted by the same reference numerals.
スペーサ７０は、開口５１と同形状の開口部７１と、成形品５０の厚さ方向側の上下面部７２，７３と、スペーサ７０の成形品５０内方側の外周面を形成する外周部７４と、この外周部７４から延設され、固定型３１方向に向かって断面コ字状の凹部を有するアンダーカット部７８とから構成される。また、スペーサ７０の厚みは、充填用キャビティ３３の間隔より所定量短いものとされている。 The spacer 70 has an opening 71 having the same shape as the opening 51, upper and lower surfaces 72 and 73 on the thickness direction side of the molded product 50, and an outer peripheral portion 74 that forms an outer peripheral surface of the spacer 70 on the inner side of the molded product 50. The undercut portion 78 extends from the outer peripheral portion 74 and has a concave portion having a U-shaped cross section toward the fixed mold 31. The thickness of the spacer 70 is shorter by a predetermined amount than the interval between the filling cavities 33.
スペーサ７０を実施例１と同様に、成形品５０と同一の発泡性樹脂４０を用いて予め形成し、固定型３１から可動型３２を開いた状態で、凹部３１ａとスペーサ７０の開口部７１とを対応させてスペーサ７０を固定型３１に配置する。この時、スペーサ７０は図示しない固定治具を用いて、スペーサ７０の下面部７３と固定型３１とが所定間隔開けた状態となるように固定される。 As in the first embodiment, the spacer 70 is formed in advance using the same foamable resin 40 as that of the molded product 50, and the recessed portion 31 a and the opening portion 71 of the spacer 70 are opened with the movable die 32 opened from the fixed die 31. The spacer 70 is disposed on the fixed mold 31 so as to correspond to each other. At this time, the spacer 70 is fixed using a fixing jig (not shown) so that the lower surface portion 73 of the spacer 70 and the fixed mold 31 are in a state of being spaced apart by a predetermined distance.
スペーサ７０を固定型３１に配置した後、可動型３２を近接移動させて型締めを行う。この時、図７ａに示すように、可動型３２とスペーサ７０の上面部７２とは当接しているが、固定型３１と下面部７３とは離間した状態で充填用キャビティ３３が形成される。
発泡性樹脂４０が射出されると、発泡性樹脂４０は充填用キャビティ３３内に充填され、スペーサ７０のアンダーカット部７５ａの背面にも流入し、充填が完了する。
After the spacer 70 is disposed on the fixed mold 31, the movable mold 32 is moved close to perform mold clamping. At this time, as shown in FIG. 7a, the movable die 32 and the upper surface portion 72 of the spacer 70 are in contact with each other, but the filling cavity 33 is formed in a state where the fixed die 31 and the lower surface portion 73 are separated from each other.
When the foamable resin 40 is injected, the foamable resin 40 is filled into the filling cavity 33 and flows into the back surface of the undercut portion 75a of the spacer 70, and the filling is completed.
図７ｂに示すように、コアバックしたときに、成形用キャビティ３３が形成される。コアバック工程では、可動型３２が成形品５０の厚み方向に移動するため、スペーサ７０は成形品形状の輪郭形成端部面の中間位置に位置することになる。
ここで、成形品５０の縁部が成形品５０の内方に向かって縮退しようとする縮退力が発生するが、成形品５０の縁部はスペーサ７０のアンダーカット部７５ａの背面に回り込んだ状態で発泡しているため、成形品５０の縁部は成形用キャビティ３３の形状を維持したまま縮退の発生はない。更に、スペーサ７０が小型にも関わらず端部面の中間位置に位置するため、高い縮退防止効果を得ることができる。
As shown in FIG. 7b, a molding cavity 33 is formed when the core is backed. In the core back process, since the movable mold 32 moves in the thickness direction of the molded product 50, the spacer 70 is positioned at an intermediate position of the contoured end surface of the molded product shape.
Here, a degeneration force is generated in which the edge portion of the molded product 50 tends to shrink toward the inside of the molded product 50, but the edge portion of the molded product 50 wraps around the back surface of the undercut portion 75 a of the spacer 70. Since the foaming is performed in the state, the edge of the molded product 50 is not degenerated while maintaining the shape of the molding cavity 33. Furthermore, since the spacer 70 is positioned at an intermediate position of the end face despite the small size, a high degeneration prevention effect can be obtained.
図８〜図１２に基づき、本発明が対象とする成形品の適用例について説明する。尚、図８〜図１２は、発泡樹脂成形品５０の図２とは異なる別の適用例を示す斜視図である。
図８〜図１０は、外周５０ｘに部分的に設けられた切欠５２を有しており、切欠５２を利用して相手部材６０の嵌合突起６２に嵌合され、位置決めされるものである。
図８は平面視で略Ｕ字状のスペーサ７０を用いる場合、図９は略Ｃ字状のスペーサ７０を用いる場合、図１０は略Ｊ字状のスペーサ７０を用いる場合の成形品適用例を示している。
Based on FIGS. 8-12, the application example of the molded article which this invention makes object is demonstrated. 8 to 12 are perspective views showing another application example of the foamed resin molded product 50 different from FIG.
8 to 10 have a notch 52 partially provided on the outer periphery 50x, and the notch 52 is used to fit and be positioned on the fitting protrusion 62 of the mating member 60. FIG.
FIG. 8 shows a case where a substantially U-shaped spacer 70 is used in plan view, FIG. 9 shows a case where a substantially C-shaped spacer 70 is used, and FIG. Show.
図２の場合、平面視で端部のない無端ループ形状であるが、前述のような、端部を有するスペーサ７０であっても、スペーサ７０内で少なくとも対向する部分を有するものであれば、一方側に発生する縮退力を他方側に発生する縮退力で相殺することができるため、縮退しようとする発泡樹脂の端部の移動を防止することができる。更に、切欠５２の開口を利用して、所定形状のスペーサ７０を可動型３２に備わる凸部に位置決めすることも可能である。 In the case of FIG. 2, it is an endless loop shape without an end in a plan view, but even the spacer 70 having an end as described above has at least a portion facing in the spacer 70. Since the contracting force generated on one side can be offset by the contracting force generated on the other side, it is possible to prevent movement of the end portion of the foamed resin to be contracted. Furthermore, it is possible to position the spacer 70 having a predetermined shape on the convex portion of the movable mold 32 by using the opening of the notch 52.
図１１、図１２は発泡樹脂成形品５０自体の構造で、別の適用例を示す斜視図である。
図１１は成形品５０に開口５１を有するもので、開口５１の内部に薄肉部５３を形成したものである。
図１２は成形品５０に切欠５２を有するもので、開口５２の内部に薄肉部５３を形成したものである。このように、薄肉部５３を備えるものであっても実施例３に示したように、スペーサ７０を成形型３０に対して位置決め固定することで本発明を適用することが可能である。
FIGS. 11 and 12 are perspective views showing another application example of the structure of the foamed resin molded product 50 itself.
In FIG. 11, the molded product 50 has an opening 51, and a thin portion 53 is formed inside the opening 51.
In FIG. 12, the molded product 50 has a notch 52, and a thin portion 53 is formed inside the opening 52. As described above, even when the thin portion 53 is provided, the present invention can be applied by positioning and fixing the spacer 70 with respect to the mold 30 as shown in the third embodiment.
次に、前記実施例を部分的に変更した変形例について説明する。
１〕前記実施例１，２，３においては、合成樹脂を用いた例について説明したが、樹脂の種類はこれに限られるものではなく、ガラス繊維を含有する合成樹脂を用いることも可能である。
Next, a modification in which the above embodiment is partially changed will be described.
1] In Examples 1, 2, and 3, the example using the synthetic resin has been described. However, the type of the resin is not limited to this, and it is also possible to use a synthetic resin containing glass fiber. .
２〕その他、当業者であれば、本発明の趣旨を逸脱することなく、前記実施例に種々の変更を付加した形態で実施可能であり、本発明はそのような変更形態も包含するものである。 2] In addition, those skilled in the art can implement the present invention in various forms added with various modifications without departing from the spirit of the present invention, and the present invention includes such modifications. is there.
１０ 成形装置
３０ 成形型
３１ 固定型
３２ 可動型
３３ キャビティ
５０ 発泡樹脂成形品
５１ 開口
７０ スペーサ
７５,７８ アンダーカット部
10 Molding equipment
30 Mold 31 Fixed mold 32 Movable mold 33 Cavity 50 Foamed resin molded product 51 Opening 70 Spacer 75, 78 Undercut part
Claims (5)
成形品形状の輪郭形成端部のうちの特定部位については成形品形状の輪郭形成端部を発泡部材にて形成して、この発泡部材を充填用キャビティに配置する工程と、
前記発泡部材が配置された状態で充填用キャビティに発泡性樹脂を充填する充填工程と、
前記可動型を前記固定型から成形品の厚み方向にコアバックして発泡性樹脂を発泡させる発泡工程と、
を備えることを特徴とする発泡樹脂成形品の成形方法。 A fixed mold is formed by forming a filling cavity between the fixed mold and the fixed mold in the same shape as the molded product shape and having a smaller thickness than the molded product shape, and core back from the fixed mold in the thickness direction of the molded product. And a movable mold for forming a molding cavity between them, filling the foamable resin into the filling cavity, and foaming the foamable resin in the molding cavity with a movable core back to obtain a molded product. A method of molding a foamed resin molded product to be molded,
For a specific part of the contoured end of the molded product shape, forming the contoured end of the molded product shape with a foamed member, and placing the foamed member in the filling cavity; and
A filling step of filling a foaming resin into a filling cavity in a state where the foaming member is disposed;
A foaming step of foaming a foamable resin by core-backing the movable mold from the fixed mold in the thickness direction of the molded product,
A method for molding a foamed resin molded product, comprising:
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| JP2013091511A (en) * | 2011-10-26 | 2013-05-16 | Sanko Co Ltd | Wall body structure for container and method for manufacturing container |
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|---|---|---|---|---|
| JP2005186542A (en) * | 2003-12-26 | 2005-07-14 | Idemitsu Kosan Co Ltd | Multi-colored molded article and its manufacturing method |
| JP2006088659A (en) * | 2004-09-27 | 2006-04-06 | Fuji Photo Film Co Ltd | Porous membrane cartridge and its manufacturing process |
| JP2007182025A (en) * | 2006-01-10 | 2007-07-19 | Mazda Motor Corp | Method for molding resin molded article |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005186542A (en) * | 2003-12-26 | 2005-07-14 | Idemitsu Kosan Co Ltd | Multi-colored molded article and its manufacturing method |
| JP2006088659A (en) * | 2004-09-27 | 2006-04-06 | Fuji Photo Film Co Ltd | Porous membrane cartridge and its manufacturing process |
| JP2007182025A (en) * | 2006-01-10 | 2007-07-19 | Mazda Motor Corp | Method for molding resin molded article |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2013091511A (en) * | 2011-10-26 | 2013-05-16 | Sanko Co Ltd | Wall body structure for container and method for manufacturing container |
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