JP2013188912A - Resin molding and mold device - Google Patents

Resin molding and mold device Download PDF

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JP2013188912A
JP2013188912A JP2012055813A JP2012055813A JP2013188912A JP 2013188912 A JP2013188912 A JP 2013188912A JP 2012055813 A JP2012055813 A JP 2012055813A JP 2012055813 A JP2012055813 A JP 2012055813A JP 2013188912 A JP2013188912 A JP 2013188912A
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resin
cavity
recess
filter member
mold
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Ryota Kita
亮太 喜多
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Panasonic Corp
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Panasonic Corp
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Abstract

PROBLEM TO BE SOLVED: To provide a resin molding that reduces the generation of residual air during casting molding and suppresses strength reduction or a molding failure of a body and to provide a mold device for molding the resin molding by casting molding.SOLUTION: A resin molding 1 formed by casting molding includes a projection 2 integrated with a rear surface 11a of a body 11 and projected from the rear surface 11a. The projection 2 is a trace of a filter part formed by flowing a resin 8 into a recess 61 of the filter part 6 for suppressing flowing of the resin 8 from a cavity 53 for casting to an exhaust port 42 during casting molding. The projection 2 has a filter member 62 of the filter part 6 in a state impregnated with the resin 8 during casting molding. Accordingly, residual air 9 is hardly generated during casting molding resulting in easily suppressing strength reduction or a molding failure of the body 11.

Description

本発明は、樹脂成型品、及びこの樹脂成型品を注型成形によって形成するための金型装置に関するものである。   The present invention relates to a resin molded product and a mold apparatus for forming the resin molded product by cast molding.

従来から、注型成形によって成形する樹脂成型品として、浴槽や、洗面台の洗面ボウルや、便器装置のボウル部や、キッチンカウンタや、樹脂シンク等がある。例えば、特許文献１等に示すように、注型成形用の金型装置を用いた樹脂成形によって、浴槽を形成するものがある。   Conventionally, resin molded products molded by casting include a bathtub, a wash bowl of a washstand, a bowl portion of a toilet device, a kitchen counter, a resin sink, and the like. For example, as shown in Patent Document 1 and the like, there is one that forms a bathtub by resin molding using a mold apparatus for cast molding.

特開平９−２７７２８０号公報Japanese Patent Laid-Open No. 9-277280

ところで、注型成形によって樹脂成型品を成形するにあたって、注型成形時に、図６に示すように、注入した樹脂８が、キャビティ５９全体に充填される前に排気口４９に至って、キャビティ５９内の空気が途中で排出されなくなる場合がある。この場合、キャビティ５９内に空気が残留した状態で樹脂成型品を形成することになり、残留した空気（残留空気９）によって型通りに形成されず、強度が設計より低下したり、成形不良を生じたりすることがある。   By the way, when molding a resin molded product by cast molding, at the time of cast molding, the injected resin 8 reaches the exhaust port 49 before filling the entire cavity 59 as shown in FIG. Air may not be exhausted on the way. In this case, a resin molded product is formed in a state where air remains in the cavity 59, and the resin is not formed as usual due to the remaining air (residual air 9). May occur.

そこで、この事情を鑑み、注型成形時の残留空気の発生を軽減して、本体の強度低下や成形不良を抑制した樹脂成型品、及び前記樹脂成型品を注型成形によって形成するための金型装置を提供することを課題とした。   Therefore, in view of this situation, a resin molded product that reduces the occurrence of residual air at the time of casting and suppresses a decrease in strength of the main body and molding defects, and a gold for forming the resin molded product by casting. An object was to provide a mold apparatus.

上記課題を解決するために、本発明は、注型成形で形成した樹脂成型品であって、本体の裏面に一体で且つ前記裏面から突出した凸部を備え、前記凸部が、前記注型成形時に注型用のキャビティから排気口への樹脂の流入を抑制するフィルター部の凹みに樹脂を充填して形成したフィルター部跡であり、前記凸部が、前記フィルター部のフィルター部材を前記注型成形時に前記樹脂を含浸した状態で有するものであることを特徴とする。   In order to solve the above-mentioned problem, the present invention is a resin molded product formed by cast molding, and is provided with a convex portion integrally formed on the back surface of the main body and protruding from the back surface, and the convex portion is the cast material. It is a filter part trace formed by filling resin into a recess of a filter part that suppresses the inflow of resin from the casting cavity to the exhaust port during molding, and the convex part is the filter member of the filter part. It is characterized by having the resin impregnated at the time of molding.

また、本発明の金型装置は、樹脂成型品注型用のキャビティを形成する型部と、該キャビティ内に樹脂を注入する樹脂注入部と、前記キャビティ内の空気を排出する排気口とを備え、前記型部が、前記樹脂成型品の裏面側形成面と前記排気口の上流開口端との間に、前記キャビティ及び前記上流開口端に連通し前記排気口への前記樹脂の流入を抑制するフィルター部を有し、前記フィルター部が、前記樹脂注入部による前記キャビティへの前記樹脂の充填時に前記キャビティを介して前記樹脂を注入する凹みと、前記上流開口端全体を覆うフィルター部材とを有し、前記フィルター部材を、前記型部に着脱自在で前記凹みに配置してあることを特徴とする。   The mold apparatus of the present invention includes a mold part that forms a cavity for casting a resin molded product, a resin injection part that injects resin into the cavity, and an exhaust port that discharges air in the cavity. The mold portion communicates with the cavity and the upstream opening end between the rear surface forming surface of the resin molded product and the upstream opening end of the exhaust port, and suppresses the inflow of the resin to the exhaust port. And a filter member that injects the resin through the cavity when the resin is filled into the cavity by the resin injection unit, and a filter member that covers the entire upstream opening end. And the filter member is detachably attached to the mold part and disposed in the recess.

このような構成としたことで、注型成形時の残留空気の発生を軽減し易くすることができて、樹脂成型品の本体を略設計通りの形状や強度で形成し易くすることができる。これによって、本発明は、例えば残留空気に伴う本体の強度低下を加味して形成した場合に比べて本体を薄肉化して所望の強度を得易くすることができる等、注型成形時の樹脂の使用量を低減し易くすることができる。更に、本発明は、前述のように薄肉化した場合、樹脂成型品を軽量化し易くすることができて、運搬費用を低減したり、樹脂成型品設置時の作業負荷を軽減したりし易くすることができる。   By adopting such a configuration, it is possible to easily reduce the generation of residual air at the time of casting, and it is possible to easily form the main body of the resin molded product with a shape and strength substantially as designed. Thereby, the present invention can reduce the thickness of the main body to make it easier to obtain a desired strength than when formed by taking into account the strength reduction of the main body due to residual air, for example. The amount used can be easily reduced. Furthermore, when the present invention is thinned as described above, the resin molded product can be easily reduced in weight, thereby reducing the transportation cost and reducing the work load when installing the resin molded product. be able to.

実施形態の一例の樹脂成型品の凸部周辺の断面図である。It is sectional drawing of the convex part periphery of the resin molded product of an example of embodiment. 同上の樹脂成型品を形成するための金型装置のフィルター部周辺の断面図である。It is sectional drawing of the filter part periphery of the metal mold | die apparatus for forming the resin molded product same as the above. 同上の金型装置における樹脂充填の説明図であり、（ａ）が樹脂注入直前であり、（ｂ）が第１部位への樹脂流入時であり、（ｃ）が第２部位への樹脂流入直前であり、（ｄ）が樹脂充填完了時である。It is explanatory drawing of resin filling in a metal mold apparatus same as the above, (a) is just before resin injection, (b) is the time of resin inflow to the 1st part, (c) is resin inflow to the 2nd part. Immediately before, (d) is when resin filling is completed. フィルター部周辺における樹脂充填時の説明図であり、（ａ）が流動末端への樹脂流入時であり、（ｂ）が本体表面側の充填完了直前であり、（ｃ）が本体裏面側の充填完了直前であり、（ｄ）が樹脂成型品の樹脂充填完了時である。It is explanatory drawing at the time of resin filling in the filter part periphery, (a) is at the time of resin inflow to a flow end, (b) is just before completion of filling on the main body surface side, (c) is filling on the back surface side of the main body. Immediately before completion, (d) is when resin filling of the resin molded product is completed. 金型装置の変形例のフィルター部周辺の断面図である。It is sectional drawing of the filter part periphery of the modification of a metal mold apparatus. 従来の樹脂充填時の説明図であり、（ａ）が流動末端への樹脂流入時であり、（ｂ）が表面側の充填完了直前であり、（ｃ）が裏面側の充填完了直前であり、（ｄ）が樹脂成型品の樹脂充填完了時である。It is explanatory drawing at the time of the conventional resin filling, (a) is the time of resin inflow to a flow end, (b) is just before completion of filling of the surface side, (c) is immediately before completion of filling of the back side. (D) is when the resin filling of the resin molded product is completed.

本発明を、添付図面に示す実施形態に基づいて説明する。   The present invention will be described based on embodiments shown in the accompanying drawings.

本実施形態の樹脂成型品１は、例えば熱硬化性の樹脂８（以下、樹脂８とする）から注型成形で形成した浴槽となっている。この浴槽は、図１に示すように、内側に貯湯空間１４を有した容器形状の本体１１で主体が構成される。本体１１は容器の側壁１２と底部１３に囲まれた貯湯空間１４を容器内側に有すると共に、この側壁１２の内面及び底部１３の内面が、外観に露出する意匠面（表面）となっている。そして、本体１１は、意匠面の反対側である容器の裏面１１ａのうち、外観に露出しない底部１３の下面１３ａに、凸部２を備える。   The resin molded product 1 of the present embodiment is a bathtub formed by cast molding from, for example, a thermosetting resin 8 (hereinafter referred to as resin 8). As shown in FIG. 1, the main body of the bathtub is composed of a container-shaped main body 11 having a hot water storage space 14 inside. The main body 11 has a hot water storage space 14 surrounded by the side wall 12 and the bottom portion 13 of the container inside the container, and the inner surface of the side wall 12 and the inner surface of the bottom portion 13 form a design surface (surface) exposed to the appearance. And the main body 11 is equipped with the convex part 2 in the lower surface 13a of the bottom part 13 which is not exposed to the external appearance among the back surfaces 11a of the container which is the other side of the design surface.

凸部２は、本体１１から下方に突出して設けてある。そして、凸部２は、本体１１と同じ樹脂８で、本体１１と一体に形成してある。また、凸部２は、フィルター部６（詳細は後述する）の凹み６１に樹脂８を注入（流入）して形成したフィルター部跡となっている。そして、凸部２はフィルター部材６２が埋設してある。   The convex portion 2 is provided so as to protrude downward from the main body 11. The convex portion 2 is formed of the same resin 8 as the main body 11 and is formed integrally with the main body 11. Further, the convex portion 2 is a filter portion trace formed by injecting (inflowing) the resin 8 into a recess 61 of the filter portion 6 (details will be described later). The convex portion 2 is embedded with a filter member 62.

フィルター部材６２（詳細は後述する）は樹脂８と共に凸部２の一部を形成する。そして、フィルター部材６２は、注型成形の樹脂８注入時に樹脂８が含浸されており、この含浸した樹脂８によって本体１１に固定してある。更に、凸部２の突出先端は、フィルター部材６２の樹脂８を含浸していない部位で形成してある。   The filter member 62 (details will be described later) forms part of the convex portion 2 together with the resin 8. The filter member 62 is impregnated with the resin 8 when the resin 8 for casting is injected, and is fixed to the main body 11 with the impregnated resin 8. Furthermore, the protruding tip of the convex portion 2 is formed at a portion of the filter member 62 that is not impregnated with the resin 8.

以下、本実施形態の樹脂成型品１における凸部２の作用効果を説明するにあたって、まず、前記浴槽（樹脂成型品１）を注型成形によって形成するための金型装置を説明する。   Hereinafter, in describing the operation and effect of the convex portion 2 in the resin molded product 1 of the present embodiment, first, a mold apparatus for forming the bathtub (resin molded product 1) by cast molding will be described.

金型装置は、図３（ａ）に示すように、キャビティ５３を形成する型部５と、キャビティ５３内の空気を排出する排気口４２と、キャビティ５３に樹脂８を注入する樹脂注入部４１とを備える。そして、金型装置は、裏面１１ａ側（下面１３ａ側）を上向きにして、樹脂成型品１（浴槽）を上下反転させた向きで成形する構成になっている。   As shown in FIG. 3A, the mold apparatus includes a mold part 5 that forms a cavity 53, an exhaust port 42 that discharges air in the cavity 53, and a resin injection part 41 that injects resin 8 into the cavity 53. With. The mold apparatus is configured to mold the resin molded product 1 (bathtub) upside down with the back surface 11a side (lower surface 13a side) facing upward.

樹脂注入部４１は、キャビティ５３の樹脂成型品１の本体１１外周端である浴槽の側壁１２の容器開口側の端部を形成する部位に、注入口４１ａが開口している。そして、樹脂注入部４１は樹脂成型品１の本体１１外周端側から内側に向かってキャビティ５３内に樹脂８を注入する。また、この樹脂８注入時には、キャビティ５３内の空気が、注入された樹脂８に押されるように流動して、排気口４２に流入する。   In the resin injection part 41, an injection port 41 a is opened at a part forming an end part on the container opening side of the side wall 12 of the bathtub, which is the outer peripheral end of the main body 11 of the resin molded product 1 of the cavity 53. The resin injection portion 41 injects the resin 8 into the cavity 53 from the outer peripheral end side of the main body 11 of the resin molded product 1 toward the inside. Further, when the resin 8 is injected, the air in the cavity 53 flows so as to be pushed by the injected resin 8 and flows into the exhaust port 42.

排気口４２は円筒形状で型部５に設けてある。そして、排気口４２は、筒の上流側の端部（上流開口端４２ａ）がキャビティ５３の上方側に開口しており、反対側である下流側の端部（下流側開口端４２ｂ）が外部に開口している。そのため、キャビティ５３内の空気は、樹脂８注入に伴い流動することで、上流開口端４２ａから排気口４２内に流入して、下流開口端４２ｂから型部５外に排出される。   The exhaust port 42 has a cylindrical shape and is provided in the mold part 5. The exhaust port 42 has an upstream end (upstream opening end 42a) of the cylinder opening above the cavity 53, and a downstream end (downstream opening end 42b) on the opposite side is external. Is open. Therefore, the air in the cavity 53 flows along with the injection of the resin 8, flows into the exhaust port 42 from the upstream opening end 42 a, and is discharged out of the mold part 5 from the downstream opening end 42 b.

型部５は、浴槽の内面側（表面側）の面形状を形成する第１型部５１と、浴槽の外面及び下面１３ａ側（裏面１１ａ側）の面形状を形成する第２型部５２とを備える。言い換えると、第１型部５１は、浴槽の内面側（表面側）の面形状を形成する表面側形成面を有し、第２型部５２は、浴槽の外面及び下面１３ａ側（裏面１１ａ側）の面形状を形成する裏面側形成面５２ａを有する。そして、型部５は、第１型部５１と第２型部５２とを合わせて型閉めすることで、前記表面側形成面及び裏面側形成面５２ａで囲まれた内部空間が、本体１１を形成するためのキャビティ５３となる。言い換えると、型部５は、型閉めすることで、内部にキャビティ５３を形成する。   The mold part 5 includes a first mold part 51 that forms a surface shape on the inner surface side (front surface side) of the bathtub, and a second mold part 52 that forms a surface shape on the outer surface and the lower surface 13a side (back surface 11a side) of the bathtub. Is provided. In other words, the 1st type | mold part 51 has the surface side formation surface which forms the surface shape of the inner surface side (surface side) of a bathtub, and the 2nd type | mold part 52 has the outer surface and lower surface 13a side (back surface 11a side) of a bathtub. ) Has a back surface forming surface 52a. Then, the mold unit 5 closes the mold by combining the first mold unit 51 and the second mold unit 52, so that the internal space surrounded by the front surface side forming surface and the back surface side forming surface 52 a It becomes the cavity 53 for forming. In other words, the mold part 5 forms the cavity 53 inside by closing the mold.

また、型部５は、図２や図４に示すように、キャビティ５３と上流開口端４２ａとの間に、キャビティ５３から上方に凹んだ凹み６１を有する。凹み６１は、排気口４２より大径の円筒状になっており、排気口４２の下方に略同心で設けてある。そして、凹み６１は円筒の上端面６１ａが平面形状になっており、平面の略中央に排気口４２の上流開口端４２ａが開口する。更に、凹み６１は下端面の略全体がキャビティ５３に開口する。   Further, as shown in FIGS. 2 and 4, the mold part 5 has a recess 61 that is recessed upward from the cavity 53 between the cavity 53 and the upstream opening end 42 a. The recess 61 has a cylindrical shape with a larger diameter than the exhaust port 42, and is provided substantially concentrically below the exhaust port 42. The upper end surface 61a of the cylinder has a planar shape in the recess 61, and the upstream opening end 42a of the exhaust port 42 opens at substantially the center of the plane. Further, the recess 61 is open to the cavity 53 at substantially the entire lower end surface.

言い換えると、凹み６１は上流開口端４２ａより上流側に設けてある。そして、凹み６１は上端面６１ａが略中央で排気口４２に連通し、下端面が略全体でキャビティ５３に連通する。そのため、下端面はキャビティ５３との連通端６３になっている。そして、連通端６３は、樹脂８が最後に流入するキャビティ５３の流動末端に設けてある。   In other words, the recess 61 is provided on the upstream side of the upstream opening end 42a. The recess 61 communicates with the exhaust port 42 at the upper end surface 61a at substantially the center and communicates with the cavity 53 at the lower end surface. Therefore, the lower end surface is a communication end 63 with the cavity 53. The communication end 63 is provided at the flow end of the cavity 53 into which the resin 8 finally flows.

具体的には、例えば、排気口４２の上流開口端４２ａをφ約５ｍｍとした場合、凹み６１がφ約１５０ｍｍになっている。そして、凹み６１は、円筒の軸方向の寸法（連通端６３から上端面６１ａまでの深さ寸法）が約１０ｍｍとなっている。更に、連通端６３は、第２型部５２の裏面側形成面５２ａのうち、浴槽の底部１３の下面１３ａ（裏面１１ａ）を形成する部位に設けてある。   Specifically, for example, when the upstream opening end 42a of the exhaust port 42 has a diameter of about 5 mm, the recess 61 has a diameter of about 150 mm. The recess 61 has a cylindrical axial dimension (a depth dimension from the communication end 63 to the upper end surface 61a) of about 10 mm. Furthermore, the communication end 63 is provided in the site | part which forms the lower surface 13a (back surface 11a) of the bottom part 13 of a bathtub among the back surface side formation surfaces 52a of the 2nd type | mold part 52. As shown in FIG.

そのため、キャビティ５３内の空気は、凹み６１を介して排気口４２に導入（流入）される。そして、凹み６１は、キャビティ５３の流動末端に位置するため、樹脂８注入時に、樹脂８がキャビティ５３に比べて流入され難い（流入されるのが遅い）構成になっている。そのため、凹み６１には、キャビティ５３内の空気が溜まり易い。   Therefore, the air in the cavity 53 is introduced (inflowed) into the exhaust port 42 via the recess 61. Since the recess 61 is located at the flow end of the cavity 53, the resin 8 is less likely to flow into the cavity 53 when the resin 8 is injected (slowly flows in). Therefore, the air in the cavity 53 tends to accumulate in the recess 61.

また、凹み６１内には、フィルター部材６２が配置してある。フィルター部材６２は、凹み６１の内部空間の略全体を占める寸法形状になっている。そのため、フィルター部材６２は、凹み６１内に配置されることで、凹み６１の上端面６１ａ及び上流開口端４２ａを覆う。具体的には、例えば、フィルター部材６２が、φ約１５０ｍｍで厚み１０ｍｍの円板形状になっている。そして、フィルター部材６２は、キャビティ５３内に充填した状態の樹脂８に比べて密度の小さい部材（軽い部材）で形成してあり、例えば、標準密度０．２０ｇ／立方ｃｍのポリエステルとなっている。   A filter member 62 is disposed in the recess 61. The filter member 62 has a dimensional shape that occupies substantially the entire internal space of the recess 61. Therefore, the filter member 62 is disposed in the recess 61 to cover the upper end surface 61 a and the upstream opening end 42 a of the recess 61. Specifically, for example, the filter member 62 has a disk shape with a diameter of about 150 mm and a thickness of 10 mm. The filter member 62 is formed of a member (light member) having a density lower than that of the resin 8 filled in the cavity 53, and is, for example, polyester having a standard density of 0.20 g / cubic cm. .

更に、フィルター部材６２は、通気性を有すると共に、内部に樹脂８を含浸可能になっている。言い換えると、フィルター部材６２は、空気が流通し易く、且つ樹脂８が空気に比べて流通し難いが浸透可能（含浸可能）になっている。そのため、フィルター部材６２を配置した凹み６１は、排気口４２への樹脂８の流入を抑制するフィルター部６として機能する。言い換えると、フィルター部６は、凹み６１と、フィルター部材６２とを備える。更に、フィルター部材６２は、含浸した樹脂８が硬化することで、本体１１に固定される。これによって、フィルター部材６２は、樹脂成型品１の一部となる。   Further, the filter member 62 has air permeability and can be impregnated with the resin 8 inside. In other words, in the filter member 62, air can easily flow and the resin 8 is less likely to flow than air, but can be penetrated (impregnated). Therefore, the dent 61 in which the filter member 62 is disposed functions as the filter unit 6 that suppresses the inflow of the resin 8 into the exhaust port 42. In other words, the filter unit 6 includes a recess 61 and a filter member 62. Further, the filter member 62 is fixed to the main body 11 when the impregnated resin 8 is cured. Thereby, the filter member 62 becomes a part of the resin molded product 1.

また、フィルター部材６２は、第２型部５２に着脱自在で取り付けてある。そして、フィルター部材６２は、樹脂成型品１を型部５から取り出す（離型する）際に、樹脂成型品１の一部として型部５から離脱する。具体的には、例えば、フィルター部材６２が、凹み６１の上端面６１ａや側面（円筒内面）等に接着剤等で接着して取り付けてある。そして、接着剤は、樹脂成型品１の離型時にフィルター部材６２の離型を妨げないものであればよく、例えば加熱部（詳細は後述する）による加熱によって劣化や軟化する等で保持（接着）を解除するもの等となっている。フィルター部材６２は、前記保持の解除によって、型部５から離脱する（離型する）。   The filter member 62 is detachably attached to the second mold part 52. The filter member 62 is detached from the mold part 5 as a part of the resin molded article 1 when the resin molded article 1 is taken out (released) from the mold part 5. Specifically, for example, the filter member 62 is attached to the upper end surface 61a or the side surface (cylindrical inner surface) of the recess 61 with an adhesive or the like. The adhesive may be any adhesive that does not interfere with the release of the filter member 62 when the resin molded product 1 is released. For example, the adhesive is retained (adhered by being deteriorated or softened by heating by a heating unit (details will be described later)). ). The filter member 62 is released (released) from the mold part 5 by releasing the holding.

また、金型装置は、充填した樹脂８を加熱する加熱部（図示せず）と、注型成形を制御する制御部（図示せず）とをさらに備える。加熱部は、型部５を加熱することで、キャビティ５３内の温度を上昇させて、キャビティ５３内に充填した樹脂８を熱硬化させる。なお、加熱部は、例えば、型部５に埋め込まれたものや、型部５の外部に設けられたもの等の注型成形用の周知の加熱手段となっている。   The mold apparatus further includes a heating unit (not shown) for heating the filled resin 8 and a control unit (not shown) for controlling the casting. The heating unit heats the mold unit 5 to increase the temperature in the cavity 53 and thermoset the resin 8 filled in the cavity 53. Note that the heating unit is a well-known heating means for cast molding such as one embedded in the mold unit 5 or one provided outside the mold unit 5.

制御部は、樹脂注入部４１に対して、樹脂８の注入開始や停止等を指令したり、樹脂８注入時に樹脂８の注入量を一定に調整する注入制御を行ったりして、金型装置の樹脂８成形を制御する。そして、制御部は樹脂８の注入制御用に、例えば、キャビティ５３に注入した樹脂８の量（注入量）を検知する検知部（図示せず）を備えており、検知部の検知結果に応じて、注入制御を行う。   The control unit instructs the resin injection unit 41 to start or stop the injection of the resin 8, or performs injection control to adjust the injection amount of the resin 8 at the time of the injection of the resin 8 to perform the mold apparatus. The resin 8 molding is controlled. And the control part is provided with the detection part (not shown) which detects the quantity (injection amount) of the resin 8 inject | poured into the cavity 53 for injection | pouring control of the resin 8, for example according to the detection result of a detection part. To perform injection control.

検知部は、例えば、樹脂注入部４１の注入量を検知し、この注入量の累積値を検知結果として制御部に出力するもの等となっている。なお、検知部は、注入量を検知するものに限らず、樹脂注入部４１の注入動作時間等の注入量の指標となる注入時間を検知して制御部に出力するもの等であってもよく、前記時間を検知する場合、制御部が検知部としての機能を兼ねてもよい。   For example, the detection unit detects an injection amount of the resin injection unit 41 and outputs a cumulative value of the injection amount to the control unit as a detection result. The detection unit is not limited to detecting the injection amount, and may be one that detects an injection time that is an index of the injection amount such as the injection operation time of the resin injection unit 41 and outputs the injection time to the control unit. When detecting the time, the control unit may also function as a detection unit.

ところで、金型装置による注型成形方法は、型部５でキャビティ５３を形成する型閉め処理と、キャビティ５３内に樹脂８を充填する充填処理と、充填した樹脂８を加熱硬化させる硬化処理と、型部５を開き樹脂成型品１を取り外す離型処理とを有する。そして、注型成形方法は、型閉め処理、充填処理、硬化処理、離型処理の順番で行われる。また、注型成形方法は、本実施形態の金型装置を用いた場合、型閉め処理の前に、フィルター部材６２を取り付ける準備処理を更に有する。   By the way, the casting molding method using the mold apparatus includes a mold closing process for forming the cavity 53 in the mold part 5, a filling process for filling the cavity 8 with the resin 8, and a curing process for heating and curing the filled resin 8. The mold part 5 is opened and the resin molded product 1 is removed. The cast molding method is performed in the order of a mold closing process, a filling process, a curing process, and a mold release process. Further, the casting method further includes a preparation process for attaching the filter member 62 before the mold closing process when the mold apparatus of the present embodiment is used.

準備処理は、型閉め前の第２型部５２の凹み６１にフィルター部材６２を取り付ける工程（処理）になっている。そして、注型成形方法は、この準備処理後、型閉め処理に移行する。   The preparation process is a process (process) of attaching the filter member 62 to the recess 61 of the second mold part 52 before the mold closing. Then, the casting molding method proceeds to the mold closing process after the preparation process.

また、充填処理においては、図３に示すように、型閉め処理によるキャビティ５３形成後、樹脂８を本体１１の側壁１２となる第１部位８ａの下端側（容器開口端側）から注入する。そして、第１部位８ａ全体に充填した後、第１部位８ａを介して底部１３となる板状の第２部位８ｂに流入して、キャビティ５３全体に充填する。そのため、金型装置は、樹脂８充填時に、第１部位８ａや第１部位８ａと第２部位８ｂとの境界等に、空気が残留し難くなっている。   In the filling process, as shown in FIG. 3, after forming the cavity 53 by the mold closing process, the resin 8 is injected from the lower end side (the container opening end side) of the first portion 8 a that becomes the side wall 12 of the main body 11. Then, after filling the entire first part 8 a, the whole flows into the cavity 53 through the first part 8 a and flows into the plate-like second part 8 b serving as the bottom portion 13. Therefore, in the mold apparatus, when the resin 8 is filled, air hardly remains at the first part 8a, the boundary between the first part 8a and the second part 8b, or the like.

更に、図４に示すように、樹脂８はキャビティ５３を介して凹み６１に流入する。そのため、金型装置は、キャビティ５３への樹脂８注入が完了した後、凹み６１への樹脂８注入が完了する。そして、凹み６１内にはフィルター部材６２が配置してあるため、樹脂８は、フィルター部材６２に浸透する（含浸する）ことで、凹み６１に流入する。   Further, as shown in FIG. 4, the resin 8 flows into the recess 61 through the cavity 53. Therefore, in the mold apparatus, after the injection of the resin 8 into the cavity 53 is completed, the injection of the resin 8 into the recess 61 is completed. Since the filter member 62 is disposed in the recess 61, the resin 8 permeates (impregnates) the filter member 62 and flows into the recess 61.

更に、キャビティ５３が上流開口端４２ａに比べて広い空間（凹み６１）を介して排気口４２に連通するため、キャビティ５３内の空気は、上流開口端４２ａを直接キャビティ５３に連通した場合に比べて、キャビティ５３内に残留し難くなっている。そして、樹脂８は、フィルター部材６２に含浸することで凹み６１へ流入するため、キャビティ５３（フィルター部材６２の無い空間）に比べて、凹み６１内に流入し難くなっている。言い換えると、樹脂８は、凹み６１に比べてキャビティ５３内の方を優先して流入し易くなっている。   Further, since the cavity 53 communicates with the exhaust port 42 through a space (dent 61) wider than the upstream opening end 42a, the air in the cavity 53 is in comparison with the case where the upstream opening end 42a communicates directly with the cavity 53. Thus, it is difficult to remain in the cavity 53. Since the resin 8 flows into the recess 61 by impregnating the filter member 62, the resin 8 is less likely to flow into the recess 61 compared to the cavity 53 (a space without the filter member 62). In other words, the resin 8 is more likely to flow in the cavity 53 in preference to the recess 61.

また、樹脂注入部４１からの樹脂８の総注入量は、キャビティ５３全体に充填する量と、フィルター部材６２に含浸して凹み６１全体に充填する量との合計より、若干少ない量になっている。そのため、金型装置は、キャビティ５３及び凹み６１への注入完了時（充填処理完了時）において、フィルター部材６２に含浸した樹脂８と凹み６１の上端面６１ａとの上下の間の少なくとも一部に、隙間を有する。そして、例えば、本実施形態では、凹み６１の深さ寸法（フィルター部材６２の厚さ）の半分以上に樹脂８が含浸してあり、且つ凹み６１の上端面６１ａの略全体と前記含浸した樹脂８との間に、隙間を有する。   Further, the total injection amount of the resin 8 from the resin injection portion 41 is slightly smaller than the sum of the amount that fills the entire cavity 53 and the amount that impregnates the filter member 62 and fills the entire recess 61. Yes. Therefore, when the injection into the cavity 53 and the recess 61 is completed (when the filling process is completed), the mold apparatus is disposed at least at a portion between the upper and lower surfaces of the resin 8 impregnated in the filter member 62 and the upper end surface 61a of the recess 61. , With a gap. For example, in the present embodiment, the resin 8 is impregnated in more than half of the depth dimension of the recess 61 (thickness of the filter member 62), and substantially the entire upper end surface 61a of the recess 61 and the impregnated resin are impregnated. 8 and a gap.

硬化処理においては、加熱部によって加熱されることで、フィルター部材６２に含浸した樹脂８である凸部２となる樹脂８と、本体１１となる樹脂８とが硬化して、フィルター部材６２を含む凸部２と本体１１とが一体の樹脂成型品１になる。   In the curing process, the resin 8 that becomes the convex portion 2 that is the resin 8 impregnated in the filter member 62 and the resin 8 that becomes the main body 11 are cured by being heated by the heating unit, and include the filter member 62. The convex part 2 and the main body 11 become an integral resin molded product 1.

型部５に着脱自在のフィルター部材６２を樹脂８で本体１１に固定したため、離型処理においては、型部５を開いた（型開きした）際に、フィルター部材６２が本体１１と共に、樹脂成型品１として、第２型部５２から離脱する（離型する）。   Since the filter member 62 detachably attached to the mold part 5 is fixed to the main body 11 with the resin 8, in the mold release process, the filter member 62 together with the main body 11 is molded with resin when the mold part 5 is opened (opened). The product 1 is detached (released) from the second mold part 52.

このように、金型装置は、流動末端で凹み６１を介してキャビティ５３と排気口４２とが連通するため、キャビティ５３への樹脂８充填完了前に、樹脂８での排気口４２の閉塞を生じ難くすることができる。これによって、金型装置は、充填処理時に、気泡等の残留空気９（図６参照）をキャビティ５３内（本体１１となる部位）に生じ難くすることができて、樹脂成型品１（本体１１）を略設計通りの形状及び強度で形成し易くすることができる。そのため、樹脂成型品１は、例えば、残留空気９に伴う本体１１の強度低下を加味して形成した場合に比べて本体１１を薄肉化して所望の強度を得易くすることができる等、注型成形時の樹脂８の使用量を低減し易くすることができる。そして、本体１１を薄肉化した場合、樹脂成型品１は軽量化し易くすることができて、樹脂成型品１の運搬費用を低減したり、樹脂成型品１設置時の作業負荷を軽減したりし易くすることができる。   In this way, in the mold apparatus, the cavity 53 and the exhaust port 42 communicate with each other through the recess 61 at the flow end. Therefore, before the resin 53 is filled into the cavity 53, the exhaust port 42 is blocked with the resin 8. It can be made difficult to occur. Accordingly, the mold apparatus can make it difficult for residual air 9 such as air bubbles (see FIG. 6) to be generated in the cavity 53 (site serving as the main body 11) during the filling process, and the resin molded product 1 (main body 11). ) Can be easily formed with a shape and strength substantially as designed. For this reason, the resin molded product 1 can be casted, for example, by making the main body 11 thinner and making it easier to obtain a desired strength compared to the case where the strength reduction of the main body 11 due to the residual air 9 is taken into account. The amount of the resin 8 used at the time of molding can be easily reduced. When the main body 11 is thinned, the resin molded product 1 can be easily reduced in weight, and the transportation cost of the resin molded product 1 can be reduced, or the work load when the resin molded product 1 is installed can be reduced. Can be made easier.

更に、金型装置は、凹み６１内にフィルター部材６２を配置して、フィルター部６としたことで、フィルター部材６２に樹脂８を浸透させながら、キャビティ５３内の空気を凹み６１を介して排気口４２に排出することができる。そして、フィルター部材６２は通気性を有し、且つ樹脂８の排気口４２への流入を抑制するため、前記空気を樹脂８に比べてフィルター部６（フィルター部材６２内）に流通し易くすることができる。これによって、金型装置は、樹脂８注入時に、樹脂８で排気口４２が閉塞され難くなり、前記空気をキャビティ５３内に残留し難くすることができる。そのため、金型装置は、残留空気９による本体１１の強度等への影響や成形不良を生じ難くして、樹脂成型品１を製造し易くすることができる。   Furthermore, the mold apparatus arranges the filter member 62 in the recess 61 to form the filter unit 6, so that the air in the cavity 53 is exhausted through the recess 61 while the resin 8 penetrates the filter member 62. It can be discharged to the mouth 42. The filter member 62 has air permeability and suppresses the inflow of the resin 8 into the exhaust port 42, so that the air can be more easily circulated through the filter portion 6 (in the filter member 62) than the resin 8. Can do. As a result, the mold apparatus does not easily block the exhaust port 42 with the resin 8 when the resin 8 is injected, and the air can hardly remain in the cavity 53. Therefore, the mold apparatus can make it difficult to produce an influence on the strength and the like of the main body 11 due to the residual air 9 and molding defects, and to easily manufacture the resin molded product 1.

更に、金型装置は、樹脂８がフィルター部材６２に含浸することで、凹み６１内に流入するため、キャビティ５３内の平面視凹み６１に重なる部位において、凹み６１への樹脂８流入に伴う前記部位の充填密度の低下を生じ難くすることができる。そのため、金型装置は、凹み６１全体に樹脂８を充填しなくても、キャビティ５３内に充填した樹脂８の凸部２周辺における充填密度の低下や樹脂成型品１の表面側のひけ等の成形不良を生じ難くすることができる。これによって、樹脂成型品１は、成形不良に伴う本体１１の強度低下や表面の意匠性の低下を生じ難くして、注型成形時の樹脂８の使用量を低減し易くすることができる。   Further, since the mold device impregnates the filter member 62 with the resin 8 and flows into the recess 61, the mold device is accompanied by the flow of the resin 8 into the recess 61 at a portion overlapping the recess 61 in plan view in the cavity 53. It is possible to make it difficult to reduce the filling density of the part. Therefore, even if the mold apparatus does not fill the entire recess 61 with the resin 8, the filling density in the vicinity of the convex portion 2 of the resin 8 filled in the cavity 53 is reduced, the sink on the surface side of the resin molded product 1, etc. Molding defects can be made difficult to occur. As a result, the resin molded product 1 can hardly reduce the strength of the main body 11 and the design of the surface due to poor molding, and can easily reduce the amount of the resin 8 used during the casting.

そして、フィルター部材６２を樹脂８に比べて軽い部材としたことで、金型装置は、フィルター部材６２が型部５から離脱した際に、未硬化の樹脂８の上方側にフィルター部材６２を浮き上がり易くすることができる。そのため、充填処理や硬化処理の途中等の樹脂８が未硬化の状態において、フィルター部材６２が型部５から離脱した際に、本体１１となる部位にフィルター部材６２の没入を抑制し易くすることができる。これによって、金型装置は、フィルター部材６２の没入（入り込み）による本体１１の強度低下を生じ難くすることができる。   Since the filter member 62 is lighter than the resin 8, the mold apparatus lifts the filter member 62 above the uncured resin 8 when the filter member 62 is detached from the mold part 5. Can be made easier. Therefore, when the filter member 62 is detached from the mold part 5 in a state where the resin 8 is not cured, such as in the middle of the filling process or the curing process, it is easy to suppress the infiltration of the filter member 62 into the portion that becomes the main body 11. Can do. Thus, the mold apparatus can make it difficult for the strength of the main body 11 to decrease due to the immersion (entrance) of the filter member 62.

また、樹脂成型品１は、本体１１の意匠面（表面）の反対側である裏面１１ａ（下面１３ａ）側に凸部２を設けたことで、凸部２を外観に露出し難い構成にし易くすることができる。そのため、樹脂成型品１は、凸部２の除去等の後処理を行わなくても、設置後等において、凸部２の露出による樹脂成型品１の意匠性の低下等を生じ難くすることができる。   In addition, the resin molded product 1 has a configuration in which the convex portion 2 is difficult to be exposed to the appearance by providing the convex portion 2 on the back surface 11a (lower surface 13a) side opposite to the design surface (front surface) of the main body 11. can do. Therefore, the resin molded product 1 may make it difficult to cause a decrease in designability of the resin molded product 1 due to the exposure of the convex portion 2 after installation, without performing post-processing such as removal of the convex portion 2. it can.

そして、排気口４２に樹脂８を流入させずに残留空気９の発生を抑制するため、排気口４２内に樹脂８を流入させて強制的に残留空気９を排出するものに比べて、樹脂成型品１を離型し易くすることができ、成形サイクルの遅延を抑制し易くすることができる。更に、平面視上流開口端４２ａに比べて大きい凹み６１内にフィルター部材６２を配置したことで、排気口４２にフィルター部材６２を配置した場合に比べて、フィルター部材６２を離脱させ易くすることができる。   In order to suppress the generation of the residual air 9 without causing the resin 8 to flow into the exhaust port 42, the resin molding is performed as compared with the case where the resin 8 flows into the exhaust port 42 and the residual air 9 is forcibly discharged. The product 1 can be easily released, and the delay of the molding cycle can be easily suppressed. Furthermore, by disposing the filter member 62 in the recess 61 that is larger than the upstream opening end 42a in plan view, the filter member 62 can be easily detached as compared with the case where the filter member 62 is disposed in the exhaust port 42. it can.

なお、樹脂成型品１は浴槽に限らず、半球形状で球内面を意匠面とした洗面ボウルや便器ボウル、上方に開口した矩形の箱状で箱内面を意匠面とした樹脂シンク等の、容器形状の樹脂成型品であってもよい。また例えば、樹脂成型品１は容器に限らず、一方の板面を意匠面としたキッチンカウンタや防水パン等の板状の樹脂成型品であってもよい。言い換えると、樹脂成型品１は、表面側となる一方の面を意匠面とし、この意匠面の反対側（裏面１１ａ側）の外観に露出し難い部位に、フィルター部跡からなる凸部２を備えたものであればよい。   In addition, the resin molded product 1 is not limited to a bathtub, but a container such as a wash bowl or a toilet bowl with a hemispherical shape and a spherical inner surface as a design surface, and a resin sink with a rectangular box shape opened upward and a box inner surface as a design surface It may be a molded resin molded product. Further, for example, the resin molded product 1 is not limited to a container, and may be a plate-shaped resin molded product such as a kitchen counter or a waterproof pan with one plate surface as a design surface. In other words, the resin molded product 1 has one surface on the front surface side as a design surface, and the convex portion 2 made of a filter portion trace is formed on a portion that is difficult to be exposed to the appearance on the opposite side (back surface 11a side) of the design surface. Anything provided is sufficient.

また例えば、金型装置は、凹み６１の円筒の周面を傾斜面６５としてもよい。例えば、図５に示すように、凹み６１の側面が、キャビティ５３との連通端６３の縁から連続して凹み６１の上端面６１ａに至る傾斜面６５になっている。そして、凹み６１は、平面視における面積が連通端６３から上端面６１ａに向かう程小さくなる形状、言い換えると断面台形状になっている。この場合、金型装置は、樹脂８注入時に、キャビティ５３内の空気を傾斜面６５によって上端面６１ａ側に移動し易くすることができて、キャビティ５３内に残留空気９を生じ難くすることができる。   Further, for example, in the mold apparatus, the cylindrical peripheral surface of the recess 61 may be the inclined surface 65. For example, as shown in FIG. 5, the side surface of the recess 61 is an inclined surface 65 that continues from the edge of the communication end 63 to the cavity 53 and reaches the upper end surface 61 a of the recess 61. The recess 61 has a shape in which the area in plan view becomes smaller from the communication end 63 toward the upper end surface 61a, in other words, a trapezoidal cross section. In this case, the mold apparatus can easily move the air in the cavity 53 to the upper end surface 61 a side by the inclined surface 65 when the resin 8 is injected, and can hardly generate the residual air 9 in the cavity 53. it can.

また、型部５は第１型部５１と第２型部５２の二つに分割されたものに限らず、三つ以上に分割されたものであってもよい。また例えば、排気口４２（上流開口端４２ａ）や樹脂注入部４１（注入口４１ａ）は一つに限らず、複数設けてもよい。そして、排気口４２（上流開口端４２ａ）を複数設けた場合、凸部２を形成するフィルター部６は排気口４２（上流開口端４２ａ）と同数設けることが好ましい。また例えば、凹み６１は円筒状に限らず、矩形筒状や、半球状等であってもよく、フィルター部材６２は、板状に限らず、半球状等であってもよい。もちろん、フィルター部材６２は、上流開口端４２ａを覆い、キャビティ５３に突出しない形状であれば、図５に示すように、凹み６１と同形状でなくてもよい。   The mold part 5 is not limited to the first mold part 51 and the second mold part 52 and may be divided into three or more parts. For example, the exhaust port 42 (upstream opening end 42a) and the resin injection part 41 (injection port 41a) are not limited to one, and a plurality of them may be provided. When a plurality of exhaust ports 42 (upstream opening ends 42a) are provided, it is preferable to provide the same number of filter parts 6 that form the convex portions 2 as the exhaust ports 42 (upstream opening ends 42a). Further, for example, the recess 61 is not limited to a cylindrical shape, and may be a rectangular tube shape, a hemispherical shape, or the like, and the filter member 62 is not limited to a plate shape, and may be a hemispherical shape or the like. Of course, as long as the filter member 62 has a shape that covers the upstream opening end 42a and does not protrude into the cavity 53, the filter member 62 does not have to have the same shape as the recess 61 as shown in FIG.

また例えば、フィルター部材６２を型部５に着脱自在で取り付ける構成は、前記接着剤等の接着を用いたものに限らず、上流開口端４２ａの内面に当接される保持用の突起をフィルター部材６２に設けた構成等であってもよい。また例えば、前記着脱自在とする構成は、フィルター部材６２の外周面を凹み６１の内周面に嵌め込んだり摩擦接触させたりして、取り付けた（保持した）構成等であってもよい。また例えば、凹み６１の上端面６１ａや側面の上部に突起を設けて、フィルター部材６２の樹脂８の含浸しない部位でフィルター部材６２を着脱自在に取り付けた（保持した）構成であってもよい。   Further, for example, the configuration in which the filter member 62 is detachably attached to the mold portion 5 is not limited to the one using the adhesive or the like, and the holding protrusion that is brought into contact with the inner surface of the upstream opening end 42a is used as the filter member. The structure etc. which were provided in 62 may be sufficient. Further, for example, the detachable configuration may be a configuration in which the outer peripheral surface of the filter member 62 is attached (held) by fitting or frictionally contacting the inner peripheral surface of the recess 61. Further, for example, a configuration may be adopted in which protrusions are provided on the upper end surface 61a of the recess 61 and the upper portion of the side surface, and the filter member 62 is detachably attached (held) at a portion of the filter member 62 that is not impregnated with the resin 8.

１ 樹脂成型品
１１本体
１１ａ 裏面
２ 凸部
５ 型部
５３ キャビティ
４２ 排気口
４２ａ 上流開口端
６ フィルター部
６１ 凹み
６２ フィルター部材
８ 樹脂 DESCRIPTION OF SYMBOLS 1 Resin molded product 11 Main body 11a Back surface 2 Convex part 5 Mold part 53 Cavity 42 Exhaust port 42a Upstream opening end 6 Filter part 61 Recess 62 Filter member 8 Resin

Claims (2)

注型成形で形成した樹脂成型品であって、
本体の裏面に一体で且つ前記裏面から突出した凸部を備え、
前記凸部が、前記注型成形時に注型用のキャビティから排気口への樹脂の流入を抑制するフィルター部の凹みに樹脂を流入して形成したフィルター部跡であり、
前記凸部が、前記フィルター部のフィルター部材を前記注型成形時に前記樹脂を含浸した状態で有するものである
ことを特徴とする樹脂成型品。 A resin molded product formed by casting,
Provided with a convex portion that is integral with the back surface of the main body and protrudes from the back surface,
The convex portion is a filter portion trace formed by flowing resin into a recess of a filter portion that suppresses the inflow of resin from the casting cavity to the exhaust port during the casting,
A resin molded product, wherein the convex portion has a filter member of the filter portion in a state of being impregnated with the resin during the casting. 樹脂成型品注型用のキャビティを形成する型部と、該キャビティ内に樹脂を注入する樹脂注入部と、前記キャビティ内の空気を排出する排気口とを備え、
前記型部が、前記樹脂成型品の裏面側形成面と前記排気口の上流開口端との間に、前記キャビティ及び前記上流開口端に連通し前記排気口への前記樹脂の流入を抑制するフィルター部を有し、
前記フィルター部が、前記樹脂注入部による前記キャビティへの前記樹脂の充填時に前記キャビティを介して前記樹脂を流入する凹みと、前記上流開口端全体を覆う通気性を有したフィルター部材とを備え、
前記フィルター部材を、前記型部に着脱自在で前記凹み内に配置してある
ことを特徴とする金型装置。
A mold part that forms a cavity for casting a resin molded product, a resin injection part that injects resin into the cavity, and an exhaust port that discharges air in the cavity,
A filter in which the mold portion communicates with the cavity and the upstream opening end between the rear surface forming surface of the resin molded product and the upstream opening end of the exhaust port and suppresses the inflow of the resin into the exhaust port. Part
The filter portion comprises a recess into which the resin flows through the cavity when the resin is filled into the cavity by the resin injection portion, and a filter member having air permeability covering the entire upstream opening end;
A mold apparatus, wherein the filter member is detachably attached to the mold part and disposed in the recess.
JP2012055813A 2012-03-13 2012-03-13 Resin molding and mold device Pending JP2013188912A (en)

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CN106346702A (en) * 2015-07-20 2017-01-25 唐健丽 Hot runner mould system provided with filtering devices

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JPS57128522A (en) * 1981-02-04 1982-08-10 Du Pont Mitsui Fluorochem Co Ltd Vent plug structure of mold for expansion molding of urethane resin
JPS61164810A (en) * 1985-01-17 1986-07-25 Mitsubishi Plastics Ind Ltd Rim molding method
JPS62238713A (en) * 1986-04-09 1987-10-19 Howa Kogyo Kk Manufacture of resin foam-molded product
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JP2004167814A (en) * 2002-11-19 2004-06-17 Toyo Tire & Rubber Co Ltd Method and device for manufacturing foamed molded product
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Publication number Priority date Publication date Assignee Title
JPS576732A (en) * 1980-06-14 1982-01-13 Achilles Corp Method of molding synthetic resin formed component
JPS57128522A (en) * 1981-02-04 1982-08-10 Du Pont Mitsui Fluorochem Co Ltd Vent plug structure of mold for expansion molding of urethane resin
JPS61164810A (en) * 1985-01-17 1986-07-25 Mitsubishi Plastics Ind Ltd Rim molding method
JPS62238713A (en) * 1986-04-09 1987-10-19 Howa Kogyo Kk Manufacture of resin foam-molded product
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JP2004167814A (en) * 2002-11-19 2004-06-17 Toyo Tire & Rubber Co Ltd Method and device for manufacturing foamed molded product
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Publication number Priority date Publication date Assignee Title
CN106346702A (en) * 2015-07-20 2017-01-25 唐健丽 Hot runner mould system provided with filtering devices

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