JP3778167B2 - Injection foam molded product and method for producing the same - Google Patents

Injection foam molded product and method for producing the same Download PDF

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Publication number
JP3778167B2
JP3778167B2 JP2002369570A JP2002369570A JP3778167B2 JP 3778167 B2 JP3778167 B2 JP 3778167B2 JP 2002369570 A JP2002369570 A JP 2002369570A JP 2002369570 A JP2002369570 A JP 2002369570A JP 3778167 B2 JP3778167 B2 JP 3778167B2
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Japan
Prior art keywords
mold
resin
foamed
injection
male
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JP2002369570A
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JP2004195897A (en
Inventor
康之 清水
大雄 近藤
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Toyota Boshoku Corp
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Toyota Boshoku Corp
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  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Molding Of Porous Articles (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、端末部における寸法精度が良好で、かつ低コストで製造することができる射出発泡成形品及びその製造方法に関するものである。
【０００２】
【従来の技術】
【特許文献１】
特開平８−２９４９２５号公報
【０００３】
従来から、射出発泡成形品は軽量性およびコストパフォ−マンス性に優れており、例えば特許文献１に示されるように、ドアトリム等の自動車用内装部品として広く利用されている。このような射出発泡成形品の製造方法として、接離自在な一対のキャビティ型とコア型からなる成形型を閉じた状態で型内へ発泡樹脂原料を射出し、次いでいずれか一方の型をわずかに寸開して発泡樹脂原料を型内面に添って発泡させるようにする方法が一般的である。
【０００４】
しかしながら、図４に示されるように、発泡樹脂原料を射出後、型をわずかに寸開すると雌型（キャビティ型）２１の端部ａと雄型（コア型）２２の端部ｂとが行き別れて型寸開分（α）だけ隙が生じる現象があった。この結果、内装材として組み付けた場合、他の部品との間に隙を生じたり、干渉したりして見栄えが著しく低下するという問題点があった。
また、これを解消するのに、図５に示されるように、雄型２２内に昇降動自在なコア型２３を設けておき、該コア型２３を型の寸開に同調して上昇させて端部ａ、ｂの行き別れを防止することが検討された。しかしながら、この場合は、型の製作費が非常に高くなるとともに、型の製作日数も長くなるため実用には供さないという問題点があった。
【０００５】
【発明が解決しようとする課題】
本発明は上記のような従来の問題点を解決して、端末部における寸法精度が良好で優れた外観品質を有するとともに、型製作費も安くかつ短期間で製作でき生産コストを大幅に低減することができる射出発泡成形品及びその製造方法を提供することを目的して完成されたものである。
【０００６】
【課題を解決するための手段】
上記の課題を解決するためになされた本発明の射出発泡成形品は、接離自在な雌雄一対の型からなる成形型内へ発泡樹脂原料を射出後、いずれか一方の型をわずかに寸開し発泡樹脂原料を型内面に添い発泡させて製造したスキン層に覆われた射出発泡成形品であって、前記スキン層を、射出発泡成形品の雌型で形成される雌型側スキン層と、射出発泡成形品の雄型で形成される雄型側スキン層と、前記雌型側スキン層と前記雄型側スキン層の端末結合部であって射出発泡成形品の厚み方向に所定幅で寸開長さ分膨出状に延設された樹脂未発泡部とからなるものとして、前記雄型側スキン層と樹脂未発泡部の接続部を起点として前記雄型側スキン層側の樹脂発泡部が前記樹脂未発泡部の寸開長さ分屈曲・膨出して水平な端末部に形成されていることを特徴とするものである。
また本発明の射出発泡成形品の製造方法は、接離自在な雌雄一対の型からなる成形型内へ発泡樹脂原料を射出後、いずれか一方の型をわずかに寸開して発泡樹脂原料を型内面に添い発泡させる射出発泡成形品の製造方法において、前記雄型上端部に設けた樹脂未発泡部形成用の凹部により端末部に寸開長さ分だけ突出した樹脂未発泡部を有する射出品を成形し、次いで寸開時に該樹脂未発泡部の境界部を起点に樹脂発泡部が樹脂未発泡部側へ屈曲・膨出されて端末部が水平面を形成することを特徴とするものである。
【０００７】
【発明の実施の形態】
以下に、図面を参照しつつ本発明の好ましい形態を示す。
図面は、本発明を自動車用ドアトリムの成形に適用した場合を示すもので、図１は本発明で得られる射出発泡成形品の要部を示す断面図、図２は成形型の要部を示す断面図、図３は成形工程を示す説明図である。
図において、１は雌型（キャビティ型）、２は雄型（コア型）であり、これらの雌雄一対の型からなる成形型内へ発泡樹脂原料を射出後、いずれか一方の型（図示のものでは雌型１）をわずかに寸開して発泡樹脂原料を型内面に添い発泡させ射出発泡成形品を製造する点は従来のものと同じである。
【０００８】
そして本発明では、雌型側スキン層１１ａと雄型側スキン層１１ｂからなるスキン層１１で覆われた射出発泡成形品１０を成形する成形型の一方型である雄型２の上端部に樹脂未発泡部形成用の凹部３が設けられており、該凹部３により端縁部に寸開長さ分だけ突出した樹脂未発泡部１２を有する射出品１０ａを成形し、次いで寸開時に樹脂未発泡部１２と雄型側スキン層１１ｂとの境界部となる接続部Ｐを起点に雄型側スキン層１１ｂ側の樹脂発泡部が樹脂未発泡部１２の寸開長さ分屈曲・膨出して水平な端末部を形成するようにした点に特徴を有する。
なお、ここでいう接続部Ｐとは、射出発泡成形品１０の雌型１で形成される雌型側スキン層１１ａと雄型２で形成される雄型側スキン層１１ｂと、雄型側スキン層１１ｂと雌型側スキン層１１ａの端末結合部であって、射出発泡成形品１０の厚み方向に所定幅で寸開長さ分膨出状に延設された樹脂未発泡部１２と、雄型側スキン層１１ｂとの接続部分であり、境界部でもある。
即ち、本発明者は射出品１０ａの端縁部に樹脂未発泡部１２を突出成形しておくと、型を寸開した場合に該樹脂未発泡部１２の接続部Ｐを起点に樹脂発泡部が樹脂未発泡部１２の突出方向に寸開長さ分屈曲・膨出されつつ発泡することを見出し、本発明をするに至った。
つまり、図３に示されるように、凹部３により端縁部に型の寸開分の高さ（α）と所定幅（ｓ）の樹脂未発泡部１２を形成しておくと、この樹脂未発泡部１２は型寸開時において開いた型に追従してそのままの形状を維持するとともに、樹脂発泡部は境界部（接続部Ｐ）を起点に樹脂未発泡部側へ屈曲しつつ発泡し、この結果、射出品１０ａの端縁部が従来のようにα分だけ寸開方向へ膨らむことなく接続部Ｐを起点に引き込まれ、水平状態の端末部を形成することとなるのである。
【０００９】
本発明者の知見によれば、樹脂は型との接触距離が１．５ｍｍ以下であると型によって冷却・固化されて樹脂未発泡部を形成する。本発明において、型の寸開寸法（α）は約１ｍｍ程度とわずかであり、従って前記凹部３の形状は高さを寸開寸法（α）と同一とし、幅（ｓ）を１．５ｍｍ以下となるように設計すればよい。
【００１０】
次に、本発明の製造工程につき説明すると、接離自在な雌雄一対の型１，２からなる成形型内へ発泡樹脂原料を射出後、いずれか一方の型をわずかに寸開して発泡樹脂原料を型内面に添い発泡させる射出発泡成形品の製造方法である点は従来と同様である。
そして本発明では、図３の左図に示されるように、前記雄型２の上端部に設けた樹脂未発泡部形成用の凹部３により端縁部に寸開長さ分だけ突出した樹脂未発泡部１２を有する射出品１０ａを成形する。次いで、雌型１をわずかに上昇して樹脂を発泡させるが、この寸開時に該樹脂未発泡部１２の接続部Ｐを起点に樹脂発泡部が樹脂未発泡部の寸開長さ分屈曲・膨出されて端末部が水平面を形成するようにする（図３の右図参照）。
【００１１】
このようにして製造した射出発泡成形品は、図１に示されるように、表面全体がスキン層１１で覆われており、しかも端末部に寸開長さ分の樹脂未発泡部１２が形成されているとともに、該樹脂未発泡部１２の接続部Ｐを起点として樹脂発泡部が樹脂未発泡部側へ屈曲・膨出して水平な端末部が形成されたものとなっており、従来のように端末部に型寸開分（α）だけ隙が生じることがない。
即ち本発明の射出発泡成形品１０は、接離自在な雌雄一対の型からなる成形型内へ発泡樹脂原料を射出後、いずれか一方の型をわずかに寸開し発泡樹脂原料を型内面に添い発泡させて製造したスキン層１１に覆われた射出発泡成形品であって、前記スキン層１１を、射出発泡成形品の雌型１で形成される雌型側スキン層１１ａと、射出発泡成形品の雄型２で形成される雄型側スキン層１１ｂと、前記雌型側スキン層１１ａと雌型側スキン層１１ｂの端末結合部であって射出発泡成形品の厚み方向に所定幅で寸開長さ分膨出状に延設された樹脂未発泡部１２とからなるものとして、雄型側スキン層１１ｂ側の樹脂発泡部が樹脂未発泡部１２の寸開長さ分屈曲・膨出して水平な端末部に形成されたものとなっている。
従って、内装材として組み付けた場合、他の部品との間に隙を生じたり、干渉したりして見栄えが著しく低下するという問題点をすべて解消することができるとともに、型内に昇降動自在なコア型を別に設ける必要もなく型製作コストを安価に、かつ短期間で製作することができることとなる。
【００１２】
【発明の効果】
以上の説明からも明らかなように、本発明は端末部における寸法精度が良好で優れた外観品質を有するとともに、型製作費も安くかつ短期間で製作でき生産コストを大幅に低減することができるものである。
よって、本発明は従来の問題点を一掃した射出発泡成形品及びその製造方法として、産業の発展に寄与するところは極めて大である。
【図面の簡単な説明】
【図１】本発明の実施の形態を示す要部の断面図である。
【図２】成形型の要部の断面図である。
【図３】本発明の成形工程を示す説明図である。
【図４】従来例を示す断面図である。
【図５】その他の従来例を示す断面図である。
【符号の説明】
１ 雌型
２ 雄型
３ 凹部
１０射出発泡成形品
１１ スキン層
11 ａ 雌型側スキン層
11 ｂ 雄型側スキン層
１２ 樹脂未発泡部
Ｐ 接続部 [0001]
BACKGROUND OF THE INVENTION
The present invention relates to an injection foam molded article that has good dimensional accuracy at a terminal portion and can be produced at low cost, and a method for producing the same.
[0002]
[Prior art]
[Patent Document 1]
Japanese Patent Laid-Open No. 8-294925
2. Description of the Related Art Conventionally, injection-foamed molded products are excellent in light weight and cost performance, and are widely used as interior parts for automobiles such as door trims as disclosed in Patent Document 1, for example. As a method for producing such an injection-foamed molded product, a foamed resin material is injected into the mold with the mold composed of a pair of detachable cavity mold and core mold closed, and then either one mold is slightly In general, the foamed resin raw material is foamed along the mold inner surface.
[0004]
However, as shown in FIG. 4, after injecting the foamed resin raw material, when the mold is slightly opened, the end a of the female mold (cavity mold) 21 and the end b of the male mold (core mold) 22 go. There was a phenomenon in which a gap was generated by the mold opening (α). As a result, when assembled as an interior material, there is a problem in that the appearance is remarkably lowered due to a gap or interference with other parts.
In order to solve this problem, as shown in FIG. 5, a core mold 23 that can be moved up and down is provided in the male mold 22, and the core mold 23 is raised in synchronization with the opening of the mold. It has been studied to prevent separation of the ends a and b. However, in this case, there is a problem that the production cost of the mold becomes very high and the number of days for producing the mold becomes long, so that it is not practically used.
[0005]
[Problems to be solved by the invention]
The present invention solves the conventional problems as described above, has a good dimensional accuracy at the terminal portion and has an excellent appearance quality, and can be manufactured in a short period of time with a low mold manufacturing cost, greatly reducing the production cost. The present invention has been completed for the purpose of providing an injection-foamed molded article and a method for producing the same.
[0006]
[Means for Solving the Problems]
The injection-foamed molded product of the present invention made to solve the above-mentioned problems is that one of the molds is slightly opened after the foamed resin raw material is injected into a mold composed of a pair of male and female that can be separated from each other. An injection foam molded article covered with a skin layer produced by foaming a foam resin raw material on the inner surface of the mold, wherein the skin layer is a female skin layer formed of a female mold of the injection foam molded article. A male side skin layer formed of a male mold of an injection foam molded article, and a terminal joint portion of the female mold side skin layer and the male mold side skin layer, and having a predetermined width in the thickness direction of the injection foam molded article. Resin foaming on the male skin layer side starting from the connection part of the male skin layer and the resin non-foamed portion, as a resin unfoamed portion extending in a bulging length parts are formed on the horizontal terminal part by slightly opening length min bend the bulging of the resin unfoamed portion And it is characterized in and.
The method for producing an injection-foamed molded product of the present invention is a method of injecting a foamed resin raw material into a mold composed of a pair of male and female that can be separated from each other, and then slightly opening one of the molds to obtain the foamed resin raw material. In the method of manufacturing an injection foam molded product to be foamed along the inner surface of the mold, a projection having a non-foamed resin portion projecting by an opening length by a recessed portion for forming a non-foamed resin portion provided at the upper end portion of the male mold. The exhibition is molded, and then the resin foamed part is bent and bulged toward the resin non-foamed part starting from the boundary part of the resin non-foamed part at the time of opening, and the terminal part forms a horizontal plane. is there.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
The drawings show the case where the present invention is applied to the molding of an automobile door trim. FIG. 1 is a cross-sectional view showing the main part of an injection foam molded product obtained by the present invention, and FIG. 2 shows the main part of a molding die. Sectional drawing, FIG. 3 is explanatory drawing which shows a formation process.
In the figure, 1 is a female mold (cavity mold), 2 is a male mold (core mold), and after injecting a foamed resin material into a mold composed of a pair of male and female molds, In the conventional method, the female mold 1) is slightly opened and the foamed resin raw material is added to the inner surface of the mold and foamed to produce an injection foam molded product.
[0008]
In the present invention, the resin is applied to the upper end portion of the male mold 2 which is one mold of the molding mold for molding the injection foam molded article 10 covered with the skin layer 11 composed of the female mold side skin layer 11a and the male mold side skin layer 11b. A recess 3 for forming an unfoamed portion is provided, and an injection product 10a having a resin unfoamed portion 12 projecting by an opening length is formed on the edge portion by the recess 3, and then the resin unexposed at the time of opening. The resin foamed part on the male skin layer 11b side is bent and bulged by the length of the unfoamed part 12 starting from the connecting part P that is the boundary between the foamed part 12 and the male skin layer 11b. It is characterized in that a horizontal terminal portion is formed.
The connection portion P here refers to a female-side skin layer 11a formed of the female mold 1 of the injection foam molded product 10, a male-side skin layer 11b formed of the male mold 2, and a male-type skin. A non-resin-foamed portion 12 that is a terminal coupling portion between the layer 11b and the female-type skin layer 11a, and extends in a swelled shape with a predetermined width in the thickness direction of the injection foamed molded article 10; It is a connection part with the type | mold side skin layer 11b, and is also a boundary part.
That is, when the inventor forms the resin non-foamed portion 12 at the edge of the injection product 10a , the resin foamed portion starts from the connecting portion P of the resin non-foamed portion 12 when the mold is opened. Was found to be foamed while being bent and bulged in the protruding direction of the resin non-foamed portion 12 by the length of the opening , and the present invention was achieved .
That is, as shown in FIG. 3, when the resin unfoamed portion 12 having a height (α) and a predetermined width (s) corresponding to the mold opening is formed on the edge portion by the recess 3, The foamed part 12 follows the opened mold at the time of mold opening and maintains the shape as it is, and the resin foamed part is foamed while being bent toward the resin non-foamed part side from the boundary part (connection part P) , As a result, the edge portion of the injection product 10a is drawn from the connection portion P without starting to bulge in the opening direction by α as in the prior art, thereby forming a horizontal end portion.
[0009]
According to the knowledge of the present inventors, the resin is cooled and solidified by the mold when the contact distance with the mold is 1.5 mm or less to form an unfoamed resin portion. In the present invention, the dimension dimension (α) of the mold is as small as about 1 mm. Therefore, the shape of the recess 3 is the same as the dimension dimension (α), and the width (s) is 1.5 mm or less. The design should be such that
[0010]
Next, the manufacturing process of the present invention will be described. After injecting the foamed resin raw material into a mold comprising a pair of male and female molds 1 and 2 that can be separated from each other, one of the molds is slightly opened and the foamed resin is opened. It is the same as the conventional method in that it is a method for producing an injection foam molded product in which the raw material is added to the inner surface of the mold and foamed.
In the present invention, as shown in the left diagram of FIG. 3, the resin non-expanded portion protruding from the end edge portion by the length of the opening is formed by the recess 3 for forming the resin non-foamed portion provided at the upper end portion of the male mold 2. An injection product 10a having a foamed portion 12 is molded. Next, the female mold 1 is slightly raised to foam the resin. At this time of opening, the resin foamed part is bent by the length of the dimension of the resin unfoamed part starting from the connection part P of the resin non-foamed part 12. The terminal portion is bulged so as to form a horizontal plane (see the right diagram in FIG. 3).
[0011]
As shown in FIG. 1, the injection-foamed molded article thus manufactured has the entire surface covered with the skin layer 11, and the resin unfoamed portion 12 corresponding to the length of the opening is formed at the terminal portion. In addition, the resin foamed part is bent and bulged toward the resin non-foamed part starting from the connection part P of the resin non-foamed part 12, and a horizontal terminal part is formed. There is no gap in the terminal portion by the size opening (α).
That is, in the injection foam molded product 10 of the present invention, after injecting the foamed resin raw material into a mold composed of a pair of detachable male and female molds, one of the molds is slightly opened and the foamed resin raw material is placed on the inner surface of the mold. An injection foam molded article covered with a skin layer 11 manufactured by foaming, wherein the skin layer 11 is formed of a female die skin layer 11a formed of a female mold 1 of an injection foam molded article, and injection foam molding. A male side skin layer 11b formed of the male mold 2 of the product, and a terminal coupling portion of the female side skin layer 11a and the female side skin layer 11b, and is dimensioned with a predetermined width in the thickness direction of the injection foam molded product. The resin foam portion on the male skin layer 11b side is bent and bulged by the dimension of the unexpanded portion 12 of the resin. It is formed in a horizontal terminal part.
Therefore, when assembled as an interior material, it is possible to eliminate all the problems of creating a gap with other parts or interfering with the other parts, resulting in a significant decrease in appearance. There is no need to provide a separate core mold, and the mold manufacturing cost can be reduced at a low cost and in a short period of time.
[0012]
【The invention's effect】
As is clear from the above description, the present invention has excellent dimensional accuracy at the terminal portion and excellent appearance quality, and the mold production cost is low and can be produced in a short period of time, thereby greatly reducing the production cost. Is.
Therefore, the present invention contributes greatly to the development of the industry as an injection foam molded article and a method for producing the same which have eliminated the conventional problems.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a main part showing an embodiment of the present invention.
FIG. 2 is a cross-sectional view of a main part of a mold.
FIG. 3 is an explanatory view showing a molding process of the present invention.
FIG. 4 is a cross-sectional view showing a conventional example.
FIG. 5 is a cross-sectional view showing another conventional example.
[Explanation of symbols]
1 Female 2 Male 3 Recess
10 injection foam moldings
11 Skin layer
11 a Female skin layer
11 b Male skin layer 12 Resin unfoamed part
P connection

Claims (2)

接離自在な雌雄一対の型からなる成形型内へ発泡樹脂原料を射出後、いずれか一方の型をわずかに寸開し発泡樹脂原料を型内面に添い発泡させて製造したスキン層に覆われた射出発泡成形品であって、前記スキン層を、射出発泡成形品の雌型で形成される雌型側スキン層と、射出発泡成形品の雄型で形成される雄型側スキン層と、前記雌型側スキン層と前記雄型側スキン層の端末結合部であって射出発泡成形品の厚み方向に所定幅で寸開長さ分膨出状に延設された樹脂未発泡部とからなるものとして、前記雄型側スキン層と樹脂未発泡部の接続部を起点として前記雄型側スキン層側の樹脂発泡部が前記樹脂未発泡部の寸開長さ分屈曲・膨出して水平な端末部に形成されていることを特徴とする射出発泡成形品。After injection the separable freely foamed resin material into a pair of male and female consisting molding mold in either one of the mold slightly slightly opening covered by a skin layer produced by foam resin raw material was soy foamed to mold the inner surface An injection-foamed molded product, wherein the skin layer is a female-type skin layer formed of a female mold of an injection-foamed molded product, and a male-type skin layer of a male mold of an injection-foamed molded product, From the female-side skin layer and the terminal-bonded portion of the male-side skin layer, and a non-resin-foamed portion extending in a swelled shape by a predetermined width in the thickness direction of the injection-foamed molded product as that is, the horizontal resin foam portion of the male-side skin layer side was slightly opening length min bend the bulging of the resin unfoamed portion connection portion of the male-side skin layer and the resin unexpanded portion as a starting point An injection foam molded product characterized by being formed in a flexible terminal portion. 接離自在な雌雄一対の型からなる成形型内へ発泡樹脂原料を射出後、いずれか一方の型をわずかに寸開して発泡樹脂原料を型内面に添い発泡させる射出発泡成形品の製造方法において、前記雄型上端部に設けた樹脂未発泡部形成用の凹部により端縁部に寸開長さ分だけ突出した樹脂未発泡部を有する射出品を成形し、次いで寸開時に該樹脂未発泡部の境界部を起点に樹脂発泡部が樹脂未発泡部側へ屈曲・膨出されて端末部が水平面を形成することを特徴とする射出発泡成形品の製造方法。  A method for producing an injection foam molded product, in which a foamed resin raw material is injected into a mold composed of a pair of detachable male and female molds, one of the molds is slightly opened, and the foamed resin raw material is added to the inner surface of the mold for foaming. In this case, an injection product having a resin non-foamed portion projecting by an opening length at the end edge portion is formed by a recess for forming a resin non-foaming portion provided at the upper end of the male mold, A method for producing an injection-foamed molded article, wherein a resin foam part is bent and bulged toward a non-resin foam part side from a boundary part of a foam part, and a terminal part forms a horizontal plane.
JP2002369570A 2002-12-20 2002-12-20 Injection foam molded product and method for producing the same Expired - Lifetime JP3778167B2 (en)

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JP4671328B2 (en) * 2004-11-09 2011-04-13 河西工業株式会社 Molding method and molding die for foamed resin molded product
JP2006346898A (en) * 2005-06-13 2006-12-28 Kasai Kogyo Co Ltd Foamed resin molded product
JP5155053B2 (en) * 2008-07-28 2013-02-27 株式会社林技術研究所 Resin foam molded product and method for producing the same
JP5553398B2 (en) * 2009-01-19 2014-07-16 積水テクノ成型株式会社 Manufacturing method of foam molded article

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