JP4539721B2 - In-mold foam molding apparatus and method, and in-mold foam molding product - Google Patents

In-mold foam molding apparatus and method, and in-mold foam molding product Download PDF

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JP4539721B2
JP4539721B2 JP2008003857A JP2008003857A JP4539721B2 JP 4539721 B2 JP4539721 B2 JP 4539721B2 JP 2008003857 A JP2008003857 A JP 2008003857A JP 2008003857 A JP2008003857 A JP 2008003857A JP 4539721 B2 JP4539721 B2 JP 4539721B2
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mold
raw material
partition member
comb teeth
molding
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JP2008120096A (en
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昌彦 鮫島
喜幸 小林
健二 山口
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Kaneka Corp
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本発明は、１つの成形品に異なる特性の原料ビーズからなる成形部分を形成するのに好適な型内発泡成形装置及び方法並びに型内発泡成形品に関する。   The present invention relates to an in-mold foam molding apparatus and method and an in-mold foam-molded product suitable for forming a molded part composed of raw material beads having different characteristics in one molded product.

熱可塑性合成樹脂からなる原料ビーズを用いて成形品を製作する型内発泡成形装置として、例えば特許文献１には、一方の金型にエアシリンダー等のアクチュエータを介して成形空間内に出没自在な仕切部材を設け、この仕切部材により成形空間内を複数の区画成形空間に区画するとともに、各区画成形空間に対して原料ビーズを供給する充填器を個別に接続し、仕切部材により成形空間内を区画した状態で、隣接する区画成形空間内に、例えば発泡倍率の異なる原料ビーズを充填し、充填後、仕切部材を後退させてから成形空間内に蒸気を供給することで、原料ビーズを加熱融着させて成形品を得るように構成した型内発泡成形技術が記載されている。   As an in-mold foam molding apparatus that manufactures a molded product using raw material beads made of a thermoplastic synthetic resin, for example, Patent Document 1 discloses that one mold can appear and disappear in a molding space via an actuator such as an air cylinder. A partition member is provided, the molding space is partitioned into a plurality of partition molding spaces by the partition member, and a filler for supplying raw material beads to each partition molding space is individually connected. In a partitioned state, the raw material beads having different expansion ratios are filled in the adjacent compartment molding space, for example, and after filling, the partition member is retracted and then steam is supplied into the molding space to heat and melt the raw material beads. An in-mold foam molding technique is described which is configured to be applied to obtain a molded product.

この型内発泡成形技術により成形された成形品においては、成形品の部位によって使用する原料ビーズを変更することで、例えば部位によって機械的特性が異なる成形品を製作することが可能で、成形品の性能や品質を向上できる利点を有しており、自動車用バンパーの芯材や、家電製品や家具等の梱包用のクッション材として採用されつつある。
米国特許５１６４２５７号公報 In molded products molded by this in-mold foam molding technology, it is possible to produce molded products with different mechanical properties depending on the part, for example, by changing the raw material beads used depending on the part of the molded product. Therefore, it is being adopted as a core material for bumpers for automobiles and as a cushioning material for packing home appliances and furniture.
US Pat. No. 5,164,257

前記特許文献１に記載の成形装置においては、仕切部材を出没させるためのアクチュエータを設ける必要があるので、成形空間の区画個数が増えると、それに応じて仕切部材の駆動系統が複雑になり、成形装置の製作コストが高くなるという問題がある。
また、隣接する区画成形空間内の充填圧に差圧が生じないように制御しないと、差圧による仕切部材の変形が懸念される。また、充填用エアの流れが仕切部材により阻害されて原料ビーズの充填性が低下するという問題もある。 In the molding apparatus described in Patent Document 1, it is necessary to provide an actuator for projecting and retracting the partition member. Therefore, when the number of sections in the molding space increases, the drive system for the partition member becomes complicated accordingly, and molding is performed. There is a problem that the manufacturing cost of the apparatus becomes high.
In addition, there is a concern about deformation of the partition member due to the differential pressure unless the control is performed so that the differential pressure does not occur in the filling pressure in the adjacent partition forming space. There is also a problem that the flow of the filling air is hindered by the partition member and the filling property of the raw material beads is lowered.

更に、この成形装置においては、金型に挿通孔を形成して、この挿通孔に仕切部材を出没自在に装着する関係上、次のような２つの理由から、成形品の表面に挿通孔に沿ってバリが形成されるという問題がある。
（１）理由１
挿通孔の内壁と仕切部材間の隙間は、原料ビーズが侵入しないようにするため、極力狭く設定することが好ましいが、このように構成すると金型の膨張や収縮により、仕切部材が挿通孔の内壁に接触して変形したり破損し、仕切部材を出没できなくなるという問題が発生する。より具体的には、金型は、原料ビーズの蒸気による加熱時には膨張し、冷却水による冷却時には収縮することになるが、前述のように挿通孔を形成すると挿通孔に臨む金型部分の強度が低下することから金型の歪みが挿通孔に集中し、挿通孔の開口幅が拡縮することにより吸収されようとする。また、挿通孔をＬ字状やコ字状などの形状に形成した場合には、特定方向に対する金型強度が低下することから挿通孔の形状が変形する。そして、このような挿通孔の拡縮や変形により、仕切部材が挿通孔の内壁に接触して変形したり破損したりする。特に、挿通孔により金型を複数の分割金型に分割構成し、これら複数の分割金型を固定板にネジ等で固定した場合には、金型に対して挿通孔を容易に形成することが可能となるが、金型の膨張や収縮により固定板に対する分割金型の取付位置がずれて、挿通孔の開口幅が大きく変動する。このような現象は、金型が大型になるほど、また挿通孔が長尺になるほど顕著になり、仕切部材を有する型内発泡成形装置の大きな課題になっている。このような理由から、成形品の表面に挿通孔に沿ってバリが形成されるという不具合を認めつつ、挿通孔の内壁と仕切部材間の隙間を大きく設定している。 Furthermore, in this molding apparatus, an insertion hole is formed on the surface of the molded product for the following two reasons, because an insertion hole is formed in the mold and the partition member is detachably mounted in the insertion hole. There is a problem that burrs are formed along.
(1) Reason 1
The gap between the inner wall of the insertion hole and the partition member is preferably set to be as narrow as possible so that the raw material beads do not enter. There is a problem that the partition member cannot be moved in and out due to deformation or damage in contact with the inner wall. More specifically, the mold expands when heated by the vapor of the raw material beads and contracts when cooled by the cooling water, but when the insertion hole is formed as described above, the strength of the mold part facing the insertion hole Therefore, the distortion of the mold concentrates on the insertion hole, and the opening width of the insertion hole tends to be absorbed and expanded. In addition, when the insertion hole is formed in a shape such as an L shape or a U shape, the shape of the insertion hole is deformed because the mold strength in a specific direction is reduced. Then, due to the expansion / contraction or deformation of the insertion hole, the partition member contacts the inner wall of the insertion hole and is deformed or damaged. In particular, when the mold is divided into a plurality of divided molds through the insertion holes, and the plurality of divided molds are fixed to the fixing plate with screws or the like, the insertion holes are easily formed in the mold. However, due to the expansion and contraction of the mold, the mounting position of the divided mold with respect to the fixed plate is shifted, and the opening width of the insertion hole varies greatly. Such a phenomenon becomes more prominent as the mold becomes larger and the length of the insertion hole becomes longer, which is a big problem for the in-mold foam molding apparatus having a partition member. For this reason, the gap between the inner wall of the insertion hole and the partition member is set large while recognizing the problem that burrs are formed along the insertion hole on the surface of the molded product.

（２）理由２
仕切部材の前端部の形状は、相手方の金型の内面形状に沿った形状に形成されているが、必ずしも挿通孔を設けた金型の内面と同じ形状であるわけではないので、原料ビーズの充填後、仕切部材を後退させたときに、仕切部材の一部は挿通孔の奧部側まで没入し、挿通孔の内部空間が成形空間に開口した状態になることがある。もっとも、挿通孔の開口幅は、原料ビーズの直径よりも小さく設定され、挿通孔内に原料ビーズが侵入しないように構成されているので、仕切部材を後退させただけでは原料ビーズが挿通孔内に侵入することはないが、成形空間内に蒸気を供給して原料ビーズを加熱融着させたときに、原料ビーズが軟化して発泡することにより、原料ビーズの一部が挿通孔内に侵入して、成形品の挿通孔に対応する位置に沿った細長いバリが突出状に形成される。 (2) Reason 2
The shape of the front end portion of the partition member is formed along the shape of the inner surface of the counterpart mold, but is not necessarily the same shape as the inner surface of the mold provided with the insertion hole. When the partition member is retracted after filling, a part of the partition member may be immersed up to the flange side of the insertion hole, and the internal space of the insertion hole may be opened to the molding space. However, since the opening width of the insertion hole is set to be smaller than the diameter of the raw material beads and the raw material beads do not enter the insertion hole, the raw material beads can be inserted into the insertion hole only by retracting the partition member. However, when the raw material beads are heated and fused by supplying steam into the molding space, the raw material beads soften and foam, so that a part of the raw material beads enter the insertion hole. Thus, an elongated burr along the position corresponding to the insertion hole of the molded product is formed in a protruding shape.

このようなバリは、表面の寸法精度に対する要求がラフな成形品に関しては大きな問題になることはないが、要求の厳しい成形品においては製品欠陥となることがある。例えば、自動車用バンパーにおいては、自動車のフロントビームの前側に型内発泡成形品としての芯材を固定し、この芯材を覆うように合成樹脂製のカバー部材を配置させたものが広く採用されているが、このような自動車用バンパーにおいては、芯材とフロントビーム間や芯材とカバー部材間に隙間が形成され、フロントビームの取付面の適正な位置に芯材を固定できなくなったり、車体の適正な位置にカバー部材を固定できなくなるという不具合が発生するので、これを防止するため芯材の成形後にバリを除去する必要があった。   Such burrs do not pose a major problem for molded products with rough surface dimensional accuracy requirements, but may cause product defects in demanding molded products. For example, in automobile bumpers, a core material as an in-mold foam molded product is fixed to the front side of the front beam of an automobile, and a synthetic resin cover member is disposed so as to cover the core material. However, in such an automobile bumper, a gap is formed between the core material and the front beam or between the core material and the cover member, and the core material cannot be fixed at an appropriate position on the front beam mounting surface. Since a problem that the cover member cannot be fixed at an appropriate position of the vehicle body occurs, it has been necessary to remove the burrs after molding the core material in order to prevent this.

本発明の目的は、１つの成形品に異なる特性の原料ビーズからなる成形部分を形成可能な成形装置の構成を格段に簡素なものとし、しかも仕切部材を設けることによる各種不具合を効果的に防止し得る型内発泡成形装置及び方法並びにバリの少ない型内発泡成形品を提供することである。   The object of the present invention is to greatly simplify the configuration of a molding apparatus that can form molded parts made of raw material beads having different characteristics in one molded product, and to effectively prevent various problems caused by providing a partition member. It is an object to provide an in-mold foam-molded apparatus and method and an in-mold foam-molded article with less burr.

本発明に係る型内発泡成形装置は、コア型とキャビティ型の少なくとも一方の金型に、成形空間内を複数の区画成形空間に区画する仕切部材を固定するとともに、各区画成形空間に原料ビーズを充填する充填器を設けて、隣接する区画成形空間に異なる特性の原料ビーズを充填可能となし、仕切部材として、隣接する区画成形空間に充填する原料ビーズの少なくとも一方が通り抜け不能な間隔をあけて型開閉方向に片持ち状に延びる複数の櫛歯を有する仕切部材を用い、エジェクタピンを有する金型に前記仕切部材を固定したものである。   The in-mold foam molding apparatus according to the present invention fixes a partition member that partitions a molding space into a plurality of partition molding spaces to at least one of a core mold and a cavity mold, and raw material beads in each partition molding space Is provided so that the adjacent compartment molding spaces can be filled with raw material beads having different characteristics, and as a partition member, at least one of the raw material beads filling the adjacent compartment molding spaces is spaced so that it cannot pass through. A partition member having a plurality of comb teeth extending in a cantilever manner in the mold opening / closing direction is used, and the partition member is fixed to a mold having an ejector pin.

この成形装置においては、仕切部材により成形空間内を複数の区画成形空間に区画した状態で、隣接する区画成形空間内に異なる特性の原料ビーズを充填できるので、区画成形空間の形成位置やサイズ、充填する原料ビーズの特性などを適正に設定することで、成形品の性能や品質を向上できる。例えば、強度面を重視する部位には、発泡倍率の低い原料ビーズを用いて成形品の強度剛性を高め、そうでない部位には発泡倍率の高い原料ビーズを用いることで成形品重量を軽減し、成形品の強度向上と重量軽減の両立を図ることが可能となる。   In this molding apparatus, the partitioning space can be filled with raw material beads having different characteristics in a state where the molding space is partitioned into a plurality of partition molding spaces by the partition member. By appropriately setting the characteristics of the raw material beads to be filled, the performance and quality of the molded product can be improved. For example, in parts where importance is placed on strength, the strength rigidity of the molded product is increased using raw material beads having a low expansion ratio, and the weight of the molded product is reduced by using raw material beads having a high expansion ratio in other parts. It is possible to achieve both improvement in strength and weight reduction of the molded product.

また、この成形装置により成形した成形品には、仕切部材の櫛歯に対応する位置に貫通孔又は有底孔が形成されるものの、仕切部材をコア型又はキャビティ型に固定的に設けているので、次のような作用が得られる。
（１）仕切部材を駆動するための駆動系が不要となるので、成形装置を格段に簡素に構成することが可能となり、成形装置の製作コストを低減できる。
（２）仕切部材の取付位置を変更することで、成形空間の区画領域を容易に変更することが可能で、成形品の設計変更等に容易に対応できる。
（３）隣接する区画成形空間内に充填した異なる特性の原料ビーズ同士も櫛歯間の隙間を介して十分に融着することになるので、成形品のうちの異なる特性の原料ビーズで成形された成形部分の接合強度を十分に確保することが可能となる。
（４）仕切部材が挿通する挿通孔を金型に設ける必要がないので、原料ビーズが挿通孔内に侵入したり、挿通孔と仕切部材間に侵入することにより、バリが形成されたりするという不具合を確実に防止できる。しかも、挿通孔の形成による金型強度の部分的な低下を防止でき、成形品精度を向上できる。 Moreover, although the through-hole or the bottomed hole is formed in the molded product molded by this molding apparatus at a position corresponding to the comb teeth of the partition member, the partition member is fixedly provided in the core mold or the cavity mold. Therefore, the following effects can be obtained.
(1) Since a drive system for driving the partition member is not required, the molding apparatus can be remarkably simplified, and the manufacturing cost of the molding apparatus can be reduced.
(2) By changing the attachment position of the partition member, it is possible to easily change the partition region of the molding space, and it is possible to easily cope with a design change of the molded product.
(3) Since the raw material beads with different characteristics filled in the adjacent partition forming spaces are sufficiently fused through the gaps between the comb teeth, they are molded with the raw material beads with different characteristics among the molded products. It is possible to sufficiently secure the bonding strength of the molded part.
(4) Since it is not necessary to provide the mold with an insertion hole through which the partition member is inserted, a raw material bead enters the insertion hole or a burr is formed by entering between the insertion hole and the partition member. Defects can be reliably prevented. In addition, it is possible to prevent a partial decrease in mold strength due to the formation of the insertion hole and improve the accuracy of the molded product.

しかも、エジェクタピンを有する金型に仕切部材を固定しているので、成形品の離型性を向上できる。つまり、金型形状によっては、型開きしたときに、成形品がエジェクタピンを有しない金型側に残置されて、離型不良が発生することがあるが、この成形装置においては、櫛歯が成形品に密着した状態で金型が型開きされるので、型開きしたとき成形品は、仕切部材を設けた金型側に残置されようとする。このため、エジェクタピンを有する金型に仕切部材を固定することで、前述のような離型不良を効果的に防止することが可能となる。   And since the partition member is being fixed to the metal mold | die which has an ejector pin, the mold release property of a molded article can be improved. In other words, depending on the shape of the mold, when the mold is opened, the molded product may remain on the mold side that does not have the ejector pin, and a mold release failure may occur. Since the mold is opened in close contact with the molded product, when the mold is opened, the molded product tends to remain on the mold side provided with the partition member. For this reason, it becomes possible to prevent the above-mentioned mold release defect effectively by fixing a partition member to the metal mold | die which has an ejector pin.

ここで、前記仕切部材を、エジェクタピンを有する金型に固定した第１仕切部材と、エジェクタピンを有しない金型に固定した第２仕切部材とで構成することも好ましい。この場合には、成形品を離型するため金型を開くときに、第１仕切部材の櫛歯と第２仕切部材の櫛歯とが相互に離間する方向へ引っ張られながら、第２仕切部材の櫛歯は成形品から抜き取られ、第１仕切部材の櫛歯は成形品に突き刺さったままに保持され、成形品は第２仕切部材を固定している一方の金型から切り離されて、第１仕切部材を固定している金型に残置されることになる。このため、成形品をエジェクタピンにて離型するときには、櫛歯に関しては、第１仕切部材の櫛歯から成形品を抜き取るだけでよいので、全ての櫛歯から成形品を抜き取る場合と比較して、離型性が格段によくなる。しかも、成形品を離型するため金型を開くときに、第１及び第２仕切部材の櫛歯が相互に離間する方向へ一旦引っ張られ、このとき成形品が残置される第１仕切部材の櫛歯と成形品との密着部分もある程度剥離されることになるから、エジェクタピンによる成形品の離型性が一層改善されることになる。   Here, it is also preferable that the partition member is composed of a first partition member fixed to a mold having an ejector pin and a second partition member fixed to a mold having no ejector pin. In this case, when the mold is opened to release the molded product, the second partition member is pulled while the comb teeth of the first partition member and the comb teeth of the second partition member are pulled away from each other. The comb teeth are extracted from the molded product, the comb teeth of the first partition member are held while being pierced into the molded product, and the molded product is separated from one mold fixing the second partition member, It will remain in the metal mold | die which fixes 1 partition member. For this reason, when the molded product is released with the ejector pin, the comb teeth need only be extracted from the comb teeth of the first partition member, so that compared with the case where the molded products are extracted from all the comb teeth. Therefore, the releasability is greatly improved. In addition, when the mold is opened to release the molded product, the comb teeth of the first and second partition members are once pulled in a direction away from each other, and at this time, the first partition member in which the molded product remains Since the close contact portion between the comb teeth and the molded product is also peeled to some extent, the mold release property of the molded product by the ejector pin is further improved.

また、このように、仕切部材を、エジェクタピンを有する金型に固定した第１仕切部材と、エジェクタピンを有しない金型に固定した第２仕切部材とで構成する場合には、第１仕切部材の櫛歯と第２仕切部材の櫛歯とを交互に配置させたり、エジェクタピンを有する第１仕切部材の櫛歯の本数を、エジェクタピンを有しない金型に固定した第２仕切部材の櫛歯の本数よりも多く設定したりすることが好ましい。前者の場合には、金型を開くときに、第１仕切部材の櫛歯と第２仕切部材の櫛歯とが相互に離間する方向へバランスよく引っ張られることになり、成形品に対して無理な力が作用することを防止できる。また、後者の場合には、金型を開いたときに、エジェクタピンを有する金型に対して確実に成形品を残置させることが可能となる。   Further, when the partition member is composed of the first partition member fixed to the mold having the ejector pins and the second partition member fixed to the mold not having the ejector pins as described above, The second partition member in which the comb teeth of the member and the comb teeth of the second partition member are alternately arranged, or the number of comb teeth of the first partition member having the ejector pin is fixed to a mold not having the ejector pin It is preferable to set more than the number of comb teeth. In the former case, when the mold is opened, the comb teeth of the first partition member and the comb teeth of the second partition member are pulled in a balanced manner, which is impossible for the molded product. Can be prevented from acting. In the latter case, when the mold is opened, the molded product can be reliably left on the mold having the ejector pins.

更に、前記第１仕切部材及び第２仕切部材の櫛歯の間隔を少なくとも一方の原料ビーズが通り抜け不能な間隔にそれぞれ設定することが好ましい。この場合には、第１仕切部材及び第２仕切部材の櫛歯の先端部を相手側の金型の内面まで延ばさなくても、両仕切部材の櫛歯の先端部を櫛歯の長さ方向に多少重ね合わせるだけで、隣接する区画成形部間における原料ビーズの移動を阻止できるので、両仕切部材の櫛歯を短尺に構成して、成形品の離型性を向上できるとともに、櫛歯に作用する曲げモーメントを小さく設定できるので、櫛歯として小径のものを採用することが可能となり、櫛歯により成形品に形成される有底孔を極力小径に構成できる。また、櫛歯の長さ設定がラフになるので、成形品形状の変更等に対しても容易に対応できるし、クラッキング充填のように、両金型間にクラッキング隙間をあけた状態で、原料ビーズを充填する場合でも、両仕切部材の櫛歯のラップ量をクラッキング隙間よりも多少大きく設定することで、隣接する区画成形空間を仕切ることが可能となる。   Furthermore, it is preferable that the interval between the comb teeth of the first partition member and the second partition member is set to an interval at which at least one raw material bead cannot pass through. In this case, the comb teeth tip portions of both partition members can be extended in the lengthwise direction without extending the comb tooth tips of the first partition member and the second partition member to the inner surface of the mating mold. Since it is possible to prevent the movement of the raw material beads between the adjacent section molding parts by simply overlapping each other, the comb teeth of both partition members can be configured in a short length to improve the mold releasability of the molded product. Since the acting bending moment can be set small, it is possible to adopt a small-diameter comb tooth, and the bottomed hole formed in the molded product by the comb tooth can be configured as small as possible. In addition, since the comb tooth length setting is rough, it can be easily adapted to changes in the shape of the molded product, etc., and the raw material with a cracking gap between both molds as in cracking filling Even when the beads are filled, it is possible to partition adjacent partition forming spaces by setting the amount of comb wrap of both partition members to be slightly larger than the cracking gap.

櫛歯の形状は任意に設定可能であるが、エジェクタピンを有する金型に固定した仕切部材の櫛歯の先端部又は途中部に、櫛歯からの成形品の離型抵抗を増大させる離型抵抗増大部を形成すると、金型を開いたときに、エジェクタピンを有する金型に対して確実に成形品を残置させることが可能となる。   The shape of the comb teeth can be set arbitrarily, but the mold release that increases the mold release resistance from the comb teeth at the tip or middle part of the comb teeth of the partition member fixed to the mold having the ejector pins When the resistance increasing portion is formed, when the mold is opened, the molded product can be reliably left with respect to the mold having the ejector pins.

また、櫛歯としては、直径が１〜１０ｍｍの棒状部材を用いることが好適である。つまり、この成形装置においては、前述のように成形品に櫛歯により貫通孔又は有底孔が形成されるので、櫛歯の直径を１０ｍｍよりも大きく設定すると、大きな貫通孔又は有底孔が形成されることになり、成形品の強度低下を招くとともに、成形品の外観が低下し、また櫛歯の直径を１ｍｍよりも小さく設定すると、櫛歯の強度を十分に確保できず、櫛歯が破損したり変形したりするという不具合が発生する。   Moreover, as a comb tooth, it is suitable to use a rod-shaped member having a diameter of 1 to 10 mm. That is, in this molding apparatus, as described above, a through hole or a bottomed hole is formed in the molded product by comb teeth. Therefore, when the diameter of the comb teeth is set to be larger than 10 mm, a large through hole or bottomed hole is formed. As a result, the strength of the molded product is reduced, the appearance of the molded product is deteriorated, and if the diameter of the comb teeth is set to be smaller than 1 mm, the strength of the comb teeth cannot be secured sufficiently, and the comb teeth This causes the problem of damage or deformation.

更に、隣接する櫛歯の間隔は、通り抜けできない原料ビーズの直径の３０〜９０％に設定することが好ましい。隣接する櫛歯の間隔は狭すぎると、該櫛歯を挟んで隣接する区画成形空間内の原料ビーズ同士の密着性が十分に確保できず、境界部分における強度が低下する。また、ポリオレフィン系樹脂からなる原料ビーズは、ポリスチレン系樹脂からなる原料ビーズよりも柔らかいので、隣接する櫛歯の間隔が広すぎると、原料ビーズが仕切部材の櫛歯間を通って隣接する区画成形空間に移動するという不具合が発生する。   Furthermore, the interval between adjacent comb teeth is preferably set to 30 to 90% of the diameter of the raw material beads that cannot pass through. If the interval between the adjacent comb teeth is too narrow, sufficient adhesion between the raw material beads in the adjacent compartment forming space across the comb teeth cannot be ensured, and the strength at the boundary portion decreases. In addition, since the raw material beads made of polyolefin resin are softer than the raw material beads made of polystyrene resin, if the interval between the adjacent comb teeth is too wide, the raw material beads pass between the comb teeth of the partition member and are adjacently molded. The problem of moving to space occurs.

本発明に係る型内発泡成形方法は、前記型内発泡成形装置を用いるとともに、原料ビーズとして櫛歯間を通り抜け不能な原料ビーズを用い、コア型とキャビティ型を型閉めして、仕切部材により成形空間を複数の区画成形空間に区画した状態で、少なくとも隣接する区画成形空間に異なる特性の原料ビーズが充填されるように各区画成形空間内に原料ビーズを充填するものである。   The in-mold foam molding method according to the present invention uses the above-described in-mold foam molding apparatus, uses raw material beads that cannot pass between the comb teeth as raw material beads, closes the core mold and the cavity mold, and uses a partition member to In the state where the molding space is partitioned into a plurality of partition molding spaces, the raw material beads are filled in each of the partition molding spaces so that at least the adjacent partition molding spaces are filled with the raw material beads having different characteristics.

この成形方法においては、前記型内発泡成形装置を用いているので、前述と同様の作用が得られる。しかも、原料ビーズとして仕切部材の櫛歯間を通り抜け不能なサイズのものを用いているので、複数の区画成形空間に対して異なる特性の原料ビーズを同時に充填することが可能となり、原料ビーズの充填時間を長くすることなく、原料ビーズを充填することが可能となる。   In this molding method, the same function as described above can be obtained because the in-mold foam molding apparatus is used. Moreover, since the raw material beads are of a size that cannot pass between the comb teeth of the partition member, it becomes possible to simultaneously fill the raw material beads having different characteristics into a plurality of partition molding spaces. The raw material beads can be filled without increasing the time.

本発明に係る他の型内発泡成形方法は、前記型内発泡成形装置を用いるとともに、原料ビーズとして櫛歯間を通り抜け不能な第１原料ビーズと通り抜け可能な第２原料ビーズを用い、コア型とキャビティ型を型閉めして、仕切部材により成形空間を複数の区画成形空間に区画した状態で、第１原料ビーズを充填した後、第２原料ビーズを充填して、少なくとも隣接する区画成形空間に異なる特性の原料ビーズが充填されるように各区画成形空間内に原料ビーズを充填するものである。   Another in-mold foam molding method according to the present invention uses the above-mentioned in-mold foam molding apparatus, uses as a raw material bead a first raw material bead that cannot pass between comb teeth and a second raw material bead that can pass through, and a core mold. And the cavity mold are closed, and after the first raw material beads are filled in the state in which the molding space is partitioned into a plurality of compartment molding spaces by the partition member, the second raw material beads are filled, and at least the adjacent compartment molding spaces The raw material beads are filled into each partition molding space so that the raw material beads having different characteristics are filled with each other.

この型内発泡成形方法においては、前記型内発泡成形装置を用いているので、前述と同様の作用が得られる。しかも、櫛歯間を通り抜け不能な第１原料ビーズを充填した後、櫛歯間を通り抜け可能な第２原料ビーズを充填するので、原料ビーズの充填時間は長くなるが、第２ビーズの一部は櫛歯を通り抜けて隣接する区画成形空間内へ移動するので、第１ビーズと第２ビーズとの接合強度をより一層高めることが可能となる。   In this in-mold foam molding method, since the in-mold foam molding apparatus is used, the same action as described above can be obtained. Moreover, since the second raw material beads that can pass between the comb teeth are filled after the first raw material beads that cannot pass between the comb teeth are filled, the filling time of the raw material beads becomes longer, but a part of the second beads Moves through the comb teeth and into the adjacent partition forming space, so that the bonding strength between the first beads and the second beads can be further increased.

また、前記異なる特性の原料ビーズとして、発泡倍率の異なる原料ビーズを仕切部材で区画された隣接する区画成形空間内に充填することが考えられる。例えば、強度面を重視する部位には、発泡倍率の低い原料ビーズを用いて成形品の強度剛性を高め、そうでない部位には発泡倍率の高い原料ビーズを用いることで成形品重量を軽減し、成形品の強度向上と重量軽減の両立を図ることが可能となる。   In addition, it is conceivable that the raw material beads having different expansion ratios are filled in the adjacent partition forming spaces partitioned by the partition members as the raw material beads having different characteristics. For example, in parts where importance is placed on strength, the strength rigidity of the molded product is increased using raw material beads having a low expansion ratio, and the weight of the molded product is reduced by using raw material beads having a high expansion ratio in other parts. It is possible to achieve both improvement in strength and weight reduction of the molded product.

本発明に係る型内発泡成形品は、前記型内発泡成形装置にて成形した型内発泡成形品であって、異なる特性の原料ビーズを用いて成形された複数の成形部分を有し、各成形部分の境界に沿って設定間隔おきに金型の型開閉方向に延びる複数の貫通孔又は有底孔が形成されてなるものである。
この成形品は、前記型内発泡成形装置により成形したものであり、仕切部材の櫛歯に対応する位置には貫通孔や有底孔が形成されることになるが、成形装置の構成を簡略にでき、しかも前述のように仕切部材を成形空間内に出没させるための挿通孔を金型に形成する必要がないことから、挿通孔により成形品の適正表面外へ突出するバリが形成されることもない。 An in-mold foam-molded product according to the present invention is an in-mold foam-molded product molded by the in-mold foam molding apparatus, and has a plurality of molded parts molded using raw material beads having different characteristics. A plurality of through holes or bottomed holes extending in the mold opening / closing direction of the mold are formed at set intervals along the boundary of the molded part.
This molded product is formed by the in-mold foam molding apparatus, and through holes and bottomed holes are formed at positions corresponding to the comb teeth of the partition member, but the configuration of the molding apparatus is simplified. In addition, as described above, since there is no need to form an insertion hole in the mold for allowing the partition member to protrude into and out of the molding space, a burr that protrudes outside the appropriate surface of the molded product is formed by the insertion hole. There is nothing.

型内発泡成形品の具体的な例としては、自動車用バンパーの芯材が考えられる。このよう自動車用バンパーの芯材は、自動車の正面衝突（正突）時における衝撃や、オフセット衝突時における衝撃や、斜め前側からの衝突（斜突）時における衝撃を効率的に吸収する必要があるとともに、車体重量を軽減するため、芯材の重量は極力軽く構成する必要がある。本発明に係る型内発泡成形品としての自動車用バンパーの芯材においては、自動車の各種前面衝突時において芯材に作用する局部的衝撃応力を受けやすい部分付近を、発泡倍率の低い原料ビーズからなる低発泡部で構成し、他の部分を低発泡部よりも発泡倍率の高い原料ビーズからなる高発泡部で構成することで、芯材の重量を極力低減しつつ、オフセット衝突時や斜突時においても、衝撃エネルギーを効果的に吸収することが可能となる。   As a specific example of the in-mold foam-molded product, a core material of an automobile bumper is conceivable. Such a bumper core material for automobiles must efficiently absorb shocks at the time of a frontal collision (normal collision) of an automobile, an impact at the time of an offset collision, and a collision from an oblique front side (an oblique collision). In addition, in order to reduce the weight of the vehicle body, it is necessary to configure the core material as light as possible. In the core material of the bumper for automobiles as the in-mold foam-molded article according to the present invention, the vicinity of the portion susceptible to local impact stress acting on the core material at the time of various frontal collisions of the automobile is made from the raw material beads having a low expansion ratio. The low-foamed part and the other parts are made of high-foamed parts made of raw material beads with a higher expansion ratio than the low-foamed part. Even at times, it is possible to effectively absorb the impact energy.

本発明に係る型内発泡成形装置によれば、仕切部材により成形空間内を複数の区画成形空間に区画した状態で、隣接する区画成形空間内に異なる特性の原料ビーズを充填できるので、区画成形空間の形成位置やサイズ、充填する原料ビーズの特性などを適正に設定することで、成形品の性能や品質を向上できる。   According to the in-mold foam molding apparatus according to the present invention, since the molding space is partitioned into a plurality of partition molding spaces by the partition member, the raw material beads having different characteristics can be filled in the adjacent partition molding spaces. By appropriately setting the formation position and size of the space and the characteristics of the raw material beads to be filled, the performance and quality of the molded product can be improved.

また、この成形装置により成形した成形品には、仕切部材の櫛歯に対応する位置に貫通孔又は有底孔が形成されるものの、仕切部材をコア型又はキャビティ型に固定的に設けているので、仕切部材を駆動するための駆動系が不要となるので、成形装置を格段に簡素に構成することが可能となり、成形装置の製作コストを低減できること、仕切部材の取付位置を変更することで、成形空間の区画領域を容易に変更することが可能で、成形品の設計変更等に容易に対応できること、隣接する区画成形空間内に充填した異なる特性の原料ビーズ同士も櫛歯間の隙間を介して十分に融着できるので、成形品のうちの異なる特性の原料ビーズで成形された成形部分の接合強度を十分に確保できること、仕切部材が挿通する挿通孔を金型に設ける必要がないので、原料ビーズが挿通孔内に侵入したり、挿通孔と仕切部材間に侵入することにより、バリが形成されたりするという不具合を確実に防止できるとともに、挿通孔の形成による金型強度の部分的な低下を防止でき、成形品精度を向上できること、などの効果が得られる。   Moreover, although the through-hole or the bottomed hole is formed in the molded product molded by this molding apparatus at a position corresponding to the comb teeth of the partition member, the partition member is fixedly provided in the core mold or the cavity mold. Therefore, since a drive system for driving the partition member is not required, the molding apparatus can be remarkably simplified, the manufacturing cost of the molding apparatus can be reduced, and the attachment position of the partition member can be changed. It is possible to easily change the partition area of the molding space, easily adapt to the design change of the molded product, etc., and the bead between the different characteristics filled in the adjacent partition molding space also has a gap between the comb teeth. Therefore, it is necessary to sufficiently secure the bonding strength of the molded portion formed of the raw material beads having different characteristics among the molded products, and it is not necessary to provide an insertion hole through which the partition member is inserted in the mold. Therefore, it is possible to surely prevent a problem that burrs are formed when the raw material beads enter the insertion hole or between the insertion hole and the partition member, and the mold strength portion due to the formation of the insertion hole. Effects can be obtained, such as prevention of general degradation and improvement of molded product accuracy.

更に、エジェクタピンを有する金型に仕切部材を固定しているので、金型を型開きしたときに、エジェクタピンを有する金型側に成形品を残置させることが可能となり、エジェクタピンを有しない金型側に成形品が残置されることによる成形品の離型不良を効果的に防止できる。   Further, since the partition member is fixed to the mold having the ejector pin, when the mold is opened, the molded product can be left on the mold side having the ejector pin, and the ejector pin is not provided. It is possible to effectively prevent a mold release failure due to the molded product remaining on the mold side.

前記仕切部材を、エジェクタピンを有する金型に固定した第１仕切部材と、エジェクタピンを有しない金型に固定した第２仕切部材とで構成すると、両仕切部材からの成形品の離型性を向上できる。また、この成形装置においては、第１仕切部材の櫛歯と第２仕切部材の櫛歯とを交互に配置させることにより、金型を開くときに、第１仕切部材の櫛歯と第２仕切部材の櫛歯とが相互に離間する方向へバランスよく引っ張られることになり、成形品に対して無理な力が作用することを防止できる。更に、エジェクタピンを有する第１仕切部材の櫛歯の本数を、エジェクタピンを有しない金型に固定した第２仕切部材の櫛歯の本数よりも多く設定すると、金型を開いたときに、エジェクタピンを有する金型に対して確実に成形品を残置させることが可能となる。   When the partition member is composed of a first partition member fixed to a mold having an ejector pin and a second partition member fixed to a mold not having an ejector pin, the release property of the molded product from both partition members Can be improved. Further, in this molding apparatus, the comb teeth of the first partition member and the second partition when the mold is opened by alternately arranging the comb teeth of the first partition member and the comb teeth of the second partition member. Since the comb teeth of the member are pulled in a direction away from each other in a balanced manner, it is possible to prevent an excessive force from acting on the molded product. Further, when the number of comb teeth of the first partition member having the ejector pins is set to be larger than the number of comb teeth of the second partition member fixed to the mold having no ejector pins, when the mold is opened, It is possible to reliably leave the molded product on the mold having the ejector pins.

前記第１仕切部材及び第２仕切部材の櫛歯の間隔を少なくとも一方の原料ビーズが通り抜け不能な間隔にそれぞれ設定すると、両仕切部材の櫛歯を短尺に構成できるので、成形品の離型性を向上できるとともに、櫛歯として小径のものを採用することが可能となり、櫛歯により成形品に形成される有底孔を極力小径に構成できる。また、櫛歯の長さ設定がラフになるので、成形品形状の変更等に対しても容易に対応できるし、クラッキング充填のように、両金型間にクラッキング隙間をあけた状態で、原料ビーズを充填する場合でも、両仕切部材の櫛歯のラップ量をクラッキング隙間よりも多少大きく設定することで、隣接する区画成形空間を仕切ることが可能となる。   When the interval between the comb teeth of the first partition member and the second partition member is set to an interval at which at least one raw material bead cannot pass through, the comb teeth of both partition members can be configured to be short, so that the release property of the molded product In addition, it is possible to adopt a small-diameter comb tooth, and the bottomed hole formed in the molded product by the comb tooth can be configured as small as possible. In addition, since the comb tooth length setting is rough, it can be easily adapted to changes in the shape of the molded product, etc., and the raw material with a cracking gap between both molds as in cracking filling Even when the beads are filled, it is possible to partition adjacent partition forming spaces by setting the amount of comb wrap of both partition members to be slightly larger than the cracking gap.

櫛歯の形状は任意に設定可能であるが、エジェクタピンを有する金型に固定した仕切部材の櫛歯の先端部又は途中部に、櫛歯からの成形品の離型抵抗を増大させる離型抵抗増大部を形成すると、金型を開いたときに、エジェクタピンを有する金型に対して確実に成形品を残置させることが可能となる。   The shape of the comb teeth can be set arbitrarily, but the mold release that increases the mold release resistance from the comb teeth at the tip or middle part of the comb teeth of the partition member fixed to the mold having the ejector pins When the resistance increasing portion is formed, when the mold is opened, the molded product can be reliably left with respect to the mold having the ejector pins.

櫛歯として、直径が１〜１０ｍｍの棒状部材を用いると、櫛歯の強度を十分に確保して、櫛歯の破損や変形を防止できるとともに、大きな貫通孔又は有底孔が形成されることによる成形品の強度低下や外観低下を極力防止することが可能となる。   When a rod-shaped member having a diameter of 1 to 10 mm is used as the comb teeth, the comb teeth can have sufficient strength to prevent the comb teeth from being damaged or deformed, and a large through hole or bottomed hole is formed. Therefore, it is possible to prevent a decrease in the strength and appearance of the molded product as much as possible.

隣接する櫛歯の間隔を、通り抜けできない原料ビーズの直径の３０〜９０％に設定すると、隣接する区画成形空間内の原料ビーズ同士の密着性を十分に確保して、境界部分における密着強度を向上できるとともに、原料ビーズが仕切部材の櫛歯間を通って隣接する区画成形空間に移動するという不具合を防止できる。   When the interval between adjacent comb teeth is set to 30 to 90% of the diameter of the raw material beads that cannot pass through, sufficient adhesion between the raw material beads in the adjacent partition molding space is sufficiently secured, and the adhesion strength at the boundary portion is improved. In addition, it is possible to prevent the problem that the raw material beads move between the comb teeth of the partition member and move to the adjacent partition forming space.

本発明に係る型内発泡成形方法によれば、前記型内発泡成形装置を用いているので、前述と同様の作用が得られる。しかも、原料ビーズとして仕切部材の櫛歯間を通り抜け不能なサイズのものを用いているので、複数の区画成形空間に対して異なる特性の原料ビーズを同時に充填することが可能となり、原料ビーズの充填時間を長くすることなく、原料ビーズを充填することが可能となる。   According to the in-mold foam molding method of the present invention, since the in-mold foam molding apparatus is used, the same operation as described above can be obtained. Moreover, since the raw material beads are of a size that cannot pass between the comb teeth of the partition member, it becomes possible to simultaneously fill the raw material beads having different characteristics into a plurality of partition molding spaces. The raw material beads can be filled without increasing the time.

本発明に係る他の型内発泡成形方法によれば、前記型内発泡成形装置を用いているので、前述と同様の作用が得られる。しかも、櫛歯間を通り抜け不能な第１原料ビーズを充填した後、櫛歯間を通り抜け可能な第２原料ビーズを充填するので、原料ビーズの充填時間は長くなるが、第２ビーズの一部は櫛歯を通り抜けて隣接する区画成形空間内へ移動するので、第１ビーズと第２ビーズとの接合強度をより一層高めることが可能となる。   According to another in-mold foam molding method according to the present invention, since the in-mold foam molding apparatus is used, the same action as described above can be obtained. Moreover, since the second raw material beads that can pass between the comb teeth are filled after the first raw material beads that cannot pass between the comb teeth are filled, the filling time of the raw material beads becomes longer, but a part of the second beads Moves through the comb teeth and into the adjacent partition forming space, so that the bonding strength between the first beads and the second beads can be further increased.

原料ビーズとして、発泡倍率の異なる原料ビーズを仕切部材で区画された隣接する区画成形空間内に充填すると、例えば、強度面を重視する部位には、発泡倍率の低い原料ビーズを用いて成形品の強度剛性を高め、そうでない部位には発泡倍率の高い原料ビーズを用いることで成形品重量を軽減し、成形品の強度向上と重量軽減の両立を図ることが可能となる。   When material beads having different expansion ratios are filled in adjacent compartment molding spaces partitioned by partition members as raw material beads, for example, material beads having a low expansion ratio are used for parts that place importance on strength. It is possible to increase the strength rigidity and reduce the weight of the molded product by using a raw material bead having a high expansion ratio at a portion other than that, thereby achieving both improvement in strength and weight reduction of the molded product.

本発明に係る型内発泡成形品によれば、型内発泡成形装置にて成形した型内発泡成形品なので、異なる特性の原料ビーズを用いて成形された複数の成形部分の境界に沿って、設定間隔おきに金型の型開閉方向に延びる複数の貫通孔又は有底孔が形成されることになるが、成形装置の構成を簡略にでき、しかも前述のように仕切部材を成形空間内に出没させるための挿通孔を金型に形成する必要がないことから、挿通孔により成形品の適正表面外へ突出するバリが形成されることもない。   According to the in-mold foam-molded product according to the present invention, since it is an in-mold foam-molded product molded by the in-mold foam molding apparatus, along the boundaries of a plurality of molded parts molded using raw material beads having different characteristics, A plurality of through holes or bottomed holes extending in the mold opening / closing direction of the mold are formed at set intervals, but the configuration of the molding apparatus can be simplified, and the partition member is placed in the molding space as described above. Since there is no need to form an insertion hole for intrusion in the mold, no burr protruding outside the appropriate surface of the molded product is formed by the insertion hole.

また、自動車用バンパーの芯材をこの型内発泡成形品で構成する場合には、この芯材のうちの自動車の各種前面衝突時において芯材に作用する局部的衝撃応力を受けやすい部分付近を発泡倍率の低い原料ビーズからなる低発泡部で構成し、他の部分を低発泡部よりも発泡倍率の高い原料ビーズからなる高発泡部で構成することで、芯材の重量を極力低減しつつ、各種前面衝突時における衝撃エネルギーを効果的に吸収することが可能となる。   Moreover, when the core material of the bumper for automobiles is composed of this in-mold foam molded product, the vicinity of the portion of the core material that is susceptible to local impact stress that acts on the core material at the time of various frontal collisions of the automobile. Consists of low-foamed parts made of raw material beads with a low expansion ratio, and other parts are made of high-foamed parts made of raw material beads with a higher expansion ratio than the low-foamed part, while reducing the weight of the core as much as possible It is possible to effectively absorb impact energy at the time of various frontal collisions.

以下、本発明の実施の形態について図面を参照しながら説明する。尚、本実施の形態は、型内発泡成形品としての自動車用バンパーの芯材と、これを成形するための型内発泡成形装置及び型内発泡成形方法に本発明を適用した場合ものである。   Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the present embodiment, the present invention is applied to a core material of an automobile bumper as an in-mold foam molded product, an in-mold foam molding apparatus and an in-mold foam molding method for molding the core material. .

先ず、型内発泡成形品としての自動車用バンパーの芯材について説明する。
図１、図２に示すように、芯材１は、両端部側を緩やかに後方へ湾曲させた前部衝撃吸収部２と、前部衝撃吸収部２の両端部から後方へ延びる側部衝撃吸収部３とを有している。前部衝撃吸収部２から側部衝撃吸収部３に至る角部４の下半部には発泡倍率の低い原料ビーズからなる低発泡部５が形成され、その他の部分は低発泡部５よりも発泡倍率の高い原料ビーズからなる高発泡部６で構成されている。 First, a core material for an automobile bumper as an in-mold foam molded product will be described.
As shown in FIG. 1 and FIG. 2, the core material 1 includes a front impact absorbing portion 2 in which both end portions are gently curved backward, and a side impact extending rearward from both ends of the front impact absorbing portion 2. And an absorbing portion 3. A low foamed portion 5 made of raw material beads having a low expansion ratio is formed in the lower half of the corner portion 4 from the front impact absorbing portion 2 to the side impact absorbing portion 3, and the other portions are lower than the low foamed portion 5. It is comprised by the high foaming part 6 which consists of a raw material bead with a high expansion ratio.

つまり、前部衝撃吸収部２の中央部は、正突時における衝撃エネルギーを吸収するためのものであるが、衝撃エネルギーの受圧面積を大きく設定できるので、発泡倍率の高い軟質軽量な原料ビーズで構成し、前部衝撃吸収部２の両端部及び側部衝撃吸収部３は、オフセット衝突時や斜突時における衝撃エネルギーを吸収するためのものであるが、衝撃エネルギーの受圧面積を大きく設定することが困難なので、他の部分よりも重たくなるが発泡倍率の低い硬質な原料ビーズからなる低発泡部５を設けることで、各種前面衝突時における十分な衝突安全性能を確保しつつ、芯材１の重量を極力低減できるように構成されている。尚、低発泡部５の長さや高さは、芯材１に作用する衝撃エネルギーを十分に吸収できるように構成されていれば、任意のサイズに設定することが可能である。また、本実施例では、低発泡部５を芯材１の角部４の下半部にのみ形成したが、角部４の全体を低発泡率の原料ビーズで構成することも可能である。また、芯材１の外観形状やサイズは、適用する自動車に応じて任意に設定可能である。   In other words, the central portion of the front impact absorbing portion 2 is for absorbing impact energy at the time of forward collision, but since the pressure receiving area of impact energy can be set large, it is a soft and lightweight raw material bead with a high expansion ratio. The both ends of the front impact absorbing portion 2 and the side impact absorbing portion 3 are configured to absorb impact energy at the time of offset collision or oblique collision, and set a large pressure receiving area for impact energy. However, by providing the low foaming portion 5 made of hard raw material beads which are heavier than other parts but have a low foaming ratio, the core material 1 is secured while ensuring sufficient collision safety performance at the time of various frontal collisions. It is comprised so that the weight of can be reduced as much as possible. The length and height of the low foamed portion 5 can be set to any size as long as it is configured to sufficiently absorb the impact energy acting on the core material 1. In the present embodiment, the low foamed portion 5 is formed only in the lower half portion of the corner portion 4 of the core material 1, but the entire corner portion 4 can also be composed of raw material beads having a low foaming rate. Moreover, the external appearance shape and size of the core material 1 can be arbitrarily set according to the motor vehicle to which it applies.

図１に示すように、低発泡部５と高発泡部６とは正面視略コ字状の境界Ｌの位置において区画され、境界Ｌに沿って一定間隔おきに芯材１を前後方向に貫通する複数の貫通孔７が形成されている。この貫通孔７は、後述する型内発泡成形装置１０により芯材１を成形したことにより形成されるものであるが、芯材１の後面側から前面側、或いは前面側から後面側へ延びる有底孔で構成することも可能である。   As shown in FIG. 1, the low foaming portion 5 and the high foaming portion 6 are partitioned at the position of a substantially L-shaped boundary L when viewed from the front, and penetrate the core material 1 in the front-rear direction along the boundary L at regular intervals. A plurality of through holes 7 are formed. The through-hole 7 is formed by molding the core material 1 with an in-mold foam molding apparatus 10 to be described later, and extends through the core material 1 from the rear surface side to the front surface side or from the front surface side to the rear surface side. It is also possible to configure with a bottom hole.

この芯材１においては、前述のように、境界Ｌに沿って一定間隔おきに芯材１を前後方向に貫通する複数の貫通孔７が形成されるものの、従来のように芯材１の表面に境界Ｌに沿ってバリが突出形成されることはないので、バリ除去のための工程を経ることなく、この芯材１をそのまま自動車のフロントビームの取付面に精度よく固定することが可能となる。また、芯材１にカバー部材を外装する場合においても、芯材１とカバー部材間に隙間が形成されることを確実に防止できる。   In the core material 1, as described above, although a plurality of through holes 7 that penetrate the core material 1 in the front-rear direction are formed at regular intervals along the boundary L, the surface of the core material 1 as in the past is formed. Since no burr protrudes along the boundary L, it is possible to fix the core material 1 as it is to the mounting surface of the front beam of the automobile with high accuracy without going through a burr removal process. Become. Further, even when the cover member is packaged on the core material 1, it is possible to reliably prevent a gap from being formed between the core material 1 and the cover member.

尚、境界Ｌは必ずしも正面視コ字状に形成する必要はなく、正面視Ｌ字状や直線状、或いは曲線状の境界に沿って芯材を区画することも可能である。また、本実施例では、自動車用バンパーの芯材１について説明したが、異なる特性の原料ビーズからなる成形部を有する成形品であれば、芯材以外の型内発泡成形品に対しても本発明を同様に適用できる。更に、成形品によっては、その使用条件に適合するように、発泡倍率以外の特性の異なる原料ビーズ、例えばビーズ嵩密度、セル径、ビーズ径、素材などの異なる特性の原料ビーズを用いて成形品を構成してもよい。   Note that the boundary L is not necessarily formed in a U-shape when viewed from the front, and the core material can be partitioned along a boundary that is L-shaped, straight, or curved as viewed from the front. Further, in the present embodiment, the core material 1 of the bumper for automobiles has been described. However, as long as the molded product has a molded part made of raw material beads having different characteristics, the present invention can be applied to in-mold foam molded products other than the core material. The invention is equally applicable. Furthermore, depending on the molded product, a molded product using raw material beads having different characteristics other than the expansion ratio, for example, raw material beads having different characteristics such as bead bulk density, cell diameter, bead diameter, and material, so as to suit the use conditions. May be configured.

原料ビーズの素材としては、製作する成形品の使用条件などに応じた物性の素材を選択することになるが、ポリスチレン系合成樹脂材料や、ポリエチレン系樹脂やポリプロピレン系樹脂材料などのポリオレフィン系合成樹脂材料や、これらの合成樹脂材料の共重合体などを採用できる。
原料ビーズの発泡倍率は、原料ビーズの素材にもよるが、３〜１５０倍の範囲内が好ましい。具体的には、ポリスチレン系合成樹脂材料からなる原料ビーズにおいては３〜１００倍、好ましくは３〜８０倍、ポリオレフィン系合成樹脂材料からなる原料ビーズにおいては、３〜９０倍、好ましくは３〜６０倍のものが好適に利用できる。また、粒径は１〜１０ｍｍ、好ましくは２．０〜８ｍｍの範囲のものが好適に利用できる。 The raw material bead material is selected according to the conditions of use of the molded product to be manufactured. Polystyrene synthetic resins such as polystyrene-based synthetic resin materials, polyethylene-based resins and polypropylene-based resin materials Materials and copolymers of these synthetic resin materials can be used.
The expansion ratio of the raw material beads is preferably in the range of 3 to 150 times, although it depends on the raw material of the raw material beads. Specifically, 3 to 100 times, preferably 3 to 80 times in raw material beads made of polystyrene synthetic resin material, 3 to 90 times, preferably 3 to 60 in raw material beads made of polyolefin synthetic resin material. Double ones can be suitably used. A particle size in the range of 1 to 10 mm, preferably 2.0 to 8 mm can be suitably used.

ポリオレフィン系樹脂材料の具体例としては、エチレンプロピレンランダムポリプロピレン樹脂、エチレンプロピレンブロックポリプロピレン樹脂、ホモポリプロピレンエチレンプロピレンブテンランダムターポリマー、直鎖状低密度ポリエチレン（ＬＬＤＰＥ）、架橋低密度ポリエチレン（架橋ＬＤＰＥ）などを好適に利用できる。   Specific examples of polyolefin resin materials include ethylene propylene random polypropylene resin, ethylene propylene block polypropylene resin, homopolypropylene ethylene propylene butene random terpolymer, linear low density polyethylene (LLDPE), and crosslinked low density polyethylene (crosslinked LDPE). Can be suitably used.

このようなポリオレフィン系樹脂材料からなる原料ビーズのセル径は、１００μｍ未満の場合には、成形時に表面伸びが悪く、ヒケ易く、適正表面外観の見栄えが劣るという問題があり、９００μｍを越える場合には、セル径が不均一になり易く、セル径が大きいため表面のきめが粗く、適正表面外観が劣るという問題があるので、１００〜９００μｍの範囲内、より好ましくは１５０〜７００μｍ、特に好ましくは１７０〜５５０μｍに設定することになる。   When the cell diameter of the raw material beads made of such a polyolefin-based resin material is less than 100 μm, there is a problem that surface elongation is poor at the time of molding, there is a problem that it is easy to sink, and the appearance of an appropriate surface appearance is inferior. Has a problem that the cell diameter is likely to be non-uniform, the cell diameter is large and the surface is rough, and the appropriate surface appearance is inferior, so it is in the range of 100 to 900 μm, more preferably 150 to 700 μm, particularly preferably. It will be set to 170-550 micrometers.

ＤＳＣ２’ｎｄピーク比は、８％〜６０％に設定することが好ましい。ＤＳＣ２’ｎｄピーク比とは、基材樹脂を加熱したときに、基材樹脂の結晶融点に起因して形成される、低温側と高温側の２つのＤＳＣ（示差走査熱量測定）のピークの合計面積に対する高温側ピークの面積の割合であり、このＤＳＣ２’ｎｄピーク比が、８％未満の場合には、成形時の加熱条件幅が狭く、成形体が収縮し易く、ヒケ易い。また、６０％を越えると、加熱条件を大幅にアップする必要があり、成形機の大型化が必要であり、且つ省エネルギーという観点からもマイナスとなるので８〜６０％、より好ましくは１０〜５０％、特に好ましくは１５〜４０％に設定することになる。   The DSC 2'nd peak ratio is preferably set to 8% to 60%. DSC 2'nd peak ratio is the total of two low temperature and high temperature DSC (differential scanning calorimetry) peaks formed due to the crystalline melting point of the base resin when the base resin is heated. When the DSC 2′nd peak ratio is less than 8%, the heating condition width at the time of molding is narrow, and the molded body tends to shrink and sink easily. On the other hand, if it exceeds 60%, it is necessary to greatly increase the heating conditions, and it is necessary to increase the size of the molding machine, and it is negative from the viewpoint of energy saving, so it is 8 to 60%, more preferably 10 to 50%. %, Particularly preferably 15 to 40%.

独立気泡率は、６５％未満の場合には、成形時の加熱圧をアップしてなんとかビーズ同士を融着させたとしても、成形体の収縮、ヒケが大きくなり易く、目標の品質の成形体が得られ難くなるので、６５％以上、より好ましくは７５％以上、特に好ましくは８５％以上に設定することになる。   If the closed cell ratio is less than 65%, even if the heating pressure at the time of molding is increased and the beads are somehow fused together, shrinkage and sink marks of the molded body tend to increase, and the molded body of the target quality. Is less than 65%, more preferably 75% or more, and particularly preferably 85% or more.

次に、前述した芯材１を成形可能な型内発泡成形装置１０について説明する。
図３に示すように、型内発泡成形装置１０は、対向配置された１組の金型としてのコア型１１及びキャビティ型１２と、コア型１１とキャビティ型１２とで形成される成形空間１３内に空気の流れに乗せて原料ビーズを充填するための充填器１４とを備えている。 Next, the in-mold foam molding apparatus 10 capable of molding the core material 1 described above will be described.
As shown in FIG. 3, the in-mold foam molding apparatus 10 includes a core mold 11 and a cavity mold 12 as a set of opposed molds, and a molding space 13 formed by the core mold 11 and the cavity mold 12. And a filling device 14 for filling the raw material beads in an air flow.

コア型１１及びキャビティ型１２は、枠状フレームと裏板とを有するハウジング１５にそれぞれ取り付けられ、コア型１１及びキャビティ型１２の背面側には１組の第１チャンバー１６及び第２チャンバー１７がそれぞれ形成され、コア型１１及びキャビティ型１２には両チャンバー１６，１７と成形空間１３とを連通する多数の通気孔１８が形成されている。尚、通気孔１８は、実際には、図４、図５に例示するように、０．５ｍｍφ程度の丸孔１９ａや幅０．５ｍｍ程度のスリット１９ｂを複数個透設した外径７〜１２ｍｍの蓋を有する筒体からなるコアベント１９を、金型１１，１２に孔明け配置したコアベント取付孔２０に嵌め込んで形成したものや、金型１１，１２に直接的に形成した０．５ｍｍφ程度のコアベントホール２１で構成されている。   The core mold 11 and the cavity mold 12 are respectively attached to housings 15 having a frame-shaped frame and a back plate. A pair of first chamber 16 and second chamber 17 are provided on the back side of the core mold 11 and the cavity mold 12. Each of the core mold 11 and the cavity mold 12 is formed with a large number of air holes 18 that communicate the chambers 16 and 17 with the molding space 13. The vent hole 18 actually has an outer diameter of 7 to 12 mm in which a plurality of round holes 19a having a diameter of about 0.5 mm and slits 19b having a width of about 0.5 mm are provided as illustrated in FIGS. A core vent 19 formed of a cylindrical body having a lid is formed by fitting into a core vent mounting hole 20 formed in a hole in the molds 11 and 12, or about 0.5 mmφ formed directly on the molds 11 and 12. Core vent hole 21.

第１チャンバー１６及び第２チャンバー１７には、蒸気や圧縮空気などの用役流体を供給するための供給管２２がそれぞれ接続されるとともに、減圧手段やドレン配管に連なる排出管２３がそれぞれ接続されている。   A supply pipe 22 for supplying a working fluid such as steam or compressed air is connected to the first chamber 16 and the second chamber 17, respectively, and a discharge pipe 23 connected to a decompression means or a drain pipe is connected to the first chamber 16 and the second chamber 17. ing.

成形空間１３内は、図３、図６に示すように、低発泡部５に対応させて設けた２組の区画手段３０を介して、低発泡部５を成形するための２つの区画成形空間１３Ａと、高発泡部６を成形するための１つの区画成形空間１３Ｂとに区画され、各区画成形空間１３Ａ，１３Ｂには原料ビーズの充填器１４がそれぞれ接続されており、隣接する区画成形空間１３Ａ，１３Ｂ内に異なる特性の原料ビーズを充填できるように構成されている。尚、本実施例では自動車用バンパーの芯材１を成形すべく、成形空間１３を３つに区画したが、成形空間１３の区画形状や区画個数や区画位置は、製作する成形品に応じて任意に設定可能である。また、発泡倍率の異なる原料ビーズを隣接する区画成形空間１３Ａ，１３Ｂに充填したが、成形品の用途などに応じて、ビーズ嵩密度、セル径、ビーズ径、素材などの特性の異なる原料ビーズを充填することも可能である。   As shown in FIGS. 3 and 6, the molding space 13 has two compartment molding spaces for molding the low foam portion 5 through two sets of compartment means 30 provided corresponding to the low foam portion 5. 13A and one compartment molding space 13B for molding the high-foamed portion 6, and a raw material bead filler 14 is connected to each compartment molding space 13A, 13B. It is comprised so that the raw material bead of a different characteristic can be filled in 13A, 13B. In this embodiment, in order to mold the core material 1 of the bumper for automobiles, the molding space 13 is divided into three. However, the shape, the number and the position of the molding space 13 depend on the molded product to be manufactured. It can be set arbitrarily. In addition, raw material beads having different expansion ratios were filled in the adjacent partition molding spaces 13A and 13B. Depending on the use of the molded product, raw material beads having different properties such as bead bulk density, cell diameter, bead diameter, and material were used. It is also possible to fill.

この区画手段３０は、図７、図８に示すように、複数本の櫛歯３１とそれを片持状に支持する支持部材３２とを有する仕切部材３３と、櫛歯３１の先端部を保持する保持孔３４を有する受部材３５とを備えている。仕切部材３３はキャビティ型１２に固定され、受部材３５はコア型１１側に固定され、両金型１１，１２を型閉じした状態で、成形空間１３が仕切部材３３により複数の区画成形空間１３Ａ，１３Ｂに区画されるように構成され、各区画成形空間１３Ａ，１３Ｂにはそれに対応させて設けた充填器１４により原料ビーズがそれぞれ供給されるように構成されている。尚、本実施例では、３枚の仕切部材３３と受部材３５とをコ字状に配置させたが、コ字状に一体形成した仕切部材及び受部材を用いてもよい。   As shown in FIGS. 7 and 8, the partitioning means 30 holds a partition member 33 having a plurality of comb teeth 31 and a support member 32 that supports the comb teeth 31 in a cantilever manner, and a tip portion of the comb teeth 31. And a receiving member 35 having a holding hole 34. The partition member 33 is fixed to the cavity mold 12, the receiving member 35 is fixed to the core mold 11, and the molding space 13 is divided into a plurality of partition molding spaces 13 </ b> A by the partition member 33 in a state where the molds 11 and 12 are closed. , 13B, and the raw material beads are supplied to the respective compartment molding spaces 13A, 13B by the fillers 14 provided in correspondence therewith. In this embodiment, the three partition members 33 and the receiving member 35 are arranged in a U shape, but a partition member and a receiving member that are integrally formed in a U shape may be used.

櫛歯３１は、金型１１，１２の型開閉方向に沿って延びる細長い棒状やパイプ状の部材で構成され、両金型１１，１２を型閉じした状態で、その先端部が受部材３５の保持孔３４に挿入保持されて、両金型１１，１２にわたって成形空間１３を横断するように配置される。   The comb teeth 31 are formed of elongated rod-like or pipe-like members extending in the mold opening / closing direction of the molds 11 and 12, and the tips of the receiving members 35 are in a state where both the molds 11 and 12 are closed. It is inserted and held in the holding hole 34 and is arranged so as to cross the molding space 13 across both molds 11 and 12.

櫛歯３１としては、細長い棒状やパイプ状の部材で構成され、外形は、多角形状や円形状や楕円形状など任意の外形のものを採用できる。また、櫛歯３１の素材は、原料ビーズの充填圧に耐え、しかも原料ビーズの加熱融着時における熱に耐え得る素材であれば、金属材料、合成樹脂材料、セラミックスなどの任意の材料で構成できる。また、この区画手段３０を用いた場合においては、図１，図２に示すように、芯材１には櫛歯３１に対応する位置に貫通孔７が形成されることになるので、櫛歯３１の直径は極力小さく設定することが好ましく、櫛歯３１の直径は、例えば１〜１０ｍｍ、好ましくは１．５〜５ｍｍに設定されている。更に、櫛歯３１として弾性変形可能な金属材料や合成樹脂材料からなるものを用いることが好ましい。このように構成すると、充填圧や発泡圧により櫛歯３１が多少変形しても元の形状に復帰できるので、櫛歯３１の塑性変形による充填不良や離型不良などの成形不良を防止しつつ、櫛歯３１の断面積を極力小さく設定して、成形品の外観低下や強度低下を抑制できる。   The comb teeth 31 are constituted by elongated rod-like or pipe-like members, and the outer shape can be of any outer shape such as a polygonal shape, a circular shape, or an elliptical shape. In addition, the material of the comb teeth 31 may be any material such as a metal material, a synthetic resin material, or ceramics as long as it can withstand the filling pressure of the raw material beads and can withstand the heat at the time of heat fusion of the raw material beads. it can. Further, when this partitioning means 30 is used, as shown in FIGS. 1 and 2, the through hole 7 is formed in the core material 1 at a position corresponding to the comb teeth 31. The diameter of 31 is preferably set as small as possible, and the diameter of the comb teeth 31 is set to, for example, 1 to 10 mm, preferably 1.5 to 5 mm. Furthermore, it is preferable to use a material made of an elastically deformable metal material or synthetic resin material as the comb teeth 31. If comprised in this way, even if the comb tooth 31 deform | transforms a little with filling pressure or foaming pressure, it can return to an original shape, While preventing the molding defects, such as a filling defect by the plastic deformation of the comb tooth 31, and a mold release defect, etc. By setting the cross-sectional area of the comb teeth 31 as small as possible, it is possible to suppress deterioration in the appearance and strength of the molded product.

隣接する櫛歯３１間の間隔Ｔは、区画成形空間１３Ａ，１３Ｂの少なくとも一方に充填する原料ビーズが通り抜けできない間隔に設定されている。この間隔Ｔは、狭すぎると、隣接する区画成形空間１３Ａ，１３Ｂ内に充填される原料ビーズ同士の密着性が十分に確保できず、成形品の強度が低下するので、通り抜けできない原料ビーズの直径の３０〜９０％、より好ましくは５０〜８０％に設定することが好ましい。   The interval T between the adjacent comb teeth 31 is set to an interval at which the raw material beads filling at least one of the partition molding spaces 13A and 13B cannot pass through. If this interval T is too narrow, the adhesiveness between the raw material beads filled in the adjacent compartment forming spaces 13A and 13B cannot be sufficiently secured, and the strength of the molded product is reduced, so the diameter of the raw material beads that cannot pass through. 30 to 90%, more preferably 50 to 80%.

尚、本実施例では、図示していないがキャビティ型１２にエジェクタピンを設けているので、仕切部材３３をキャビティ型１２に固定し、受部材３５をコア型１１に固定したが、コア型１１にエジェクタピンを設ける場合には、コア型１１側に仕切部材３３を固定し、キャビティ型１２に受部材３５を固定することが好ましい。つまり、仕切部材３３を設けた金型は、櫛歯３１と芯材１との密着により離型抵抗が増大するので、エジェクタピンを有する金型に仕切部材３３を設けると、金型を型開きしたときにエジェクタピンを有する金型に成形品を確実に残置させることが可能となり、エジェクタピンを有しない金型に成形品が残置されることによる離型不良を確実に防止できる。但し、櫛歯３１の長さが短い場合や本数が少ない場合には、離型抵抗の増大が十分に期待できないことから、エジェクタピンを有する金型に成形品に残置できなくなることがあるので、芯材１の離型抵抗を増大させるため、櫛歯３１の途中部や先端部に外方へ膨出した球状や円錐状の離型抵抗増大部を形成したり、櫛歯３１に逆テーパ部を形成して、離型抵抗を大きくしてもよい。また、櫛歯３１の長さが長い場合や本数が多い場合には、成形品の離型抵抗が大きくなりすぎるので、櫛歯３１を先細りに構成して、芯材１の離型抵抗を低下させてもよい。   In the present embodiment, although not shown, since the ejector pins are provided in the cavity mold 12, the partition member 33 is fixed to the cavity mold 12 and the receiving member 35 is fixed to the core mold 11. In the case where the ejector pins are provided, it is preferable that the partition member 33 is fixed to the core mold 11 side and the receiving member 35 is fixed to the cavity mold 12. In other words, the mold provided with the partition member 33 has an increased mold release resistance due to the close contact between the comb teeth 31 and the core material 1. Therefore, when the partition member 33 is provided on the mold having the ejector pins, the mold is opened. In this case, it is possible to reliably leave the molded product in the mold having the ejector pin, and it is possible to reliably prevent a mold release failure due to the molded product remaining in the mold having no ejector pin. However, when the length of the comb teeth 31 is short or when the number of the comb teeth 31 is small, an increase in mold release resistance cannot be expected sufficiently, so that it may not be left in the molded product in the mold having the ejector pins. In order to increase the mold release resistance of the core material 1, a spherical or conical mold release resistance increasing portion bulging outward is formed in the middle or tip of the comb tooth 31, or a reverse tapered portion is formed on the comb tooth 31. May be formed to increase the mold release resistance. In addition, when the length of the comb teeth 31 is long or the number of the comb teeth 31 is large, the mold release resistance of the molded product becomes too large, so that the comb teeth 31 are tapered to reduce the mold release resistance of the core material 1. You may let them.

支持部材３２は、複数本の櫛歯３１を一定間隔おきに片持状に支持できるものであれば、任意の構成のものを採用できる。また、受部材３５は、櫛歯３１の撓みにより櫛歯３１の間隔が変動することを防止するためのものであるが、櫛歯３１の撓みが少ない場合には必ずしも設ける必要はなく、例えば櫛歯３１の直径を大きく設定する場合や、厚さの薄い成形品を製作する場合や、コア型１１に保持孔３４を直接的に形成する場合には省略してもよい。また、櫛歯３１の先端部がコア型１１に接触しないように構成してもよく、この場合には、櫛歯３１により形成される孔を有底孔に構成でき、成形品のうちの少なくともコア型１１により成形される表面には孔があかないので、成形品の外観低下を抑制できる。   The support member 32 may be of any configuration as long as it can support a plurality of comb teeth 31 in a cantilever manner at regular intervals. The receiving member 35 is for preventing the interval between the comb teeth 31 from fluctuating due to the bending of the comb teeth 31, but is not necessarily provided when the bending of the comb teeth 31 is small. It may be omitted when the diameter of the tooth 31 is set large, when a thin molded product is manufactured, or when the holding hole 34 is directly formed in the core mold 11. Moreover, you may comprise so that the front-end | tip part of the comb tooth 31 may not contact the core type | mold 11, In this case, the hole formed by the comb tooth 31 can be comprised by a bottomed hole, Since there are no holes in the surface molded by the core mold 11, it is possible to suppress deterioration of the appearance of the molded product.

次に、区画手段３０の構成を部分的に変更した他の実施例について説明する。尚、前記実施例と同一部材には同一符号を付してその詳細な説明を省略する。
（１）図９に示す区画手段４０のように、左右の第１仕切部材４１をキャビティ型１２に固定し、上部の第２仕切部材４２をコア型１１に固定してもよい。この場合には、成形品の離型のため、両金型１１，１２を型開きするときに、エジェクタピンを有しないコア型１１の櫛歯３１が成形品から抜き取られることになるので、その分離型抵抗を少なくしてエジェクタピンを用いた成形品の離型性を向上できる。また、キャビティ型１２に固定した第１仕切部材４１の櫛歯３１の本数を、コア型１１に固定した第２仕切部材４１の櫛歯３１の本数よりも多く設定すると、両金型１１，１２を型開きするときに、エジェクタピンを有するキャビティ型１２に対して確実に成形品を残置させることが可能となる。 Next, another embodiment in which the configuration of the partition unit 30 is partially changed will be described. The same members as those in the above embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.
(1) Like the partitioning means 40 shown in FIG. 9, the left and right first partition members 41 may be fixed to the cavity mold 12, and the upper second partition member 42 may be fixed to the core mold 11. In this case, when the molds 11 and 12 are opened to release the molded product, the comb teeth 31 of the core mold 11 having no ejector pins are extracted from the molded product. The releasability of the molded product using the ejector pin can be improved by reducing the separation-type resistance. Further, when the number of the comb teeth 31 of the first partition member 41 fixed to the cavity mold 12 is set larger than the number of the comb teeth 31 of the second partition member 41 fixed to the core mold 11, both molds 11, 12 are used. When the mold is opened, the molded product can be reliably left with respect to the cavity mold 12 having the ejector pins.

（２） 成形空間１３を区画するため境界Ｌに沿って配置した複数の櫛歯３１を、図１０に示すように、キャビティ型１２に固定される第１仕切部材４６と、コア型１１に固定される第２仕切部材４７とに交互に固定した区画手段４５を用いてもよい。この場合には、金型１１，１２を型開きするときに成形品に対してバランスよく櫛歯３１の引き抜き力を作用させることが可能となるので好ましい。 (2) A plurality of comb teeth 31 arranged along the boundary L for partitioning the molding space 13 are fixed to the first partition member 46 fixed to the cavity mold 12 and the core mold 11 as shown in FIG. Alternatively, partition means 45 fixed alternately to the second partition member 47 may be used. In this case, when the molds 11 and 12 are opened, the pulling force of the comb teeth 31 can be applied to the molded product in a balanced manner, which is preferable.

また、このような第１仕切部材４６と第２仕切部材４７を用いる場合には、第１仕切部材４６の櫛歯３１の間隔と、第２仕切部材４７の櫛歯３１の間隔をそれぞれ区画成形空間１３Ａ，１３Ｂの少なくとも一方に充填する原料ビーズが通り抜けできない間隔に設定することが好ましい。この場合には、第１仕切部材４６及び第２仕切部材４７の櫛歯３１の先端部を相手側の金型の内面まで延ばさなくても、両仕切部材４６，４７の櫛歯３１の先端部を型開閉方向に多少重ね合わせるだけで、隣接する区画成形部間１３Ａ，１３Ｂにおける原料ビーズの移動を阻止できるので、両仕切部材４６，４７の櫛歯３１を短尺に構成して、成形品の離型性を向上できるとともに、櫛歯３１に作用する曲げモーメントを小さく設定できるので、櫛歯３１として小径のものを採用することが可能となり、櫛歯３１により成形品に形成される有底孔を極力小径に構成できる。また、櫛歯３１の長さ設定がラフになるので、成形品形状の変更等に対しても容易に対応できるし、クラッキング充填のように、両金型間にクラッキング隙間をあけた状態で、原料ビーズを充填する場合でも、両仕切部材４６，４７の櫛歯３１のラップ量をクラッキング隙間よりも多少大きく設定することで、隣接する区画成形空間を仕切ることが可能となる。   Moreover, when using such a 1st partition member 46 and the 2nd partition member 47, the space | interval of the comb tooth 31 of the 1st partition member 46 and the space | interval of the comb tooth 31 of the 2nd partition member 47 are division molding, respectively. It is preferable to set an interval at which the raw material beads filling at least one of the spaces 13A and 13B cannot pass through. In this case, the tips of the comb teeth 31 of the partition members 46 and 47 can be extended without extending the tips of the comb teeth 31 of the first partition member 46 and the second partition member 47 to the inner surface of the mating mold. Since the movement of the raw material beads between the adjacent partition molding parts 13A and 13B can be prevented by only slightly overlapping the mold opening and closing direction, the comb teeth 31 of both partition members 46 and 47 are configured to be short, Since the releasability can be improved and the bending moment acting on the comb teeth 31 can be set small, it is possible to adopt a small diameter as the comb teeth 31, and the bottomed holes formed in the molded product by the comb teeth 31. Can be made as small as possible. In addition, since the length setting of the comb teeth 31 becomes rough, it can easily cope with changes in the shape of the molded product, etc., and in a state where a cracking gap is opened between both molds as in the case of cracking filling, Even when the raw material beads are filled, the adjacent partition forming spaces can be partitioned by setting the wrap amount of the comb teeth 31 of both partition members 46 and 47 to be slightly larger than the cracking gap.

尚、第１仕切部材に固定する櫛歯と、第２仕切部材に固定する櫛歯の割り振りは、区画形状等に応じて任意に設定可能であり、前述した区画手段４０，４５に限定されるものではない。
また、図１１に示す区画手段５０のように、低発泡部５と高発泡部６の境界Ｌの角部や端部に対応させて柱状の固定仕切部材５１をコア型１１又はキャビティ型１２に一体的に設けたり、図１２に示す区画手段５５のように、低発泡部５と高発泡部６の境界Ｌの途中部に壁状の固定仕切部材５６をコア型１１又はキャビティ型１２に一体的に設けたりしてもよい。この場合には、図１１に示すように、成形品１Ａには固定仕切部材５２により貫通孔５７及び溝部５８が形成され、また図１２に示すように、成形品１Ｂには固定仕切部材５６により長孔状の貫通孔５９が形成されるが、櫛歯３１により区画困難な、成形品の薄肉部などを固定仕切部材５１，５６により区画することが可能となるので、成形品形状に応じて採用することが好ましい。 Note that the allocation of the comb teeth fixed to the first partition member and the comb teeth fixed to the second partition member can be arbitrarily set according to the partition shape and the like, and is limited to the partition means 40 and 45 described above. It is not a thing.
Further, like the partition means 50 shown in FIG. 11, the column-shaped fixed partition member 51 is made into the core mold 11 or the cavity mold 12 so as to correspond to the corners or the end portions of the boundary L between the low foaming part 5 and the high foaming part 6. A wall-like fixed partition member 56 is integrated with the core mold 11 or the cavity mold 12 in the middle of the boundary L between the low foaming part 5 and the high foaming part 6 as in the case of the partition means 55 shown in FIG. May be provided. In this case, as shown in FIG. 11, the molded product 1 </ b> A is formed with a through hole 57 and a groove 58 by the fixed partition member 52, and as shown in FIG. 12, the molded product 1 </ b> B is fixed by the fixed partition member 56. Although a long hole-like through hole 59 is formed, it becomes possible to partition the thin part of the molded product, which is difficult to be partitioned by the comb teeth 31, by the fixed partition members 51, 56. It is preferable to adopt.

更に、前記実施例では、各仕切部材の複数の櫛歯３１を同一平面内に配置して、各仕切部材による低発泡部５と高発泡部６との境界面を平坦面で構成したが、この境界面が例えば矩形波状や三角波状やサイン波状などの波形面状になるように、櫛歯３１を配置すると、隣接する原料ビーズの接触面積を増やして、両者の結合強度を向上できるので好ましい。また、低発泡部５と高発泡部６との境界Ｌが正面視略コ字状の場合について説明したが、その他の形状、例えばＬ字状やクランク状や直線状の場合においても、本発明を同様に適用できる。   Furthermore, in the said Example, although the several comb tooth 31 of each partition member was arrange | positioned in the same plane, the boundary surface of the low foaming part 5 by each partition member and the high foaming part 6 was comprised with the flat surface, It is preferable to arrange the comb teeth 31 so that the boundary surface has a wave shape such as a rectangular wave shape, a triangular wave shape, or a sine wave shape, because the contact area between adjacent raw material beads can be increased and the bonding strength between the two can be improved. . Moreover, although the case where the boundary L between the low foaming portion 5 and the high foaming portion 6 is substantially U-shaped in front view has been described, the present invention is applicable to other shapes such as L-shape, crank shape, and linear shape. Can be applied as well.

尚、型内発泡成形装置１０に代えて、図１３に示すように、コア型１１及びキャビティ型１２から通気孔１８を完全に或いは略完全に省略した型内発泡成形装置６０を採用することも可能である。この場合には、コア型１１とキャビティ型１２とを型閉めした状態においても成形空間１３内に開口するクリアランス６１を両金型１１，１２の合わせ目に沿って形成し、このクリアランス６１を介して両チャンバー１６，１７とは独立に成形空間１３内に対して蒸気等の用役流体を供給したり、成形空間１３からドレン等を排出することになる。このような成形装置６０においては、通気孔１８の跡のない表面美麗な芯材１を製作できること、通気孔１８を形成することによる金型１１，１２の強度低下を防止できるので、金型１１，１２を薄肉に構成してその熱容量を小さく設定することが可能となり、加熱冷却の熱効率を向上したり、温度制御の精度を向上できること、通気孔１８を形成するための加工コストを大幅に削減でき、金型１１，１２の製作コストを低減できること、通気孔１８の目詰まりに基づく加熱不良、離型不良、冷却不良が発生せず、コアベント１９の取替えまたは定期的な高圧洗浄水による洗浄などのメンテナンス作業が全く不要となること、冷却工程で用いられる冷却水が成形空間１３内に侵入しなくなるので、芯材１の水分を従来の６〜１０％程度から０．５〜２％程度にまで低下でき、乾燥工程が不要となり、サイクル時間短縮に大いに寄与できること、などの効果が得られる。   Instead of the in-mold foam molding apparatus 10, as shown in FIG. 13, an in-mold foam molding apparatus 60 in which the air holes 18 are completely or substantially completely omitted from the core mold 11 and the cavity mold 12 may be adopted. Is possible. In this case, even when the core mold 11 and the cavity mold 12 are closed, a clearance 61 that opens into the molding space 13 is formed along the joint between both the molds 11 and 12. Thus, a working fluid such as steam is supplied into the molding space 13 independently of the chambers 16 and 17, and drains and the like are discharged from the molding space 13. In such a molding apparatus 60, the core material 1 having a beautiful surface with no trace of the vent hole 18 can be manufactured, and the strength of the molds 11 and 12 due to the formation of the vent hole 18 can be prevented from being reduced. , 12 can be made thin so that the heat capacity can be set small, the heat efficiency of heating and cooling can be improved, the accuracy of temperature control can be improved, and the processing cost for forming the vent hole 18 is greatly reduced. The manufacturing cost of the molds 11 and 12 can be reduced, the heating failure due to the clogging of the vent hole 18, the mold release failure, the cooling failure does not occur, the core vent 19 is replaced, or the high-pressure cleaning water is periodically cleaned. This eliminates the need for maintenance work, and the cooling water used in the cooling process does not enter the molding space 13, so that the moisture in the core material 1 is reduced from about 6 to 10% of the conventional one. Can decrease to about 5-2%, the drying process becomes unnecessary, can contribute greatly to shorten the cycle time, effects such as are obtained.

尚、本実施例では、型内発泡成形品として自動車用バンパーの芯材１を製作するための型内発泡成形装置１０、５０について説明したが、芯材１以外の成形品を製作する成形装置に対しても本発明を同様に適用することが可能である。   In the present embodiment, the in-mold foam molding apparatuses 10 and 50 for manufacturing the core material 1 of the bumper for automobiles as the in-mold foam molded product have been described. However, the molding apparatus for manufacturing a molded product other than the core material 1 is described. The present invention can be similarly applied to the above.

次に、図３に示す発泡成形装置１０を用いた芯材１の成形方法の一例について説明する。
先ず、区画成形空間１３Ａ，１３Ｂに原料ビーズを充填するため、コア型１１とキャビティ型１２とを型閉めして仕切部材３３により成形空間１３内を３つの区画成形空間１３Ａ，１３Ｂに区画する。 Next, an example of the molding method of the core material 1 using the foam molding apparatus 10 shown in FIG. 3 will be described.
First, in order to fill the raw material beads into the compartment molding spaces 13A and 13B, the core mold 11 and the cavity mold 12 are closed, and the molding space 13 is partitioned into three compartment molding spaces 13A and 13B by the partition member 33.

次に、充填器１４から区画成形空間１３Ａ，１３Ｂに対して、櫛歯３１間の隙間よりも大きな直径で且つ異なる特性の原料ビーズを空気の流れに乗せてそれぞれ個別に供給し、成形空間１３内に原料ビーズを充填する。このとき、隣接する区画成形空間１３Ａ，１３Ｂに充填された原料ビーズは、櫛歯３１間の隙間を介して相互に接触した状態となる。尚、本実施例では、自動車バンパーの芯材１を成形すべく、発泡倍率が５倍の原料ビーズを区画成形空間１３Ａに充填し、発泡倍率が２０倍の原料ビーズを区画成形空間１３Ｂに充填する。但し、原料ビーズの発泡倍率は芯材１の強度等を考慮して任意に設定することが可能である。また、成形品の用途などに応じて、発泡倍率以外の特性の異なる原料ビーズ、例えばビーズ嵩密度、セル径、ビーズ径、素材などの異なる特性の原料ビーズを充填することも可能である。また、原料ビーズとして、ポリオレフィン系樹脂からなる原料ビーズを用いる場合には、原料ビーズの充填前に、図示外の成含タンク内に原料ビーズを充填して、０．０３〜０．２ＭＰａの無機ガスを原料ビーズに圧入することで、原料ビーズの発泡力を高めるように構成してもよい。原料ビーズの具体的な充填方法としては、クラッキング充填法、加圧充填法、圧縮充填法などの周知の充填方法を採用できる。   Next, raw material beads having a diameter larger than the gap between the comb teeth 31 and different characteristics are supplied individually from the filler 14 to the compartment molding spaces 13A and 13B on the air flow. The raw material beads are filled inside. At this time, the raw material beads filled in the adjacent partition forming spaces 13A and 13B are in contact with each other through the gaps between the comb teeth 31. In this embodiment, in order to mold the core material 1 of the automobile bumper, the material beads having a foaming ratio of 5 are filled in the partition molding space 13A, and the material beads having a foaming ratio of 20 are filled in the partition molding space 13B. To do. However, the expansion ratio of the raw material beads can be arbitrarily set in consideration of the strength of the core material 1 and the like. In addition, depending on the use of the molded product, raw material beads having different characteristics other than the expansion ratio, for example, raw material beads having different characteristics such as bead bulk density, cell diameter, bead diameter, and raw material can be filled. In addition, when using raw material beads made of polyolefin resin as raw material beads, before filling the raw material beads, the raw material beads are filled in a containing tank (not shown) to form an inorganic material of 0.03 to 0.2 MPa. You may comprise so that the foaming power of a raw material bead may be improved by press-fitting gas into a raw material bead. As a specific filling method of the raw material beads, a known filling method such as a cracking filling method, a pressure filling method, and a compression filling method can be employed.

次に、両チャンバー１６，１７及び通気孔１８を介して成形空間１３に蒸気を供給して原料ビーズを加熱した後、蒸気圧を開放することで原料ビーズを発泡させ、原料ビーズを略隙間なく相互に融着させることになる。このとき原料ビーズ間に空気が残存していると原料ビーズ同士の密着性が低下するので、両チャンバー１６，１７及び成形空間１３内の空気を蒸気に置き換える作業を予め行うことになる。また、この蒸気による加熱により、隣接する区画成形空間１３Ａ，１３Ｂの原料ビーズ同士も櫛歯３１間の隙間を介して相互に融着することになる。   Next, steam is supplied to the molding space 13 through the chambers 16 and 17 and the vent hole 18 to heat the raw material beads, and then the raw material beads are foamed by releasing the vapor pressure so that the raw material beads are substantially free of gaps. It will be fused to each other. At this time, if air remains between the raw material beads, the adhesion between the raw material beads decreases, and therefore, the operation of replacing the air in the chambers 16 and 17 and the molding space 13 with steam is performed in advance. Further, due to the heating by the steam, the raw material beads in the adjacent partition forming spaces 13A and 13B are fused to each other through the gaps between the comb teeth 31.

次に、コア型１１及びキャビティ型１２に向けて図示外のノズルから冷却水を噴霧し、成形空間１３内の芯材１を冷却してから、金型１１，１２を型開きするが、キャビティ型１２には仕切部材３３が設けられ、キャビティ型１２に対する芯材１の離型抵抗は、コア型１１の離型抵抗よりも大きくなるので、金型１１，１２を型開きした状態で、芯材１はキャビティ型１２側に残置されることになる。こうして、金型１１，１２を型開きして、芯材１をキャビティ型１２側に残置させた状態とし、図示外のエジェクタピンを用いて芯材１をキャビティ型１２から離型する。   Next, cooling water is sprayed from a nozzle (not shown) toward the core mold 11 and the cavity mold 12 to cool the core material 1 in the molding space 13, and then the molds 11 and 12 are opened. The mold 12 is provided with a partition member 33, and the release resistance of the core material 1 with respect to the cavity mold 12 is larger than the release resistance of the core mold 11. The material 1 is left on the cavity mold 12 side. In this way, the molds 11 and 12 are opened, the core material 1 is left on the cavity mold 12 side, and the core material 1 is released from the cavity mold 12 using an ejector pin (not shown).

尚、原料ビーズとして、櫛歯３１間を通り抜け不能な直径の第１原料ビーズと、櫛歯３１間を通り抜け可能な第２原料ビーズとを用いる場合には、成形空間１３への原料ビーズの充填時に、第１原料ビーズを区画成形空間１３Ｂに充填した後、第２原料ビーズを区画成形空間１３Ａに充填することになる。この場合には、第１原料ビーズの一部が櫛歯３１間を通って区画成形空間１３Ａ内へ移動するので、第１原料ビーズと第２原料ビーズの密着性をより一層高めることが可能となる。   When the first raw material beads having a diameter that cannot pass between the comb teeth 31 and the second raw material beads that can pass between the comb teeth 31 are used as the raw material beads, the raw material beads are filled into the molding space 13. Sometimes, after filling the first raw material beads into the compartment molding space 13B, the second raw material beads are filled into the compartment molding space 13A. In this case, since a part of the first raw material beads moves between the comb teeth 31 and into the compartment forming space 13A, it is possible to further improve the adhesion between the first raw material beads and the second raw material beads. Become.

また、前記型内発泡成形装置５０を用いて成形を行う場合には、芯材１の外面の目立つ場所を成形する成形部に通気孔１８が形成されていないコア型１１及びキャビティ型１２を用いていることから、原料ビーズの充填時には原料ビーズとともに成形空間１３内に供給される充填用エアを、クリアランス５１を介して成形空間１３外へ排出することになる。また、蒸気により原料ビーズを加熱融着するときには、チャンバー１６，１７に蒸気を供給するとともに、クリアランス５１を介して成形空間１３内へ蒸気を供給することになる。
本実施例では、自動車用バンパーの芯材１を成形するための成形方法について説明したが、芯材１以外の型内発泡成形品を成形する場合においても、本発明を同様に適用できる。 Further, when molding is performed using the in-mold foam molding apparatus 50, the core mold 11 and the cavity mold 12 in which the air holes 18 are not formed in the molding portion for molding a conspicuous place on the outer surface of the core material 1 are used. Therefore, when filling the raw material beads, the filling air supplied into the molding space 13 together with the raw material beads is discharged out of the molding space 13 through the clearance 51. Further, when the raw material beads are heated and fused with steam, the steam is supplied to the chambers 16 and 17 and the steam is supplied into the molding space 13 through the clearance 51.
In the present embodiment, the molding method for molding the core material 1 of the bumper for automobiles has been described. However, the present invention can be similarly applied to molding an in-mold foam molded product other than the core material 1.

自動車用バンパーの芯材の斜視図Perspective view of automotive bumper core 図１のII-II線断面図II-II sectional view of FIG. 型内発泡成形装置の縦断面図Vertical section of in-mold foam molding equipment 通気孔付近の金型の縦断面図Longitudinal section of the mold near the vent コアベントの正面図Core vent front view 図３のIV-IV線断面図Sectional view taken along line IV-IV in FIG. 区画手段の説明図Explanatory drawing of partition means 仕切部材の斜視図Perspective view of partition member 他の構成の区画手段の斜視図The perspective view of the division means of another structure 他の構成の区画手段の説明図Explanatory drawing of the division means of another structure （ａ）は他の構成の成形品の斜視図、（ｂ）は同成形品を成形するための成形装置の説明図(A) is a perspective view of the molded product of another structure, (b) is explanatory drawing of the shaping | molding apparatus for shape | molding the molded product （ａ）は他の構成の成形品の斜視図、（ｂ）は同成形品を成形するための成形装置の説明図(A) is a perspective view of the molded product of another structure, (b) is explanatory drawing of the shaping | molding apparatus for shape | molding the molded product 他の構成の成形装置の縦断面図Longitudinal sectional view of another configuration of molding equipment

符号の説明Explanation of symbols

１ 芯材 ２ 前部衝撃吸収部
３ 側部衝撃吸収部 ４ 角部
５ 低発泡部 ６ 高発泡部
７ 貫通孔
１０ 型内発泡成形装置
１１ コア型 １２ キャビティ型
１３ 成形空間
１３Ａ 区画成形空間 １３Ｂ 区画成形空間
１４ 充填器 １５ ハウジング
１６ 第１チャンバー １７ 第１チャンバー
１８ 通気孔 １９ コアベント
１９ａ 丸孔 １９ｂ スリット
２０ コアベント取付孔
２１ コアベントホール
２２ 供給管 ２３ 排出管
３０ 区画手段 ３１ 櫛歯
３２ 支持部材 ３３ 仕切部材
３４ 保持孔 ３５ 受部材
４０ 区画手段 ４１ 第１仕切部材
４２ 第２仕切部材
４５ 区画手段 ４６ 第１仕切部材
４７ 第２仕切部材
５０ 区画手段 ５１ 固定仕切部材
１Ａ 成形品 ５７ 貫通孔
５８ 溝部
５５ 区画手段 ５６ 固定仕切部材
１Ｂ 成形品 ５９ 貫通孔
６０ 型内発泡成形装置
６１ クリアランス
DESCRIPTION OF SYMBOLS 1 Core material 2 Front part impact absorption part 3 Side part impact absorption part 4 Corner | angular part 5 Low foam part 6 High foam part 7 Through-hole 10 In-mold foam molding apparatus 11 Core mold 12 Cavity mold 13 Molding space 13A Compartment molding space 13B Section Molding space 14 Filler 15 Housing 16 1st chamber 17 1st chamber 18 Ventilation hole 19 Core vent 19a Round hole 19b Slit 20 Core vent attachment hole 21 Core vent hole 22 Supply pipe 23 Discharge pipe 30 Partition means 31 Comb tooth 32 Support member 33 Partition Member 34 holding hole 35 receiving member 40 partition means 41 first partition member 42 second partition member 45 partition means 46 first partition member 47 second partition member 50 partition means 51 fixed partition member 1A molded product 57 through hole 58 groove 55 partition Means 56 Fixed partition member 1B Molded product 59 Through-hole 60 In-mold foam molding apparatus 61 Clearer The

Claims (13)

コア型とキャビティ型の少なくとも一方の金型に、成形空間内を複数の区画成形空間に区画する仕切部材を固定するとともに、各区画成形空間に原料ビーズを充填する充填器を設けて、隣接する区画成形空間に異なる特性の原料ビーズを充填可能となし、仕切部材として、隣接する区画成形空間に充填する原料ビーズの少なくとも一方が通り抜け不能な間隔をあけて型開閉方向に片持ち状に延びる複数の櫛歯を有する仕切部材を用い、エジェクタピンを有する金型に前記仕切部材を固定したことを特徴とする型内発泡成形装置。   A partition member for partitioning the molding space into a plurality of partition molding spaces is fixed to at least one of the core mold and the cavity mold, and a filler for filling the raw material beads in each partition molding space is provided adjacent to each other. A plurality of raw material beads having different characteristics can be filled in the compartment molding space, and as a partitioning member, at least one of the raw material beads filling the adjacent compartment molding space is cantilevered in a mold opening / closing direction with an interval through which it cannot pass. An in-mold foam molding apparatus characterized in that the partition member is fixed to a mold having an ejector pin using a partition member having a plurality of comb teeth. 前記仕切部材を、エジェクタピンを有する金型に固定した第１仕切部材と、エジェクタピンを有しない金型に固定した第２仕切部材とで構成した請求項１記載の型内発泡成形装置。   2. The in-mold foam molding apparatus according to claim 1, wherein the partition member includes a first partition member fixed to a mold having an ejector pin and a second partition member fixed to a mold having no ejector pin. 前記第１仕切部材の櫛歯と第２仕切部材の櫛歯とを交互に配置させた請求項２記載の型内発泡成形装置。   The in-mold foam molding apparatus according to claim 2, wherein the comb teeth of the first partition member and the comb teeth of the second partition member are alternately arranged. 前記第１仕切部材の櫛歯の本数を、第２仕切部材の櫛歯の本数よりも多く設定した請求項２又は３記載の型内発泡成形装置。   The in-mold foam molding apparatus according to claim 2 or 3, wherein the number of comb teeth of the first partition member is set larger than the number of comb teeth of the second partition member. 前記第１仕切部材及び第２仕切部材の櫛歯の間隔を少なくとも一方の原料ビーズが通り抜け不能な間隔にそれぞれ設定した請求項２〜４のいずれか１項記載の型内発泡成形装置。   The in-mold foam molding apparatus according to any one of claims 2 to 4, wherein an interval between comb teeth of the first partition member and the second partition member is set to an interval at which at least one raw material bead cannot pass through. エジェクタピンを有する金型に固定した仕切部材の櫛歯の先端部又は途中部に、櫛歯からの成形品の離型抵抗を増大させる離型抵抗増大部を形成した請求項１〜５のいずれか１項記載の型内発泡成形装置。   6. The release resistance increasing portion for increasing the release resistance of the molded product from the comb teeth is formed at the tip or middle portion of the comb teeth of the partition member fixed to the mold having the ejector pins. The in-mold foam molding apparatus according to claim 1. 前記櫛歯として直径が１〜１０ｍｍの棒状部材を用いた請求項１〜６のいずれか１項記載の型内発泡成形装置。   The in-mold foam molding apparatus according to any one of claims 1 to 6, wherein a rod-shaped member having a diameter of 1 to 10 mm is used as the comb teeth. 隣接する櫛歯の間隔を、通り抜けできない原料ビーズの直径の３０〜９０％に設定した請求項１〜７のいずれか１項記載の型内発泡成形装置。   The in-mold foam molding apparatus according to any one of claims 1 to 7, wherein an interval between adjacent comb teeth is set to 30 to 90% of a diameter of a raw material bead that cannot pass through. 請求項１〜８のいずれか１項記載の型内発泡成形装置を用いるとともに、原料ビーズとして櫛歯間を通り抜け不能な原料ビーズを用い、コア型とキャビティ型を型閉めして、仕切部材により成形空間を複数の区画成形空間に区画した状態で、少なくとも隣接する区画成形空間に異なる特性の原料ビーズが充填されるように各区画成形空間内に原料ビーズを充填することを特徴とする型内発泡成形方法。   While using the in-mold foam molding apparatus of any one of Claims 1-8, using the raw material bead which cannot pass between comb teeth as a raw material bead, and closing a core type | mold and a cavity type | mold, and by a partition member In the mold characterized in that, in a state where the molding space is divided into a plurality of compartment molding spaces, each compartment molding space is filled with raw material beads so that at least adjacent compartment molding spaces are filled with raw material beads having different characteristics. Foam molding method. 請求項１〜８のいずれか１項記載の型内発泡成形装置を用いるとともに、原料ビーズとして櫛歯間を通り抜け不能な第１原料ビーズと通り抜け可能な第２原料ビーズを用い、コア型とキャビティ型を型閉めして、仕切部材により成形空間を複数の区画成形空間に区画した状態で、第１原料ビーズを充填した後、第２原料ビーズを充填して、少なくとも隣接する区画成形空間に異なる特性の原料ビーズが充填されるように各区画成形空間内に原料ビーズを充填することを特徴とする型内発泡成形方法。   A core mold and a cavity using the in-mold foam molding apparatus according to any one of claims 1 to 8, and using a first raw material bead that cannot pass between comb teeth and a second raw material bead that can pass through as a raw material bead. After the mold is closed and the molding space is partitioned into a plurality of partition molding spaces by the partition member, after filling the first raw material beads, the second raw material beads are filled, and at least the adjacent partition molding spaces are different. An in-mold foam molding method characterized by filling raw material beads into each compartment molding space so as to be filled with characteristic raw material beads. 前記複数の区画成形空間に発泡倍率の異なる原料ビーズを充填する請求項９又は１０記載の型内発泡成形方法。   The in-mold foam molding method according to claim 9 or 10, wherein the plurality of compartment molding spaces are filled with raw material beads having different expansion ratios. 請求項１〜８のいずれか１項記載の型内発泡成形装置にて成形した型内発泡成形品であって、異なる特性の原料ビーズを用いて成形された複数の成形部分を有し、各成形部分の境界に沿って設定間隔おきに金型の型開閉方向に延びる複数の貫通孔又は有底孔が形成されてなる型内発泡成形品。   An in-mold foam-molded product molded by the in-mold foam-molding apparatus according to any one of claims 1 to 8, comprising a plurality of molded parts molded using raw material beads having different characteristics, An in-mold foam-molded product in which a plurality of through holes or bottomed holes extending in the mold opening / closing direction of the mold are formed at set intervals along the boundary of the molded part. 前記型内発泡成形品が自動車用バンパーの芯材であり、この芯材は、自動車の各種前面衝突時において芯材に作用する局部的衝撃応力を受けやすい部分付近が発泡倍率の低い原料ビーズからなる低発泡部で構成され、他の部分は低発泡部よりも発泡倍率の高い原料ビーズからなる高発泡部で構成されている請求項１２記載の型内発泡成形品。
The in-mold foam-molded product is a core material for a bumper for automobiles. This core material is formed from a raw material bead having a low expansion ratio in the vicinity of a portion that is susceptible to local impact stress acting on the core material at the time of various frontal collisions of an automobile. The in-mold foam-molded product according to claim 12, wherein the other part is composed of a high-foamed part composed of raw material beads having a foaming ratio higher than that of the low-foamed part.
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