JP5200846B2 - Manufacturing method of resin foam molding - Google Patents

Manufacturing method of resin foam molding Download PDF

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JP5200846B2
JP5200846B2 JP2008266552A JP2008266552A JP5200846B2 JP 5200846 B2 JP5200846 B2 JP 5200846B2 JP 2008266552 A JP2008266552 A JP 2008266552A JP 2008266552 A JP2008266552 A JP 2008266552A JP 5200846 B2 JP5200846 B2 JP 5200846B2
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skin
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剛正 奥村
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Tokai Chemical Industries Ltd
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Description

この発明は、表皮の内側に発泡層を有する表皮付きの樹脂発泡成形品の製造方法に関する。 This invention relates to the production how the epidermis with a resin foam molded article having a foamed layer on the inside of the epidermis.

従来、熱可塑性のソリッド状態の表皮と、その内側に形成された同じ材質の熱可塑性樹脂の発泡層とを、硬質の樹脂製の芯材に積層状態に一体化し、末端部の一対の側面と、それら一対の側面の同じ側の各端を繋ぐ頂面とを有する、全体として扁平形状をなす樹脂発泡成形品を製造する方法として発泡射出成形方法が知られている。
この製造方法は、自動車のドアトリム等の自動車の内装品その他の製造方法に好適な方法として近年広く用いられるようになってきている。 Conventionally, a thermoplastic solid skin and a foam layer of the same thermoplastic resin formed inside thereof are integrated into a hard resin core in a laminated state, and a pair of side surfaces at the end portion A foam injection molding method is known as a method of manufacturing a resin foam molded product having a flat shape as a whole, which has a top surface connecting the ends of the pair of side surfaces on the same side.
This manufacturing method has been widely used in recent years as a method suitable for manufacturing automobile interior parts such as automobile door trims and the like.

この製造方法では、型開き方向に第１分割型と第２分割型とに分割された金型の第１キャビティに、硬質の樹脂製の芯材を一方の第１分割型に重ねてセットし保持させた状態で、熱可塑性樹脂の基材に発泡剤を含有させた発泡樹脂材料を射出して第１キャビティに充填し、しかる後芯材を保持した一方の第１分割型を第２分割型に対し所定ストローク型開き方向に相対的に後退移動させて第１キャビティを拡大し、発泡樹脂材料を発泡させることによって、基材が金型内面で固化して形成された表皮と、発泡樹脂材料の発泡にて形成された、表皮の内側の発泡層及び芯材を積層状態に一体に有する樹脂発泡成形品を成形する。   In this manufacturing method, a hard resin core material is set on one of the first divided molds in the first cavity of the mold divided into the first divided mold and the second divided mold in the mold opening direction. In a state of being held, a foamed resin material containing a foaming agent is injected into a thermoplastic resin base material to fill the first cavity, and then the first divided mold holding the core material is divided into the second divided parts. A skin formed by solidifying the base material on the inner surface of the mold by expanding the first cavity by expanding the first cavity relative to the mold in a predetermined stroke mold opening direction and foaming the foamed resin material, and the foam resin A resin foam-molded product formed by foaming the material and integrally having a foam layer and a core material inside the skin in a laminated state is molded.

更にこの樹脂発泡成形品の製造方法として、異材質を成す芯材と発泡層及び表皮とをほぼ同時的に連続して成形する２色成形方法も知れられている。
例えば下記特許文献１，特許文献２にその製造方法が開示されている。
図８はその具体例を示している。 Further, as a method for producing this resin foam molded article, a two-color molding method is known in which a core material, a foam layer and a skin made of different materials are molded almost simultaneously.
For example, the following Patent Document 1 and Patent Document 2 disclose the manufacturing method.
FIG. 8 shows a specific example thereof.

図８において、２００は第１分割型、２０２は第３分割型、２０３は型締状態でそれら第１分割型２００と第３分割型２０２とで形成される第２キャビティである。
ここでは先ず第２キャビティ２０３に芯材用の熱可塑性の樹脂材料を射出して芯材２０４を成形する。 In FIG. 8, 200 is a first split mold, 202 is a third split mold, and 203 is a second cavity formed by the first split mold 200 and the third split mold 202 in a clamped state.
Here, first, the core material 204 is molded by injecting a thermoplastic resin material for the core material into the second cavity 203.

そして芯材２０４の成形後、第１分割型２００を芯材２０４を保持した状態で第３分割型２０２に対して型開き方向に図中上向きに相対的に後退移動させ、しかる後第３分割型２０２と第２分割型２０６とを取り替えて型締めし、第１分割型２００と第２分割型２０６とで表皮及び発泡層成形用の第１キャビティを形成する。
図９（Ｉ）はこのときの状態を示している。 Then, after forming the core material 204, the first split mold 200 is moved backward relative to the third split mold 202 in the mold opening direction while holding the core material 204, and then the third split mold is divided. The mold 202 and the second split mold 206 are replaced and clamped, and the first split mold 200 and the second split mold 206 form the first cavity for forming the skin and the foam layer.
FIG. 9I shows the state at this time.

同図において、２０８は第１分割型２００と第２分割型２０６とで形成された第１キャビティである。
この製造方法では、熱可塑性樹脂の基材に発泡剤を含有させた発泡樹脂材料２１０を射出して第１キャビティ２０８に充填し、しかる後、第１分割型２００を型開き方向に図中上向きに所定ストローク後退移動させ、第１キャビティ２０８を拡大させる。 In the figure, reference numeral 208 denotes a first cavity formed by a first split mold 200 and a second split mold 206.
In this manufacturing method, a foamed resin material 210 containing a foaming agent in a thermoplastic resin base material is injected to fill the first cavity 208, and then the first split mold 200 is directed upward in the figure in the mold opening direction. Is moved backward by a predetermined stroke to enlarge the first cavity 208.

すると容積の拡大に伴う第１キャビティ２０８内の圧力の低下によって発泡樹脂材料２１０が発泡し、発泡層２１７を形成する。
またこのとき金型の内面に沿って、詳しくは第２分割型２０６の内面に沿って表皮２１５が形成される。
この表皮２１５は、熱可塑性樹脂の基材が金型の内面で冷却され固化することによって生ずる。
尚、２１２は第１分割型２００の第１摺動面，２１４は第２分割型２０６の第２摺動面で、これら第１，第２摺動面２１２，２１４は型開閉方向に延びて互いに摺動し、型締状態及び第１キャビティの拡大時に第１キャビティ２０８を閉鎖状態に維持する。 Then, the foamed resin material 210 foams due to a decrease in the pressure in the first cavity 208 as the volume increases, and a foamed layer 217 is formed.
At this time, a skin 215 is formed along the inner surface of the mold, specifically along the inner surface of the second split mold 206.
The skin 215 is generated when the thermoplastic resin substrate is cooled and solidified on the inner surface of the mold.
Reference numeral 212 denotes a first sliding surface of the first split mold 200, 214 denotes a second sliding surface of the second split mold 206, and the first and second sliding surfaces 212 and 214 extend in the mold opening / closing direction. Sliding together, the first cavity 208 is kept closed when the mold is clamped and the first cavity is enlarged.

図１０は、同様の製造方法による他の形状の樹脂発泡成形品の製造例を比較例として示したものである。
図１０（III）において、２１８は芯材２０４と発泡層２１７と表皮２１５を積層状態に一体化して成る樹脂発泡成形品で、型開閉方向にストレート形状で延びる末端部の一対の側面２２０，２２２とそれら側面２２０，２２２の同じ側（図中上側）の各端を繋ぐ頂面２２４を有する全体として扁平な形状をなしている。
尚、２２６は芯材２０４に形成された図中右方向に延びる板状の取付部である。 FIG. 10 shows, as a comparative example, a manufacturing example of a resin foam molded product of another shape by the same manufacturing method.
In FIG. 10 (III), reference numeral 218 denotes a resin foam molded product in which a core material 204, a foam layer 217, and a skin 215 are integrated in a laminated state, and a pair of side surfaces 220 and 222 at the end extending in a straight shape in the mold opening / closing direction. And a top surface 224 connecting the ends of the side surfaces 220 and 222 on the same side (upper side in the drawing) as a whole has a flat shape.
Reference numeral 226 denotes a plate-like mounting portion formed on the core member 204 and extending in the right direction in the figure.

図１０（Ｉ），（II）は、この樹脂射出成形品２１８を発泡射出成形によって製造する際の要部工程を示している。
図１０（Ｉ）は、第１分割型２００に芯材２０４をセットし保持させた状態で、第１分割型２００と第２分割型２０６とを型締めし、そしてそれらの間に形成される第１キャビティ２０８に発泡樹脂材料を射出し充填した状態を示している。 FIGS. 10 (I) and 10 (II) show the main process when the resin injection molded product 218 is manufactured by foam injection molding.
FIG. 10I shows that the first split mold 200 and the second split mold 206 are clamped in a state where the core material 204 is set and held on the first split mold 200 and is formed therebetween. A state in which the foamed resin material is injected and filled in the first cavity 208 is shown.

このとき、第２分割型２０６による冷却作用で熱可塑性樹脂の基材がその内面に沿って固化し、表皮２１５が形成される。
尚ここでは、芯材２０４の板状の取付部２２６のために、第１分割型２００が主型２００-１とスライド型２００-２とに分割されている。 At this time, the base material of the thermoplastic resin is solidified along the inner surface by the cooling action by the second split mold 206, and the skin 215 is formed.
Here, the first split mold 200 is divided into a main mold 200-1 and a slide mold 200-2 for the plate-like attachment portion 226 of the core member 204.

ここでスライド型２００-２は、成形後に図中右方向にスライド移動して、樹脂発泡成形品２１８の脱型を可能とする。
第１分割型２００における一対の第１摺動面２１２の一方は、このスライド型２００-２の側に形成されている。 Here, the slide mold 200-2 slides in the right direction in the figure after molding, and the resin foam molded product 218 can be removed.
One of the pair of first sliding surfaces 212 in the first split mold 200 is formed on the slide mold 200-2 side.

図１０（II）は、（Ｉ）の状態から第１キャビティ２０８に射出し充填した発泡樹脂材料を発泡させるために、第１分割型２００を第２分割型２０６に対して図中下向きに所定ストローク相対的に後退移動させ、第１キャビティ２０８を拡大したときの状態を表している。   FIG. 10 (II) shows a state in which the first split mold 200 is predetermined downward with respect to the second split mold 206 in order to foam the foamed resin material injected and filled into the first cavity 208 from the state of (I). The state is shown when the first cavity 208 is enlarged by moving backward relative to the stroke.

図１０（II）に示しているようにこのとき、第１キャビティ２０８を形成する第２分割型２０６の左右の末端部に空隙Ｋが生じてしまい、図１０（III）に示しているように樹脂発泡成形品２１８の左右の末端部が第２分割型２０６の成形面に沿って良好に成形されないといった問題が従来生じていた。   At this time, as shown in FIG. 10 (II), gaps K are generated at the left and right end portions of the second split mold 206 forming the first cavity 208, as shown in FIG. 10 (III). There has conventionally been a problem that the left and right end portions of the resin foam molded product 218 are not well molded along the molding surface of the second split mold 206.

これは、図１０（Ｉ）に示す状態で即ち第１キャビティ２０８に発泡樹脂材料を充填した段階で表皮２１５が形成され、そして図１０（Ｉ）に示す状態から図１０（II）に示す状態まで第２分割型２０６が第１分割型２００に対して相対移動したとき、側面２２０の表皮２１５-１が、頂面２２４の表皮２１５-２を末端部で引張ってしまって、頂面２２４の表皮２１５-２の末端部が第２分割型２０６に追従して移動しないことにより生ずるものである。   This is because the skin 215 is formed in the state shown in FIG. 10 (I), that is, at the stage where the first cavity 208 is filled with the foamed resin material, and from the state shown in FIG. 10 (I) to the state shown in FIG. 10 (II). When the second split mold 206 is moved relative to the first split mold 200, the skin 215-1 of the side surface 220 pulls the skin 215-2 of the top face 224 at the end, and the top face 224 This is caused by the fact that the end portion of the skin 215-2 does not move following the second split mold 206.

その結果、樹脂発泡成形品２１８における頂面２２４と側面２２０との交差部の形状が、第２分割型２０６の成形面に応じたシャープな目的形状２２８に成形されず、同部分が形状ダレを生じてしまう。図中２３０はその形状ダレの部分を表している。   As a result, the shape of the intersection of the top surface 224 and the side surface 220 in the resin foam molded product 218 is not molded into a sharp target shape 228 corresponding to the molding surface of the second split mold 206, and the same portion is not shaped. It will occur. In the figure, reference numeral 230 denotes the shape sag portion.

而してこのような形状ダレ２３０が生じてしまうと、樹脂発泡成形品２１８の外観が損なわれ、また寸法が不安定化してしまう。
尚、こうした問題点については下記特許文献３，４等にも指摘されている。 Thus, when such a shape sag 230 occurs, the appearance of the resin foam molded product 218 is impaired and the dimensions become unstable.
Such problems are also pointed out in Patent Documents 3 and 4 below.

実際にはこうした形状ダレの問題から、第１キャビティの拡大時の型開き方向のストロークを小さくし、形状ダレによる外観不良，寸法の不安定化を防ぐようにしているのが実情である。
しかしながらそのようにした場合、必然的に樹脂発泡成形品の発泡倍率が小さいものとなって、発泡樹脂成形品２１８の軽量化，触感（軟質感）を十分に高めることができない。
以上、芯材を有する樹脂発泡成形品の製造方法を例として述べたが、以上のような問題はこのような芯材を有しない表皮付き樹脂発泡成形品を製造するに際しても生ずる問題である。 In fact, due to the problem of the shape sag, the actual situation is that the stroke in the mold opening direction when the first cavity is enlarged is reduced to prevent the appearance defect and the dimensional instability due to the shape sag.
However, in such a case, the foaming ratio of the resin foam molded product is inevitably small, and the weight reduction and touch (soft texture) of the foamed resin molded product 218 cannot be sufficiently increased.
As mentioned above, although the manufacturing method of the resin foam molded product which has a core material was described as an example, the above problems are problems which arise also when manufacturing the resin foam molded product with a skin which does not have such a core material.

特開平７−８０８８５号公報Japanese Patent Laid-Open No. 7-80885 特開平７−８８８７８号公報JP-A-7-88878 特開２００６−１３０８７８号公報JP 2006-130878 A 特開２００８−１８３８３４号公報JP 2008-183834 A

本発明は以上のような事情を背景とし、発泡樹脂材料の発泡のためのキャビティ拡大に起因して樹脂発泡成形品が形状ダレを生じる問題を解決し、外観が良好で寸法の安定性も高く、しかも発泡倍率を高くし得て、軽量で触感に優れた樹脂発泡成形品を得ることのできる表皮付き樹脂発泡成形品の製造方法を提供することを目的としてなされたものである。 The present invention is based on the above situation, and solves the problem that the resin foam molded product causes shape sag due to expansion of the cavity for foaming of the foamed resin material, and has a good appearance and high dimensional stability. , yet-obtained by increasing the expansion ratio, has been made for the purpose of providing a manufacturing how the skinned, resin-molded foam which can obtain excellent resin molded foam in touch lightweight.

而して請求項１は樹脂発泡成形品の製造方法に関するもので、型開き方向に第１分割型と第２分割型とに分割された金型の第１キャビティに、熱可塑性樹脂の基材に発泡剤を含有させた発泡樹脂材料を射出して充填し、しかる後前記一方の第１分割型を前記第２分割型に対し所定ストローク前記型開き方向に相対的に後退移動させて前記第１キャビティを拡大し、前記発泡樹脂材料を発泡させることによって、前記型開閉方向と直角方向の末端部の一対の側面と、該一対の側面の同じ側の各端を繋ぐ頂面とを有する、金型内面で固化した表皮の内側に発泡層を有する表皮付きの樹脂発泡成形品を製造する樹脂発泡成形品の製造方法であって、前記側面を成形する一対の側面成形面と、前記頂面を成形する頂面成形面とを備えた前記第２分割型の少なくとも一方の側面成形面を、該側面の、型締状態で該側面成形面に沿って形成された前記表皮の基端よりも前記頂面側の上側部分の少なくとも一部を前記型開閉方向と直角方向の外方の突形状部に成形する突成形部を有するものとなして、前記第１キャビティの拡大時に、該突成形部にて前記表皮に形成された突形状部を保持して前記第１分割型に対して前記型開き方向に相対移動させるようになすとともに、前記第２分割型の、前記第１分割型の側の第１摺動面に対して摺動する、前記型開閉方向に延びた第２摺動面を前記一方の側面成形面に連続して形成し、前記第１キャビティの拡大時に該第２摺動面を前記側面の成形用として用い、該第２摺動面に沿って、前記型締状態で形成された表皮に連続した新たな表皮を形成するようになしたことを特徴とする。   Thus, claim 1 relates to a method for producing a resin foam molded article, wherein a thermoplastic resin substrate is provided in a first cavity of a mold divided into a first divided mold and a second divided mold in the mold opening direction. A foamed resin material containing a foaming agent is injected and filled into the first divided mold, and then the first divided mold is moved backward relative to the second divided mold by a predetermined stroke in the mold opening direction. By enlarging one cavity and foaming the foamed resin material, and having a pair of side surfaces of the end portion perpendicular to the mold opening and closing direction and a top surface connecting the ends on the same side of the pair of side surfaces, A method for producing a resin foam molded article for producing a resin foam molded article with a skin having a foam layer on the inner side of the skin solidified on the inner surface of the mold, the pair of side molding surfaces for molding the side surfaces, and the top surface The second split mold having a top surface molding surface for molding At least a part of the upper side surface of the side surface of the upper surface side of the side surface of the side surface of the skin formed in a mold-clamped state along the side surface molding surface is defined as the mold opening / closing direction. It has a projecting part that is molded into an outward projecting part in a right angle direction, and when the first cavity is enlarged, the projecting part formed on the skin is held by the projecting part. The mold opening and closing that is moved relative to the first split mold in the mold opening direction and that slides on the first sliding surface of the second split mold on the first split mold side. A second sliding surface extending in the direction is continuously formed on the one side molding surface, and the second sliding surface is used for molding the side surface when the first cavity is enlarged. A new epidermis that is continuous with the epidermis formed in the clamping state is formed along the surface. Characterized in that it has none.

請求項２のものは、請求項１において、前記突形状部が、前記型締状態で形成された前記側面の表皮の前記基端から前記頂面に向って漸次前記軸直角方向の外方への突出量を拡大する形態のアンダーカット形状であることを特徴とする。   According to a second aspect of the present invention, in the first aspect, the protruding portion is gradually outward in the direction perpendicular to the axis from the base end of the side skin formed in the mold-clamped state toward the top surface. It is the undercut shape of the form which expands the protrusion amount of this.

請求項３のものは、請求項１，２の何れかにおいて、前記樹脂発泡成形品が熱可塑性樹脂から成る硬質の芯材付きのものであって、前記型締状態で予め前記第１分割型にセットし保持させてある前記芯材の、前記型開閉方向に延びる縦の面を前記第１分割型の側の第１摺動面として、前記第２摺動面を該第１分割型に対し金属接触させることなく摺動させるようになしてあることを特徴とする。   According to a third aspect of the present invention, in any one of the first and second aspects, the resin foam molded product is provided with a hard core material made of a thermoplastic resin, and the first divided mold is previously held in the mold-clamped state. A vertical surface extending in the mold opening / closing direction of the core material set and held on the core member is defined as a first sliding surface on the first split mold side, and the second sliding surface is defined as the first split mold. It is characterized by being slid without being brought into contact with metal.

請求項４のものは、型開き方向に第１分割型と第２分割型とに分割された金型の第１キャビティに、熱可塑性樹脂の基材に発泡剤を含有させた発泡樹脂材料を射出して充填し、しかる後前記一方の第１分割型を前記第２分割型に対し所定ストローク前記型開き方向に相対的に後退移動させて前記第１キャビティを拡大し、前記発泡樹脂材料を発泡させることによって、型開閉方向と直角方向の末端部の一対の側面と、該一対の側面の同じ側の各端を繋ぐ頂面とを有する、金型内面で固化した表皮の内側に発泡層を有する表皮付きの樹脂発泡成形品を製造する樹脂発泡成形品の製造方法であって、前記側面を形成する一対の側面成形面と、前記頂面を成形する頂面成形面とを備えた前記第２分割型の少なくとも一方の側面成形面を、型締状態で前記側面の前記頂面側の上部を前記型開閉方向と直角方向の外方の突形状部に成形する上突成形部と、基端側の下部を該基端に到るまで該外方の突形状部に成形する下突成形部とを有するものとなして、前記第１キャビティの拡大時に、前記上突成形部にて前記表皮に形成された上突形状部を保持し且つ該表皮に形成された下突形状部を該下突成形部から離し変形させることで前記型開き方向の相対移動を吸収することにより根元部を前記第１分割型側に残す状態で、前記側面成形面を前記第１分割型に対して前記型開き方向に相対移動させるようになしたことを特徴とする。 According to a fourth aspect of the present invention, there is provided a foamed resin material in which a foaming agent is contained in a thermoplastic resin base material in a first cavity of a mold that is divided into a first split mold and a second split mold in the mold opening direction. Injecting and filling, and then expanding the first cavity by moving the one first divided mold relatively backward with respect to the second divided mold by a predetermined stroke in the mold opening direction, A foam layer on the inside of the skin solidified on the inner surface of the mold, having a pair of side surfaces of the end portion perpendicular to the mold opening and closing direction and a top surface connecting the ends of the same side of the pair of side surfaces by foaming A resin foam molded article manufacturing method for manufacturing a resin foam molded article with a skin, comprising: a pair of side molding surfaces that form the side surfaces; and a top surface molding surface that molds the top surface At least one side molding surface of the second split mold is clamped An upper protrusion forming portion for forming the upper portion of the top surface side of the side surface into an outward protruding shape portion perpendicular to the mold opening and closing direction, and a lower portion of the base end side until the base end is reached. A lower projecting portion that is molded into a projecting shape portion, and when the first cavity is enlarged, the upper projecting shape portion formed on the outer skin is held by the upper projecting molding portion, and In the state where the base part is left on the first split mold side by absorbing the relative movement in the mold opening direction by separating the lower projecting shape part formed from the lower projecting molding part and deforming the side molding surface. The first split mold is relatively moved in the mold opening direction.

請求項５のものは、請求項４において、前記上突形状部が、前記側面の前記頂面側の端に向って漸次前記軸直角方向の外方への突出量を拡大する形態のアンダーカット形状であることを特徴とする。 According to a fifth aspect of the present invention, there is provided an undercut according to the fourth aspect, wherein the upper projecting shape portion gradually increases the outward projecting amount in the direction perpendicular to the axis toward the top surface side end of the side surface. It is a shape .

発明の作用・効果Effects and effects of the invention

以上のように請求項１の製造方法は、第２分割型における少なくとも一方の側面成形面を以下のような形状、即ち型締状態で側面成形面に沿って形成された表皮の基端よりも頂面側の上側部分の少なくとも一部を、型開閉方向と直角方向の外方の突形状部に成形する突成形部を有するものとなし、第１キャビティの拡大時にその突成形部にて表皮の突形状部を保持し、これを第１分割型に対して型開き方向に相対移動させるようになしたものである。   As described above, in the manufacturing method according to claim 1, at least one side molding surface in the second split mold has the following shape, that is, more than the base end of the skin formed along the side molding surface in the mold-clamped state. At least a part of the upper part on the top surface side has a projecting part for forming an outward projecting part perpendicular to the mold opening / closing direction, and the skin is formed by the projecting part when the first cavity is enlarged. The protruding portion is held and moved relative to the first split mold in the mold opening direction.

このようにすれば、表皮における頂面と側面との交差部が第２分割型とともに第１分割型に対して型開き方向に相対移動するため、表皮における頂面と側面との交差部を、第２分割型における頂面成形面と側面成形面との交差部に沿ったシャープな形状に良好に成形することができる。   In this way, since the intersection of the top surface and the side surface in the epidermis moves relative to the first split mold in the mold opening direction together with the second split mold, the intersection of the top surface and the side surface in the epidermis is It can be satisfactorily molded into a sharp shape along the intersection of the top surface molding surface and the side surface molding surface in the second split mold.

この請求項１の製造方法では、上記の側面成形面に連続する形で、第２分割型の型開閉方向に延びる第２摺動面を形成しており、そしてこの第２摺動面を発泡樹脂成形品、詳しくは表皮の側面の成形用として利用している点を他の特徴としている。   In the manufacturing method of claim 1, the second sliding surface extending in the mold opening / closing direction of the second split mold is formed in a form continuous with the side molding surface, and the second sliding surface is foamed. Another feature is that it is used for molding a resin molded product, specifically the side surface of the skin.

単に側面成形面に突成形部を設け、その突成形部にて表皮に形成された突形状部を保持してこれを第２分割型とともに第１キャビティの拡大時に相対移動させるようにしただけであると、既に形成されている表皮の基端側の部分がちぎれ、破れてしまうこととなる。   Simply providing a projecting part on the side molding surface, holding the projecting part formed on the skin at the projecting part, and relatively moving it together with the second split mold when the first cavity is enlarged If it exists, the part of the base end side of the already formed epidermis will be torn and torn.

しかるにこの請求項１の製造方法では、側面成形面に連続して第２摺動面が型開閉方向に延びる形態で設けてあり、そしてその第２摺動面の一部が側面成形用として働いて、この第２摺動面に沿って、既に形成されている表皮に連続した形で新たな表皮が形成される。
従って第１キャビティの拡大時に表皮が破れることがあっても何等問題は生じない。 However, in the manufacturing method of claim 1, the second sliding surface is provided in a form extending in the mold opening / closing direction continuously to the side molding surface, and a part of the second sliding surface works for side molding. Thus, a new skin is formed along the second sliding surface in a form continuous with the already formed skin.
Therefore, no problem occurs even if the skin is broken when the first cavity is enlarged.

この請求項１の製造方法によれば、樹脂発泡成形品の外観を良好となすことができる。
またこの請求項１の製造方法によれば、頂面と側面との交差部の形状ダレを生じないことから、第１キャビティ拡大の際の第１分割型と第２分割型との相対移動のストロークを大きく取ることが可能となり、これにより第１キャビティの容積を十分に拡大し得て、発泡樹脂材料を十分に発泡させることができる。 According to the manufacturing method of the first aspect, the appearance of the resin foam molded product can be improved.
Further, according to the manufacturing method of claim 1, since the shape sag at the intersection of the top surface and the side surface does not occur, the relative movement between the first divided mold and the second divided mold when the first cavity is enlarged is achieved. It becomes possible to take a large stroke, whereby the volume of the first cavity can be sufficiently expanded, and the foamed resin material can be sufficiently foamed.

これにより、厚みが厚く且つ高発泡倍率の樹脂発泡成形品を、形状ダレを心配することなく製造することが可能となり、樹脂発泡成形品を従来に増して軽量化することができ、また柔らかな触感を従来に増して高めることが可能となる。   As a result, it is possible to manufacture a resin foam molded product having a large thickness and a high foaming ratio without worrying about shape sag. It becomes possible to increase the tactile sensation more than before.

この請求項１の製造方法において、上記突形状部を、型締状態で形成された側面の表皮の基端から頂面に向って漸次軸直角方向の外方に突出量を拡大させる形態のアンダーカット形状となしておくことができる（請求項２）。   2. The manufacturing method according to claim 1, wherein the projecting shape portion is formed under a shape in which the projecting amount is gradually increased outward in the direction perpendicular to the axis from the base end of the side skin formed in the mold-clamped state toward the top surface. It can be made into a cut shape (Claim 2).

更にこの請求項１の製造方法は、熱可塑性樹脂から成る硬質の芯材付きの樹脂発泡成形品の製造方法に適用し、型締状態で第１分割型にセットし保持させてある芯材の、上記型開閉方向に延びる縦の面を第１分割型の側の第１摺動面として、これに対し上記の第２分割型の第２摺動面を第１分割型に対し金属接触させることなく摺動させるようになしておくことができる（請求項３）。   Furthermore, the manufacturing method according to claim 1 is applied to a manufacturing method of a resin foam molded product with a hard core made of a thermoplastic resin, and the core material is set and held in the first split mold in a clamped state. The vertical surface extending in the mold opening / closing direction is the first sliding surface on the first split mold side, and the second sliding surface of the second split mold is in metal contact with the first split mold. It can be made to slide without (claim 3).

このようにすれば、摺動面が金属接触し摺動することによって摺動面が擦られ摩耗して隙間を大きくし、その隙間から発泡樹脂材料の液が外部に漏出してしまうのを良好に防止することができる。
そしてこれにより、液の漏出によりバリが発生し、またそのバリ除去のための仕上げ工程を必要とするといった問題を解決することができる。 In this way, the sliding surface contacts the metal and slides, and the sliding surface is rubbed and worn to increase the gap, and the foamed resin material liquid leaks out from the gap. Can be prevented.
Thus, it is possible to solve the problem that burrs are generated due to the leakage of the liquid and that a finishing process for removing the burrs is required.

次の請求項４は、第２分割型の側面成形面を、型締状態で側面の頂面側の上部を突形状部に成形する上突成形部と、基端側の下部をその基端に到るまで突形状部に成形する下突成形部とを有するものとなし、第１キャビティの拡大時に上突成形部にて表皮に形成された上突形状部を保持し、また表皮に形成された下突形状部を第１分割型の側に残す状態で、側面成形面を第１分割型に対し型開き方向に相対移動させるようになしたものである。   According to a fourth aspect of the present invention, the side molding surface of the second split mold is formed in such a manner that an upper projection molding portion that molds the upper portion of the top surface side of the side surface into a projecting shape portion in a clamped state, and the lower portion on the proximal end side is the proximal end It has a lower projecting part that is molded into a projecting part until it reaches the top, and holds the upper projecting part formed on the skin at the upper projecting part when the first cavity is enlarged, and also forms on the skin The side molding surface is moved relative to the first split mold in the mold opening direction in a state in which the lower projecting shape portion is left on the first split mold side.

この請求項４の製造方法においても、表皮における側面と頂面との交差部を、第２分割型の頂面成形面と側面成形面との交差部の形状に正確に追従した形状のシャープな形状に成形することができる。   Also in the manufacturing method of this claim 4, the shape of the intersecting portion between the side surface and the top surface of the epidermis exactly following the shape of the intersecting portion between the top surface forming surface and the side surface forming surface of the second split mold is sharp. It can be formed into a shape.

この請求項４の製造方法では、表皮における上突形状部の下側に下突形状部が成形される。
而して上突形状部が第２分割型の側面成形面と一体に型開き方向に相対移動したとき、表皮における下突形状部が直線形状となろうとする方向に変形を生じ、そしてその変形によって、表皮における上記の上突形状部の下側部分が破れを生じるのを防止することができる。
即ち、表皮における下突形状部の変形によって上突形状部の移動ストロークを吸収することができる。 In the manufacturing method according to the fourth aspect, the lower protruding portion is formed below the upper protruding portion of the skin.
Thus, when the upper projecting shape part moves relative to the side molding surface of the second split mold in the mold opening direction, the lower projecting shape part on the skin is deformed in a direction to become a linear shape, and the deformation By this, it is possible to prevent the lower portion of the upper protruding portion of the epidermis from being broken.
In other words, the movement stroke of the upper protruding portion can be absorbed by the deformation of the lower protruding portion in the skin.

この請求項４の製造方法においても、上記の上突形状部を、頂面側の端に向って漸次軸直角方向の外方に突出量を拡大する形態のアンダーカット形状となしておくことができる（請求項５）。   Also in the manufacturing method of claim 4, the upper protruding portion may have an undercut shape in which the protruding amount is gradually expanded outward in the direction perpendicular to the axis toward the end on the top surface side. (Claim 5).

これら請求項１〜５において、上記第１分割型と、上記第２分割型とは別の第３分割型とを型締めして、それら第１分割型と第３分割型とで形成される第２キャビティに芯材用の熱可塑性樹脂を射出し、芯材を成形した後、第３分割型と第２分割型とを取り替えて、それら第１分割型と第２分割型とで形成される第１キャビティに、上記発泡樹脂材料を充填及び発泡させて表皮と発泡層とを成形し、芯材に一体化させるようになすことができる。 In these first to fifth aspects, the first split mold and the third split mold different from the second split mold are clamped to form the first split mold and the third split mold. After the thermoplastic resin for the core material is injected into the second cavity and the core material is molded, the third split mold and the second split mold are replaced to form the first split mold and the second split mold. The first cavity can be filled and foamed with the foamed resin material to form the skin and the foamed layer, and can be integrated with the core material .

次に本発明の実施形態を図面に基づいて詳しく説明する。
図１において、１０は自動車のドアトリムその他自動車の内装品等に好適に用いられる樹脂発泡成形品で、この樹脂発泡成形品１０は、硬質の熱可塑性樹脂から成る芯材１２と、芯材１２に積層された熱可塑性樹脂の発泡層１４と、発泡層１４と同じ材質の樹脂から成り、発泡層１４の外表面を覆うソリッド樹脂から成る表皮１６とを積層状態に一体に有している。
この樹脂発泡成形品１０は、全体的に図中上向きに太鼓状に膨出した扁平な形状を成している。 Next, embodiments of the present invention will be described in detail with reference to the drawings.
In FIG. 1, reference numeral 10 denotes a resin foam molded article that is suitably used for automobile door trims and other automobile interior parts. The resin foam molded article 10 includes a core material 12 made of a hard thermoplastic resin, and a core material 12. A laminated thermoplastic resin foam layer 14 and a skin 16 made of a resin made of the same material as the foam layer 14 and covering the outer surface of the foam layer 14 are integrally provided in a laminated state.
The resin foam molded product 10 has a flat shape that bulges upward in the figure like a drum.

芯材１２は、樹脂発泡成形品１０の形状の保持と相手側への取付部としての機能を有するもので、発泡層１４及び表皮１６から図中右向きに延び出した取付部２４を有している。
取付部２４には取付孔２６が設けられており、取付部２４はこの取付孔２６において相手側部材に取付固定される。 The core material 12 has a function of holding the shape of the resin foam molded article 10 and an attachment portion to the other side, and has an attachment portion 24 extending rightward in the drawing from the foam layer 14 and the skin 16. Yes.
An attachment hole 26 is provided in the attachment portion 24, and the attachment portion 24 is attached and fixed to the counterpart member in the attachment hole 26.

図１において、１８は樹脂発泡成形品１０における図中左側の末端部の側面を、また２０は図中右側の末端部の側面を示しており、更に２２はそれら一対の側面１８，２０の同じ側の端、詳しくは図中上側の端を結ぶ頂面を表している。   In FIG. 1, reference numeral 18 denotes a side surface of the left end portion in the figure of the resin foam molded article 10, 20 denotes a side surface of the right end portion in the drawing, and 22 denotes the same of the pair of side surfaces 18 and 20. The top surface which connects the edge of a side, specifically the upper edge in the figure is represented.

図に示しているように左側の側面１８は、頂面２２側の上側部分が図中左方向に突出する突形状部をなしており、そしてその突形状部の図中下側部分が、図１中上下方向にストレート形状で延びるストレート形状部をなしている。
一方右側の側面２０は、頂面２２側の上部が図中右方向に突出した上突形状部をなしており、またその下側の部分が発泡層１４の下端に到るまで図中右方向に突出した下突形状部をなしている。 As shown in the figure, the left side surface 18 forms a protruding portion in which the upper portion on the top surface 22 side protrudes in the left direction in the drawing, and the lower portion of the protruding portion in the drawing is the figure. 1 has a straight shape portion extending in a straight shape in the vertical direction.
On the other hand, the right side surface 20 forms an upper protruding portion whose upper portion on the top surface 22 side protrudes in the right direction in the drawing, and the lower portion thereof reaches the lower end of the foam layer 14 in the right direction in the drawing. The lower protrusion shape part which protruded in the is formed.

ここで図中左側の側面１８における突形状部は、頂面２２に向って図中上方に進むにつれて左方向への突出量を漸次拡大形態のアンダーカット形状をなしている。
更に右側の側面２０における上突形状部もまた、頂面２２に向って上側に進むにつれ右方向への突出量を漸次拡大する形態のアンダーカット形状をなしている。 Here, the protruding portion on the side surface 18 on the left side in the drawing has an undercut shape in which the amount of protrusion in the left direction gradually increases as it proceeds upward in the drawing toward the top surface 22.
Further, the upper protruding portion on the right side surface 20 also has an undercut shape in which the amount of protrusion in the right direction gradually increases as it proceeds upward toward the top surface 22.

図１において、１６-１は頂面２２の表皮を、１６-２は図中左側の側面１８の表皮を、また１６-３は図中右側の側面２０の表皮をそれぞれ表している。
更に１６-２Ａは、左側の側面１８における突形状部の表皮を、また１６-２Ｂは側面１８におけるストレート形状部の表皮を表している。 In FIG. 1, 16-1 represents the epidermis of the top surface 22, 16-2 represents the epidermis of the left side 18 in the figure, and 16-3 represents the epidermis of the right side 20 in the figure.
Further, 16-2A represents the skin of the protruding portion on the left side surface 18, and 16-2B represents the skin of the straight portion on the side surface 18.

ここで突形状部の表皮１６-２Ａは、側面１８における突形状部に対応したアンダーカット形状をなしており、またストレート形状部１６-２Ｂもまたこれに対応した上下方向のストレート形状をなしている。
一方１６-３Ａは、図中右側の側面２０における上突形状部の表皮を、また１６-３Ｂは下突形状部における表皮を表している。 Here, the skin 16-2A of the protruding portion has an undercut shape corresponding to the protruding portion on the side surface 18, and the straight shape portion 16-2B also has a vertical shape corresponding to this. Yes.
On the other hand, 16-3A represents the skin of the upper protruding portion on the right side surface 20 in the drawing, and 16-3B represents the skin of the lower protruding portion.

上突形状部の表皮１６-３Ａはアンダーカット形状をなしている。
一方下突形状部の表皮１６-３Ｂは、緩い角度で傾斜する上側の表皮１６-３Ｂａと、急角度で立ち上がる下側の表皮１６-３Ｂｂとを有している。 The skin 16-3A of the upper protruding portion has an undercut shape.
On the other hand, the skin 16-3B of the lower protruding portion has an upper skin 16-3Ba that is inclined at a gentle angle and a lower skin 16-3Bb that rises at a steep angle.

ここで表皮１６-３Ｂａと１６-３Ｂｂとは、後述する図３（II）の成形時点でそれぞれ図中左右の水平方向と上下の垂直方向の向きをなしていたものが、その後の第１キャビティの拡大時における第１分割型２８と第２分割型３４の相対移動によって、それぞれ図１に示す形状となったものである。   Here, the outer skins 16-3Ba and 16-3Bb are oriented in the horizontal direction in the horizontal direction and the vertical direction in the vertical direction in the drawing at the time of forming in FIG. The shapes shown in FIG. 1 are obtained by relative movement of the first split mold 28 and the second split mold 34 during enlargement.

本実施形態において、発泡層１４及び表皮１６を構成する熱可塑性樹脂として、様々な種類の樹脂を用いることが可能であるが、ここではこれら発泡層１４及び表皮１６を構成する熱可塑性樹脂として熱可塑性エラストマー（ＴＰＥ）が用いられている。
またＴＰＥとしてスチレン系（スチレン・ブロック・コポリマー（ＳＢＣ）），オレフィン系（ＴＰＯ），ウレタン系（ＴＰＵ），ポリエステル系（ＴＰＥＥ），ポリアミド系（ＴＰＡＥ），１，２-ポリブタジエン系，塩ビ系（ＴＰＶＣ），フッ素系その他のものを用いることが可能であるが、ここでは特に好適なものとしてオレフィン系の熱可塑性エラストマー（ＴＰＯ）が用いられている。 In the present embodiment, various types of resins can be used as the thermoplastic resin constituting the foam layer 14 and the skin 16, but here, as the thermoplastic resin constituting the foam layer 14 and the skin 16, heat is used. Plastic elastomer (TPE) is used.
Also, as TPE, styrene (styrene block copolymer (SBC)), olefin (TPO), urethane (TPU), polyester (TPEE), polyamide (TPAE), 1,2-polybutadiene, vinyl chloride ( TPVC), fluorine-based materials, and the like can be used, but olefin-based thermoplastic elastomers (TPO) are particularly preferable here.

一方、芯材１２は上記の機能から剛性を有する硬質の熱可塑性樹脂を用いる必要があり、この実施形態ではかかる芯材１２を構成する熱可塑性樹脂として様々な樹脂を用いることが可能であるが、特に好適なものとしてここではポリプロピレン樹脂が用いられている。
尚、芯材１２は硬質のものであることが必要で、ここではロックウェル硬度（Ｒスケール）が８０〜１００、或いは１００〜１２０程度のものが用いられているが、この芯材１２としてはロックウェル硬度で５０以上のものを用いるのが望ましい。
尚、芯材１２はここではその厚みが２．３ｍｍである。芯材１２としては厚みが１．５ｍｍ以上であることが望ましい。 On the other hand, the core material 12 needs to use a rigid thermoplastic resin having rigidity due to the above functions. In this embodiment, various resins can be used as the thermoplastic resin constituting the core material 12. In this case, a polypropylene resin is used as a particularly preferable one.
The core material 12 is required to be hard, and here, the Rockwell hardness (R scale) of about 80 to 100, or about 100 to 120 is used. It is desirable to use a Rockwell hardness of 50 or higher.
Here, the thickness of the core material 12 is 2.3 mm. The core material 12 preferably has a thickness of 1.5 mm or more.

一方、上記発泡層１４は熱可塑性樹脂の基材に予め発泡剤を含有させた発泡樹脂材料を射出成形して発泡させたもので、その発泡の手段として物理的発泡法と化学的発泡法の何れも使用可能である。
具体的には、物理的発泡法として溶融状態の基材樹脂に、窒素や二酸化炭素等の発泡性ガスを物理的に強制的に注入し、これを射出成形後に発泡させる方法、或いは熱分解により発泡性ガスを放出する発泡剤を樹脂材料中に加えておいて、射出成形後においてこれを熱分解させて発泡させる方法の何れも可能である。 On the other hand, the foamed layer 14 is obtained by injection-molding a foamed resin material containing a foaming agent in advance on a thermoplastic resin base material, and as a means for foaming, a physical foaming method and a chemical foaming method are used. Either can be used.
Specifically, as a physical foaming method, a foaming gas such as nitrogen or carbon dioxide is physically forcibly injected into a molten base resin and foamed after injection molding, or by thermal decomposition. Any method can be used in which a foaming agent that releases foamable gas is added to the resin material, and the foamed material is thermally decomposed after injection molding.

後者の化学的発泡法を用いる場合には、発泡剤としてアゾ化合物やニトロソ化合物等の有機発泡剤又は重炭酸ナトリウム等の無機発泡剤を使用することができるが、ここでは重炭酸ナトリウムを発泡剤として用いている。   When the latter chemical foaming method is used, an organic foaming agent such as an azo compound or a nitroso compound or an inorganic foaming agent such as sodium bicarbonate can be used as the foaming agent. Here, sodium bicarbonate is used as the foaming agent. It is used as.

図２〜図５は、樹脂発泡成形品１０の製造方法を具体的に示している。
ここでは樹脂発泡成形品１０を２色成形によって成形し、金型の一部を共通に用いて先ず芯材１２を成形した後、続いて発泡層１４及び表皮１６を連続して成形し、それらを一体化する。 2 to 5 specifically show a method for manufacturing the resin foam molded article 10.
Here, the resin foam molded product 10 is molded by two-color molding, the core material 12 is first molded using a part of the mold in common, and then the foamed layer 14 and the skin 16 are continuously molded. Is integrated.

図２は、先ず芯材１２を成形する際の方法を示している。
図において、芯材１２を成形する金型は雄型としての第１分割型２８と、雌型としての第３分割型３０との分割構造とされており、それら第１分割型２８と第３分割型３０とによって、芯材１２の形状に対応した形状の第２キャビティ３２を形成している。 FIG. 2 shows a method for forming the core material 12 first.
In the figure, the mold for molding the core material 12 has a divided structure of a first divided mold 28 as a male mold and a third divided mold 30 as a female mold. The split mold 30 forms a second cavity 32 having a shape corresponding to the shape of the core material 12.

ここでは、図２（II）に示しているように芯材１２用の樹脂材料を射出成形によって第２キャビティ３２に充填し、そこでこれを固化させることによって芯材１２を成形する。
芯材１２を成形したら、第１分割型２８と第３分割型３０とを図中上下方向に型開きする。
このとき、成形された芯材１２は第１分割型２８の側に残りそこに保持される。 Here, as shown in FIG. 2 (II), the resin material for the core material 12 is filled into the second cavity 32 by injection molding, and the core material 12 is molded by solidifying it.
After the core material 12 is molded, the first split mold 28 and the third split mold 30 are opened in the vertical direction in the figure.
At this time, the molded core 12 remains on the first split mold 28 side and is held there.

図３〜図５は、発泡射出成形によって発泡層１４と表皮１６とを成形し且つこれを芯材１２に一体化する際の方法を示している。
図３に示しているように、発泡層１４及び表皮１６を成形する金型は、図２に示す第１分割型２８と、第２分割型３４との分割構造をなしている。
即ち、発泡層１４及び表皮１６を成形する発泡射出成形用の金型は、芯材１２成形用の第１分割型２８を共通の金型として備えている。 3 to 5 show a method in which the foam layer 14 and the skin 16 are formed by foam injection molding and integrated into the core material 12.
As shown in FIG. 3, the mold for molding the foam layer 14 and the skin 16 has a divided structure of the first divided mold 28 and the second divided mold 34 shown in FIG. 2.
In other words, the foam injection molding mold for molding the foam layer 14 and the skin 16 includes the first split mold 28 for molding the core material 12 as a common mold.

具体的には、芯材１２成形用の図２の第３分割型３０と、図３の第２分割型３４とを取り替えることで、発泡層１４及び表皮１６の発泡射出成形用の金型が構成される。
尚この実施形態において、第２分割型３４は主型３４-１と一対のスライド型３４-２，３４-３とで構成されている。
そしてこれら主型３４-１，一対のスライド型３４-２，３４-３にて構成される第２分割型３４と、第１分割型２８とで第１キャビティ３６を形成している。 Specifically, by replacing the third split mold 30 in FIG. 2 for molding the core material 12 and the second split mold 34 in FIG. Composed.
In this embodiment, the second split mold 34 is composed of a main mold 34-1 and a pair of slide molds 34-2 and 34-3.
A first cavity 36 is formed by the second split mold 34 constituted by the main mold 34-1 and the pair of slide molds 34-2 and 34-3 and the first split mold 28.

ここで第２分割型３４は、図１の樹脂発泡成形品１０における図中左側の側面１８を成形する側面成形面３８と、図１中右側の側面２０を成形する側面成形面４０及び頂面２２を成形する頂面成形面４２を有している。
ここで図１中左側の側面１８を成形する側面成形面３８は、上記のアンダーカット形状の突形状部を成形する突成形部４４を有している。ここで突成形部４４は、図３（Ｉ）に示す型締状態で芯材１２の側端面５２の上端にまで達している。 Here, the second split mold 34 includes a side molding surface 38 that molds the left side surface 18 in the resin foam molded article 10 of FIG. 1, a side molding surface 40 that molds the right side surface 20 in FIG. 22 has a top surface forming surface 42.
Here, the side surface forming surface 38 for forming the left side surface 18 in FIG. 1 has a protrusion forming portion 44 for forming the above-described undercut protrusion. Here, the projecting portion 44 reaches the upper end of the side end face 52 of the core member 12 in the mold clamping state shown in FIG.

図３（Ｉ）中５４は、図中上下方向即ち型開閉方向に縦の面をなす側端面５２を、第１分割型２８の側の第１摺動面としてこれに接触し、摺動する第２分割型３４の第２摺動面を表している。
第２摺動面５４は、図３（Ｉ）に示す型締状態で側端面５２に接触して第１キャビティ３６の図中左端を閉鎖し、また後述の第１キャビティ３６の拡大時に、この側端面５２から成る第１摺動面に対して摺動し、第１キャビティ３６の図中左端側を閉鎖状態に維持する。
この第２摺動面５４は、全期間を通じて第１分割型２８側に金属接触することはない。 3 (I), the side end surface 52 that forms a vertical surface in the vertical direction in the drawing, that is, the mold opening / closing direction, contacts and slides as the first sliding surface on the first split mold 28 side. The 2nd sliding surface of the 2nd division | segmentation type | mold 34 is represented.
The second sliding surface 54 comes into contact with the side end surface 52 in the mold clamping state shown in FIG. 3 (I) to close the left end of the first cavity 36 in the drawing, and when the first cavity 36 described later is enlarged, It slides with respect to the 1st sliding surface which consists of the side end surface 52, and the left end side in the figure of the 1st cavity 36 is maintained in a closed state.
The second sliding surface 54 does not make metal contact with the first split mold 28 side throughout the entire period.

一方、図１の樹脂発泡成形品１０の図中右側の側面２０を成形する第２分割型３４の側面成形面４０は、側面２０における上突形状部を成形する上突成形部４８と、下突形状部を成形する、厳密には図３（II）に示す第１キャビティ３６に発泡樹脂材料を射出し充填したときに図３（II）の形状の下突形状部の表皮１６-３Ｂａ′，１６-３Ｂｂ′を成形する、下突成形部５０を有している。
この下突成形部５０は、図３中左右方向の水平な成形面と垂直な成形面とを備えている。 On the other hand, the side molding surface 40 of the second split mold 34 that molds the right side surface 20 of the resin foam molded article 10 of FIG. 1 includes an upper projection molding portion 48 that molds the upper projection shape portion on the side surface 20, and a lower projection molding portion 48. When the protruding portion is molded, strictly speaking, when the foamed resin material is injected and filled into the first cavity 36 shown in FIG. 3 (II), the skin 16-3Ba ′ of the lower protruding portion shown in FIG. 3 (II) is formed. , 16-3Bb ′ is formed.
The lower protrusion forming portion 50 includes a horizontal forming surface in the left-right direction in FIG. 3 and a vertical forming surface.

図３（II）は、型締状態の下で第１キャビティ３６に発泡樹脂材料を射出し、充填したときの状態を示している。
このとき、第１キャビティ３６に射出充填された発泡樹脂材料の基材が、第２分割型３４の内面、詳しくは頂面成形面４２と側面成形面３８及び４０に接してそこで固まることによって、表皮１６の中間形状体１６′が形成される。 FIG. 3 (II) shows a state when the foamed resin material is injected into the first cavity 36 and filled under the mold clamping state.
At this time, the base material of the foamed resin material injected and filled into the first cavity 36 comes into contact with the inner surface of the second split mold 34, specifically, the top surface molding surface 42 and the side surface molding surfaces 38 and 40, and is solidified there. An intermediate shape body 16 ′ of the skin 16 is formed.

このとき、図中左側の側面には図１に示す表皮１６-２のうち、突形状部における表皮１６-２Ａのみが形成される。
また図中右側の側面においては、上突形状部の表皮１６-３Ａと下形状部の表皮１６-３Ｂａ′，１６-３Ｂｂ′が形成される。
但しこの段階では表皮１６-３Ｂａ′は型開き方向と直角な方向の図中水平向きであり、また表皮１６-３Ｂｂ′はこれと直角方向の縦向きである。 At this time, only the skin 16-2A in the protruding shape portion is formed on the side surface on the left side in the drawing, of the skin 16-2 shown in FIG.
Further, on the right side surface in the drawing, an upper skin 16-3A and a lower skin 16-3Ba ', 16-3Bb' are formed.
However, at this stage, the skin 16-3Ba 'is horizontal in the direction perpendicular to the mold opening direction, and the skin 16-3Bb' is vertically oriented in the direction perpendicular thereto.

図３（III）は発泡樹脂材料を発泡させるべく、第１キャビティ３６を拡大させた状態を表している。
詳しくは、第１分割型２８を第２分割型３４に対して相対的に所定ストローク後退移動させ、第１キャビティ３６を拡大させたときの状態を表している。
尚このとき、第２分割型３４の第２摺動面５４は芯材１２の側端面５２に沿って摺動する。
尚、芯材１２の厚み詳しくは側端面５２の高さは、その際に必要な金型の相対移動ストローク以上の厚みで予め設定してある。 FIG. 3 (III) shows a state in which the first cavity 36 is enlarged in order to foam the foamed resin material.
Specifically, the first split mold 28 is moved backward by a predetermined stroke relative to the second split mold 34, and the first cavity 36 is enlarged.
At this time, the second sliding surface 54 of the second split mold 34 slides along the side end surface 52 of the core member 12.
In addition, the thickness of the core material 12, more specifically, the height of the side end face 52 is set in advance at a thickness equal to or greater than the relative movement stroke of the mold required at that time.

この実施形態では、図３（II）に示す状態から（III）に示す状態まで第１分割型２８と第２分割型３４とを型開き方向に所定ストローク相対移動させると、図４（Ｉ）及び（II）に示すように第２分割型３４の側面成形面３８における突成形部４４より、突形状部の表皮１６-２Ａがその内側の発泡樹脂材料とともに保持された状態で図４中上向きに相対移動する。
この結果、図４（II）に示すように先に形成された表皮１６-２Ａの下端が一時的に芯材１２から引き離され、ちぎられてしまう。 In this embodiment, when the first split mold 28 and the second split mold 34 are relatively moved by a predetermined stroke in the mold opening direction from the state shown in FIG. 3 (II) to the state shown in (III), FIG. 4 and in the state in which the skin 16-2A of the projecting shape portion is held together with the foamed resin material inside the projecting portion 44 on the side molding surface 38 of the second split mold 34 as shown in (II). Move relative to.
As a result, as shown in FIG. 4 (II), the lower end of the previously formed skin 16-2A is temporarily pulled away from the core member 12 and torn off.

但しこのとき、第２分割型３４の第２摺動面５４が芯材１２の側端面５２の上側に移動して第１キャビティ３６内の発泡樹脂材料に接触するため、発泡樹脂材料の基材がこの第２摺動面５４に接してそこで冷却固化し、図４（III）に示すように表皮１６-２Ａに連続した新たな表皮１６-２Ｂ（図１参照）を形成する。
即ちアンダーカット形状をなす樹脂発泡成形品１０における図中左側の突形状部の下側の、図中上下方向即ち型開き方向にストレート形状をなす表皮１６-２Ｂを形成する。 However, at this time, since the second sliding surface 54 of the second split mold 34 moves to the upper side of the side end surface 52 of the core member 12 and contacts the foamed resin material in the first cavity 36, the base material of the foamed resin material Comes into contact with the second sliding surface 54 and is cooled and solidified there to form a new skin 16-2B (see FIG. 1) continuous to the skin 16-2A as shown in FIG. 4 (III).
That is, the skin 16-2B having a straight shape is formed in the vertical direction in the drawing, that is, in the mold opening direction, below the protruding portion on the left side in the drawing in the resin foam molded product 10 having the undercut shape.

一方、図３の右側の側面成形面４０においては、図５（Ｉ），（II）に示すように上突成形部４８により、既に形成されている表皮１６-３Ａを内側の発泡樹脂材料とともに保持してこれを図中上向きに相対移動させる。
このとき、図中下側の下突形状部の表皮１６-３Ｂａ′，１６-３Ｂｂ′は側面成形面４０による保持によって図中上方に持ち上げられることはなく、下突形状部の表皮１６-３Ｂの根元部は第１分割型２８の側詳しくは芯材１２の側に残される。 On the other hand, in the side molding surface 40 on the right side of FIG. 3, as shown in FIGS. 5 (I) and (II), the skin 16-3A that has already been formed by the upper projection molding portion 48 together with the foamed resin material on the inside. Hold it and move it relative upward in the figure.
At this time, the skins 16-3Ba 'and 16-3Bb' of the lower projecting shape portion on the lower side in the figure are not lifted upward in the drawing by the holding by the side surface forming surface 40, and the skin 16-3B of the lower projecting shape portion is shown. Is left on the side of the first split mold 28, specifically on the core 12 side.

その結果、図５（II）に示すように当初水平向き，垂直向きであった表皮１６-３Ｂａ′，１６-３Ｂｂ′が、引張力を受けて図５（II）及び図１に示す形状の表皮１６-３Ｂａ，１６-３Ｂｂに変形する。
即ち水平向きであった表皮１６-３Ｂａ′が緩い傾斜角度で傾き、また直立していた表皮１６-３Ｂｂ′が立上り角度の急な傾斜形状に変形する。
そして表皮１６-３Ｂａ′及び１６-３Ｂｂ′の変形によって、上突形状部の表皮１６-３Ａの図中上向きの移動が吸収される。 As a result, as shown in FIG. 5 (II), the skins 16-3Ba ′ and 16-3Bb ′ that were initially in the horizontal and vertical directions receive the tensile force and have the shapes shown in FIG. 5 (II) and FIG. The skin is transformed into 16-3Ba and 16-3Bb.
That is, the horizontal skin 16-3Ba 'is inclined at a gentle inclination angle, and the upright skin 16-3Bb' is deformed into an inclined shape having a steep rise angle.
The upward movement of the skin 16-3A of the upper protruding portion in the figure is absorbed by the deformation of the skins 16-3Ba 'and 16-3Bb'.

このようにして第１キャビティ３６が拡大せしめられると、第２キャビティ４２の圧力の低下によって発泡樹脂材料中の発泡剤がガス化し、これにより発泡樹脂材料が発泡して図１の表皮１６にて囲まれた内側の発泡層１４を形成する   When the first cavity 36 is enlarged in this way, the foaming agent in the foamed resin material is gasified due to a decrease in the pressure of the second cavity 42, thereby foaming the foamed resin material, and in the skin 16 of FIG. 1. Forming the enclosed inner foam layer 14

その後、第１分割型２８と第２分割型３４とを図中上下方向に大きく相対移動させて型開きし、成形された樹脂発泡成形品１０を金型から脱型する。
その際、スライド型３４-２，３４-３を図中左右方向にスライド移動させることによって、樹脂発泡成形品１０を容易に金型から脱型することができる。
ここで、スライド型３４-２，３４-３を使用しているが、アンダーカットの形状や樹脂発泡成形品１０がもつ弾性力によって、スライド型３４-２，３４-３を第２分割型３４と一体とし、樹脂発泡成形品１０を弾性変形させながら脱型することも可能である。 Thereafter, the first split mold 28 and the second split mold 34 are moved relative to each other in the vertical direction in the drawing to open the mold, and the molded resin foam molded article 10 is removed from the mold.
At that time, the resin foam molded product 10 can be easily removed from the mold by sliding the slide molds 34-2 and 33-3 in the horizontal direction in the drawing.
Here, although the slide molds 34-2 and 34-3 are used, the slide molds 34-2 and 33-3 are made into the second divided mold 34 by the undercut shape and the elastic force of the resin foam molded product 10. It is also possible to remove the resin foam molded product 10 while elastically deforming it.

以上のような本実施形態の製造方法によれば、第１キャビティ３６の拡大時に表皮１６における頂面２２と側面１８，２０との交差部が、第２分割型３４とともに第１分割型２８に対して型開き方向に相対移動するため、表皮１６における頂面２２と側面１８，２０との交差部を、第２分割型３４における頂面成形面４２と側面成形面３８，４０との交差部に沿ったシャープな形状に良好に成形することができる。   According to the manufacturing method of the present embodiment as described above, when the first cavity 36 is enlarged, the intersection between the top surface 22 and the side surfaces 18 and 20 of the skin 16 becomes the first split mold 28 together with the second split mold 34. For the relative movement in the mold opening direction, the intersection between the top surface 22 and the side surfaces 18 and 20 in the skin 16 is the intersection between the top surface molding surface 42 and the side molding surfaces 38 and 40 in the second split mold 34. Can be formed into a sharp shape along the line.

またこの製造方法では、側面成形面３８に連続して第２摺動面５４を型開閉方向に延びる形態で設け、そしてその第２摺動面５４の一部を側面成形用として働かせて、この第２摺動面５４に沿って、既に形成されている表皮１６-２Ａに連続した形で新たな表皮１６-２Ｂを形成させる。
従って第１キャビティ３６の拡大時に表皮１６が破れることがあっても何等問題は生じない。 Further, in this manufacturing method, the second sliding surface 54 is provided in a form extending in the mold opening / closing direction continuously to the side molding surface 38, and a part of the second sliding surface 54 is used for side molding. A new skin 16-2B is formed along the second sliding surface 54 in a form continuous with the already formed skin 16-2A.
Therefore, no problem occurs even if the skin 16 is torn when the first cavity 36 is enlarged.

更にこの製造方法では、第２分割型３４の側面成形面４０を、型締状態で側面の頂面２２側の上部を突形状部に成形する上突成形部４８と、基端側の下部をその基端に到るまで突形状部に成形する下突成形部５０とを有するものとなし、第１キャビティ３６の拡大時に上突成形部４８にて上突形状部の表皮１６-３Ａを保持し、また下突形状部の表皮１６-３Ｂを第１分割型２８の側に残す状態で、側面成形面４０を第１分割型２８に対し型開き方向に相対移動させるようになしていることから、表皮１６における側面２０と頂面２２との交差部を、第２分割型３４の頂面成形面４２と側面成形面４０との交差部の形状に正確に追従した形状のシャープな形状に成形することができる。   Further, in this manufacturing method, the side molding surface 40 of the second split mold 34 is formed with an upper projection molding portion 48 that molds the upper portion of the side top surface 22 side into a projecting shape portion in a mold-clamped state, and a lower portion on the proximal end side. It has a lower protrusion forming portion 50 that is formed into a protruding shape portion until reaching the base end, and the upper protrusion forming portion 48 holds the skin 16-3A of the upper protruding portion when the first cavity 36 is enlarged. In addition, the side molding surface 40 is moved relative to the first split mold 28 in the mold opening direction in a state where the skin 16-3B of the lower protrusion shape portion is left on the first split mold 28 side. Therefore, the intersection of the side surface 20 and the top surface 22 of the skin 16 is sharply shaped to accurately follow the shape of the intersection of the top surface molding surface 42 and the side surface molding surface 40 of the second split mold 34. Can be molded.

而して上突形状部の表皮１６-３Ａが第２分割型３４の側面成形面４０と一体に型開き方向に相対移動したとき、下突形状部の表皮１６-３Ｂが直線形状となろうとする方向に変形を生じ、そしてその変形によって上突形状部の表皮１６-３Ａの下側部分が破れを防止する。
即ち下突形状部の表皮１６-３Ｂの変形によって上突形状部の表皮１６-３Ａの移動ストロークを吸収することができる。 Thus, when the skin 16-3A of the upper projecting shape portion moves relative to the side molding surface 40 of the second split mold 34 in the mold opening direction, the skin 16-3B of the lower projecting shape portion will become a linear shape. In this direction, the lower part of the upper skin 16-3A prevents the tearing.
That is, the movement stroke of the upper skin 16-3A can be absorbed by the deformation of the lower skin 16-3B.

このような製造方法によれば、樹脂発泡成形品１０の外観を良好となすことができる。
またこの製造方法によれば、頂面２２と側面１８及び２０との交差部の形状ダレを生じないことから、第１キャビティ３６拡大の際の第１分割型２８と第２分割型３４との相対移動のストロークを大きく取ることが可能となり、これにより第１キャビティ３６の容積を十分に拡大し得て、発泡樹脂材料を十分に発泡させることができる。
因みにこの製造方法によれば、従来発泡倍率１．８倍程度が限度であったのが、同一材料の下で２〜２．５倍まで発泡倍率を高くすることが可能である。 According to such a manufacturing method, the appearance of the resin foam molded article 10 can be improved.
Further, according to this manufacturing method, since the shape sag at the intersection of the top surface 22 and the side surfaces 18 and 20 does not occur, the first split mold 28 and the second split mold 34 when the first cavity 36 is enlarged are used. The relative movement stroke can be made large, whereby the volume of the first cavity 36 can be sufficiently expanded, and the foamed resin material can be sufficiently foamed.
Incidentally, according to this manufacturing method, the expansion ratio can be increased up to 2 to 2.5 times under the same material, although the conventional expansion ratio was about 1.8.

これにより、厚みが厚く且つ高発泡倍率の樹脂発泡成形品１０を、形状ダレを心配することなく製造することが可能となり、樹脂発泡成形品１０を従来に増して軽量化することができ、また柔らかな触感を従来に増して高めることが可能となる。   Thereby, it becomes possible to manufacture the resin foam molded article 10 having a large thickness and a high foaming ratio without worrying about the shape sag, and the resin foam molded article 10 can be reduced in weight compared to the conventional one. It becomes possible to increase the soft touch more than before.

更にこの製造方法では第２分割型３４の、型開き方向に延びて第１分割型２８の側に対して摺動する第２摺動面５４が、第１分割型２８にセットし保持させてある芯材１２の側端面５２を第１分割型２８の側の第１摺動面として、これに対し第１分割型２８に対し金属接触させることなく摺動するようになしてあるため、摺動面が金属接触し摺動することによって摺動面が擦られ摩耗して隙間を大きくし、その隙間から発泡樹脂材料の液が外部に漏出してしまうのを良好に防止することができる。
そしてこれにより、液の漏出によりバリが発生し、またそのバリ除去のための仕上げ工程を必要とするといった問題を解決することができる。 Further, in this manufacturing method, the second sliding surface 54 of the second split mold 34 extending in the mold opening direction and sliding with respect to the first split mold 28 is set and held on the first split mold 28. Since the side end surface 52 of a certain core material 12 is used as the first sliding surface on the first split mold 28 side, it slides without being brought into metal contact with the first split mold 28. When the moving surface comes into contact with the metal and slides, the sliding surface is rubbed and worn to increase the gap, and it is possible to satisfactorily prevent the liquid of the foamed resin material from leaking out from the gap.
Thus, it is possible to solve the problem that burrs are generated due to the leakage of the liquid and that a finishing process for removing the burrs is required.

尚、上例では第２分割型３４の第２摺動面５４を芯材１２の側端面５２に対してだけ摺動させるようにしているが、図６に示しているように、第２摺動面５４を第１分割型２８の金属の第１摺動面５６に対して摺動させるようになすことも可能である。   In the above example, the second sliding surface 54 of the second split mold 34 is slid only with respect to the side end surface 52 of the core member 12, but as shown in FIG. It is also possible to make the moving surface 54 slide with respect to the metal first sliding surface 56 of the first split mold 28.

更に図７に示しているように芯材１２に縦の壁５８を設けて、その縦の壁５８の型開閉方向に延びる外面６０を第１摺動面として、これに対し第２分割型３４の第２摺動面５４を摺動させるようになすことも可能である。   Further, as shown in FIG. 7, a vertical wall 58 is provided on the core member 12, and an outer surface 60 extending in the mold opening / closing direction of the vertical wall 58 is defined as a first sliding surface. It is also possible to make the second sliding surface 54 slide.

これら図６，図７に示す実施形態では第１分割型２８と第２分割型３４との第１キャビティ３６拡大時の相対移動のストロークを、上例に比べてより大きく確保することが可能となる。   In the embodiment shown in FIGS. 6 and 7, it is possible to secure a larger stroke of the relative movement when the first cavity 28 and the second cavity 34 are enlarged in the first cavity 36 than in the above example. Become.

以上本発明の実施形態を詳述したがこれはあくまで一例示であり、本発明は他の様々な樹脂発泡成形品の成形に適用することも可能であるし、また芯材を有しない樹脂発泡成形品の製造に適用することも可能である等、本発明はその趣旨を逸脱しない範囲において種々変更を加えた態様で実施することが可能である。   Although the embodiment of the present invention has been described in detail above, this is merely an example, and the present invention can be applied to molding various other resin foam molded products, and the resin foam does not have a core material. The present invention can be implemented in a mode in which various changes are made without departing from the gist of the present invention, such as being applicable to the manufacture of molded articles.

本発明の一実施形態の樹脂発泡成形品を示した断面図である。It is sectional drawing which showed the resin foam molded product of one Embodiment of this invention. 図１の樹脂発泡成形品の芯材の成形方法の説明図である。It is explanatory drawing of the shaping | molding method of the core material of the resin foam molded product of FIG. 図１の樹脂発泡成形品の発泡層と表皮の成形方法の要部工程の説明図である。It is explanatory drawing of the principal part process of the molding method of the foaming layer and skin of the resin foam molded product of FIG. 図３の工程図の要部を更に拡大して示す図である。It is a figure which expands and shows the principal part of the process drawing of FIG. 図４とは異なる部分の要部を更に拡大して示す図である。It is a figure which expands and shows the principal part of a different part from FIG. 本発明の他の実施形態の要部工程の図である。It is a figure of the principal part process of other embodiment of this invention. 本発明の更に他の実施形態の要部工程の図である。It is a figure of the principal part process of further another embodiment of this invention. 従来公知の樹脂発泡成形品の製造方法の要部工程の説明図である。It is explanatory drawing of the principal part process of the manufacturing method of a conventionally well-known resin foam molded product. 図８に続く製造方法の要部工程の説明図である。It is explanatory drawing of the principal part process of the manufacturing method following FIG. 本発明の背景説明のために示した比較例図である。It is a comparative example figure shown for the background description of this invention.

１０ 樹脂発泡成形品
１２ 芯材
１４ 発泡層
１６ 表皮
１８，２０ 側面
２２ 頂面
２８ 第１分割型
３０ 第３分割型
３２ 第２キャビティ
３４ 第２分割型
３６ 第１キャビティ
３８，４０ 側面成形面
４２ 頂面成形面
４４ 突成形部
４８ 上突成形部
５０ 下突成形部
５４ 第２摺動面
５８ 縦の壁 DESCRIPTION OF SYMBOLS 10 Resin foam molding 12 Core material 14 Foam layer 16 Skin 18,20 Side surface 22 Top surface 28 1st division type 30 3rd division type 32 2nd cavity 34 2nd division type 36 1st cavity 38,40 Side surface 42 Top surface molding surface 44 Projection molding part 48 Upper projection molding part 50 Lower projection molding part 54 Second sliding surface 58 Vertical wall

Claims (5)

型開き方向に第１分割型と第２分割型とに分割された金型の第１キャビティに、熱可塑性樹脂の基材に発泡剤を含有させた発泡樹脂材料を射出して充填し、しかる後前記一方の第１分割型を前記第２分割型に対し所定ストローク前記型開き方向に相対的に後退移動させて前記第１キャビティを拡大し、前記発泡樹脂材料を発泡させることによって、前記型開閉方向と直角方向の末端部の一対の側面と、該一対の側面の同じ側の各端を繋ぐ頂面とを有する、金型内面で固化した表皮の内側に発泡層を有する表皮付きの樹脂発泡成形品を製造する樹脂発泡成形品の製造方法であって
前記側面を成形する一対の側面成形面と、前記頂面を成形する頂面成形面とを備えた前記第２分割型の少なくとも一方の側面成形面を、該側面の、型締状態で該側面成形面に沿って形成された前記表皮の基端よりも前記頂面側の上側部分の少なくとも一部を前記型開閉方向と直角方向の外方の突形状部に成形する突成形部を有するものとなして、前記第１キャビティの拡大時に、該突成形部にて前記表皮に形成された突形状部を保持して前記第１分割型に対して前記型開き方向に相対移動させるようになすとともに、
前記第２分割型の、前記第１分割型の側の第１摺動面に対して摺動する、前記型開閉方向に延びた第２摺動面を前記一方の側面成形面に連続して形成し、前記第１キャビティの拡大時に該第２摺動面を前記側面の成形用として用い、該第２摺動面に沿って、前記型締状態で形成された表皮に連続した新たな表皮を形成するようになしたことを特徴とする樹脂発泡成形品の製造方法。 The first cavity of the mold divided into the first divided mold and the second divided mold in the mold opening direction is injected and filled with a foamed resin material containing a foaming agent in a thermoplastic resin base material. Then, the first divided mold is moved backward relative to the second divided mold by a predetermined stroke in the mold opening direction to enlarge the first cavity, and the foamed resin material is foamed. A resin with a skin having a foam layer on the inner side of the skin solidified on the inner surface of the mold, having a pair of side surfaces at the ends perpendicular to the opening and closing direction and a top surface connecting the ends of the pair of side surfaces on the same side A method for producing a resin foam molded article for producing a foam molded article, comprising at least one of the second split molds including a pair of side molding surfaces for molding the side surfaces and a top surface molding surface for molding the top surfaces. The side molding surface of the side surface in the mold-clamped state. Having a projecting part that molds at least a part of the upper part on the top surface side from the base end of the skin formed along the molding surface into an outward projecting part perpendicular to the mold opening and closing direction Thus, when the first cavity is enlarged, the projecting portion formed on the skin is held by the projecting portion and is moved relative to the first split mold in the mold opening direction. With
A second sliding surface extending in the mold opening / closing direction that slides on the first sliding surface of the second divided mold on the first divided mold side is continuously connected to the one side molding surface. Forming a new skin that is continuous with the skin formed in the mold-clamped state along the second sliding surface when the second sliding surface is used for forming the side surface when the first cavity is enlarged A method for producing a resin foam molded article, characterized in that the method is formed. 請求項１において、前記突形状部が、前記型締状態で形成された前記側面の表皮の前記基端から前記頂面に向って漸次前記軸直角方向の外方への突出量を拡大する形態のアンダーカット形状であることを特徴とする樹脂発泡成形品の製造方法。   2. The form according to claim 1, wherein the projecting shape portion gradually increases the outward projecting amount in the direction perpendicular to the axis from the base end of the side skin formed in the mold-clamped state toward the top surface. A method for producing a resin foam-molded article characterized by having an undercut shape. 請求項１，２の何れかにおいて、前記樹脂発泡成形品が熱可塑性樹脂から成る硬質の芯材付きのものであって、
前記型締状態で予め前記第１分割型にセットし保持させてある前記芯材の、前記型開閉方向に延びる縦の面を前記第１分割型の側の第１摺動面として、前記第２摺動面を該第１分割型に対し金属接触させることなく摺動させるようになしてあることを特徴とする樹脂発泡成形品の製造方法。 In any one of Claims 1 and 2, the resin foam molded article has a hard core material made of a thermoplastic resin,
A vertical surface extending in the mold opening / closing direction of the core material set and held in the first divided mold in advance in the mold clamping state is defined as the first sliding surface on the first divided mold side. 2. A method for producing a resin foam molded article, wherein two sliding surfaces are slid without being brought into metal contact with the first split mold. 型開き方向に第１分割型と第２分割型とに分割された金型の第１キャビティに、熱可塑性樹脂の基材に発泡剤を含有させた発泡樹脂材料を射出して充填し、しかる後前記一方の第１分割型を前記第２分割型に対し所定ストローク前記型開き方向に相対的に後退移動させて前記第１キャビティを拡大し、前記発泡樹脂材料を発泡させることによって、型開閉方向と直角方向の末端部の一対の側面と、該一対の側面の同じ側の各端を繋ぐ頂面とを有する、金型内面で固化した表皮の内側に発泡層を有する表皮付きの樹脂発泡成形品を製造する樹脂発泡成形品の製造方法であって
前記側面を形成する一対の側面成形面と、前記頂面を成形する頂面成形面とを備えた前記第２分割型の少なくとも一方の側面成形面を、型締状態で前記側面の前記頂面側の上部を前記型開閉方向と直角方向の外方の突形状部に成形する上突成形部と、基端側の下部を該基端に到るまで該外方の突形状部に成形する下突成形部とを有するものとなして
前記第１キャビティの拡大時に、前記上突成形部にて前記表皮に形成された上突形状部を保持し且つ該表皮に形成された下突形状部を該下突成形部から離し変形させることで前記型開き方向の相対移動を吸収することにより根元部を前記第１分割型側に残す状態で、前記側面成形面を前記第１分割型に対して前記型開き方向に相対移動させるようになしたことを特徴とする樹脂発泡成形品の製造方法。 The first cavity of the mold divided into the first divided mold and the second divided mold in the mold opening direction is injected and filled with a foamed resin material containing a foaming agent in a thermoplastic resin base material. Thereafter, the one first divided mold is moved backward relative to the second divided mold by a predetermined stroke in the mold opening direction to enlarge the first cavity and foam the foamed resin material, thereby opening and closing the mold. A resin foam with a skin having a foam layer on the inside of the skin solidified on the inner surface of the mold, having a pair of side surfaces of the end portion perpendicular to the direction and a top surface connecting the ends of the pair of side surfaces on the same side A method for producing a resin foam molded article for producing a molded article, comprising: a pair of side molding surfaces that form the side surfaces; and a top surface molding surface that molds the top surface. The side molding surface is the top surface side of the side surface in a clamped state An upper projecting part for forming the upper part of the upper part into an outward projecting part perpendicular to the mold opening and closing direction, and a lower part for molding the lower part on the base end side into the outer projecting part until reaching the base end. when expanded without as having a突成form part of the first cavity, said on the lower protrusion-shaped portion formed on the holding and epidermis the protrusion-shaped part on which is formed on the skin by突成form part In the state where the root portion is left on the first split mold side by absorbing the relative movement in the mold opening direction by separating and deforming from the lower projection forming part , the side molding surface with respect to the first split mold A method for producing a resin foam molded article, wherein the mold is relatively moved in the mold opening direction. 請求項４において、前記上突形状部が、前記側面の前記頂面側の端に向って漸次前記軸直角方向の外方への突出量を拡大する形態のアンダーカット形状であることを特徴とする樹脂発泡成形品の製造方法。   5. The upper projecting shape portion according to claim 4, wherein the upper projecting shape portion has an undercut shape in which the outward projecting amount in the direction perpendicular to the axis is gradually increased toward the top surface side end of the side surface. A method for producing a resin foam molded product.
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