JP5782876B2 - Mold structure for molding foamed resin molded products - Google Patents

Mold structure for molding foamed resin molded products Download PDF

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JP5782876B2
JP5782876B2 JP2011153028A JP2011153028A JP5782876B2 JP 5782876 B2 JP5782876 B2 JP 5782876B2 JP 2011153028 A JP2011153028 A JP 2011153028A JP 2011153028 A JP2011153028 A JP 2011153028A JP 5782876 B2 JP5782876 B2 JP 5782876B2
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mold
main body
molding
rib
foamed resin
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JP2013018187A (en
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嗣久 宮本
嗣久 宮本
金子　満晴
満晴 金子
小川　淳一
淳一 小川
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Mazda Motor Corp
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Mazda Motor Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/58—Moulds
    • B29C44/582—Moulds for making undercut articles

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  • Moulds For Moulding Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Description

この発明は、発泡樹脂成形品を成形するための金型構造に関し、特に、溶融状態の発泡性樹脂をキャビティに充填した後にキャビティの容積を拡大することにより表面層であるスキン層と該スキン層の内側に設けられる発泡層とを有する発泡樹脂成形品を成形し、その後にスキン層の一部を剥離して発泡層を露出させるようにした発泡樹脂成形品成形用の金型構造に関する。   The present invention relates to a mold structure for molding a foamed resin molded article, and in particular, a skin layer which is a surface layer by filling the cavity with a foamed resin in a molten state and the skin layer The present invention relates to a mold structure for molding a foamed resin molded product in which a foamed resin molded product having a foamed layer provided inside is molded, and then a part of the skin layer is peeled to expose the foamed layer.

従来より、例えば自動車用部品などの種々の工業用部品の分野において、軽量性、断熱性及び防音性等の優れた特性を有する発泡樹脂成形品が幅広く採用されている。かかる発泡樹脂成形品は、使用される目的及び用途などに応じて、好適な使用材料を選定し、また、成形品内部の気泡の形態や発泡倍率などの諸条件を好適に設定して成形されている。   Conventionally, in the field of various industrial parts such as automobile parts, foamed resin molded articles having excellent characteristics such as lightness, heat insulation and soundproofing have been widely adopted. Such a foamed resin molded product is molded by selecting a suitable material for use according to the purpose and application to be used, and by suitably setting various conditions such as the form of bubbles inside the molded product and the expansion ratio. ing.

このような発泡樹脂成形品の成形方法として、樹脂に発泡剤を含有させた発泡性樹脂を固定型と可動型とでなる金型内に充填した後に可動型を型開き方向に移動させてキャビティの容積を拡大することにより発泡性樹脂の発泡を促進させるようにした成形方法（所謂コアバック法）が知られている。   As a method of molding such a foamed resin molded product, after filling a foamable resin containing a foaming agent into the resin into a mold composed of a fixed mold and a movable mold, the movable mold is moved in the mold opening direction to form a cavity. A molding method (so-called core back method) is known in which foaming of a foamable resin is promoted by enlarging the volume of the foamed resin.

かかる成形方法によって成形された発泡樹脂成形品は、金型内に充填した発泡性樹脂が金型によって表面から冷却されることにより、発泡樹脂成形品の表面に表面層である非発泡のスキン層が形成されるとともに該スキン層の内側に発泡性樹脂の発泡が促進された発泡層が形成されることとなる。   The foamed resin molded product molded by such a molding method is a non-foamed skin layer which is a surface layer on the surface of the foamed resin molded product by cooling the foamable resin filled in the mold from the surface by the mold. And a foamed layer in which foaming of the foamable resin is promoted is formed inside the skin layer.

このようにして成形される発泡樹脂成形品を断熱材や防音材として使用する場合、発泡樹脂成形品の表面に形成されるスキン層によって断熱効果や防音効果が低下することとなるので、断熱効果や防音効果を効果的に得るためには表面に形成されるスキン層を取り除くことが望まれる。   When the foamed resin molded product molded in this way is used as a heat insulating material or a soundproofing material, the heat insulating effect and the soundproofing effect are lowered by the skin layer formed on the surface of the foamed resin molded product. In order to effectively obtain a soundproofing effect, it is desirable to remove the skin layer formed on the surface.

断熱効果や防音効果が低下することを抑制するためにスキン層を取り除くものではないが、例えば特許文献１には、発泡体の表面に接着性シートを積層した後に、接着性シートと反対側の発泡体面に形成されたスキン層全体をスライス刃によりスライス除去するようにしたものが開示されている。   Although it does not remove the skin layer in order to prevent the heat insulation effect and the soundproofing effect from decreasing, for example, in Patent Document 1, after laminating the adhesive sheet on the surface of the foam, it is on the side opposite to the adhesive sheet. A structure in which the entire skin layer formed on the foam surface is removed by slicing with a slicing blade is disclosed.

特開平６−３４４４５９号公報JP-A-6-344459

前記特許文献１に記載されるように、表面に形成されるスキン層全体をスライス除去することにより、発泡層を露出させて発泡樹脂成形品において断熱効果や防音効果を効果的に得ることができるものの、スキン層全体を除去すると発泡樹脂成形品の強度が大きく低下することが問題となる。   As described in Patent Document 1, by removing the entire skin layer formed on the surface by slicing, the foamed layer can be exposed to effectively obtain a heat insulating effect and a soundproofing effect in the foamed resin molded product. However, if the entire skin layer is removed, the strength of the foamed resin molded product is greatly reduced.

これに対し、発泡樹脂成形品を成形した後に表面に形成されるスキン層の一部を剥離して発泡層を露出させることにより、発泡樹脂成形品の強度が低下することを抑制しつつ断熱効果や防音効果を効果的に得ることができるものと考えられる。   On the other hand, by exfoliating a part of the skin layer formed on the surface after molding the foamed resin molded product and exposing the foamed layer, the heat insulating effect is suppressed while suppressing the strength of the foamed resin molded product from decreasing. It is considered that a soundproofing effect can be obtained effectively.

このように表面に形成されるスキン層の一部を剥離して発泡層を露出させる方法として、発泡樹脂成形品の本体部とリブ部とを一体的に形成した後に、このリブ部を折除することによってリブ部に連続する本体部のスキン層を剥離して発泡層を露出させることが考えられる。   As a method of peeling off a part of the skin layer formed on the surface in this way and exposing the foam layer, the main body part and the rib part of the foamed resin molded product are integrally formed, and then the rib part is broken. By doing so, it is conceivable that the skin layer of the main body portion continuous to the rib portion is peeled to expose the foam layer.

図１０は、発泡樹脂成形品においてスキン層の一部を剥離して発泡層を露出させる方法を説明するための説明図であり、図１０（ａ）は、発泡樹脂成形品の本体部とリブ部とを一体的に形成した状態を示し、図１０（ｂ）は、リブ部を折除して発泡樹脂成形品の本体部の発泡層を露出させた状態を示している。   FIG. 10 is an explanatory view for explaining a method of peeling a part of the skin layer in the foamed resin molded product to expose the foamed layer, and FIG. 10 (a) is a diagram illustrating a main body and ribs of the foamed resin molded product. FIG. 10B shows a state in which the rib portion is broken to expose the foam layer of the main body portion of the foamed resin molded product.

図１０（ａ）に示すように、表面に形成された非発泡のスキン層１０２と該スキン層１０２の内側に設けられた発泡層１０３とを有する本体部１０１と、該本体部１０１の表面のスキン層に立設された非発泡のリブ部１０５とが一体的に形成された発泡樹脂成形品１００を成形した後に、前記リブ部１０５に外部から所定の倒し込み力Ｆ１を作用させることにより、図１０（ｂ）に示すように、該リブ部１０５とともに該リブ部１０５に連続する本体部１０１のスキン層１０２を剥離して、スキン層１０２に開口部１０２ａを形成して発泡層１０３を露出させることが考えられる。   As shown in FIG. 10A, a main body portion 101 having a non-foamed skin layer 102 formed on the surface and a foam layer 103 provided inside the skin layer 102, and a surface of the main body portion 101. After molding the foamed resin molded product 100 integrally formed with the non-foamed rib portion 105 erected on the skin layer, a predetermined folding force F1 is applied to the rib portion 105 from the outside, As shown in FIG. 10B, the skin layer 102 of the main body portion 101 continuous with the rib portion 105 is peeled off together with the rib portion 105, and an opening 102a is formed in the skin layer 102 to expose the foam layer 103. It is possible to make it.

図１１は、発泡樹脂成形品の本体部とリブ部とを一体的に形成する方法を説明するための説明図であり、図１１（ａ）は、固定型と可動型とでなる金型においてキャビティに発泡性樹脂を充填した状態を示し、図１１（ｂ）は、キャビティに発泡性樹脂を充填した後に可動型を型開き方向に移動した状態を示している。   FIG. 11 is an explanatory diagram for explaining a method of integrally forming the main body portion and the rib portion of the foamed resin molded product, and FIG. 11 (a) is a diagram illustrating a mold including a fixed mold and a movable mold. FIG. 11 (b) shows a state where the movable mold is moved in the mold opening direction after filling the cavity with the foamable resin.

図１０（ａ）に示す発泡樹脂成形品１００は、図１１（ａ）に示すように、固定型１１１と可動型１２１とによってキャビティ１１０ａが形成されるとともに固定型１１１のキャビティ成形面１１１ａに凹状に形成されたリブ部成形部１１１ｂが設けられた金型１１０を用い、該金型１１０のキャビティ１１０ａに注入経路１１６を通じて溶融状態の発泡性樹脂１３１を充填した後に、図１１（ｂ）に示すように、キャビティ１１０ａの容積が拡大するように可動型１２１を型開き方向（矢印Ｘ１で示す方向）に移動させて発泡性樹脂１３１の発泡を促進させることにより成形することができる。   A foamed resin molded article 100 shown in FIG. 10A has a cavity 110a formed by the fixed mold 111 and the movable mold 121 and a concave shape on the cavity molding surface 111a of the fixed mold 111, as shown in FIG. 11B is used after filling the cavity 110a of the mold 110 with the foamable resin 131 in a molten state through the injection path 116, using the mold 110 provided with the rib-shaped molding part 111b formed in FIG. As described above, the movable mold 121 can be moved in the mold opening direction (the direction indicated by the arrow X1) so as to increase the volume of the cavity 110a to promote foaming of the foamable resin 131.

図１２は、発泡樹脂成形品のリブ部を折除した状態を説明するための説明図である。図１１に示すようにして成形された発泡樹脂成形品１００においてリブ部１０５を折除するために、図１２（ａ）に示すように、リブ部１０５に該リブ部１０５の立設方向と略直交する方向に外部から所定の倒し込み力Ｆ１を作用させると、図１２（ｂ）に示すように、リブ部１０５が倒し込み力Ｆ１の作用方向に傾いた後に、図１２（ｃ）に示すように、リブ部１０５が折除され、本体部１０１のスキン層１０２の一部を剥離して発泡層１０３を露出させることができる。   FIG. 12 is an explanatory diagram for explaining a state in which the rib portion of the foamed resin molded product is broken. In order to break the rib portion 105 in the foamed resin molded product 100 molded as shown in FIG. 11, the rib portion 105 is substantially in the standing direction of the rib portion 105 as shown in FIG. When a predetermined falling force F1 is applied from the outside in the orthogonal direction, as shown in FIG. 12 (b), the rib portion 105 is inclined in the direction in which the falling force F1 is applied, and then shown in FIG. 12 (c). As described above, the rib portion 105 is broken, and a part of the skin layer 102 of the main body portion 101 can be peeled to expose the foam layer 103.

しかしながら、このようにしてスキン層１０２の一部を剥離して発泡層１０３を露出させる場合、図１２（ｂ）及び図１２（ｃ）に示すように、リブ部１０５の倒し込み力作用面部１０７と反対側の面部１０８によって発泡層１０３の一部が窪むように圧潰され、発泡樹脂成形品１００の強度が低下する畏れがある。   However, when part of the skin layer 102 is peeled and the foamed layer 103 is exposed in this way, as shown in FIGS. 12B and 12C, the inclining force acting surface portion 107 of the rib portion 105 is used. A part of the foam layer 103 is crushed by the surface portion 108 on the opposite side, and the strength of the foamed resin molded product 100 may be reduced.

また、図１３は、発泡樹脂成形品のリブ部を折除した別の状態を説明するための説明図である。図１２（ａ）に示すように、発泡樹脂成形品１００のリブ部１０５に外部から所定の倒し込み力Ｆ１を作用させると、図１３に示すように、リブ部１０５の倒し込み力作用面部１０７と反対側の面部１０８に倒し込み力Ｆ１の作用方向に連続する本体部１０１のスキン層１０２がリブ部１０５とともに大きく剥離して発泡樹脂成形品１００の強度が低下する畏れがある。   Moreover, FIG. 13 is explanatory drawing for demonstrating another state which removed the rib part of the foamed resin molded product. As shown in FIG. 12A, when a predetermined falling force F1 is applied to the rib portion 105 of the foamed resin molded product 100 from the outside, the falling force acting surface portion 107 of the rib portion 105 is shown in FIG. There is a possibility that the skin layer 102 of the main body 101 that is continuous in the direction in which the falling force F1 is applied to the surface 108 on the opposite side is largely peeled together with the ribs 105 and the strength of the foamed resin molded product 100 is lowered.

そこで、本発明は、発泡樹脂成形品の強度低下を抑制しつつスキン層の一部を剥離して発泡層を露出させた発泡樹脂成形品を成形することができる発泡樹脂成形品成形用の金型構造を提供することを目的とする。   Therefore, the present invention provides a gold for molding a foamed resin molded product that can mold a foamed resin molded product in which a foamed layer is exposed by peeling a part of the skin layer while suppressing a decrease in strength of the foamed resin molded product. The object is to provide a mold structure.

このため、本願の請求項１に係る発明は、発泡樹脂成形品を成形するためのキャビティを有するとともに該キャビティの容積が拡大可能に構成された金型を備え、溶融状態の発泡性樹脂を該キャビティに充填した後に該キャビティの容積を拡大することにより表面層であるスキン層と該スキン層の内側に設けられる発泡層とを有する発泡樹脂成形品を成形し、その後に前記スキン層の一部を剥離して前記発泡層を露出させるようにした発泡樹脂成形品成形用の金型構造であって、前記金型は、発泡樹脂成形品の本体部を成形するための本体部成形部と、前記本体部の表面に立設されるリブ部を成形するためのリブ部成形部とを有し、該リブ部成形部は、前記リブ部の立設方向に対してアンダーカット状に形成される前記リブ部を成形するように形成され、前記金型は、前記本体部と前記リブ部とを有する発泡樹脂成形品を成形した後に該発泡樹脂成形品を取り出す際に、前記リブ部成形部に前記リブ部を保持した状態で前記リブ部の立設方向に前記リブ部と前記本体部とを離間させることにより、前記リブ部に連続する前記本体部のスキン層を剥離して前記本体部の発泡層を露出させるように構成され、前記金型は、前記キャビティを形成する本体部と該本体部に設けられた開口部内に移動可能に挿入されたコア部とを有し、前記リブ部成形部が、前記コア部に設けられた前記リブ部を成形するための溝部と前記本体部の開口部とによって形成され、前記発泡樹脂成形品のリブ部と本体部とを離間させた後に前記コア部を移動させることにより前記本体部の開口部によって成形された前記リブ部の成形面を露出させるように構成されている、ことを特徴とする。 For this reason, the invention according to claim 1 of the present application includes a mold having a cavity for molding a foamed resin molded article and capable of expanding the volume of the cavity, and the foamable resin in a molten state is provided with the mold. After filling the cavity, the volume of the cavity is expanded to form a foamed resin molded article having a skin layer as a surface layer and a foam layer provided inside the skin layer, and then a part of the skin layer Is a mold structure for molding a foamed resin molded product so as to expose the foamed layer, wherein the mold is a main body molding part for molding the main body part of the foamed resin molded product, A rib part molding part for molding a rib part standing on the surface of the main body part, and the rib part molding part is formed in an undercut shape with respect to the standing direction of the rib part. To mold the rib part The mold is formed in a state in which the rib portion is held by the rib portion molding portion when the foamed resin molding product is taken out after the foam resin molding product having the main body portion and the rib portion is molded. The rib portion and the main body portion are separated from each other in the standing direction of the rib portion, so that the skin layer of the main body portion continuous with the rib portion is peeled to expose the foam layer of the main body portion. The mold includes a main body part that forms the cavity and a core part that is movably inserted into an opening provided in the main body part, and the rib part molding part is provided in the core part. It is formed by a groove for molding the provided rib part and an opening of the main body part, and the core part is moved by moving the core part after separating the rib part and the main body part of the foamed resin molded product. Molded by the opening of the main body And it is configured to expose the molding surface of the rib portion, characterized in that.

また、本願の請求項２に係る発明は、請求項１に係る発明において、前記金型は、前記本体部成形部から前記発泡樹脂成形品の本体部を突出させる突出部材を備え、前記発泡樹脂成形品を取り出す際に、前記リブ部成形部に前記リブ部を保持した状態で前記突出部材によって前記本体部成形部から前記本体部を突出させて前記リブ部と前記本体部とを離間させるように構成されている、ことを特徴とする。   The invention according to claim 2 of the present application is the invention according to claim 1, wherein the mold includes a projecting member for projecting a main body portion of the foamed resin molded product from the main body portion molding portion, and the foam resin. When the molded product is taken out, the main body part is projected from the main body part molding part by the projecting member in a state where the rib part is held in the rib part molding part so that the rib part and the main body part are separated from each other. It is comprised in that.

本願の請求項１に係る発明によれば、金型は、発泡樹脂成形品の本体部を成形するための本体部成形部と、本体部の表面に立設されるリブ部を成形するためのリブ部成形部とを有し、リブ部成形部は、リブ部の立設方向に対してアンダーカット状に形成されるリブ部を成形するように形成され、金型は、本体部とリブ部とを有する発泡樹脂成形品を成形した後に取り出す際に、リブ部成形部にリブ部を保持した状態でリブ部の立設方向にリブ部と本体部とを離間させることにより、リブ部に連続する本体部のスキン層を剥離して本体部の発泡層を露出させるように構成され、金型は、キャビティを形成する本体部と該本体部に設けられた開口部内に挿入されたコア部とを有し、リブ部成形部が、コア部に設けられた溝部と本体部の開口部とによって形成され、発泡樹脂成形品のリブ部と本体部とを離間させた後にコア部を移動させることによりリブ部の成形面を露出させるように構成されている。これにより、比較的簡単な構成を有する金型を用い、発泡樹脂成形品のスキン層の一部を剥離して発泡層を露出させることができ、発泡樹脂成形品の強度低下を抑制しつつスキン層の一部を剥離して発泡層を露出させた発泡樹脂成形品を成形することができる。 According to the invention according to claim 1 of the present application, the mold is for molding a main body portion molding portion for molding the main body portion of the foamed resin molded product and a rib portion standing on the surface of the main body portion. A rib part molding part, and the rib part molding part is formed so as to mold a rib part formed in an undercut shape with respect to the standing direction of the rib part. When molding a foamed resin molded product having a rib portion, the rib portion and the main body portion are separated from each other in the standing direction of the rib portion in a state where the rib portion is held in the rib portion molding portion. The skin layer of the main body portion is peeled off to expose the foam layer of the main body portion, and the mold includes a main body portion forming a cavity and a core portion inserted into an opening provided in the main body portion. And the rib part molding part is formed in the groove part provided in the core part and the opening part of the main body part. It formed me, and is configured to expose the molding surface of the rib portion by moving the core portion after being separated from the rib portion and the body portion of the foamed resin molded article. Accordingly, a mold having a relatively simple structure can be used to peel a part of the skin layer of the foamed resin molded product to expose the foamed layer, and the skin while suppressing a decrease in strength of the foamed resin molded product. A foamed resin molded article in which a part of the layer is peeled to expose the foamed layer can be molded.

また、本願の請求項２に係る発明によれば、金型は、本体部成形部から発泡樹脂成形品の本体部を突出させる突出部材を備え、発泡樹脂成形品を取り出す際に、リブ部成形部にリブ部を保持した状態で突出部材によって本体部成形部から本体部を突出させてリブ部と本体部とを離間させるように構成されている。これにより、発泡樹脂成形品を取り出す際にリブ部と本体部とを離間させることができるので、発泡樹脂成形品を成形するための成形サイクルタイムを延長化させることなく、前記効果を得ることができる。   According to the invention of claim 2 of the present application, the mold is provided with a projecting member for projecting the main body part of the foamed resin molded product from the main body part molding part, and when the foamed resin molded product is taken out, the rib part molding is performed. In a state where the rib portion is held in the portion, the main body portion is protruded from the main body portion molding portion by the protruding member, and the rib portion and the main body portion are separated from each other. Thereby, when taking out the foamed resin molded product, the rib portion and the main body portion can be separated from each other, so that the above-described effect can be obtained without extending the molding cycle time for molding the foamed resin molded product. it can.

本発明の第１の実施形態に係る金型を備えた成形装置を示す概略説明図である。It is a schematic explanatory drawing which shows the shaping | molding apparatus provided with the metal mold | die which concerns on the 1st Embodiment of this invention. 図１に示す金型において発泡樹脂成形品の本体部とリブ部とを形成する方法を説明するための断面説明図である。It is a cross-sectional explanatory view for explaining a method of forming a main body portion and a rib portion of a foamed resin molded product in the mold shown in FIG. 図１に示す金型において発泡樹脂成形品の本体部とリブ部とを離間させる方法を説明するための断面説明図である。FIG. 2 is an explanatory cross-sectional view for explaining a method of separating a main body portion and a rib portion of a foamed resin molded product in the mold shown in FIG. 1. 本発明の第２の実施形態に係る金型を示す断面説明図である。It is sectional explanatory drawing which shows the metal mold | die which concerns on the 2nd Embodiment of this invention. 図４に示す金型において発泡樹脂成形品の本体部とリブ部とを形成する方法を説明するための断面説明図である。FIG. 5 is an explanatory cross-sectional view for explaining a method of forming the main body portion and the rib portion of the foamed resin molded product in the mold shown in FIG. 4. 図４に示す金型において発泡樹脂成形品の本体部とリブ部とを離間させる方法を説明するための断面説明図である。FIG. 5 is an explanatory cross-sectional view for explaining a method of separating the main body portion and the rib portion of the foamed resin molded product in the mold shown in FIG. 4. 本発明の第３の実施形態に係る金型を示す断面説明図である。It is a section explanatory view showing a metallic mold concerning a 3rd embodiment of the present invention. 図７に示す金型において発泡樹脂成形品の本体部とリブ部とを形成する方法を説明するための断面説明図である。FIG. 8 is an explanatory cross-sectional view for explaining a method of forming the main body portion and the rib portion of the foamed resin molded product in the mold shown in FIG. 7. 図７に示す金型において発泡樹脂成形品の本体部とリブ部とを離間させる方法を説明するための断面説明図である。FIG. 8 is an explanatory cross-sectional view for explaining a method of separating the main body portion and the rib portion of the foamed resin molded product in the mold shown in FIG. 7. 発泡樹脂成形品においてスキン層の一部を剥離して発泡層を露出させる方法を説明するための説明図である。It is explanatory drawing for demonstrating the method to peel a part of skin layer and to expose a foam layer in a foamed resin molded product. 発泡樹脂成形品の本体部とリブ部とを一体的に形成する方法を説明するための説明図である。It is explanatory drawing for demonstrating the method to form the main-body part and rib part of a foamed resin molded product integrally. 発泡樹脂成形品のリブ部を折除した状態を説明するための説明図である。It is explanatory drawing for demonstrating the state which fractured the rib part of the foamed resin molded product. 発泡樹脂成形品のリブ部を折除した別の状態を説明するための説明図である。It is explanatory drawing for demonstrating another state which broke the rib part of the foamed resin molded product.

以下、本発明の実施形態について添付図面を参照しながら説明する。
図１は、本発明の第１の実施形態に係る金型を備えた成形装置を示す概略説明図である。図１に示すように、本発明の第１の実施形態に係る金型を備えた成形装置Ｍは、発泡樹脂成形品を成形するためのものであり、開閉可能な金型１０と、金型１０内に溶融状態の発泡性樹脂を注入する射出装置３０とを備えている。 Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.
FIG. 1 is a schematic explanatory view showing a molding apparatus provided with a mold according to the first embodiment of the present invention. As shown in FIG. 1, a molding apparatus M including a mold according to the first embodiment of the present invention is for molding a foamed resin molded product. 10 includes an injection device 30 for injecting a foamed resin in a molten state.

金型１０は、固定型１１と可動型２１とによって構成され、固定型１１と可動型２１とを型閉めすることにより金型１０内に発泡樹脂成形品を成形するためのキャビティ１０ａが形成されるようになっている。固定型１１は、キャビティ成形面１１ａを有するとともに、射出装置３０からキャビティ１０ａに発泡性樹脂を注入するための注入経路１６を有している。   The mold 10 includes a fixed mold 11 and a movable mold 21. By closing the fixed mold 11 and the movable mold 21, a cavity 10a for forming a foamed resin molded product is formed in the mold 10. It has become so. The fixed mold 11 has a cavity molding surface 11a and an injection path 16 for injecting a foamable resin from the injection device 30 into the cavity 10a.

一方、可動型２１は、キャビティ成形面２２ａを有するとともに固定型１１と組み合わせられる本体部２２を備え、該本体部２２には、金型１０の開閉方向（矢印Ｘ２で示す方向）において断面略矩形状に形成される開口部２２ｂが設けられるとともに金型１０の開閉方向において断面略円形状に形成される孔部２２ｃが設けられている。   On the other hand, the movable die 21 has a body portion 22 that has a cavity molding surface 22a and is combined with the fixed die 11. The body portion 22 has a substantially rectangular cross section in the opening / closing direction of the mold 10 (direction indicated by the arrow X2). An opening 22b formed in a shape is provided, and a hole 22c formed in a substantially circular cross section in the opening / closing direction of the mold 10 is provided.

本体部２２の開口部２２ｂには、断面略矩形状に形成されるコア部２３が金型１０の開閉方向に移動可能に挿入され、本体部２２の孔部２２ｃには、断面略円形状に形成される突出部材としてのピン部２４が金型１０の開閉方向に移動可能に挿入されている。また、ピン部２４はそれぞれ、ピン部保持プレート２５に結合され、少なくともコア部２３の近傍に設けられている。   A core portion 23 formed in a substantially rectangular cross section is inserted into the opening portion 22b of the main body portion 22 so as to be movable in the opening and closing direction of the mold 10, and the hole portion 22c of the main body portion 22 has a substantially circular cross section. A pin portion 24 as a protruding member to be formed is inserted so as to be movable in the opening / closing direction of the mold 10. In addition, each of the pin portions 24 is coupled to the pin portion holding plate 25 and provided at least in the vicinity of the core portion 23.

可動型２１のコア部２３及びピン部２４はそれぞれ、キャビティ成形面２３ａ及び２４ａを有し、コア部２３のキャビティ成形面２３ａには、図１に示すように、断面略Ｌ字状に窪んで形成される溝部２３ｂが設けられている。コア部２３の溝部２３ｂは、金型１０の開閉方向と略直交する方向に延びる縦壁部２３ｃと、該縦壁部２３ｃから金型１０の開閉方向に延びるとともに縦壁部２３ｃと鋭角をなす横壁部２３ｄとによって形成されている。   The core part 23 and the pin part 24 of the movable mold 21 have cavity molding surfaces 23a and 24a, respectively, and the cavity molding surface 23a of the core part 23 is recessed in a substantially L-shaped cross section as shown in FIG. A groove 23b to be formed is provided. The groove part 23b of the core part 23 extends in a direction substantially orthogonal to the opening / closing direction of the mold 10, and extends from the vertical wall part 23c in the opening / closing direction of the mold 10 and forms an acute angle with the vertical wall part 23c. The horizontal wall portion 23d is formed.

本実施形態では、発泡樹脂成形品は、製品形状となる本体部と該本体部の表面に立設されるリブ部とが一体的に形成された後に発泡樹脂成形品の本体部とリブ部とを離間させるので、コア部２３の溝部２３ｂと金型１０の開閉方向に延びる本体部２２の開口部２２ｂとによって発泡樹脂成形品のリブ部を成形するためのリブ部成形部１０ｂが形成され、該リブ部成形部１０ｂは、前記リブ部の立設方向に対してアンダーカット状に形成される前記リブ部を成形するように形成されている。ここで、アンダーカット状とは、発泡樹脂成形品を取り出す際に、前記リブ部の立設方向に離型できない形状をいうものである。   In the present embodiment, the foamed resin molded product is obtained by integrally forming the main body portion and the rib portion of the foamed resin molded product after the main body portion having a product shape and the rib portion standing on the surface of the main body portion are integrally formed. Therefore, the rib part molding part 10b for molding the rib part of the foamed resin molded product is formed by the groove part 23b of the core part 23 and the opening part 22b of the main body part 22 extending in the opening and closing direction of the mold 10. The rib portion forming portion 10b is formed so as to shape the rib portion formed in an undercut shape with respect to the standing direction of the rib portion. Here, the undercut shape refers to a shape that cannot be released in the standing direction of the rib portion when taking out the foamed resin molded product.

一方、発泡樹脂成形品の本体部を成形するための本体部成形部１０ｃは、本体部２２のキャビティ成形面２２ａ、コア部２３のキャビティ成形面２３ａ及びピン部２４のキャビティ成形面２４ａからなる可動側の本体部成形部と、固定型１１のキャビティ成形面１１ａからなる固定側の本体部成形部とによって形成されている。なお、本体部成形部１０ｃを構成するキャビティ成形面２２ａは、その周縁部に断面Ｌ字状に窪む段差部２２ｄを備え、本体部成形部１０ｃは、発泡樹脂成形品の本体部の周縁部に縦壁部を形成することができるように構成されている。   On the other hand, the main body part molding part 10c for molding the main body part of the foamed resin molded product is composed of a cavity molding surface 22a of the main body part 22, a cavity molding surface 23a of the core part 23, and a cavity molding surface 24a of the pin part 24. It is formed by a main body molding part on the side and a main body molding part on the fixed side composed of the cavity molding surface 11 a of the fixed mold 11. The cavity molding surface 22a that constitutes the main body molding portion 10c includes a step portion 22d that is recessed in an L-shaped cross section at the peripheral edge, and the main body molding portion 10c is the peripheral edge of the main body portion of the foamed resin molded product. It is comprised so that a vertical wall part can be formed.

金型１０はまた、固定型１１に対して可動型２１の本体部２２、コア部２３及びピン部２４が一体的に金型１０の開閉方向に移動可能に構成され、固定型１１と可動型２１とを型閉めした後に可動型２１を金型１０の型開き方向に移動させることによりキャビティ１０ａの容積が拡大可能に構成されている。また、可動型２１のコア部２３及びピン部２４はそれぞれ、本体部２２に対して金型１０の開閉方向に移動可能に構成されている。   The mold 10 is also configured such that the main body portion 22, the core portion 23, and the pin portion 24 of the movable mold 21 are integrally movable in the opening / closing direction of the mold 10 with respect to the fixed mold 11. After the mold 21 is closed, the volume of the cavity 10a can be increased by moving the movable mold 21 in the mold opening direction of the mold 10. The core part 23 and the pin part 24 of the movable mold 21 are configured to be movable in the opening / closing direction of the mold 10 with respect to the main body part 22.

一方、射出装置３０は、溶融状態の発泡性樹脂３１を金型１０のキャビティ１０ａに注入するものであり、樹脂３２を混練溶融させるシリンダ３３を備え、シリンダ３３の内部にはスクリュー３４が備えられている。また、スクリュー３４の後端には、スクリュー駆動機構及び射出機構（共に不図示）が連結されている。   On the other hand, the injection device 30 is for injecting a molten foamable resin 31 into the cavity 10a of the mold 10 and includes a cylinder 33 for kneading and melting the resin 32. A screw 34 is provided inside the cylinder 33. ing. A screw drive mechanism and an injection mechanism (both not shown) are connected to the rear end of the screw 34.

射出装置３０では、シリンダ３３の周囲に設けられた加熱ヒータ（不図示）とスクリュー３４とによって、シリンダ３３に投入された樹脂３２を順次加熱するとともに混練溶融させるように構成されている。そして、混練溶融された樹脂３２に対し、二酸化炭素又は窒素等の不活性ガスを含むボンベ３５から超臨界流体発生装置３６を介して超臨界状態にされた前記不活性ガスが、超臨界流体注入装置３７によって注入され、樹脂３２に発泡剤を含有させた発泡性樹脂３１が形成されるようになっている。   The injection device 30 is configured to sequentially heat and knead and melt the resin 32 put into the cylinder 33 by a heater (not shown) and a screw 34 provided around the cylinder 33. Then, the inert gas made supercritical through the supercritical fluid generator 36 from a cylinder 35 containing an inert gas such as carbon dioxide or nitrogen is injected into the kneaded and melted resin 32 through supercritical fluid injection. A foamable resin 31 that is injected by the device 37 and contains a foaming agent in the resin 32 is formed.

このシリンダ３３内の発泡性樹脂３１は、スクリュー３４が前記スクリュー駆動機構によって回転されるとともに前記射出機構によって射出されることによって金型１０のキャビティ１０ａに注入される。   The foamable resin 31 in the cylinder 33 is injected into the cavity 10a of the mold 10 by the screw 34 being rotated by the screw drive mechanism and injected by the injection mechanism.

本実施形態では、樹脂３２としては、例えばポリプロピレン樹脂などの熱可塑性樹脂が用いられる。また、本実施形態では、発泡性樹脂３１に含有される発泡剤に、物理発泡剤として超臨界状態にある流体を用いているが、その他の物理発泡剤を用いてもよい。あるいは、化学発泡剤を使用することも可能である。   In the present embodiment, as the resin 32, for example, a thermoplastic resin such as a polypropylene resin is used. Moreover, in this embodiment, although the fluid in a supercritical state is used as a physical foaming agent for the foaming agent contained in the foamable resin 31, other physical foaming agents may be used. Alternatively, chemical blowing agents can be used.

また、具体的には図示しなかったが、成形装置Ｍは、該成形装置Ｍを総合的に制御する制御ユニットを備えている。該制御ユニットは、例えばマイクロコンピュータを主要部として構成されており、金型１０の作動制御、射出装置３０の作動制御等の各種制御を行うように構成されている。   Although not specifically illustrated, the molding apparatus M includes a control unit that comprehensively controls the molding apparatus M. The control unit is configured with, for example, a microcomputer as a main part, and is configured to perform various controls such as operation control of the mold 10 and operation control of the injection device 30.

次に、前記成形装置Ｍを用いた発泡樹脂成形品の成形について説明する。
図１に示すように金型１０が型閉めされた状態で、金型１０のキャビティ１０ａに樹脂３２に発泡剤として超臨界状態の流体を含有させた発泡性樹脂３１が射出装置３０から注入され、溶融状態の発泡性樹脂３１がキャビティ１０ａに充填された後に、キャビティ１０ａの容積を拡大させるように可動型２１が型開き方向に移動される。 Next, molding of a foamed resin molded product using the molding apparatus M will be described.
As shown in FIG. 1, in a state where the mold 10 is closed, a foamable resin 31 containing a resin 32 containing a supercritical fluid as a foaming agent is injected into the cavity 10 a of the mold 10 from the injection device 30. After the molten foamable resin 31 is filled in the cavity 10a, the movable mold 21 is moved in the mold opening direction so as to increase the volume of the cavity 10a.

図２は、図１に示す金型において発泡樹脂成形品の本体部とリブ部とを形成する方法を説明するための断面説明図であり、図２（ａ）は、キャビティ１０ａに発泡性樹脂３１が充填された状態を示し、図２（ｂ）は、キャビティ１０ａに発泡性樹脂３１が充填された後に可動型２１が型開き方向に移動された状態を示している。   FIG. 2 is a cross-sectional explanatory view for explaining a method of forming the main body portion and the rib portion of the foamed resin molded product in the mold shown in FIG. 1, and FIG. 2 (a) shows a foamable resin in the cavity 10a. FIG. 2B shows a state in which the movable mold 21 is moved in the mold opening direction after the cavity 10a is filled with the foamable resin 31. FIG.

図２（ａ）に示すように、金型１０のキャビティ１０ａに注入経路１６を通じて発泡性樹脂３１が充填された後に、図２（ｂ）に示すように、キャビティ１０ａの容積を拡大するように可動型２１を型開き方向（矢印Ｘ３で示す方向）に移動させて発泡性樹脂３１の発泡を促進させる。   As shown in FIG. 2A, after the cavity 10a of the mold 10 is filled with the foamable resin 31 through the injection path 16, the volume of the cavity 10a is expanded as shown in FIG. The movable mold 21 is moved in the mold opening direction (direction indicated by the arrow X3) to promote foaming of the foamable resin 31.

可動型２１が型開き方向に移動されると、製品形状となる本体部４１と、該本体部４１の表面に該表面と略直交する方向に略四角柱状に立設されるリブ部４５とを有する発泡樹脂成形品４０が成形され、リブ部４５は、リブ部４５の立設方向に対してアンダーカット状に形成されている。発泡樹脂成形品４０の本体部４１は本体部成形部１０ｃによって成形され、発泡樹脂成形品４０のリブ部４５はリブ部成形部１０ｂによって成形される。   When the movable mold 21 is moved in the mold opening direction, a main body portion 41 having a product shape and a rib portion 45 erected on the surface of the main body portion 41 in a substantially quadrangular prism shape in a direction substantially perpendicular to the surface. The foamed resin molded product 40 is formed, and the rib portion 45 is formed in an undercut shape with respect to the standing direction of the rib portion 45. The main body portion 41 of the foamed resin molded product 40 is molded by the main body portion molded portion 10c, and the rib portion 45 of the foamed resin molded product 40 is molded by the rib portion molded portion 10b.

また、発泡樹脂成形品４０では、本体部４１は、その表面が表面層である非発泡のスキン層４２によって形成されるとともに該スキン層４２の内側に発泡性樹脂３１の発泡が促進された発泡層４３が形成され、リブ部４５は、非発泡状態で形成されている。なお、発泡樹脂成形品４０の本体部４１には、その周縁部に縦壁部４４が形成されており、該縦壁部４４は、非発泡状態で形成されている。   In the foamed resin molded product 40, the main body 41 is formed by a non-foamed skin layer 42 whose surface is a surface layer, and foaming of the foamable resin 31 is promoted inside the skin layer 42. The layer 43 is formed, and the rib portion 45 is formed in a non-foamed state. In addition, the vertical wall part 44 is formed in the peripheral part in the main-body part 41 of the foamed resin molded product 40, and this vertical wall part 44 is formed in the non-foamed state.

このようにして本体部４１とリブ部４５とを有する発泡樹脂成形品４０を成形した後に発泡樹脂成形品４０を取り出す際には、可動型２１が型開き方向に移動されて金型１０が型開きされ、その後に、リブ部成形部１０ｂにリブ部４５を保持した状態で、リブ部４５の立設方向にリブ部４５と本体部４１とを離間させることにより、リブ部４５に連続する本体部４１のスキン層４２を剥離して発泡層４３を露出させる。   When the foamed resin molded product 40 having the main body portion 41 and the rib portion 45 is molded as described above and then taken out, the movable mold 21 is moved in the mold opening direction so that the mold 10 is molded. The main body that is opened and then continues to the rib portion 45 by separating the rib portion 45 and the main body portion 41 in the standing direction of the rib portion 45 in a state where the rib portion 45 is held in the rib portion molding portion 10b. The skin layer 42 of the portion 41 is peeled off to expose the foam layer 43.

図３は、図１に示す金型において発泡樹脂成形品の本体部とリブ部とを離間させる方法を説明するための断面説明図であり、図３（ａ）は、金型を型開きした状態を示し、図３（ｂ）は、可動型の本体部に対してピン部を突出させた状態を示し、図３（ｃ）は、可動型の本体部に対してコア部を移動させた状態を示している。   FIG. 3 is a cross-sectional explanatory diagram for explaining a method of separating the main body portion and the rib portion of the foamed resin molded product in the mold shown in FIG. 1, and FIG. 3 (a) shows the mold opened. FIG. 3B shows a state in which the pin portion protrudes from the movable main body portion, and FIG. 3C shows the state in which the core portion is moved relative to the movable main body portion. Indicates the state.

図３（ａ）に示すように、発泡樹脂成形品４０を成形した後に取り出す際には、本体部２２、コア部２３及びピン部２４を一体として可動型２１を型開き方向（矢印Ｘ３に示す方向）に移動ささせて金型１０を型開きし、リブ部成形部１０ｂにリブ部４５を保持した状態で発泡樹脂成形品４０全体を可動型２１とともに移動させる。   As shown in FIG. 3A, when the foamed resin molded product 40 is taken out and then taken out, the main body 22, the core 23 and the pin 24 are integrated into the movable die 21 in the mold opening direction (indicated by the arrow X3). The mold 10 is opened, and the entire foamed resin molded product 40 is moved together with the movable die 21 with the rib portion 45 held by the rib portion molding portion 10b.

金型１０が型開きされると次に、図３（ｂ）に示すように、リブ部成形部１０ｂにリブ部４５を保持した状態で、可動型２１の本体部２２に対してピン部２４をリブ部４５の立設方向である金型１０の型閉じ方向（矢印Ｘ４で示す方向）に突出させ、本体部成形部１０ｃ、具体的には可動側の本体部成形部を構成する本体部２２のキャビティ成形面２２ａ及びコア部２３のキャビティ成形面２３ａからリブ部４５の立設方向に発泡樹脂成形品４０の本体部４１を突出させる。   When the mold 10 is opened, next, as shown in FIG. 3 (b), the pin portion 24 with respect to the main body portion 22 of the movable die 21 with the rib portion 45 held in the rib portion molding portion 10 b. Projecting in the mold closing direction of the mold 10 (the direction indicated by the arrow X4), which is the direction in which the rib portion 45 is erected, to form the main body molding portion 10c, specifically, the main body molding portion on the movable side The main body portion 41 of the foamed resin molded product 40 protrudes from the cavity molding surface 22a of 22 and the cavity molding surface 23a of the core portion 23 in the standing direction of the rib portion 45.

発泡樹脂成形品４０の本体部４１が突出されるとき、発泡樹脂成形品４０のリブ部４５は該リブ部４５の立設方向にアンダーカット状に形成されているのでリブ部成形部１０ｂに保持された状態で、リブ部４５に連続する本体部４１のスキン層４２がリブ部４５とともに剥離され、本体部４１のスキン層４２に開口部４２ａが形成されて発泡層４３が露出させられる。   When the main body portion 41 of the foamed resin molded product 40 is protruded, the rib portion 45 of the foamed resin molded product 40 is formed in an undercut shape in the direction in which the rib portion 45 is erected, and thus is held by the rib portion molded portion 10b. In this state, the skin layer 42 of the main body portion 41 continuous with the rib portion 45 is peeled together with the rib portion 45, and an opening 42 a is formed in the skin layer 42 of the main body portion 41 to expose the foam layer 43.

発泡樹脂成形品４０の本体部４１はまた、ピン部２４によって突出させられて金型１０から落下し、発泡樹脂成形品４０が取り出されることとなるが、図示しない取出装置を用いて金型１０から取り出すようにすることも可能である。このようにして、金型１０を用いて、スキン層４２の一部を剥離して発泡層４３を露出させた発泡樹脂成形品４０を製造することができる。   The main body portion 41 of the foamed resin molded product 40 is also protruded by the pin portion 24 and dropped from the mold 10, and the foamed resin molded product 40 is taken out. It is also possible to take it out from. In this way, using the mold 10, it is possible to manufacture a foamed resin molded product 40 in which a part of the skin layer 42 is peeled and the foamed layer 43 is exposed.

発泡樹脂成形品４０を製造した後には、図３（ｃ）に示すように、コア部２３を金型１０の型閉じ方向（矢印Ｘ４で示す方向）に移動することにより、リブ部成形部１０ｂに保持されたリブ部４５が金型１０から落下して取り除かれることとなるが、リブ部成形部１０ｂにエアー（空気）を吹き付けることによってリブ部４５を確実に落下させるようにすることも可能である。   After the foamed resin molded product 40 is manufactured, as shown in FIG. 3C, the core portion 23 is moved in the mold closing direction of the mold 10 (the direction indicated by the arrow X4), thereby forming the rib portion molded portion 10b. The rib portion 45 held in the mold is dropped and removed from the mold 10, but it is also possible to reliably drop the rib portion 45 by blowing air (air) to the rib portion molding portion 10b. It is.

なお、本実施形態では、発泡樹脂成形品４０のリブ部４５が略四角柱状に形成されるとともにリブ部４５の立設方向に対してアンダーカット状に形成されているが、リブ部が略円柱状に形成されるとともにリブ部の立設方向に対してアンダーカット状に形成されるなど、リブ部がリブ部の立設方向に対してアンダーカット状に形成されるその他の形状に形成することも可能である。   In the present embodiment, the rib portion 45 of the foamed resin molded product 40 is formed in a substantially quadrangular prism shape and is formed in an undercut shape with respect to the standing direction of the rib portion 45, but the rib portion is substantially circular. The rib portion is formed in a columnar shape and in other shapes in which the rib portion is formed in an undercut shape with respect to the standing direction of the rib portion. Is also possible.

このように、本実施形態に係る発泡樹脂成形品成形用の金型構造は、発泡樹脂成形品４０を成形するためのキャビティ１０ａを有するとともにキャビティ１０ａの容積が拡大可能に構成された金型１０を備え、溶融状態の発泡性樹脂３１をキャビティ１０ａに充填した後にキャビティ１０ａの容積を拡大することにより表面層であるスキン層４２とスキン層４２の内側に設けられる発泡層４３とを有する発泡樹脂成形品４０を成形し、その後にスキン層４２の一部を剥離して発泡層４３を露出させるように構成されている。   As described above, the mold structure for molding the foamed resin molded product according to the present embodiment includes the cavity 10a for molding the foamed resin molded product 40 and the mold 10 configured so that the volume of the cavity 10a can be expanded. A foamed resin having a skin layer 42 as a surface layer and a foam layer 43 provided inside the skin layer 42 by enlarging the volume of the cavity 10a after filling the meltable foamable resin 31 into the cavity 10a The molded product 40 is molded, and then the skin layer 42 is partially peeled to expose the foamed layer 43.

特に、金型１０は、発泡樹脂成形品４０の本体部４１を成形するための本体部成形部１０ｃと、本体部４１の表面に立設されるリブ部４５を成形するためのリブ部成形部１０ｂとを有し、リブ部成形部１０ｂは、リブ部４５の立設方向に対してアンダーカット状に形成されるリブ部４５を成形するように形成され、金型１０は、本体部４１とリブ部４５とを有する発泡樹脂成形品４０を成形した後に発泡樹脂成形品４０を取り出す際に、リブ部成形部１０ｂにリブ部４５を保持した状態でリブ部４５の立設方向にリブ部４５と本体部４１とを離間させることにより、リブ部４５に連続する本体部４１のスキン層４２を剥離して本体部４１の発泡層４３を露出させるように構成されている。   In particular, the mold 10 includes a main body portion molding portion 10c for molding the main body portion 41 of the foamed resin molded product 40 and a rib portion molding portion for molding the rib portion 45 standing on the surface of the main body portion 41. 10b, and the rib portion forming portion 10b is formed so as to shape the rib portion 45 formed in an undercut shape with respect to the standing direction of the rib portion 45. When the foamed resin molded product 40 having the rib portions 45 is molded and then taken out, the rib portions 45 are arranged in the standing direction of the rib portions 45 in a state where the rib portions 45 are held in the rib portion molded portions 10b. By separating the main body 41 from the main body 41, the skin layer 42 of the main body 41 continuing to the rib 45 is peeled off to expose the foam layer 43 of the main body 41.

これにより、比較的簡単な構成を有する金型１０を用い、発泡樹脂成形品４０のスキン層４２の一部を剥離して発泡層４３を露出させることができ、発泡樹脂成形品４０の強度低下を抑制しつつスキン層４２の一部を剥離して発泡層４３を露出させた発泡樹脂成形品４０を成形することができる。   As a result, the mold 10 having a relatively simple configuration can be used to peel a part of the skin layer 42 of the foamed resin molded product 40 to expose the foamed layer 43, thereby reducing the strength of the foamed resin molded product 40. The foamed resin molded product 40 in which a part of the skin layer 42 is peeled off and the foamed layer 43 is exposed can be molded.

また、金型１０は、本体部成形部１０ｃから発泡樹脂成形品４０の本体部４１を突出させる突出部材２４を備え、発泡樹脂成形品４０を取り出す際に、リブ部成形部１０ｂにリブ部４５を保持した状態で突出部材２４によって本体部成形部１０ｃから本体部４１を突出させてリブ部４５と本体部４１とを離間させるように構成されている。   In addition, the mold 10 includes a protruding member 24 that protrudes the main body 41 of the foamed resin molded product 40 from the main body molded portion 10c. When the foamed resin molded product 40 is taken out, the rib portion 45 is formed on the rib portion molded portion 10b. The main body 41 is protruded from the main body molding portion 10c by the projecting member 24 in a state in which the rib 45 and the main body 41 are separated from each other.

これにより、発泡樹脂成形品４０を取り出す際にリブ部４５と本体部４１とを離間させることができるので、発泡樹脂成形品４０を成形するための成形サイクルタイムを延長化させることなく、前記効果を得ることができる。   Thereby, since the rib part 45 and the main-body part 41 can be spaced apart when taking out the foamed resin molded product 40, the said effect is achieved, without extending the molding cycle time for shape | molding the foamed resin molded product 40. Can be obtained.

図４は、本発明の第２の実施形態に係る金型を示す断面説明図である。本発明の第２の実施形態に係る金型は、本発明の第１の実施形態に係る金型１０において、固定型にリブ部成形部が設けられるとともに該固定型に固定型取付プレートが備えられ、且つ可動型にコア部が備えられていないものであり、本発明の第１の実施形態に係る金型１０と同様の構成については同一符号を付して説明を省略する。   FIG. 4 is a cross-sectional explanatory view showing a mold according to the second embodiment of the present invention. The mold according to the second embodiment of the present invention is the mold 10 according to the first embodiment of the present invention, wherein the fixed mold is provided with the rib portion molding portion and the fixed mold is provided with the fixed mold mounting plate. In addition, the movable mold is not provided with a core, and the same reference numerals are given to the same components as those of the mold 10 according to the first embodiment of the present invention, and the description thereof is omitted.

図４に示すように、本発明の第２の実施形態に係る金型５０は、固定型５１と可動型６１に加えて固定型５１に重ね合わせられる固定型取付プレート５２をさらに備え、固定型５１、可動型６１及び固定型取付プレート５２をともに型閉めすることにより金型５０内に発泡樹脂成形品を成形するためのキャビティ５０ａが形成されるようになっている。   As shown in FIG. 4, the mold 50 according to the second embodiment of the present invention further includes a fixed mold mounting plate 52 that is superposed on the fixed mold 51 in addition to the fixed mold 51 and the movable mold 61, and includes a fixed mold. 51, the movable mold 61 and the fixed mold mounting plate 52 are closed together to form a cavity 50a for molding a foamed resin molded product in the mold 50.

固定型５１は、キャビティ成形面５１ａを有しており、該キャビティ成形面５１ａに、金型５０の開閉方向（矢印Ｘ２で示す方向）において断面略矩形状に窪んで形成される複数の溝部５１ｂが設けられ、該溝部５１ｂは、固定型５１の端面５１ｃまで開口するように形成されている。   The fixed mold 51 has a cavity molding surface 51a, and a plurality of grooves 51b formed in the cavity molding surface 51a so as to be recessed in a substantially rectangular cross section in the opening / closing direction of the mold 50 (direction indicated by the arrow X2). The groove 51b is formed so as to open to the end surface 51c of the fixed mold 51.

固定型５１の溝部５１ｂは、金型５０の開閉方向に延びる上壁部５１ｄと、金型５０の開閉方向に延びるとともに固定型取付プレート５２側に向かうにつれて下方に傾斜する下壁部５１ｅとを備えるとともに、該上壁部５１ｄ及び下壁部５１ｅの図面の表面及び裏面に図示しない側壁部を備えている。   The groove 51b of the fixed mold 51 includes an upper wall 51d extending in the opening / closing direction of the mold 50 and a lower wall 51e extending in the opening / closing direction of the mold 50 and inclined downward toward the fixed mold mounting plate 52 side. In addition, the upper wall 51d and the lower wall 51e are provided with side walls (not shown) on the front and back surfaces of the drawing.

金型５０では、固定型５１の溝部５１ｂと固定型取付プレート５２の端面５２ａとによって発泡樹脂成形品のリブ部を成形するためのリブ部成形部５０ｂが形成され、該リブ部成形部５０ｂは、前記リブ部の立設方向に対してアンダーカット状に形成されるリブ部を成形するように形成されている。   In the mold 50, a rib portion molding portion 50b for molding a rib portion of a foamed resin molded product is formed by the groove portion 51b of the fixed die 51 and the end surface 52a of the fixed die mounting plate 52. The rib portion formed in an undercut shape with respect to the standing direction of the rib portion is formed.

本実施形態ではまた、固定型取付プレート５２に対して固定型５１が金型５０の開閉方向に移動可能に構成されている。なお、固定型５１及び固定型取付プレート５２にはそれぞれ、射出装置３０からキャビティ５０ａに発泡性樹脂を注入するための注入経路１６が設けられている。   In the present embodiment, the stationary mold 51 is configured to be movable in the opening / closing direction of the mold 50 with respect to the stationary mold mounting plate 52. Each of the fixed mold 51 and the fixed mold mounting plate 52 is provided with an injection path 16 for injecting a foamable resin from the injection device 30 into the cavity 50a.

一方、可動型６１は、キャビティ成形面２２ａを有するとともに固定型５１と組み合わせられる本体部２２を備え、該本体部２２には、金型５０の開閉方向において断面略円形状に形成される孔部２２ｃが設けられ、該孔部２２ｃに、断面略円形状に形成される突出部材としてのピン部２４が金型５０の開閉方向に移動可能に挿入されている。   On the other hand, the movable mold 61 includes a main body 22 having a cavity molding surface 22a and combined with the fixed mold 51. The main body 22 has a hole formed in a substantially circular cross section in the opening and closing direction of the mold 50. 22c is provided, and a pin portion 24 as a protruding member formed in a substantially circular cross section is inserted into the hole portion 22c so as to be movable in the opening and closing direction of the mold 50.

金型５０ではまた、発泡樹脂成形品の本体部を成形するための本体部成形部５０ｃは、本体部２２のキャビティ成形面２２ａ及びピン部２４のキャビティ成形面２４ａからなる可動側の本体部成形部と、固定型５１のキャビティ成形面５１ａからなる固定側の本体部成形部とによって形成されている。なお、本体部成形部５０ｃを構成するキャビティ成形面２２ａは、その周縁部に断面Ｌ字状に窪む段差部２２ｄを備え、本体部成形部５０ｃは、発泡樹脂成形品の本体部の周縁部に縦壁部を形成することができるように構成されている。   In the mold 50, the main body molding portion 50c for molding the main body portion of the foamed resin molded product is a movable main body molding composed of the cavity molding surface 22a of the main body portion 22 and the cavity molding surface 24a of the pin portion 24. And a fixed-side main body forming part formed of the cavity forming surface 51 a of the fixed mold 51. The cavity molding surface 22a constituting the main body part molding part 50c includes a step part 22d that is recessed in an L-shaped cross section at the peripheral part thereof, and the main body part molding part 50c is a peripheral part of the main body part of the foamed resin molded product. It is comprised so that a vertical wall part can be formed.

金型５０においても、固定型５１に対して可動型６１の本体部２２及びピン部２４が一体的に金型５０の開閉方向に移動可能に構成され、固定型５１と可動型６１とを型閉めした後に可動型６１を金型５０の型開き方向に移動させることによりキャビティ５０ａの容積が拡大可能に構成されている。また、可動型６１のピン部２４は、本体部２２に対して金型５０の開閉方向に移動可能に構成されている。   Also in the mold 50, the main body portion 22 and the pin portion 24 of the movable mold 61 can be integrally moved in the opening / closing direction of the mold 50 with respect to the fixed mold 51. By moving the movable mold 61 in the mold opening direction of the mold 50 after closing, the volume of the cavity 50a can be expanded. The pin portion 24 of the movable mold 61 is configured to be movable in the opening / closing direction of the mold 50 with respect to the main body portion 22.

このようにして構成される金型５０を用いる場合においても、図４に示すように金型５０が型閉めされた状態で、キャビティ５０ａに発泡性樹脂３１が射出装置３０から注入され、溶融状態の発泡性樹脂３１がキャビティ５０ａに充填された後に、キャビティ５０ａの容積を拡大させるように可動型６１が型開き方向に移動される。   Even when the mold 50 configured as described above is used, the foamable resin 31 is injected from the injection device 30 into the cavity 50a with the mold 50 closed as shown in FIG. After the foamable resin 31 is filled in the cavity 50a, the movable mold 61 is moved in the mold opening direction so as to increase the volume of the cavity 50a.

図５は、図４に示す金型において発泡樹脂成形品の本体部とリブ部とを形成する方法を説明するための断面説明図である。図５に示すように、キャビティ５０ａに発泡性樹脂３１が充填された後に可動型６１が型開き方向（矢印Ｘ３で示す方向）に移動されると、製品形状となる本体部７１と、該本体部７１の表面に該表面と略直交する方向に略四角柱状に立設されるリブ部７５とを有する発泡樹脂成形品７０が成形され、リブ部７５は、リブ部７５の立設方向に対してアンダーカット状に形成されている。発泡樹脂成形品７０の本体部７１は本体部成形部５０ｃによって成形され、発泡樹脂成形品７０のリブ部７５はリブ部成形部５０ｂによって成形される。   FIG. 5 is a cross-sectional explanatory view for explaining a method of forming the main body portion and the rib portion of the foamed resin molded product in the mold shown in FIG. 4. As shown in FIG. 5, when the movable mold 61 is moved in the mold opening direction (the direction indicated by the arrow X3) after the foamable resin 31 is filled in the cavity 50a, the main body 71 having a product shape, and the main body A foamed resin molded product 70 having a rib portion 75 standing in a substantially quadrangular prism shape in a direction substantially orthogonal to the surface is formed on the surface of the portion 71, and the rib portion 75 is formed with respect to the standing direction of the rib portion 75. It is formed in an undercut shape. The main body portion 71 of the foamed resin molded product 70 is molded by the main body portion molded portion 50c, and the rib portion 75 of the foamed resin molded product 70 is molded by the rib portion molded portion 50b.

また、発泡樹脂成形品７０では、本体部７１は、その表面が表面層である非発泡のスキン層７２によって形成されるとともに該スキン層７２の内側に発泡性樹脂３１の発泡が促進された発泡層７３が形成され、リブ部７５は、非発泡状態で形成されている。なお、発泡樹脂成形品７０の本体部７１には、その周縁部に縦壁部７４が形成されており、該縦壁部７４は、非発泡状態で形成されている。   Further, in the foamed resin molded product 70, the main body 71 is formed by a non-foamed skin layer 72 whose surface is a surface layer, and foaming of the foamable resin 31 is promoted inside the skin layer 72. The layer 73 is formed, and the rib portion 75 is formed in a non-foamed state. The main body 71 of the foamed resin molded product 70 has a vertical wall 74 formed at the peripheral edge thereof, and the vertical wall 74 is formed in a non-foamed state.

このようにして本体部７１とリブ部７５とを有する発泡樹脂成形品７０を成形した後に発泡樹脂成形品７０を取り出す際には、可動型６１が型開き方向に移動されて金型５０が型開きされ、リブ部成形部５０ｂにリブ部７５を保持した状態で、リブ部７５の立設方向にリブ部７５と本体部７１とを離間させることにより、リブ部７５に連続する本体部７１のスキン層７２を剥離して発泡層７３を露出させる。   In this way, when the foamed resin molded product 70 having the main body portion 71 and the rib portion 75 is molded and then taken out, the movable mold 61 is moved in the mold opening direction so that the mold 50 is molded. In a state where the rib portion 75 is held in the rib portion molding portion 50b and the rib portion 75 and the main body portion 71 are separated in the standing direction of the rib portion 75, the main body portion 71 continuous to the rib portion 75 is separated. The skin layer 72 is peeled off to expose the foam layer 73.

図６は、図４に示す金型において発泡樹脂成形品の本体部とリブ部とを離間させる方法を説明するための断面説明図であり、図６（ａ）は、金型を型開きした状態を示し、図６（ｂ）は、可動型の本体部に対してピン部を突出させた状態を示し、図６（ｃ）は、固定型取付プレートに対して固定型を移動させた状態を示している。   6 is a cross-sectional explanatory view for explaining a method of separating the main body portion and the rib portion of the foamed resin molded product in the mold shown in FIG. 4, and FIG. 6 (a) shows the mold opened. FIG. 6 (b) shows a state in which the pin portion protrudes from the movable body portion, and FIG. 6 (c) shows a state in which the fixed die is moved relative to the fixed die mounting plate. Is shown.

図６（ａ）に示すように、発泡樹脂成形品７０を成形した後に取り出す際には、本体部２２及びピン部２４を一体として可動型６１を型開き方向（矢印Ｘ３に示す方向）に移動させて金型５０を型開きし、リブ部成形部５０ｂにリブ部７５を保持した状態で、発泡樹脂成形品７０の本体部７１を可動型６１とともに移動させる。なお、本体部７１は、その周縁部に縦壁部７４を備え、可動型６１を移動させる際に可動型６１に保持されるように形成されている。   As shown in FIG. 6A, when the foamed resin molded product 70 is molded and taken out, the movable die 61 is moved in the die opening direction (direction indicated by the arrow X3) with the main body portion 22 and the pin portion 24 integrated. Then, the mold 50 is opened, and the main body 71 of the foamed resin molded product 70 is moved together with the movable die 61 in a state where the rib portion 75 is held by the rib portion molding portion 50b. The main body 71 is provided with a vertical wall 74 at the periphery thereof, and is formed to be held by the movable die 61 when the movable die 61 is moved.

発泡樹脂成形品７０の本体部７１が可動型６１とともに移動されるとき、リブ部７５は該リブ部７５の立設方向にアンダーカット状に形成されているのでリブ部成形部５０ｂに保持された状態で、リブ部７５に連続する本体部７１のスキン層７２がリブ部７５とともに本体部７１から剥離され、本体部７１のスキン層７２に開口部７２ａが形成されて発泡層７３が露出させられる。   When the main body portion 71 of the foamed resin molded product 70 is moved together with the movable die 61, the rib portion 75 is formed in an undercut shape in the standing direction of the rib portion 75, and thus is held by the rib portion molding portion 50b. In this state, the skin layer 72 of the main body 71 continuous to the rib 75 is peeled from the main body 71 together with the rib 75, and an opening 72a is formed in the skin layer 72 of the main body 71 to expose the foam layer 73. .

金型５０が型開きされると次に、図６（ｂ）に示すように、可動型６１の本体部２２に対してピン部２４を金型５０の型閉じ方向（矢印Ｘ４で示す方向）に突出させ、本体部成形部５０ｃ、具体的には可動側の本体部成形部を構成する本体部２２のキャビティ成形面２２ａから金型５０の開閉方向に発泡樹脂成形品７０の本体部７１を突出させ、これにより、発泡樹脂成形品７０の本体部７１が金型５０から落下し、発泡樹脂成形品７０が取り出されることとなる。このようにして、金型５０を用いて、スキン層７２の一部を剥離して発泡層７３を露出させた発泡樹脂成形品７０を製造することができる。   When the mold 50 is opened, next, as shown in FIG. 6B, the pin portion 24 is closed with respect to the main body portion 22 of the movable mold 61 (the direction indicated by the arrow X4). The body portion 71 of the foamed resin molded product 70 is moved in the opening / closing direction of the mold 50 from the cavity molding surface 22a of the body portion 22 constituting the body portion molding portion 50c, specifically the movable body portion molding portion. Thus, the main body 71 of the foamed resin molded product 70 falls from the mold 50 and the foamed resin molded product 70 is taken out. In this way, using the mold 50, it is possible to manufacture a foamed resin molded product 70 in which a part of the skin layer 72 is peeled and the foamed layer 73 is exposed.

発泡樹脂成形品７０を製造した後には、図６（ｃ）に示すように、固定型５１を可動型６１側（矢印Ｘ５で示す方向）に移動させ、その後に、リブ部成形部５０ｂに保持されたリブ部７５に対して図示しないエアー供給装置からエアーを吹き付けることによりリブ部７５が金型５０から落下して取り除かれる。   After the foamed resin molded product 70 is manufactured, as shown in FIG. 6C, the fixed mold 51 is moved to the movable mold 61 side (in the direction indicated by the arrow X5), and then held by the rib portion molding portion 50b. By blowing air from an air supply device (not shown) to the rib portion 75 that has been formed, the rib portion 75 falls from the mold 50 and is removed.

このように、本発明の第２の実施形態に係る金型を用いる場合においても、金型５０は、発泡樹脂成形品７０の本体部７１を成形するための本体部成形部５０ｃと、本体部７１の表面に立設されるリブ部７５を成形するためのリブ部成形部５０ｂとを有し、リブ部成形部５０ｂは、リブ部７５の立設方向に対してアンダーカット状に形成されるリブ部７５を成形するように形成され、金型５０は、本体部７１とリブ部７５とを有する発泡樹脂成形品７０を成形した後に発泡樹脂成形品７０を取り出す際に、リブ部成形部５０ｂにリブ部７５を保持した状態でリブ部７５の立設方向にリブ部７５と本体部７１とを離間させることにより、リブ部７５に連続する本体部７１のスキン層７２を剥離して本体部７１の発泡層７３を露出させるように構成されている。   As described above, even when the mold according to the second embodiment of the present invention is used, the mold 50 includes the body part molding part 50c for molding the body part 71 of the foamed resin molded product 70, and the body part. And a rib portion molding portion 50b for molding a rib portion 75 standing on the surface of 71, and the rib portion molding portion 50b is formed in an undercut shape with respect to the standing direction of the rib portion 75. The rib 50 is formed to mold the rib portion 75. When the mold 50 is taken out of the foamed resin molded product 70 having the main body portion 71 and the rib portion 75, the rib portion molded portion 50b is formed. The rib portion 75 and the main body portion 71 are separated from each other in the standing direction of the rib portion 75 while the rib portion 75 is held, thereby peeling the skin layer 72 of the main body portion 71 continuous with the rib portion 75. 71 so that the foam layer 73 of 71 is exposed. It is.

これにより、比較的簡単な構成を有する金型５０を用い、発泡樹脂成形品７０のスキン層７２の一部を剥離して発泡層７３を露出させることができ、発泡樹脂成形品７０の強度低下を抑制しつつスキン層７２の一部を剥離して発泡層７３を露出させた発泡樹脂成形品７０を成形することができる。   As a result, the mold 50 having a relatively simple configuration can be used to peel a part of the skin layer 72 of the foamed resin molded product 70 to expose the foamed layer 73, thereby reducing the strength of the foamed resin molded product 70. It is possible to mold the foamed resin molded article 70 in which a part of the skin layer 72 is peeled and the foamed layer 73 is exposed while suppressing the above.

なお、第２の実施形態に係る金型５０において、可動型６１に、第１の実施形態に係る金型１０と同様のコア部２３をさらに備えるようにすることも可能である。かかる金型を用いることで、発泡樹脂成形品の本体部の両側の表面において発泡層を露出させることができる。   In the mold 50 according to the second embodiment, the movable mold 61 may further include a core portion 23 similar to that of the mold 10 according to the first embodiment. By using such a mold, the foamed layer can be exposed on the surfaces on both sides of the main body of the foamed resin molded product.

図７は、本発明の第３の実施形態に係る金型を示す断面説明図である。本発明の第３の実施形態に係る金型は、本発明の第２の実施形態に係る金型５０において、リブ部成形部の形状が異なるものであり、第２の実施形態に係る金型５０と同様の構成については同一符号を付して説明を省略する。   FIG. 7 is a cross-sectional explanatory view showing a mold according to the third embodiment of the present invention. The mold according to the third embodiment of the present invention is different from the mold 50 according to the second embodiment of the present invention in that the shape of the rib portion molding portion is different, and the mold according to the second embodiment. The same components as those in FIG.

図７に示すように、本発明の第３の実施形態に係る金型８０は、固定型８１、可動型６１及び固定型取付プレート５２を備え、固定型８１、可動型６１及び固定型取付プレート５２を型閉めすることにより金型８０内に発泡樹脂成形品を成形するためのキャビティ８０ａが形成されるようになっている。   As shown in FIG. 7, a mold 80 according to the third embodiment of the present invention includes a fixed mold 81, a movable mold 61, and a fixed mold mounting plate 52, and the fixed mold 81, the movable mold 61, and the fixed mold mounting plate. By closing the mold 52, a cavity 80a for molding a foamed resin molded product is formed in the mold 80.

固定型８１は、キャビティ成形面８１ａを有し、該キャビティ成形面８１ａに、金型８０の開閉方向（矢印Ｘ２で示す方向）において断面略矩形状に窪んで形成される複数の第１溝部８１ｂが設けられている。固定型８１ではまた、複数の第１溝部８１ｂを連結するように固定型８１の端面８１ｃに、金型８０の開閉方向と略直交する方向において断面略矩形状に窪んで形成される第２溝部８１ｄが設けられている。   The fixed die 81 has a cavity molding surface 81a, and a plurality of first groove portions 81b formed in the cavity molding surface 81a so as to be recessed in a substantially rectangular cross section in the opening / closing direction of the mold 80 (direction indicated by the arrow X2). Is provided. In the fixed die 81, a second groove portion is formed in the end surface 81c of the fixed die 81 so as to connect the plurality of first groove portions 81b so as to be recessed in a substantially rectangular shape in a direction substantially orthogonal to the opening / closing direction of the mold 80. 81d is provided.

金型８０では、固定型８１の第１溝部８１ｂ及び第２溝部８１ｄと固定型取付プレート５２の端面５２ａとによって発泡樹脂成形品のリブ部を成形するためのリブ部成形部８０ｂが形成され、該リブ部成形部８０ｂは、前記リブ部の立設方向に対してアンダーカット状に形成されるリブ部を成形するように形成されている。   In the mold 80, the first groove portion 81b and the second groove portion 81d of the fixed mold 81 and the end surface 52a of the fixed mold mounting plate 52 form a rib portion molding portion 80b for molding the rib portion of the foamed resin molded product, The rib portion molding portion 80b is formed so as to mold a rib portion formed in an undercut shape with respect to the standing direction of the rib portion.

具体的には、リブ部成形部８０ｂは、発泡樹脂成形品の本体部の表面と略直交する方向に延びる複数のリブ部本体部と、該リブ部本体部の立設方向と略直交する方向に延び複数のリブ部本体部の端部どうしを連結するリブ部連結部とを有するリブ部を成形するように形成され、前記リブ部、具体的には前記リブ部本体部の立設方向に対してアンダーカット状に形成されるリブ部を成形するように形成されている。   Specifically, the rib portion molding portion 80b includes a plurality of rib portion main body portions extending in a direction substantially orthogonal to the surface of the main body portion of the foamed resin molded product, and a direction substantially orthogonal to the standing direction of the rib portion main body portion. A rib portion having a rib portion connecting portion that connects end portions of the plurality of rib portion main body portions to each other, and is formed in the standing direction of the rib portion, specifically, the rib portion main body portion. On the other hand, the rib portion formed in an undercut shape is formed.

一方、発泡樹脂成形品の本体部を成形するための本体部成形部８０ｃは、本体部２２のキャビティ成形面２２ａ及びピン部２４のキャビティ成形面２４ａからなる可動側の本体部成形部と、固定型８１のキャビティ成形面８１ａからなる固定側の本体部成形部とによって形成されている。   On the other hand, the main body molding part 80c for molding the main body part of the foamed resin molded product is fixed to the movable main body molding part composed of the cavity molding surface 22a of the main body part 22 and the cavity molding surface 24a of the pin part 24. The mold 81 is formed by a fixed-side main body molding portion comprising the cavity molding surface 81a of the mold 81.

このようにして構成される金型８０を用いる場合においても、図７に示すように金型８０が型閉めされた状態で、キャビティ８０ａに発泡性樹脂３１が射出装置３０から注入され、溶融状態の発泡性樹脂３１がキャビティ８０ａに充填された後に、キャビティ８０ａの容積を拡大させるように可動型６１が型開き方向に移動される。   Even in the case of using the mold 80 configured as described above, the foamable resin 31 is injected from the injection device 30 into the cavity 80a with the mold 80 closed as shown in FIG. After the foamable resin 31 is filled in the cavity 80a, the movable mold 61 is moved in the mold opening direction so as to increase the volume of the cavity 80a.

図８は、図７に示す金型において発泡樹脂成形品の本体部とリブ部とを形成する方法を説明するための断面説明図である。図８に示すように、キャビティ８０ａに発泡性樹脂３１が充填された後に可動型６１が型開き方向（矢印Ｘ３で示す方向）に移動されると、本体部９１と、該本体部９１の表面に立設されるリブ部９５とを有する発泡樹脂成形品９０が成形され、リブ部９５は、本体部９１の表面と略直交する方向に延びる複数のリブ部本体部９６と、該リブ部本体部９６の立設方向と略直交する方向に延び複数のリブ部本体部９６の端部どうしを連結するリブ部連結部９７とを有し、リブ部９５、具体的にはリブ部本体部９６の立設方向に対してアンダーカット状に形成されている。発泡樹脂成形品９０の本体部９１は本体部成形部８０ｃによって成形され、発泡樹脂成形品９０のリブ部９５はリブ部成形部８０ｂによって成形される。   FIG. 8 is a cross-sectional explanatory view for explaining a method of forming the main body portion and the rib portion of the foamed resin molded product in the mold shown in FIG. As shown in FIG. 8, when the movable mold 61 is moved in the mold opening direction (the direction indicated by the arrow X3) after the cavity 80a is filled with the foamable resin 31, the main body portion 91 and the surface of the main body portion 91 are moved. A foamed resin molded product 90 having a rib portion 95 standing upright is formed. The rib portion 95 includes a plurality of rib portion main body portions 96 extending in a direction substantially orthogonal to the surface of the main body portion 91, and the rib portion main body. A rib portion connecting portion 97 that extends in a direction substantially orthogonal to the standing direction of the portion 96 and connects end portions of the plurality of rib portion main body portions 96, and includes a rib portion 95, specifically, the rib portion main body portion 96. It is formed in an undercut shape with respect to the standing direction. The main body portion 91 of the foamed resin molded product 90 is molded by the main body portion molded portion 80c, and the rib portion 95 of the foamed resin molded product 90 is molded by the rib portion molded portion 80b.

また、発泡樹脂成形品９０においても、本体部９１は、その表面が表面層である非発泡のスキン層９２によって形成されるとともに該スキン層９２の内側に発泡性樹脂３１の発泡が促進された発泡層９３が形成され、リブ部９５は、非発泡状態で形成されている。なお、発泡樹脂成形品９０の本体部９１には、その周縁部に縦壁部９４が形成されており、該縦壁部９４は、非発泡状態で形成されている。   Also in the foamed resin molded product 90, the main body 91 is formed by a non-foamed skin layer 92 whose surface is a surface layer, and foaming of the foamable resin 31 is promoted inside the skin layer 92. The foam layer 93 is formed, and the rib portion 95 is formed in a non-foamed state. The main body 91 of the foamed resin molded product 90 has a vertical wall 94 formed at the peripheral edge thereof, and the vertical wall 94 is formed in a non-foamed state.

このようにして本体部９１とリブ部９５とを有する発泡樹脂成形品９０を成形した後に発泡樹脂成形品９０を取り出す際には、可動型６１が型開き方向に移動されて金型８０が型開きされ、リブ部成形部８０ｂにリブ部９５を保持した状態で、リブ部９５の立設方向にリブ部９５と本体部９１とを離間させることにより、リブ部９５に連続する本体部９１のスキン層９２を剥離して発泡層９３を露出させる。   When the foamed resin molded product 90 having the main body portion 91 and the rib portion 95 is formed in this way and then taken out, the movable mold 61 is moved in the mold opening direction, and the mold 80 is moved to the mold. In the state where the rib portion 95 is held in the rib portion molding portion 80b, the rib portion 95 and the main body portion 91 are separated in the standing direction of the rib portion 95, so that the main body portion 91 continuous with the rib portion 95 is removed. The skin layer 92 is peeled off to expose the foam layer 93.

図９は、図７に示す金型において発泡樹脂成形品の本体部とリブ部とを離間させる方法を説明するための断面説明図であり、図９（ａ）は、金型を型開きした状態を示し、図９（ｂ）は、可動型の本体部に対してピン部を突出させた状態を示し、図９（ｃ）は、固定型取付プレートに対して固定型を移動させた状態を示している。   FIG. 9 is a cross-sectional explanatory diagram for explaining a method of separating the main body portion and the rib portion of the foamed resin molded product in the mold shown in FIG. 7, and FIG. 9 (a) shows the mold opened. FIG. 9 (b) shows a state in which the pin portion protrudes from the movable body portion, and FIG. 9 (c) shows a state in which the fixed die is moved relative to the fixed die mounting plate. Is shown.

図９（ａ）に示すように、発泡樹脂成形品９０を成形した後に取り出す際には、本体部２２及びピン部２４を一体として可動型６１を型開き方向（矢印Ｘ３に示す方向）に移動させて金型８０を型開きし、リブ部成形部８０ｂにリブ部９５を保持した状態で、発泡樹脂成形品９０の本体部９１を可動型６１とともに移動させる。なお、本体部９１は、その周縁部に縦壁部９４を備え、可動型６１を移動させる際に可動型６１に保持されるように形成されている。   As shown in FIG. 9A, when the foamed resin molded product 90 is molded and taken out, the movable part 61 is moved in the mold opening direction (direction indicated by the arrow X3) with the main body part 22 and the pin part 24 integrated. Then, the mold 80 is opened, and the main body 91 of the foamed resin molded product 90 is moved together with the movable die 61 in a state where the rib portion 95 is held by the rib portion molding portion 80b. The main body portion 91 includes a vertical wall portion 94 at the periphery thereof, and is formed to be held by the movable die 61 when the movable die 61 is moved.

発泡樹脂成形品９０の本体部９１が可動型６１とともに移動されるとき、リブ部９５はリブ部連結部９７によってリブ部９５の立設方向にアンダーカット状に形成されているのでリブ部成形部８０ｂに保持された状態で、リブ部９５に連続する本体部９１のスキン層９２がリブ部９５とともに本体部９１から剥離され、本体部９１のスキン層９２に開口部９２ａが形成されて発泡層９３が露出させられる。   When the main body portion 91 of the foamed resin molded product 90 is moved together with the movable die 61, the rib portion 95 is formed in an undercut shape in the standing direction of the rib portion 95 by the rib portion connecting portion 97. The skin layer 92 of the main body 91 that continues to the rib portion 95 is peeled from the main body 91 together with the rib 95 while being held at 80b, and an opening 92a is formed in the skin layer 92 of the main body 91 to form a foam layer. 93 is exposed.

金型８０が型開きされると次に、図９（ｂ）に示すように、可動型６１の本体部２２に対してピン部２４を金型８０の型閉じ方向（矢印Ｘ４で示す方向）に突出させ、本体部成形部８０ｃ、具体的には可動側の本体部成形部を構成する本体部２２のキャビティ成形面２２ａから金型８０の開閉方向に発泡樹脂成形品９０の本体部９１を突出させ、これにより、発泡樹脂成形品９０の本体部９１が金型８０から落下し、発泡樹脂成形品９０が取り出されることとなる。このようにして、金型８０を用いて、スキン層９２の一部を剥離して発泡層９３を露出させた発泡樹脂成形品９０を製造することができる。   When the mold 80 is opened, next, as shown in FIG. 9B, the pin 24 is closed with respect to the main body 22 of the movable mold 61 (the direction indicated by the arrow X4). The main body portion 91 of the foamed resin molded product 90 is moved in the opening / closing direction of the mold 80 from the cavity molding surface 22a of the main body portion 22 constituting the main body portion molding portion 80c. Thus, the main body 91 of the foamed resin molded product 90 falls from the mold 80, and the foamed resin molded product 90 is taken out. In this way, using the mold 80, it is possible to produce a foamed resin molded product 90 in which a part of the skin layer 92 is peeled and the foamed layer 93 is exposed.

発泡樹脂成形品９０を製造した後には、図９（ｃ）に示すように、固定型８１を可動型６１側（矢印Ｘ５で示す方向）に移動させ、その後に、リブ部成形部８０ｂに保持されたリブ部９５に対して図示しないエアー供給装置からエアーを吹き付けることによりリブ部９５が金型８０から落下して取り除かれる。   After the foamed resin molded product 90 is manufactured, as shown in FIG. 9C, the fixed die 81 is moved to the movable die 61 side (in the direction indicated by the arrow X5), and then held by the rib portion molding portion 80b. The rib 95 is dropped from the mold 80 and removed by blowing air from an air supply device (not shown) to the rib 95 formed.

このように、本発明の第３の実施形態に係る金型を用いる場合においても、金型８０は、発泡樹脂成形品９０の本体部９１を成形するための本体部成形部８０ｃと、本体部９１の表面に立設されるリブ部９５を成形するためのリブ部成形部８０ｂとを有し、リブ部成形部８０ｂは、リブ部９５の立設方向に対してアンダーカット状に形成されるリブ部９５を成形するように形成され、金型８０は、本体部９１とリブ部９５とを有する発泡樹脂成形品９０を成形した後に発泡樹脂成形品９０を取り出す際に、リブ部成形部８０ｂにリブ部９５を保持した状態でリブ部９５の立設方向にリブ部９５と本体部９１とを離間させることにより、リブ部９５に連続する本体部９１のスキン層９２を剥離して本体部９１の発泡層９３を露出させるように構成されている。   As described above, even when the mold according to the third embodiment of the present invention is used, the mold 80 includes the main body molding portion 80c for molding the main body 91 of the foamed resin molded product 90, and the main body. The rib portion molding portion 80b for molding the rib portion 95 standing on the surface of 91 is formed, and the rib portion molding portion 80b is formed in an undercut shape with respect to the standing direction of the rib portion 95. The rib 80 is formed to mold the rib portion 95. The mold 80 is formed when the foamed resin molded product 90 is taken out after the foamed resin molded product 90 having the main body portion 91 and the rib portion 95 is molded. The rib portion 95 and the main body portion 91 are separated in the standing direction of the rib portion 95 while the rib portion 95 is held, whereby the skin layer 92 of the main body portion 91 continuous with the rib portion 95 is peeled off to separate the main body portion. 91 so that the foam layer 93 is exposed. It is.

これにより、比較的簡単な構成を有する金型８０を用い、発泡樹脂成形品９０のスキン層９２の一部を剥離して発泡層９３を露出させることができ、発泡樹脂成形品９０の強度低下を抑制しつつスキン層９２の一部を剥離して発泡層９３を露出させた発泡樹脂成形品９０を成形することができる。   As a result, the mold 80 having a relatively simple configuration can be used to peel off a part of the skin layer 92 of the foamed resin molded product 90 to expose the foamed layer 93, thereby reducing the strength of the foamed resin molded product 90. A foamed resin molded product 90 in which a part of the skin layer 92 is peeled and the foamed layer 93 is exposed can be molded while suppressing the above.

本発明は、例示された実施の形態に限定されるものではなく、本発明の要旨を逸脱しない範囲において、種々の改良及び設計上の変更が可能であることは言うまでもない。   The present invention is not limited to the illustrated embodiments, and it goes without saying that various improvements and design changes can be made without departing from the gist of the present invention.

以上のように、本発明によれば、発泡樹脂成形品の強度低下を抑制しつつスキン層の一部を剥離して発泡層を露出させた発泡樹脂成形品を成形することができる発泡樹脂成形品成形用の金型構造を提供することが可能となるから、樹脂成形の技術分野において好適に利用される可能性がある。   As described above, according to the present invention, a foamed resin molded product capable of molding a foamed resin molded product in which a foamed layer is exposed by peeling a part of the skin layer while suppressing a decrease in strength of the foamed resin molded product. Since it becomes possible to provide a mold structure for molding an article, it may be suitably used in the technical field of resin molding.

１０、５０、８０、１１０ 金型
１０ａ、５０ａ、８０ａ、１１０ａ キャビティ
１０ｂ、５０ｂ、８０ｂ リブ部成形部
１０ｃ、５０ｃ、８０ｃ 本体部成形部
３１ 発泡性樹脂
４０、７０、９０、１００ 発泡樹脂成形品
４１、７１、９１、１０１ 本体部
４２、７２、９２、１０２ スキン層
４３、７３、９３、１０３ 発泡層
４５、７５、９５、１０５ リブ部 10, 50, 80, 110 Mold 10a, 50a, 80a, 110a Cavity 10b, 50b, 80b Rib part molding part 10c, 50c, 80c Body part molding part 31 Expandable resin 40, 70, 90, 100 Foamed resin molded product 41, 71, 91, 101 Body portion 42, 72, 92, 102 Skin layer 43, 73, 93, 103 Foam layer 45, 75, 95, 105 Rib portion

Claims (2)

発泡樹脂成形品を成形するためのキャビティを有するとともに該キャビティの容積が拡大可能に構成された金型を備え、溶融状態の発泡性樹脂を該キャビティに充填した後に該キャビティの容積を拡大することにより表面層であるスキン層と該スキン層の内側に設けられる発泡層とを有する発泡樹脂成形品を成形し、その後に前記スキン層の一部を剥離して前記発泡層を露出させるようにした発泡樹脂成形品成形用の金型構造であって、
前記金型は、発泡樹脂成形品の本体部を成形するための本体部成形部と、前記本体部の表面に立設されるリブ部を成形するためのリブ部成形部とを有し、該リブ部成形部は、前記リブ部の立設方向に対してアンダーカット状に形成される前記リブ部を成形するように形成され、
前記金型は、前記本体部と前記リブ部とを有する発泡樹脂成形品を成形した後に該発泡樹脂成形品を取り出す際に、前記リブ部成形部に前記リブ部を保持した状態で前記リブ部の立設方向に前記リブ部と前記本体部とを離間させることにより、前記リブ部に連続する前記本体部のスキン層を剥離して前記本体部の発泡層を露出させるように構成され、
前記金型は、前記キャビティを形成する本体部と該本体部に設けられた開口部内に移動可能に挿入されたコア部とを有し、前記リブ部成形部が、前記コア部に設けられた前記リブ部を成形するための溝部と前記本体部の開口部とによって形成され、前記発泡樹脂成形品のリブ部と本体部とを離間させた後に前記コア部を移動させることにより前記本体部の開口部によって成形された前記リブ部の成形面を露出させるように構成されている、
ことを特徴とする発泡樹脂成形品成形用の金型構造。 A mold having a cavity for molding a foamed resin molded product and capable of expanding the volume of the cavity, and expanding the volume of the cavity after filling the cavity with a molten foamable resin. To form a foamed resin molded article having a skin layer as a surface layer and a foam layer provided on the inside of the skin layer, and then peeling off a part of the skin layer to expose the foam layer. A mold structure for molding a foamed resin molded product,
The mold has a main body part molding part for molding the main body part of the foamed resin molded product, and a rib part molding part for molding a rib part standing on the surface of the main body part, The rib part molding part is formed so as to mold the rib part formed in an undercut shape with respect to the standing direction of the rib part,
The mold has the rib portion in a state where the rib portion is held in the rib portion molding portion when the foamed resin molded product is taken out after the foam resin molding product having the main body portion and the rib portion is molded. By separating the rib portion and the main body portion in the standing direction, the skin layer of the main body portion continuous to the rib portion is peeled off to expose the foam layer of the main body portion ,
The mold includes a main body part that forms the cavity and a core part that is movably inserted into an opening provided in the main body part, and the rib part molding part is provided in the core part. The rib part is formed by a groove part and an opening part of the main body part, and the core part is moved by moving the core part after separating the rib part and the main body part of the foamed resin molded product. It is configured to expose the molding surface of the rib part molded by the opening,
A mold structure for molding a foamed resin molded product. 前記金型は、前記本体部成形部から前記発泡樹脂成形品の本体部を突出させる突出部材を備え、前記発泡樹脂成形品を取り出す際に、前記リブ部成形部に前記リブ部を保持した状態で前記突出部材によって前記本体部成形部から前記本体部を突出させて前記リブ部と前記本体部とを離間させるように構成されている、
ことを特徴とする請求項１に記載の発泡樹脂成形品成形用の金型構造。 The mold includes a projecting member for projecting the main body portion of the foamed resin molded product from the main body portion molding portion, and the rib portion is held in the rib portion molding portion when the foamed resin molded product is taken out. The projecting member is configured to project the body part from the body part molding part to separate the rib part and the body part,
The mold structure for molding a foamed resin molded product according to claim 1.
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