DE112018006986T5 - RESIN MOLDING AND MOLDING PROCESS FOR A RESIN MOLD - Google Patents

Abstract

Provided are: a resin mold which is formed by gas pressure molding in which a sealant for a resin molding mold is not required and which is not limited by a parting line and which is both weight reduction by slimming the resin -Form as well as gain from it; and a molding method for the resin mold. A front cover 52 is molded by applying a pressurized gas to molten resin in a resin molding die 75. In the front cover 52, a gas seal rib 52d is integrally formed in a wall 52x, and the gas seal rib 52d is arranged to surround a predetermined area of the wall 52x. A thickness of the wall 52x in a portion surrounded by the gas seal rib 52d is formed to be smaller than a thickness of other parts of the wall 52x.

Description

Technical field

The present invention relates to a resin mold and a molding method for the resin mold.

State of the art

It is conventionally known that a cavity is provided inside a resin mold and molten resin is pressurized with inert gas in an injection mold to prevent sink marks from occurring due to the shrinkage of the resin (see, for example Patent Literature 1 and Patent Literature 2).

Further, in order to increase the strength of a protruding part formed in the resin mold, an arcuate rib (so-called “corner R”) is provided at the corner of the base of the protrusion by a gas assist method (see Patent Literature 1).

List of quotes

Patent literature

• Patent Literature 1: Japanese patent publication number 2008-911
• Patent literature 2: Japanese Patent Publication Number 10-058477

Summary of the invention

Technical problem

In each of Patent Literature 1 and 2, a gas passage is provided for the gas to pass inside the resin mold, resulting in an increase in the thickness of the resin, and therefore not in reducing the weight of the whole resin mold and reducing it Materials contributes. In order to cause gas pressure to act directly on the cavity surface of the molten resin, a sealant is required on the mating surface of the resin molding die along a parting line so that the gas does not leak from the parting line of the resin molding die.

An object of the present invention is to provide: a resin mold formed by gas pressure molding in which a sealant for a resin molding mold is not required and which is not limited by a parting line and both Can achieve reinforcement as well as weight reduction by slimming the resin mold; and a molding method for the resin mold.

the solution of the problem

This description includes all the contents of the Japanese Patent Application No. 2018-015910 , which was registered on January 31, 2018.

The present invention is a resin molding mold which is produced by applying a pressurized gas to a resin in a resin molding mold ( 22nd , 75 ) is shaped, with an elongated rib-like protrusion ( 10a , 52d , 56k) integral in a wall ( 10b , 52x) is formed, wherein the elongated rib-like projection ( 10a , 52d , 56k) is arranged around a predetermined area of the wall ( 52x) to surround, and a thickness of the wall ( 10b , 52x) in a section which extends over the elongated rib-like projection ( 10a , 52d , 56k) is surrounded, is designed to be smaller than thicknesses of other parts of the wall ( 10b , 52x) .

In the above invention, a reinforcement rib ( 52m , 52q , 52r , 56a) which has a greater extent of protrusion from a face of the wall ( 52x) than the elongated rib-like protrusion ( 52d) , in the wall ( 52x) be provided integrally and a gradually changing thickness part ( 56d) in which there is a thickness of the wall ( 52x) changes gradually, between the elongated rib-like protrusion ( 52d) and the reinforcement rib ( 52m , 52q , 52r , 56a) be provided.

In the above invention, the elongated rib-like protrusion ( 52d) the reinforcement rib ( 52q , 52r) Cut at an angle of at least 20 degrees or more and a height of the elongated rib-like protrusion ( 52d) can be less than a height of the reinforcement rib ( 52q , 52r) .

Further, in the above invention, the elongated rib-like protrusion ( 52d) continuously on one edge of the wall ( 52x) be provided.

In the above invention, an opening ( 56j) in the wall ( 52x) be provided and the elongated rib-like projection ( 52d) can be continuous along a contour of the opening ( 56j) the Wall ( 52x) be provided.

The present invention is a molding method for a resin mold which is produced by applying a pressurized gas to a resin in a resin molding mold ( 22nd , 75 ) is shaped, with an elongated rib-like protrusion ( 10a , 52d , 56k) which covers a predetermined area of a surface of a wall ( 52x) surrounds, in the wall ( 52x) the resin mold ( 10 , 52 ) is formed and an enclosed part ( 10c , 56x) , which over the elongated rib-like projection ( 10a , 52d , 56k) is surrounded, is sealed to the pressurized to hold displaced gas by a directional solidification, in which resin in the elongated rib-like protrusion ( 10a , 52d , 56k) solidifies faster than other places.

In the above invention, a reinforcement rib ( 52m , 52q , 52r , 56a) which has a greater extent of protrusion from a face of the wall ( 52x) than the elongated rib-like protrusion ( 52d) , in the wall ( 52x) be integrally formed and a gradually changing thickness part ( 56d) in which there is a thickness of the wall ( 52x) changes gradually, between the elongated rib-like protrusion ( 52d) and the reinforcement rib ( 52m , 52q , 52r , 56a) be provided.

In the above invention, the elongated rib-like protrusion ( 52d) from the reinforcement rib ( 52q , 52r) cut at an angle of at least 20 degrees or more and a height of the elongated rib-like protrusion ( 52d) can be made smaller than a height of the reinforcement rib ( 52q , 52r) .

Further, in the above invention, the elongated rib-like protrusion ( 52d) continuously on one edge of the wall ( 52x) be provided.

In the above invention, an opening ( 56j) in the wall ( 52x) be provided and the elongated rib-like projection ( 52d) can be continuous along a contour of the opening ( 56j) the Wall ( 52x) be provided.

Advantageous Effects of the Invention

In the present invention, the elongated rib-like protrusion is integrally formed in the wall, the elongated rib-like protrusion being arranged to surround a predetermined area of the wall and the thickness of the wall in the portion which is above the elongated ribs -like protrusion is formed to be smaller than the thicknesses of other parts of the wall, so that it is possible to reduce the thickness of the resin mold and reduce the weight of the resin mold. Further, the resin mold can be reinforced by reinforcing its rigidity with the elongated rib-like projection, thereby improving the anti-impact durability of the resin mold. In addition, sealing is possible to prevent the pressurized gas from leaking to the outside in the elongated rib-like protrusion, thereby enabling the production of the slender and reinforced resin mold described above, wherein the sealant intended for the resin mold is not required and is not limited by a parting line.

In the above invention, the reinforcement rib, which has a larger amount of protrusion from one face of the wall than the elongated rib-like protrusion, is integrally provided in the wall, and a gradually changing thickness part in which the thickness of the Wall gradually changes is provided between the elongated rib-like protrusion and the reinforcement rib so that it is possible to appropriately arrange a portion which requires rigidity and a portion which does not require so much rigidity in the wall.

In the above invention, the elongated rib-like protrusion intersects the reinforcing rib at an angle of at least 20 degrees or more, and the height of the elongated rib-like protrusion is smaller than the height of the reinforcing rib, thereby making it possible to reduce the load -Reduce concentration at a point where the elongated rib-like protrusion and reinforcement ribs intersect, and prevent an insert groove from being formed at the interface.

Further, in the above invention, with the elongated rib-like projection continuously provided on an edge of the wall, the wall near the edge of the resin mold can be made thinner without impairing the appearance of the resin mold.

In the above invention, the opening is provided in the wall and the elongated rib-like projection is continuously provided along the contour of the opening of the wall so that the wall near the opening of the resin mold can be slimmed down without the appearance of Impact resin mold.

In the present invention, in the wall of the resin mold, an elongated rib-like protrusion surrounding a predetermined area of a face of a wall is formed, and the enclosed part surrounded by the elongated rib-like protrusion is sealed to hold the pressurized gas by directional solidification, in which resin in the elongated rib-like protrusion is solidified faster than in the other places, so that it is possible to reduce the thickness of the resin mold and the weight reduce the resin mold. Further, by increasing its rigidity with the elongated rib-like protrusion, the resin mold can be reinforced, thereby improving the anti-impact durability of the resin mold. In addition, by performing the seal to prevent the pressurized gas from leaking to the outside in the elongated rib-like protrusion, it is possible to be slimmed down and The reinforced resin mold described above can be produced without being limited by a parting line of the resin molding mold.

In the above invention, the reinforcement rib, which has a larger amount of projection from the surface of the wall than the elongated rib-like projection, is integrally formed in the wall and the gradually changing thickness part in which a thickness of the Wall gradually changes has been provided between the elongated rib-like protrusion and the reinforcement rib, so that it is possible to appropriately arrange a portion which requires the rigidity and a portion which does not require so much rigidity in the wall.

In the above invention, the elongated rib-like protrusion has been cut from the reinforcement rib at an angle of at least 20 degrees or more, and the height of the elongated rib-like protrusion has been made smaller than the height of the reinforcement rib, thereby making it It is possible to reduce the stress concentration at a point where the elongated rib-like protrusion and the reinforcement ribs intersect and prevent an insert groove from being formed at the interface.

Further, in the above invention, the elongated rib-like projection has been continuously provided on an edge of the wall, and therefore the wall near the edge of the resin mold can be slimmed down without deteriorating the appearance of the resin mold.

In the above invention, the opening has been provided in the wall and the elongated rib-like projection is continuously provided along the contour of the opening of the wall so that the wall near the opening of the resin mold can be slimmed down without the appearance affect the resin mold.

Figure list

• 1 Fig. 13 is an action view showing principles of a resin mold and a molding method for the resin mold according to the present invention.
• 2 FIG. 13 is an enlarged view of a main part of FIG 1 .
• 3 Fig. 13 is a perspective view showing a motorcycle.
• 4th Fig. 13 is a perspective view showing the front of a vehicle body of the motorcycle.
• 5 Fig. 13 is a perspective view showing a rear surface of a front cover.
• 6th Fig. 13 is a front view showing the rear surface of the front cover.
• 7th FIG. 13 is a perspective view showing part A of FIG 6th shows.
• 8th FIG. 8 is a sectional view taken along a line VIII-VIII in FIG 7th .
• 9 FIG. 14 is an enlarged view showing part B of FIG 6th shows.
• 10 FIG. 14 is a sectional view taken along line XX of FIG 9 .
• 11 FIG. 13 is a perspective view including a cross section taken along a line XI-XI in FIG 6th .
• 12 Fig. 13 is a transparent view of a core mold in a resin molding mold from the cavity mold side.
• 13 FIG. 13 is a sectional view taken along a line XIII-XIII in FIG 12 .
• 14th FIG. 13 is a perspective view showing part C of FIG 6th shows.
• 15th FIG. 15 is a perspective view including a cross section taken along a line XV-XV in FIG 14th .
• 16 FIG. 13 is a perspective view showing part D of FIG 6th shows.
• 17th FIG. 16 is a sectional view taken along a line XVII-XVII of FIG 6th .
• 18th Fig. 13 is a perspective view showing a lower part of the front cover.
• 19th Fig. 13 is a perspective view showing the lower part of the front cover from a rear surface side.
• 20th Fig. 13 is a front view showing a part of a front surface of an inclined core.
• 21st FIG. 10 is a sectional view taken along a line XXI-XXI in FIG 19th .
• 22nd Fig. 13 is a perspective view showing an opening and its vicinity of a back bend wall in the front cover.

Description of an embodiment

The following describes an embodiment of the present invention with reference to the drawings.

1 Fig. 13 is an action view showing principles of a resin mold 10 and a molding method for the resin mold 10 according to the present invention shows, and 2 FIG. 13 is an enlarged view of a main part of FIG 1 .

As shown in 1 includes an injection molding device 20th an injection molding machine 21st and a resin molding mold 22nd which with the injection molding machine 21st connected is.

The injection molding machine 21st includes a cylinder 23 . In the cylinder 23 resin which is introduced into the inside is heated and melted, and further the melted resin (melted resin 38 ) from a nozzle 23a into the resin-forming mold 22nd injected which at a tip of the cylinder 23 is provided.

The resin-forming mold 22nd is of a fortified form 25th which with the injection molding machine 21st connected, and a movable shape 26th formed which in the fortified form 25th is slidably provided. The fortified form 25th and the movable form 26th are on a dividing line 27 combined and the fortified form 25th and the movable form 26th form a cavity 28 which is a resin mold 10 forms.

The fortified form 25th includes a passage 25a through which molten resin 38 passes through. The passage 25a has one end with the nozzle 23a the injection molding machine 21st connected and the other end to the cavity 28 connected on.

The movable form 26th includes a recess 31 showing the cavity 28 forms, and a gas channel 32 , which one with the recess 31 communicates.

The recess 31 includes a groove 31a which is continuously formed in an endless shape on the circumference. At the time of making the resin mold 10 forms the groove 31a a gas seal rib 10a as an elongated rib-like protrusion and the recess 31 forms a plate-like wall 10b showing the gas seal rib 10a includes.

The gas duct 32 is from a main passage 34 which is connected to an external gas supply source, and a plurality of sub-passages 35 formed which in the main passage 34 are formed, and a tip of the sub-passage 35 communicates with the recess 31 .

Next is an effect of the injection molding apparatus 20th to be discribed.

In 1 becomes the melted resin first 38 in the cylinder 23 from the nozzle 23a into the resin-forming mold 22nd injected. The melted resin 38 flows into the cavity 28 through the passage 25a . From the melted resin 38 , which in the cavity 28 has flowed, directional solidification becomes the molten resin 38 in the groove 31 a solidifies faster than the molten resin 38 in the other sections.

At that time, as indicated by an arrow in 2 for example, nitrogen gas is displayed as an inert gas from the gas channel 32 between a floor area 31b the recess 31 and the melted resin 38 in the cavity 28 while being pressurized as compressed to a predetermined pressure.

As a result, the gas pressure acts on the unsolidified molten resin 38 in the cavity 28 one and the melted resin 38 becomes against an inner cavity surface 25b the attached form 25th pressed. At this time, the gas seal becomes rib 10a , which by solidification in the groove 31a is formed, a sealing part and allows leakage of the injected nitrogen gas from the cavity 28 to the outside of the resin molding mold 22nd across the dividing line 27 prevent. This eliminates the need specifically for a sealing member in the resin molding mold 22nd to provide.

By continuing the action of gas pressure on the unsolidified molten resin 38 can be a thickness T of the resin mold 10 caused by the solidification of the molten resin 38 is formed in an enclosed part 10c be made small, the one with the annular gas seal rib 10a in the wall 10b is surrounded. This can be the weight of the resin mold 10 to reduce. Furthermore, the gas seal rib 10a the stability of the resin mold 10 improve.

Next, a description will be given of an example of application of the resin mold 10 and the molding method for the resin mold 10 on a motorcycle 40 are given. In the following description, directions such as front and rear, right and left, and up and down are assumed to be directions with respect to a vehicle body unless otherwise described. Further, in each figure, a reference symbol FR denotes the front of the vehicle body, a reference symbol UP denotes the upper part of the vehicle body, and a reference symbol LH denotes the left side of the vehicle body.

3 Fig. 13 is a perspective view showing a motorcycle 40 shows, and 4th Fig. 13 is a perspective view showing a front body part 44 of the motorcycle 40 shows.

As shown in 3 , is the motorcycle 40 a scooter-type vehicle. The motorcycle 40 includes: the front body part 44 , which with a front wheel 41 is provided and handles 42 to steer the front wheel 41 ; a back part of the body 48 , which one with a rear wheel 45 which is a drive wheel and a seat 46 which is above the rear wheel 45 is arranged; and a step floor 49 which is between the front body part 44 and the back of the body 48 connects.

Additionally are the front body part 44 and the back part of the body 48 with a body cover 51 covered.

As shown in 4th that includes the body cover 51 in the front part of the body 44 a front cover 52 , a pair of right and left leg shields 53 and a handle cover 54 . In 4th is the front cover 52 in a state in which it has been removed from the vehicle body.

The front cover 52 covers a front fork (not shown) to the front wheel 41 to hold (see 3 ) while by the handle 42 rotated from the front.

The right and left leg shields 53 extend from right and left edges of the front cover 52 to the rear sloping side to legs of a driver who is on the seat 46 sits (see 3 ) to cover from the front.

The handle cover 54 covers a central part of the handle 42 . 5 Fig. 13 is a perspective view showing a rear surface of the front cover 52 shows and a posterior surface 52a the front cover 52 shows. 6th Fig. 3 is a front view showing the rear face 52a the front cover 52 shows. Though the gas seal rib 52d which is shown below is a single rib that continuously extends in an annular shape, has been given a reference number "52d" to each of the upper part, the lower part and both sides of the gas seal rib 52d added to make it easier to capture the shape.

As shown in 5 and 6th is in the front cover 52 a posterior surface 52a provided integrally with: a reinforcement rib assembly 52b which is formed from a plurality of reinforcement ribs; a gas seal rib 52d which in an endless shape on a perimeter 52c or near the perimeter 52c is formed; and a protrusion arrangement 52e which is formed from a plurality of protruding portions. In other words, are in the front cover 52 the reinforcement rib arrangement 52b who have favourited Gas Seal Rib 52d and the protrusion arrangement 52e from the rear face 52a a wall 52x in front.

The projection arrangement 52e is made up of a pair of right and left clip-nut mounting seats 52f , a pair of right and left undercut rib parts 52g , a plurality of clip fasteners 52h , a plurality of set projection fastening parts 52y and a ribbed protrusion attachment member 52k educated.

A clip nut is on an upper part of the clip nut mounting seat 52f appropriate. The undercut rib part 52g includes a rib for reinforcement of each of right and left sides of an upper part of the front cover 52 . The clip fastener 52h is with each of the right and left leg shields 53 (please refer 4th ) engaged by a clip (not shown). The set protrusion fastener 52y has a screw hole formed in a tip face of a column and the ribbed protrusion fixing part 52k is a portion in which a plurality of ribs are radially formed on an outer peripheral surface of a column, and has a screw hole on the tip surface of the column. The set protrusion fastener 52y and the ribbed protrusion attachment part 52k attach a reinforcement plate (not shown) to the front cover 52 with a screw.

As shown in 6th are a plurality of inclined cores 61 to 67 for sticking out a plurality of undercuts (including the pair of right and left undercut rib parts 52g) which on the rear surface 52a the front cover 52 are provided in a resin molding mold 75 arranged (see 12 ).

7th FIG. 13 is a perspective view showing part A of FIG 6th shows, and 8th FIG. 8 is a sectional view taken along a line VIII-VIII in FIG 7th .

As shown in 7th , is the gas seal rib 52d along an edge reinforcement rib 52m inside the edge reinforcement rib 52m formed on the periphery of the front cover 52 is formed.

From the edge reinforcement ribs 52m , extend between reinforcement ribs 52n , 52p , toward one side of a central part of the front cover 52 .

The gas seal rib 52d while it extends the intermediate reinforcement ribs 52n , 52p cuts.

As shown in 8th when a height of the gas seal rib 52d H1 and a width of an upper end of the gas seal rib 52d W1 is, the height H1 is smaller than a height He of the edge reinforcement ribs 52m (H1 <He) and the width W1 is smaller than a width We of the edge reinforcement ribs 52m (W1 <We). When a thickness of the wall 52x between the gas seal rib 52d and the edge reinforcement rib 52m Tg is (see also 13 ) and a thickness of the wall 52x on the opposite side to the edge reinforcement rib 52m the gas seal rib 52d Tf is (see also 13 ) the width W1 is smaller than the thickness Tf (W1 <Tf).

As described therefore, the gas seal rib 52d an elongated rib with a smaller cross-sectional area than that of the edge reinforcement rib 52m and is therefore easier to solidify than the other portions in a state of the molten resin. This can make the thickness Tf smaller than the thickness Tg as described above.

As described above, is the thickness of the wall 52x between the gas seal rib 52d and the edge reinforcement rib 52m has been set to the fixed thickness Tg, but the wall 52x can from the side of the gas seal rib 52d to the side of the edge reinforcement rib 52m be gradually thickened by a predetermined distance L by a gradually changing thickness part 56d (please refer 15th ) to build.

9 FIG. 14 is an enlarged view showing part B of FIG 6th shows, and 10 FIG. 14 is a sectional view taken along line XX of FIG 9 .

As shown in 9 , two intermediate reinforcement ribs extend 52q , 52r to a central side of the wall 52x from the edge reinforcement ribs 52m . The two intermediate reinforcement ribs 52q , 52r intersect each other and the gas seal rib 52d cuts the intermediate reinforcement ribs 52q , 52r .

An angle θ1 made between the inter-reinforcement rib 52q and the gas seal rib 52d and an angle θ2 formed between the inter-reinforcement ribs 52r and the gas seal rib 52d is formed are each 20 ° or more (θ1 20 °, θ2 20 °).

For example, when θ1 <20 ° and θ2 <20 ° are set, the volume of the intersecting portion increases. Therefore tends to be in a molding process for the intermediate reinforcement ribs 52q , 52r and the gas seal rib 52d an insert groove (dent) to be formed by pressurized gas acting on a place where the molten resin is slowly solidified at the cutting portion. The insert groove is a portion that deteriorates strength, and it is necessary to prevent the insert groove from being formed.

In the present embodiment, by setting θ1 20 ° and θ2 20 °, the volume of the cutting portion becomes small and the solidification of the cutting portion becomes faster, so it is possible to prevent the insertion groove from being formed. Further, by setting θ1 20 ° and θ2 20 °, the stress concentration at the cutting portion can be reduced. In addition, if θ1 20 ° and θ2 20 ° are set, the durability of the mold with respect to the mold is improved.

As in 10 shown, it is assumed that a height of the intermediate reinforcement rib 52q from the rear face 52a H2 and a width of a tip of the inter-reinforcement ribs 52q W2 is. The height H2 is greater than the height H1 of the gas seal ribs 52d , what a 8th and 9 is shown. The width W2 is greater than the width W1 of the gas seal ribs 52d , what a 8th and 9 are shown.

As shown in 8th and 9 , which are described above, intersects the gas seal rib 52d the intermediate reinforcement ribs 52q , 52r than the reinforcement ribs at an angle of at least 20 ° or more and the height of the gas seal rib 52d is less than the height of each of the intermediate reinforcement ribs 52q , 52r .

With this configuration, it is possible to reduce the stress concentration at the point where the gas seal rib 52d the intermediate reinforcement ribs 52q , 52r cuts, and to prevent the formation of the insert groove at the cutting point.

11 FIG. 13 is a perspective view showing a cross section taken along a line XI-XI in FIG 6th shows.

A honeycomb reinforcement part 52t in which a plurality of honeycomb reinforcement ribs 52s which protrude in a hexagonal shape is on the rear surface 52a the Wall 52x the front cover 52 integrally formed.

In the honeycomb reinforcement part 52t is an ultra-thin part 52w (see also 13 ) using a resin molding mold in the wall 52x within a predetermined honeycomb reinforcement rib 52s1 (which has the same shape as the honeycomb reinforcement ribs 52s , but has a reference number, which has been made different for an identification). It is assumed that a thickness of the ultra-thin part 52w Te is.

Further is the wall 52x inside honeycomb reinforcement ribs 52s2 , 52s3 (each of which has the same shape as the honeycomb reinforcement ribs 52s but a numeral has been made different for identification) to the honeycomb reinforcement rib 52s1 formed adjacently to have a thickness Te which is the same as the thickness of the ultra-thin part 52w , using the resin molding mold. When a thickness of each of ultra-thin parts 52z , 52z Tf is holds Te <Tf.

A gas duct slot 70 is in a core part 78 (please refer 12 ) the resin molding mold 75 formed, the honeycomb reinforcement part 52t forming (see 13 ). From the gas duct slot 70 the pressurized gas acts on the molten resin, which is the ultra-thin part 52w the Wall 52x which forms which with each of honeycomb reinforcement ribs 52s1 , 52s2 , 52s3 , ... is surrounded. Therefore, the pressurized gas makes the ultra-thin part 52w still smaller than the thickness determined by the resin molding die.

12 Figure 13 is a transparent view of a core shape 77 in the resin molding form 75 from the side of the posterior surface. Here for the identification of the cavity shape 76 and the core shape 77 To simplify, the cavity shape 76 represented by a broken line and the core shape 77 is represented by a solid line for simplicity. The shape of each part of the core shape 77 corresponds to the shape of each part of the front cover 52 , what a 6th is shown. However, it is the core shape 77 in relation to the front cover 52 , what a 6th is described as inverted right and left.

The resin-forming mold 75 includes a cavity shape 76 which is a fixed shape, a core shape 77 which is a movable shape, a core part 78 which is the honeycomb reinforcement part 52t forms (see 6th ), inclined nuclei 61 to 67 , a plurality of gas duct pins 79 and a plurality of ejector pins 80 .

The core part 78 for the honeycomb reinforcement part 52t and the inclined cores 61 to 67 are from one edge of the front cover 52 arranged away (see 6th ) and a plurality of (here five) gas channel slots 70 to 74 are parallel to the core part 78 provided.

In a case where the pressurized gas is applied to a compartment which is provided with the gas seal rib 52d surrounded are the plurality of gas channel pins 79 and the plurality of gas channel slots 70 to 74 in the core form 77 the resin molding mold 75 consistent with the shape of the front cover 52 , which is a work piece, suitably arranged (see 6th ).

In the present embodiment, the pressurized gas is delivered to an area which is passed through the plurality of honeycomb reinforcement ribs 52f is divided, formed by the core part 78 , over the gas duct slots 70 to 74 delivered which in the core part 78 are provided.

Places, with the exception of the honeycomb reinforcement part 52t , are divided by each reinforcement rib, and an opening larger than a width of each reinforcement rib is at a discharge port of the gas duct pin 79 provided, which is arranged at a tip of each reinforcement rib (see also 13 ), and the pressurized gas is supplied to a plurality of areas which are divided by each reinforcement rib. Also, depending on the location of the front cover 52 , there is also a place in which the gas duct pin 79 straight towards the wall 52x is provided.

13 FIG. 13 is a sectional view taken along a line XIII-XIII in FIG 12 .

The cavity shape 76 and the core shape 77 are on the dividing line 81 matching each other.

The cavity shape 76 includes an injection port 76a . The core shape 77 includes a gas distributor 83 in which a main passage 83a of the pressurized gas is formed, and a plurality of gas channel pins 79 which is from the main passage 83a of the gas distributor 83 extend. The main passage 83a of the gas distributor 83 is with a gas introduction passage 77a for introducing the pressurized gas from the outside of the resin molding mold 75 to the main passage 83a educated. The pressurized gas passes through the gas introduction passage 77a and the main passage 83a and also passes through the plurality of gas channel pins 79 and the gas duct slots 70 to 74 through (see 12 ) to go to each area inside the gas seal rib 52d to be delivered.

For the thickness of the wall 52x the molded front cover 52 becomes the ultra-thin part 52w in the central part of the wall 52x formed (comprising part of the honeycomb reinforcement part 52t) , a thick part 52y is on the edge of the wall 52x formed (a section outside the gas seal rib 52d) and the medium thin part 52z is in a section between the ultra-thin part 52w and the edge of the wall 52x formed (comprising part of the honeycomb reinforcement part 52t) . When appropriate thicknesses of the ultra-thin part 52w , the medium-thin part 52z and the thick part 52y Te, Tf and Tg, the relationship under each thickness is Te <Tf <Tg.

As described above, in the present embodiment, the wall 52x is set to zones of three levels of thicknesses thereof, such as an ultra-thin zone E, which is the ultra-thin part 52w has a medium-thin zone F which defines the medium-thin part 52z and a thick zone G which the thick part 52y having. It should be noted that a molding die for forming the thicknesses Te, Tf is set to have a thickness slightly increased from the thicknesses Te, Tf assuming molding with the pressurized gas. The molten resin is injected and the injection time is reduced according to the increased thickness.

As described above, is a connected part 56x inside the gas seal rib 52d in the wall 52x formed to have a thickness which is smaller than the outside of the gas seal rib 52d in the wall 52x .

14th FIG. 13 is a perspective view showing part C of FIG 6th shows. 15th FIG. 15 is a perspective view showing a cross section taken along a line XV-XV in FIG 14th shows.

As shown in 14th and 15th are the gas seal rib 52d and a reinforcement rib 56a integral in the wall 52x formed, with the reinforcement rib 56a along the gas seal rib 52d separate from the gas seal rib 52d is arranged.

A thin part 56b , which has a small thickness, is in the wall 52x formed which with the gas seal rib 52d is surrounded, and a thick part 56c which is the greater thickness Tg than the thickness Tf of the thin part 56b has is in the wall 52x formed on the side which is from the gas seal rib 52d is further away than the reinforcement rib 56a .

As shown in 15th , are in the wall 52x a thin part 56y and a part with gradually changing the thickness 56d in which the thickness gradually increases towards the thin part 56y changes are in a wall 56z formed which between the gas seal rib 52d and the reinforcement rib 56a is provided. The wall 56z forms part of the wall 52x .

The thin part 56y is a portion with a fixed thickness that extends from the gas seal rib 52d is formed spaced apart by a predetermined distance L. A thickness of the thin part 56y is to that of the thin part 56b equal to or greater than that of the thin part 56b . A thickness of the gradually changing thickness part 56d rises in a tapered shape in a cross section from the side of the thin part 56y towards the side of the reinforcement rib 56a in an area from an edge of the thin part 56y to the reinforcement rib 56a on.

A thickness of an edge in contact with the thin part 56y of the part with gradually changing thickness 56d (the smallest thickness in the gradually changing thickness part 56d) is the same as that of the thin part 56y . A thickness of an edge in contact with the reinforcement rib 56a of the part with gradually changing thickness 56d (the greatest thickness in the gradually changing thickness part 56d) is the same as that of the thick part 56c .

The part with gradually changing thickness 56d is from a point which is from the gas seal rib 52d to the side of the reinforcement rib 56a spaced by the predetermined distance L to the reinforcement rib 56a educated.

As the thickness of the part with gradually changing thickness 56d especially near the reinforcement rib 56a large is in the molding process for the front cover 52 the solidification is slower than near the gas seal rib 52d due to the directional solidification of the molten resin. Hence when close to the reinforcement rib 56a in the part with gradually changing thickness 56d is pressed with the pressurized gas during melting, the molten resin is fitted into a soft portion on the inside to form an insert groove on the surface of the molten resin. Hence, the gas seal rib holds 52d the pressure of the pressurized gas from it near the reinforcement rib 56a of the part with gradually changing thickness 56d to act.

16 FIG. 13 is a perspective view showing part D of FIG 6th shows, and 17th FIG. 16 is a sectional view taken along a line XVIII-XVIII in FIG 6th .

As shown in 16 , is the edge reinforcement rib 52m the front cover 52 with one end of each of two reinforcement ribs 56e , 56f connected. A reinforcement rib also extends 56g along the edge reinforcement ribs 52m to one end with a reinforcement rib 56e connected and the reinforcement rib 56f to have cutting.

The gas seal rib 52d extends along the reinforcement ribs 56e , is curved and extends along the edge reinforcement ribs 52m and also cuts the reinforcement ribs 56g .

When it is difficult to seal the gas rib 52d inside the edge reinforcement rib 52m the front cover 52 as shown in 17th and 12 to be described later is the gas seal rib 52d integral in a backward curved wall 56h formed which the edge reinforcement rib 52m and an undercut of the front cover 52 having.

As shown in 16 and 17th , can be the gas seal rib 52d not just along an outer edge near an outer edge of the wall 52x the front cover 52 are provided, but also on the edge reinforcement ribs 52m which is on the outer edge of the wall 52x are provided, whereby a sealing member of nitrogen gas can be arranged so that leakage from a gap of the parting line 81 to the outside of the resin molding mold 75 prevented (see 13 ). It is thereby possible not only to omit a seal member that is for the resin molding die 75 is determined, but also the thickness extensively to the vicinity of the outer peripheral edge of the front cover 52 to reduce, so that an amount of the resin material can be reduced, resulting in a cost reduction and a significant weight reduction.

Furthermore, as in 14th and 15th Shown are the reinforcement rib 56a showing a greater amount of a protrusion from the face of the wall 52x has than the gas seal rib 52d , and the part with gradually changing thickness 56d which is the thickness of the wall 56z gradually between the gas seal rib 52d and reinforcement rib 52a changes in the wall 52x provided on each side end of the front cover 52 is arranged, and it is thereby possible to have a portion which requires rigidity, and a portion which through the gas seal rib 52d can be streamlined, appropriately arranged.

In addition, as shown in 6th , 17th and 19th , is the gas seal rib 52d also on the edge of the wall 52x continuously deployed and the wall 52x may get near the edge of the front cover 52 can be slimmed down without the appearance of the front cover 52 to affect.

18th Fig. 13 is a perspective view showing a lower part of the front cover 52 shows.

The front cover 52 includes a backward curved wall 56h bent toward the rear of a vehicle in a lower part of the wall 52x .

An opening 56y is in a central part in a vehicle width direction of the backward curved wall 56h open. A horn (not shown) is inside the front cover 52 arranged and a sound of the horn is applied to the outside of a vehicle body through the opening 56y submitted. By providing the opening 56y a sound volume of the horn outside the vehicle body can be guaranteed.

The opening 56y is by an inclined core 85 (please refer 19th ) which is in the resin molding mold 75 is provided (see 13 ).

19th Fig. 3 is a perspective view showing the lower part of the front cover 52 from the side of the posterior surface 52a shows.

At the time of molding the front cover 52 is the inclined core 85 in a section of the front cover 52 arranged which the rear face 52a the backward curved wall 56h is.

The inclined core 85 is for processing an undercut at the opening 56y (please refer 18th ) and around the opening 56y . A solid line indicates a state in which the inclined core 85 is located in the portion which the rear surface 52a the backward curved wall 56h and the two-dot chain line indicates a state in which the inclined core, after solidification of the molten resin, is at the position of the solid line from the backward curved wall 56h is pushed away.

20th Fig. 13 is a front view showing part of a front face 85a of the inclined core 85 shows, and 21st FIG. 10 is a sectional view taken along a line XXI-XXI in FIG 19th .

As shown in 20th , includes the inclined core 85 on the front surface 85a a head start 85b to form the opening 56y (please refer 18th ) the front cover 52 (please refer 18th ) and an annular groove 85c which is so formed around the protrusion 85b at a predetermined distance from the protrusion 85b away to surround.

As shown in 21st is the lead 85b of the inclined core 85 a section showing the opening 56y the backward curved wall 56h forms. The annular groove 85c of the inclined core 85 is a portion which has an annular gas seal rib 56k forms, protruding from the rear surface 52a the backward curved wall 56h to the opening 56y .

22nd Figure 4 is a perspective view showing the opening 56y the backward curved wall 56h and their surroundings in the front cover 52 shows.

The continuous annular gas seal rib 56k is around the opening 56y educated. The gas seal rib 56k is inside the gas seal rib 52d educated.

As shown in 21st and 22nd , is by the directional solidification at the time of injection molding the front cover 52 the molten resin in the annular groove 85c of the inclined core 85 in the resin molding form 75 (please refer 12 ) solidifies faster than the molten resin around the annular groove 85c . As a result, the gas seal rib becomes 56k educated. There is also a reinforcement rib on the edge 52m the backward curved wall 56h the front cover 52 the gas seal rib 52d from the rear face 52a the front cover 52 continuously formed. From the above, there will be a space between the gas seal rib 52d and the gas seal rib 56k in the resin molding form 75 a sealed room.

Therefore, when the pressurized gas is caused, on the molten resin, which from the gas seal rib 52d and the gas seal rib 56k is surrounded to act, the pressurized gas can be prevented from coming to the side of the opening 56y through the gas seal rib 56k exit so that the wall 52x around the gas seal rib 56k can be streamlined. As described above, the wall can 52x in the lower part of the front cover 52 near the opening 56y be streamlined.

As above in 6th and 13 shown is the front cover 52 as the resin mold by applying the pressurized gas to the molten resin in the resin molding mold 75 shaped. In the front cover 52 is the gas seal rib 52d as the elongated rib-like protrusion integrally in the wall 52x formed and the gas seal rib 52d is arranged to cover a predetermined area of the wall 52x surrounds. The thickness of the wall 52x in the section that goes over the gas seal rib 52d surrounded is formed to be smaller than the thicknesses of the other places on the wall 52x .

Also in the process of molding the front cover 52 obtained by adding the pressurized gas to the resin in the resin molding mold 75 is formed, the wall 52x the front cover 52 with the gas seal rib 52d formed covering a predetermined area of the face of the wall 52x surrounds. Due to the directional solidification in which the resin is in the gas seal rib 52d is solidified faster than the other places, the enclosed part becomes 56x which goes through the gas seal rib 52d is surrounded, sealed so that it holds the pressurized gas.

With the above configuration, it is possible to adjust the thickness of the front cover 52 and reduce the weight of the front cover 52 to reduce. Furthermore, the front cover 52 by increasing its rigidity with the gas seal rib 52d reinforced, thereby increasing the anti-impact durability of the front cover 52 is improved. In addition, the seal is possible so as to prevent the pressurized gas from coming to the outside in the gas seal rib 52d exit, thereby producing the thin and reinforced front cover 52 , which has been described above, is enabled using a sealant used for the resin molding mold 75 is determined, is not required, and which is not on the dividing line 81 is limited.

Furthermore, as shown in 18th and 22nd , is the opening 56y in the wall 52x provided and on the rear surface 52a the Wall 52x is the gas seal rib 52d continuously along the outer edge of the inner surface of the front cover 52 and along the contour (edge) of the opening 56y provided.

With this configuration the wall can 52x near the opening 56y the front cover 52 can be slimmed down without the appearance of the front cover 52 to affect.

Embodiments which have been described above are those showing only one aspect of the present invention and can be modified or applied in any manner without departing from the gist of the present invention.

For example, the gas seal rib 52d be placed in at least one location where the pressurized gas easily exits, along the outer edge of the resin mold and the contour of the opening, and the gas seal rib 52d may be partially arranged instead of being provided circumferentially.

The present invention is not to a case of applying the front cover 52 on the motorcycle 40 limited but can also be applied to parts other than the front cover 52 .

The present invention is not in the case of application to the motorcycle 40 limited but can also apply to articulated vehicles, including vehicles apart from the motorcycle 40 , and can be applied to vehicles other than articulated vehicles. It should be noted that the articulated vehicles include vehicles to travel generally over the vehicle body, not only motorcycles (including motorized two-wheelers), but also three-wheeled vehicles and four-wheeled vehicles, each classified as an all-terrain vehicle (ATV) (a Vehicle driving on an uneven surface).

List of reference symbols

10

Resin mold

10a, 52d, 56k

Gas seal rib (elongated rib-like protrusion)

10b, 52x

wall

10c, 56x

included part

22, 75

Resin molding mold

52

front cover (resin mold)

52a

rear surface (undesigned surface)

52m

Edge reinforcement rib (reinforcement rib)

52q, 52r

Intermediate reinforcement rib (reinforcement rib)

56a

Reinforcement rib

56d

Part with gradually changing thickness

56y

opening

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• JP 2008911 [0003]
• JP 10058477 [0003]
• JP 2018015910 [0006]

Claims (10)

Resin mold which is molded by applying a pressurized gas to a resin in a resin molding mold (22, 75), wherein an elongated rib-like projection (10a, 52d, 56k) is integrally formed in a wall (10b, 52x), wherein the elongated rib-like projection (10a, 52d, 56k) is arranged to surround a predetermined area of the wall (52x), and a thickness of the wall (10b, 52x) in a portion which is about surrounding the elongated rib-like protrusion (10a, 52d, 56k) is formed to be smaller than thicknesses of other parts of the wall (10b, 52x). Resin mold according to Claim 1 wherein a reinforcing rib (52m, 52q, 52r, 56a) having a greater degree of projection from a surface of the wall (52x) than the elongated rib-like projection (52d) is integrally provided in the wall (52x) and a gradually changing thickness part (56d), in which a thickness of the wall (52x) gradually changes, between the elongated rib-like projection (52d) and the reinforcing rib (52m, 52q, 52r, 56a) is provided. Resin mold according to Claim 2 wherein the elongated rib-like projection (52d) intersects the reinforcement rib (52q, 52r) at an angle of at least 20 degrees or more, and a height of the elongated rib-like projection (52d) is smaller than a height of the reinforcement- Rib (52q, 52r). Resin mold according to one of the Claims 1 to 3 wherein the elongated rib-like projection (52d) is continuously provided on an edge of the wall (52x). Resin mold according to one of the Claims 1 to 4th wherein an opening (56j) is provided in the wall (52x) and the elongated rib-like projection (52d) is provided continuously along a contour of the opening (56j) of the wall (52x). Molding method for a resin mold which is molded by applying a pressurized gas to a resin in a resin molding mold (22, 75), wherein an elongated rib-like projection (10a, 52d, 56k) which surrounds a predetermined area of a surface of a wall (52x) in which wall (52x) of the resin mold (10, 52) is formed and an enclosed part (10c, 56x) which extends over the elongated rib-like projection (10a, 52d, 56k) is sealed to hold the pressurized gas by directional solidification in which resin in the elongated rib-like protrusion (10a, 52d, 56k) is solidified faster than other locations. Molding process for resin mold according to Claim 6 wherein a reinforcing rib (52m, 52q, 52r, 56a) having a greater degree of protrusion from a face of the wall (52x) than the elongated rib-like protrusion (52d) is integrally formed in the wall (52x) and a gradually changing thickness part (56d), in which a thickness of the wall (52x) gradually changes, between the elongated rib-like projection (52d) and the reinforcing rib (52m, 52q, 52r, 56a) is provided. Molding process for resin mold according to Claim 7 wherein the elongated rib-like protrusion (52d) is cut from the reinforcing rib (52q, 52r) at an angle of at least 20 degrees or more, and a height of the elongated rib-like protrusion (52d) is made smaller than a height the reinforcement rib (52q, 52r). Molding method for the resin mold according to one of the Claims 6 to 8th wherein the elongated rib-like projection (52d) is continuously provided on an edge of the wall (52x). Molding method for the resin mold according to one of the Claims 6 to 9 wherein an opening (56j) is provided in the wall (52x) and the elongated rib-like projection (52d) is provided continuously along a contour of the opening (56j) of the wall (52x).

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