JP2000160425A - Molding of helmet liner and device for molding the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for molding a helmet liner, capable of molding a conventional combination obtained by laminating independently molded liners having different times and different raw materials, respectively, also as an integrally laminated multi-layered liner wherein the layers are continuously molded. SOLUTION: This is a method for molding a resin into a helmet liner with a molding device equipped with the first convex mold 10, the second convex mold and a concave mold 30. Therein, the method comprises the first process for injecting the first resin into a cavity space K1 formed with the concave mold 30 and the first convex mold 10 to foam and mold the resin, the first mold-opening process for opening the concave mold 30 and the first convex mold 10 after the first process, a process for closing the concave mold 30 and the second convex mold in a state that the molded product molded in the first process in held in the concave mold 30, the second process for injecting, foaming and molding the second resin in cavity space (excluding the molded product) formed with the concave mold and the second convex mold, and a process for opening the mold and the taking out the molded product after the second process.

Description

DETAILED DESCRIPTION OF THE INVENTION

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a helmet liner and, more particularly, to a method and an apparatus for forming a helmet liner suitably used for a vehicle used outdoors such as a motorcycle.

[0002]

2. Description of the Related Art Generally, a helmet comprises an outer shell and a shock absorbing liner. The shock absorbing liner is provided inside the shell as shown in FIG. 11, and protects the head of the occupant or the worker safely when an external shock is applied. As the impact absorbing liner, a polystyrene (PS) foam (foam), a polypropylene (PP) foam (foam), and the like have been conventionally used.

In a helmet having the above structure, when an impact force is received, the impact force is dispersed over a wide range by the high rigidity of the shell, and the pressure applied to the liner is reduced as much as possible.
It absorbs the pressure by compressive deformation of the liner and exerts shock damping performance. Conventionally, when enhancing the shock damping performance, use a high-strength FRP as a shell material or reduce the thickness of the liner. Had increased.

[0004] When the impact damping performance is enhanced as in the above-described conventional example, if a high-strength FRP is used as the shell material or the thickness of the liner is increased, the shape of the helmet becomes large or the product becomes heavy. In addition, there have been inconveniences such as an increase in manufacturing cost and the inability to satisfy demands of consumers in terms of design.

[0005]

Therefore, as shown in FIG. 12, a shock absorbing liner 101 having a two-layer structure comprising an outer liner 102 and an inner liner 103 having different expansion ratios.
A technology is known in which the impact force received by the helmet is transmitted in two stages from the shell to the outer liner 102 and from the outer liner 102 to the inner liner 103 to attenuate the impact. By using the shock absorbing liner having the two-layer structure as described above, it is possible to exhibit the shock damping performance without specially increasing the thickness of the liner.

Conventionally, in order to obtain a shock absorbing liner having the two-layer structure, a single-layer liner is divided, or two types of liners made of different densities and different materials are manufactured. Have been adopted to form a two-layered shock-absorbing liner by bonding them with an adhesive or the like.

In the method of joining two different types of liners, each step of manufacturing two types of liners is required, and the liner cannot be manufactured efficiently.
There were problems with productivity and cost. In addition, since the outer liner and the inner liner are joined with an adhesive or the like, it is necessary to handle the adhesive, and there is a problem associated with handling the adhesive. In addition, there is also a disadvantage such as a displacement during joining of the outer liner and the inner liner.

An object of the present invention is to provide a molding method and a molding method for a helmet liner in which a combination of different magnifications and different raw materials obtained by forming a multilayer of an independently molded liner is also performed by a continuously molded multilayer integrally molded liner. It is to provide a device. Another object of the present invention is to provide a method and an apparatus for forming a helmet liner capable of improving the impact attenuation characteristics without increasing the number of parts and the number of assembling steps.

Still another object of the present invention is to provide a method and apparatus for forming a helmet liner capable of easily forming a helmet liner having good impact damping characteristics.

[0010]

According to a first aspect of the present invention, there is provided a method for forming a helmet liner, comprising the steps of:
A method for molding a helmet liner molded by a molding device having a second convex mold and a concave mold, wherein a first resin is injected into a cavity space formed by the concave mold and the first convex mold. A first step of foaming and molding, a first mold opening step of opening the concave mold and the first convex mold after the first step, and holding the molded article molded in the first step in the concave mold. Holding the mold with the second convex mold as it is, positioning a molded product on the second convex mold side, and placing the molded product in a space excluding the molded product of the cavity space formed by the concave mold and the second convex mold. 2
This is solved by providing a second step of injecting the resin and foam-molding, and a step of opening the mold and taking out the molded product after the second step.

According to the helmet liner forming apparatus of the second aspect of the present invention, there is provided a helmet liner forming apparatus formed by a first convex mold, a second convex mold, and a concave mold. Is formed at least two resin injection means, the cavity space formed by the concave mold and the first convex mold is formed smaller than the cavity space formed by the concave mold and the second convex mold, The first resin is injected into the cavity formed by the concave mold and the first convex mold by the resin injecting means, and then the resin is injected into the cavity formed by the concave mold and the second convex mold. This problem can be solved by injecting the second resin by means and integrally molding the first resin and the second resin to form a helmet liner.

As described above, in the present invention, the first resin is molded between the first convex mold and the concave mold, and then the first resin is molded into the second convex mold.
A molded article made of the above resin is arranged, the second resin is molded between the second convex mold and the concave mold, and the first resin and the second resin are integrally molded to form a helmet liner. So
A helmet liner having an outer layer and an inner layer having different expansion ratios and raw materials can be easily manufactured as an integrally molded product.

A helmet liner having an outer layer and an inner layer having different expansion ratios and raw materials transmits an impact force received by the helmet from the shell to the outer layer and from the outer layer to the inner layer in two stages. Since the impact is attenuated, good impact attenuation performance can be obtained.

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Helmet liner 1 of the present invention
Is molded by a molding apparatus S having a first convex mold 10, a second convex mold 20, and a concave mold 30. As a method of molding the helmet liner 1, first, as a first step, a cavity space K1 formed by the concave mold 30 and the first convex mold 10 is formed.
And the first resin is injected and foamed to obtain a molded product P1. Next, as the first mold opening step, the concave mold 30 and the first convex mold 1
Open mold 0.

Next, while holding the molded product P1 molded in the first step in the concave mold 30, the mold is clamped to the second convex mold 20. Further, as a second step, the molded product P1 is positioned on the second convex mold 20 side, and the second resin is filled in a space excluding the molded product P1 of the cavity space K2 formed by the concave mold 30 and the second convex mold 20. Inject and foam. After the second step, the concave mold 30 and the second convex mold 20 are opened, and the helmet liner 1 as the molded product P2 is taken out.

The helmet liner 1 of the present invention
The molding apparatus S has a first convex mold 10, a second convex mold 20, and a concave mold 30, and the concave mold 30 is formed with at least two resin injection means. The cavity space K1 formed by the concave mold 30 and the first convex mold 10 is formed smaller than the cavity space K2 formed by the concave mold 30 and the second convex mold 20.

The first tree J1 is injected into the cavity K1 formed by the concave mold 30 and the first convex mold 10 by the resin injecting means 31, and thereafter, is formed by the concave mold 30 and the second convex mold 20. The second resin is injected into the cavity K2 by the resin injection means 32, and the first resin and the second resin are integrally formed to form the helmet liner 1.

[0018]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to the drawings. Note that the members, arrangements, and the like described below do not limit the present invention, and it is needless to say that various modifications can be made in accordance with the gist of the present invention.

1 to 10 show an embodiment of the present invention. FIG. 1 is a perspective view showing a helmet liner of the present invention, FIG. 2 is a sectional explanatory view of the helmet liner of the present invention, and FIGS. FIG. 10 is an explanatory view showing a manufacturing process of the helmet liner of the present invention.

The helmet liner 1 according to the present invention is disposed inside a shell (not shown), and is composed of two layers, an outer layer 2 and an inner layer 3, and is formed in a substantially hemispherical shape.

The outer layer 2 is made of, for example, polystyrene for bead foaming (hereinafter abbreviated as EPS) molded at a foaming ratio of 5 times, and the inner layer 3 is made of EPS molded at a foaming ratio of 20 times, for example. Become. When the same material is used for the outer layer 2 and the inner layer 3, the specific gravity between the outer layer 2 and the inner layer 3 is changed by changing the expansion ratio.

In addition to the above-mentioned polystyrene, a material capable of bead foaming such as polypropylene (PP), AS resin, ABS resin, polycarbonate (PC) and the like can be used. Even when these materials are used, the expansion ratio of the outer layer 2 and the inner layer 2 is different. Alternatively, the outer layer 2 and the inner layer 3 may be formed of different materials by combining these materials.

Next, a molding apparatus S and a molding method of the helmet liner 1 of the present invention will be described. The molding device S of the helmet liner 1 in the present embodiment has the first convex mold 10, the second convex mold 20, and the concave mold 30 as main components. In this example, the first convex 10 and the second convex 20 are fixed sides, and the concave 3
0 is the moving side. The concave mold 30 is connected to an injection molding device, and the concave mold 30 has injection means 31 and 32 for supplying resin injected from the injection device into the concave mold 30.
Are formed.

Then, the first resin, which is the molten resin, is injected from a supply device (not shown) of the molten resin into the cavity K1 between the first convex mold 10 and the concave mold 30 through the injection means 31 of the concave mold 30, and injected. The second convex and concave 3 via the means 32
The second resin having a different expansion ratio or a different raw material from the first resin is injected into the cavity K2 between 0 and 0.

Further, in the present embodiment, the structure is such that cooling or the like can be performed after the pressing mold is clamped by the first convex mold 10 or the second convex mold 20 and the concave mold 30. The injection of the molten resin, the mold clamping, and the like can be performed by a known technique.

As shown in FIGS. 3 and 4, the first convex 10 of this embodiment includes a base 11 having a stepped portion, and a base 11 having a stepped portion.
A hemispherical convex portion 12 which is located above and forms a space in which a wearer's head can be inserted, and a peripheral wall formed to protrude around the hemispherical convex portion 11 at a predetermined distance from the hemispherical convex portion 12 A hemispherical projection 11 and a peripheral wall-shaped projection 12
And a groove 14 is formed between them.

Since the base 11 of the first convex mold 10 is formed in a stepped shape in which the front side of the helmet liner 1 is high and the rear side is low, the base 11 of the hemispherical convex part 12 and the peripheral wall-shaped convex part 13 are formed. The groove portion 14 formed therebetween is formed so that the front side of the helmet liner 1 is shallow and the rear side of the helmet liner 1 is deep.

As shown in FIG. 6, the second convex mold 20 of this embodiment forms a base 21 having a step and a space located on the base 21 to accommodate the wearer's head. And a hemispherical convex portion 22. The hemispheric convex part 22 is formed in the same size as the hemispheric convex part 11 of the first convex mold 10. Further, the height of the base 21 of the second protrusion 20 is formed to be lower than the height of the base 11 of the first protrusion 10,
The cavity K2 formed between the second convex mold 20 and the concave mold 30 is configured to be larger than the cavity K1 formed between the first convex mold 10 and the concave mold 30.

The concave mold 30 of the present embodiment forms hemispherical cavities K1 and K2 between the first convex mold and the second convex mold, and as shown in FIG.
Means 31 for injecting the resin of
2 has an injection means 32 for injecting the second resin.

Further, the concave mold 30 is provided with an eject pin 33. The eject pin 33 is disposed at the top of the concave mold 30 so as to penetrate the concave mold 30. The eject pin 33 pushes the molded product held by the concave mold 30 from outside the top of the concave mold 30, and detaches the molded product from the concave mold 30.

Further, a resin used as a substrate in the present invention,
That is, as the molten resin to be injected, for example, polystyrene (PS), polypropylene (PP), AS resin, AB
A material capable of bead foaming, such as S resin and polycarbonate (PC), can be used.

When the same material is used for the outer layer 2 and the inner layer 3 of the helmet liner 1 as the base material, those having different expansion ratios are used. Alternatively, different base materials are used for the outer layer 2 and the inner layer 3 of the helmet liner 1.

Next, a method of manufacturing a molded article using the helmet liner molding apparatus having the above-described configuration will be described. First, as shown in FIG. 3, the first convex mold 10 and the concave mold 30 are clamped. Thus, a first cavity K1 is formed.

Then, the first resin is injected into the cavity K1 from the first injection means 31 by a known in-mold molding method.
Between the first convex mold 10 and the concave mold 30, as shown in FIG.
The inner layer 3 of the helmet liner 1 is formed as a first molded product P1. In this example, EPS having a foaming ratio of 20 times is used as the first resin.

Next, as shown in FIG. 5, the first convex mold 10 and the concave mold 30 are removed to open the mold. At this time, the inner layer 3 obtained as the first molded product P1 is held on the concave mold 30 side.

Next, as shown in FIG. 6, while the first molded product P1 is held in the concave mold 30, the convex mold is exchanged from the first convex mold 10 to the second convex mold 20 below the concave mold 30. I do. After the replacement of the convex shape is performed in this manner, as shown in FIG.
The first molded product P1 is positioned on the second convex mold 20 side by projecting the top of the molded product P1 with the eject pin 33.

Next, as shown in FIG. 8, the second convex mold 20 and the concave mold 30 are clamped. Thus, the concave mold 30
A cavity K2 is formed between the second protrusion 20 and the second protrusion 20.
Next, as shown in FIG. 9, the second
The second resin is injected into the cavity K2 from the injection means 32 of the second mold, and the second molded product P is inserted between the second convex mold 20 and the concave mold 30.
As 2, the helmet liner 1 in which the outer layer 2 is integrally formed with the inner layer 3 is formed. In this example, EPS set to a 5-fold expansion ratio is used as the second resin.

Finally, as shown in FIG. 10, the second convex 20 and the concave 30 are removed to open the mold. Then, the helmet liner 1 as the second molded product P2 held on the concave mold 30 side is removed from the concave mold 30 with the eject pin 33.

As described above, according to the present invention, a helmet liner 1 having a two-layer foam molded body having different expansion ratios and raw materials can be easily manufactured as an integrally molded product.

Further, the manufacturing apparatus S for the helmet liner 1 of the present invention includes the base 11 of the first convex mold 10 or the second convex mold 20.
By changing the base 21 to a desired height, the thickness of the formed helmet liner can be arbitrarily set. In particular, the surface hardness of the helmet liner 1 is significantly improved by setting the thickness of the outer layer to 3 mm to 5 mm and making the raw material ultra-low magnification (about 5 times or less), so that the shell is integrally formed with the helmet liner 1. The structure as described above can be obtained.

[0041]

As described above, according to the present invention, the number of parts and the number of assembling steps are increased by manufacturing a helmet liner made of a two-layer foam molded body having different expansion ratios and raw materials as an integrally molded product. It is possible to easily manufacture without causing any problem. As described above, the helmet liner having different expansion ratios and materials between the outside and the inside attenuates the shock by transmitting the impact force received by the helmet from the shell to the outer layer and from the outer layer to the inner layer in two stages. Therefore, good impact damping performance can be obtained.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a helmet liner of the present invention.

FIG. 2 is an explanatory sectional view of a helmet liner of the present invention.

FIG. 3 is an explanatory view showing a manufacturing process of the helmet liner of the present invention.

FIG. 4 is an explanatory view showing a manufacturing process of the helmet liner of the present invention.

FIG. 5 is an explanatory view showing a manufacturing process of the helmet liner of the present invention.

FIG. 6 is an explanatory view showing a manufacturing process of the helmet liner of the present invention.

FIG. 7 is an explanatory view showing a manufacturing process of the helmet liner of the present invention.

FIG. 8 is an explanatory view showing a manufacturing process of the helmet liner of the present invention.

FIG. 9 is an explanatory view showing a manufacturing process of the helmet liner of the present invention.

FIG. 10 is an explanatory view showing a manufacturing process of the helmet liner of the present invention.

FIG. 11 is an explanatory diagram showing a conventional example.

FIG. 12 is an explanatory diagram showing a conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Helmet liner 2 Outer layer 3 Inner layer 10 1st convex type 11 base 12 hemispherical convex part 13 Peripheral wall-shaped convex part 14 groove part 20 2nd convex type 21 base 22 hemispherical convex part 30 concave type K1, K2 cavity P1, P2 Molding S Helmet liner molding equipment

Claims (2)

[Claims] 1. A method for molding a helmet liner, which is molded by a molding apparatus having a first convex mold, a second convex mold, and a concave mold, wherein the helmet liner is formed by the concave mold and the first convex mold. A first step of injecting a first resin into the cavity space to form a foam, and a first mold opening step of opening the concave mold and the first convex mold after the first step; First
A step of clamping the second convex mold with the molded article held in the step, and positioning the molded article on the second convex mold side to form a cavity formed by the concave mold and the second convex mold A second step of injecting a second resin into a space excluding a molded product in the space to perform foam molding, and a step of opening the mold and taking out the molded product after the second process. Helmet liner molding method. 2. A molding device for a helmet liner molded by a first convex mold, a second convex mold, and a concave mold, wherein the concave mold is formed with at least two resin injection means, The cavity space formed by the concave mold and the first convex mold is formed smaller than the cavity space formed by the concave mold and the second convex mold, and the cavity formed by the concave mold and the first convex mold. The first resin is injected into the cavity formed by the resin injection means, and then the second resin is injected into the cavity formed by the concave mold and the second convex mold by the resin injection means. Resin and second
A helmet liner molding apparatus characterized in that a helmet liner is formed by integrally molding a resin and a helmet liner.