JP2001300941A - Insert, mold assembly, and method for molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an insert capable of being relatively easily regulated in the case of mounting the insert in a mold, reducing a manufacturing cost of a mold assembly, surely preventing an occurrence of a damage of an end or an edge of the insert and having excellent transferability of a cavity surface of the insert to a surface of a molding and being durable against molding for a long period. SOLUTION: The insert 15 is arranged in molds 10, 11 used to mold the molding of a thermoplastic resin to constitute a part of the cavity 14 provided in the molds 10, 11. The insert 15 comprises an insert body 115 made of zirconia ceramics, an active metal film 16 formed on at least a partial surface of the body 115, and a metal layer 16 formed on the film 16.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mold assembly for molding a molded article made of thermoplastic resin, a nest suitable for use in such a mold assembly, and a mold assembly using such a mold assembly. To a method for molding a molded article made of a thermoplastic resin.

[0002]

2. Description of the Related Art Zirconia (ZrO ₂ ) containing partially stabilized zirconia (partially stabilized zirconium oxide, ZrO ₂ ) in a mold for molding a molded article made of a thermoplastic resin.
A technique for improving the surface appearance and the like of a molded product by incorporating a ceramic nest is disclosed in, for example, Japanese Patent Application Laid-Open No. H8-3185.
No. 34 discloses this. In the mold including the first mold portion and the second mold portion disclosed in this patent publication, a nest is disposed on the first mold portion, and the first mold portion and the second mold portion are connected to each other. A pressing plate for protecting the nest end is attached to the first mold part so as not to place a burden on the nest when the mold is clamped with the mold part, thereby preventing the nest from being damaged. Then, the surface of the nest forming a part of the cavity (hereinafter, referred to as
The clearance between the nested cavity surface and the holding plate is set to 0.03 mm or less.

However, in the mold assembly having the structure disclosed in Japanese Patent Application Laid-Open No. 8-318534, the holding plate cannot be arranged inside the mold depending on the shape of the molded product. There may be restrictions on the installation position and the shape of the molded product. That is, the nest may not be able to be attached to a mold portion corresponding to a molded product portion to which excellent surface characteristics are to be imparted. For example, when a molded article is provided with an undercut portion, it is necessary to provide a slide core in the mold assembly in order to take out the molded article having the undercut portion from the mold assembly. However, in a mold assembly having such a structure, it is difficult to dispose the holding plate in the mold assembly.

In such a case, Japanese Patent Application Laid-Open No. H11-426
This problem can be dealt with by the technique disclosed in Japanese Patent Publication No. 50. The mold including the first mold part and the second mold part disclosed in this patent publication does not have a holding plate, but, for example, a nest is disposed in the first mold part, and the nest cavity is provided. The structure has a structure in which the portion of the second mold portion facing the surface is a nested covering portion, thereby improving the appearance of the entire molded product.
The clearance between the nested cavity surface and the nested covering portion is set to 0.03 mm or less.

[0005]

In the technology disclosed in these patent publications, the nest is made of a brittle inorganic material such as ceramics or glass.
In addition, since the end portion of the nest has a weak shape in terms of strength, if a stress is applied to the end portion of the nest during assembling the mold, there is a problem that the nest is broken. Further, for example, in the mold disclosed in Japanese Patent Application Laid-Open No. H11-42650, when the mold is clamped, the parallelism between the cavity surface of the nest and the nest covering portion that is the opposite surface is not sufficiently high.
There is a risk that the nested end will make point contact with the nested covering, resulting in breakage of the nested end.

[0006] Zirconia ceramics used for nesting has twice or more hardness as compared with metals. Therefore,
It is difficult to cut with a normal metal working machine. Further, even when cutting is performed, the rigidity is inferior to that of alumina ceramics, the tip portion of the cutting tool easily escapes, and cutting is difficult. Therefore, in order to mount the nest inside the mold part with a clearance of 0.03 mm or less with high accuracy, the
It is manufactured with an accuracy of 0.01 mm or less, and not only improves the processing accuracy of the nest itself, but also adjusts the mold part (called a nest mounting part) to which the nest is mounted and the nest covering part to the size of the nest. It is necessary to perform delicate processing and adjustment. Furthermore, if the nest is composed of a three-dimensional shape,
There is a problem that the degree of difficulty in metal processing of the mold portion near the nesting portion is extremely high, and the operator must rely on an ultra-precision processing machine or a skilled operator. In addition, as the processing accuracy of the nest increases, the manufacturing cost of the nest increases, and the cost of the mold itself increases.

In addition, when the nest made of zirconia ceramics is mounted on the mold portion provided with the nest coating portion, or when the nest is mounted on the first and second mold portions, the mounting is performed with high accuracy. Failure to do so may result in breakage of the nest, but the different machining machines for processing for ceramics and metal also make it difficult to mount the nest.

That is, it is difficult to cut a nest made of ceramics with a metal plane cutter. Therefore,
Engraving the nest mounting part according to the height (or thickness) of the nest made, or cutting the back of the metal plate attached to the back of the nest using adhesive,
It is necessary to adjust the height (or thickness) of the nest and the nest mounting portion. However, these processes are complicated operations. In addition, if the thickness of the adhesive is uneven, it is necessary to cut the back surface of the metal plate and adjust the height (or thickness) of the nest several times, which increases the number of steps, thus reducing costs. It leads to up. Furthermore,
At the time of cutting, for example, the cutting must be performed using a precision cutting machine so that the parallelism between the mold parting surface and the insert is improved. If the degree of parallelism between the nest and the mold parting surface is poor, there is a problem that the nest may be damaged in the worst case.

If a metal layer having a thickness that can be machined by a general metal working machine is formed on the surface of the nest made of zirconia ceramics, the metal working accuracy of the mold portion near the nest mounting portion will be extremely high. There is no need to raise it. That is, the metal layer formed on the surface of the nest made of zirconia ceramics is machined by using a metal processing machine, so that the nest can be finely adjusted with respect to the mold or the nest mounting portion.

However, ordinary zirconia ceramics are non-conductive, and a metal layer can be formed on the surface of the nest by a chemical vapor deposition method (Japanese Patent Laid-Open No. 11-34068). CVD method), vacuum evaporation method, sputtering method, ion plating method, ion beam evaporation method, IVD method (ion vapor deposition method)
It is necessary to employ a physical vapor deposition method (PVD method). According to these methods, generally, 2
It is possible to form a metal layer of 0 μm or less. However, with these methods, it is difficult to form a metal layer having a thickness on the order of a cutting allowance that can be machined by a general cutting machine on the surface of the nest. Further, there is a problem that the cost of forming the metal layer is high, and that the adhesion of the metal layer to the nest surface is not so high.

A method of forming a thicker metal layer on the surface of the nest made of zirconia ceramics by a plating method is also conceivable. The metal layer cannot be formed. When a metal layer is formed by a plating method, it is necessary to provide an intermediate film or an intermediate layer on the surface of the nest so that the metal layer can obtain high adhesion to zirconia ceramics.

A nest made of zirconia ceramics has a particularly low strength at the edges, and is usually cut with a C-plane or an R.
Processing is applied to the edge. However, depending on the shape of the molded article, a sharp edge is required for the insert. In some cases, the parting surface to which the mold clamping force is applied needs to be formed from nested edges. In these cases,
If the edge of the nest can be reliably prevented from being broken, the degree of freedom of the shape of the molded product can be considerably improved.

Accordingly, it is an object of the present invention to adjust the mounting of the nest to the mold part relatively easily, to reduce the manufacturing cost of the mold assembly, and to set the end or edge of the nest. Nest that can reliably prevent the occurrence of breakage of the nest, excels in transferability of the cavity surface of the nest to the surface of the molded product, and can withstand long-term molding, a mold assembly using such nest, and such a mold It is an object of the present invention to provide a method for molding a molded article made of a thermoplastic resin using a mold assembly.

[0014]

An object of the present invention is to form a part of a cavity provided in a mold, which is disposed inside a mold used for molding a molded article made of a thermoplastic resin. A nest, comprising a nest body made of zirconia ceramics, an active metal film formed on at least a part of the surface of the nest body, and a metal layer formed on the active metal film. First of the invention
This can be achieved by the nesting according to the aspect.

Here, forming a part of the cavity means forming a part of the cavity surface which defines the outer shape of the molded product. More specifically, the cavity
For example, a surface forming a cavity (a cavity surface of the mold portion) formed in a mold, a first mold portion or a second mold portion described later, and a portion of a cavity formed in a nest. Surface (nested cavity surface) and, in some cases, a surface (cavity surface of the coating plate) forming a cavity formed in the coating plate described later. The same applies to the following description. The cavity surface of the nest may be constituted by the surface of the nest body or may be constituted by a metal layer.
Note that the surface of the nesting body that forms the nesting cavity surface may be referred to as the cavity forming surface of the nesting body.

The above object is to provide a nest that is disposed inside a mold used for molding a molded article made of a thermoplastic resin and constitutes a part of a cavity provided in the mold. The nest according to the second aspect of the present invention is characterized in that the nest includes a nest body made of a refractory zirconia ceramic and a metal layer formed on at least a part of the surface of the nest body.

In the nest according to the first aspect of the present invention, the activation metal layer and the metal layer are formed on the surface of which part of the nest body, and in the nest according to the second aspect of the present invention, Which part of the surface of the nest body is formed on the surface depends on the configuration of the mold part on which the nest is disposed, the configuration of the nest, the shape of the molded product to be molded, and the like. It should be noted that the two-layer structure of the nested metal layer and the metal layer according to the first aspect of the present invention and the metal layer in the nest according to the second aspect of the present invention are collectively referred to as a thin layer. There are cases.

As will be described later, a nest is provided on the first mold part, and the second mold part and the nest are placed in a state where the first mold part and the second mold part are clamped. When the surfaces of a part of the nest body face each other, it is necessary to form a thin layer on at least the surface of the part of the nesting body facing the second mold part. The nest is disposed on the second mold part, and the first mold part and a part of the surface of the nest face each other in a state where the first mold part and the second mold part are clamped. In such a case, it is necessary to form a thin layer on at least the surface of the nest body facing the first mold portion. In addition, a thin layer may be formed in other portions of the nesting main body.

Alternatively, the mold assembly may further include a coating plate attached to the first or second mold part, forming a part of the cavity, and covering the end face of the nest. Is overlapped with the covering plate, and the nest is disposed on the first mold portion, and at least the covering plate faces the covering plate in a state where the first mold portion and the second mold portion are clamped. It is necessary to form a thin layer on the surface of the part of the nesting body. In addition, a thin layer may be formed in other portions of the nesting main body.

Further, the mold assembly further includes a coating plate attached to the second mold portion, forming a part of the cavity, and covering a part of the end face of the nest.
If the nest is located in the first mold part, the first
In a state where the mold part and the second mold part are clamped,
It is necessary to form a thin layer on at least the surface of the nest body facing the cover plate, and to form a thin layer on at least the surface of the nest body facing the second mold part. In addition, a thin layer may be formed in other portions of the nesting main body.

In the case where the nest is composed of a first nest provided in the first mold part and a second nest provided in the second mold part, In a state where the first mold part and the second mold part are clamped, at least the surface of the nest body of the first nest facing the second nest, and at least facing the first nest. Second
It is necessary to form a thin layer on the surface of the nest body portion of the nest. It should be noted that a thin layer may be formed on other portions of the first nesting body and / or other portions of the second nesting body.

The surface of the nest body where the thin layer is to be formed as described above may be referred to as a thin layer forming surface of the nest body for convenience.

The object of the present invention is as follows: (A) A mold for molding a thermoplastic resin molded article, which comprises a first mold part and a second mold part, and has a cavity formed at the time of mold clamping. Type and
(B) a molten thermoplastic resin introduction part arranged in the first mold part or the second mold part for introducing the molten thermoplastic resin into the cavity; and (C) the first mold part and / Or second
A nest that is provided in the mold part and forms a part of the cavity, wherein the nest is formed on a surface of a nest body made of zirconia ceramics and at least a part of the nest body. The present invention can be achieved by the mold assembly according to the first aspect of the present invention, comprising the active metal film and the metal layer formed on the active metal film.

Further, the above object is achieved by (A) a mold having a first mold part and a second mold part, wherein a cavity is formed at the time of mold clamping, and (B) a first mold part. A molten thermoplastic resin introduction portion disposed in the mold portion or the second mold portion for introducing the molten thermoplastic resin into the cavity; and (C) a first mold portion and / or a second mold. A nest, which is disposed in the part and forms a part of the cavity, the nest comprises a nest body made of zirconia ceramics, an active metal film formed on at least a part of the surface of the nest body, and an active metal film. A method for molding a thermoplastic resin molded product using a mold assembly composed of a formed metal layer, wherein a first mold part and a second mold part are clamped. After introducing the molten thermoplastic resin into the cavity from the molten thermoplastic resin introduction part, A method of molding a molded article made of a thermoplastic resin according to the first aspect of the present invention, wherein the thermoplastic resin in the cavity is cooled and solidified, then the mold is opened, and the molded article is removed from the mold. Can be achieved by:

In the nesting or mold assembly and the molding method according to the first aspect of the present invention (hereinafter, these may be collectively referred to as the first aspect of the present invention), the active metal film has at least It may be formed on the thin layer forming surface of the nesting body, for example, it may be formed only on the thin layer forming surface of the nesting body, or may be formed on the entire surface of the nesting body. As a method of forming an active metal film on at least a part of the surface of the nest body, an active metal solder method can be mentioned. By employing the active metal solder method, the active metal film can obtain high adhesion to the surface of the nest body. In addition, the metal layer can obtain high adhesion to the nest body. Furthermore, by providing the active metal film, conductivity can be imparted to the surface of the nest body made of non-conductive zirconia ceramics, and the metal layer can be formed by, for example, an electrolytic plating method. Here, the active metal solder method is to apply a paste made of a metal material forming the active metal film to at least a part of the surface of the nest body (at least a thin layer forming surface of the nest body) by, for example, a screen printing method. In vacuum or inert gas,
It refers to a method of baking at a high temperature of about 800 ° C. to 1000 ° C.

In a first embodiment of the present invention, an active metal film
Is a metal selected from the group consisting of Ti, Zr and Be
(Active metal) and a group consisting of Ni, Cu, Ag and Fe
Eutectic composition with a metal selected from the group consisting of active metals
The film thickness is 1 × 10^-6m to 1 × 10^-Fivem, desirably
Is 3 × 10^-6m to 5 × 10^-6preferably m
No. More specifically, as the eutectic composition, for example, Ti
-Ni, Ti-Cu, Ti-Cu-Ag, Ti-Ni-
Ag, Zr-Ni, Zr-Fe, Be-Cu, Be-N
i. The thickness of the active metal film is 1 × 10
^-6m to 1 × 10 ^-Fivem, high conductivity
An active metal film having a non-conductive property can be obtained.
To provide conductivity to zirconia ceramics
And the activity for zirconia ceramics
The adhesion of the conductive metal film can be improved.
Active when forming active metal film on Konia ceramics
Problems such as warpage caused by shrinkage of the metal film
Can be prevented. In addition, the active metal film is
By constituting from heat resistance, mechanical strength, electricity
Film with excellent mechanical properties and baking at low temperature
Becomes possible.

The object of the present invention is to (A) mold a thermoplastic resin molded article comprising a first mold part and a second mold part, wherein a cavity is formed at the time of mold clamping. And (B) a molten thermoplastic resin introduction part arranged in the first mold part or the second mold part for introducing the molten thermoplastic resin into the cavity; Mold part and / or
Or a mold assembly provided in the second mold portion and having a nest forming a part of the cavity, wherein the nest comprises:
A nested body made of conductive zirconia ceramics,
This can be achieved by the mold assembly according to the second aspect of the present invention, which is constituted by a metal layer formed on the surface of at least a part of the nest body.

Further, the above object is achieved by (A) a mold comprising a first mold part and a second mold part, wherein a cavity is formed at the time of mold clamping; and (B) a first mold part. A molten thermoplastic resin introduction portion disposed in the mold portion or the second mold portion for introducing the molten thermoplastic resin into the cavity; and (C) a first mold portion and / or a second mold. A nest that is disposed in the portion and forms a part of the cavity, wherein the nest comprises a nest body made of conductive zirconia ceramics and a metal layer formed on a surface of at least a part of the nest body. A method for molding a molded article made of a thermoplastic resin using a mold assembly, comprising clamping a first mold part and a second mold part and melting the cavity from a molten thermoplastic resin introduction part into a cavity. After introducing the thermoplastic resin, the thermoplastic resin in the cavity is cooled and solidified. Is allowed, then performs mold opening can be achieved by a second method of molding a molded article of a thermoplastic resin according to aspects of the present invention characterized by taking out the molded product from the mold.

In the nesting or mold assembly and the molding method according to the second aspect of the present invention (hereinafter sometimes collectively referred to as the second aspect of the present invention),
It may be formed at least on the thin layer forming surface of the nesting body. For example, it may be formed only on the thin layer forming surface of the nesting body, or may be formed on the entire surface of the nesting body. The volume specific resistance of the conductive zirconia ceramics is 1 × 10 ⁹ Ω · cm or less, preferably 1 × 10 ⁴ Ω · cm.
It is desirable to be Ω · cm or less. If the volume resistivity of the conductive zirconia ceramic exceeds 1 × 10 ⁹ Ω · cm, the zirconia ceramic becomes an insulator, and it is difficult to directly form a metal layer on the thin layer forming surface of the nest body. The lower limit of the volume resistivity of the conductive zirconia ceramic is desirably 1 × 10 ⁻⁴ Ω · cm.

In the first or second embodiment of the present invention, the zirconia ceramic or the conductive zirconia ceramic is preferably composed of partially stabilized zirconia ceramic. When the zirconia ceramic is made of partially stabilized zirconia ceramic in the first embodiment of the present invention, or when the conductive zirconia ceramic is made of partially stabilized zirconia ceramic in the second embodiment of the present invention, the partially stabilized zirconia ceramic is used. Partial stabilizers in zirconia ceramics include calcia (calcium oxide, CaO), yttria (yttrium oxide, Y ₂ O ₃ ), magnesia (magnesium oxide, MgO), and silica (silicon oxide, S
Preferably, it is made of at least one material selected from the group consisting of iO ₂ ) and ceria (cerium oxide, CeO ₂ ). The ratio of the partial stabilizer contained in the zirconia ceramics or the conductive zirconia ceramics is 3 mol% to 15 mol%, preferably 6 mol% to 10 mol when the partial stabilizer is calcia.
%, 1 mol% to 8 mol%, preferably 2 mol% to 5 mol% for yttria, and 4 mol% to 15 mol%, preferably 8 mol for magnesia.
% To 10 mol%, in the case of ceria, 3 mol% to 1
It is desirably 8 mol%, preferably 6 mol% to 12 mol%.

In the second embodiment of the present invention, in order to make the zirconia ceramic conductive, a conductivity-imparting agent may be added to the zirconia ceramic. Fe ₂ O ₃ , NiO, Co ₃ O ₄ , Cr ₂ O ₃ , T
At least one of iO ₂ and TiN can be mentioned, or TiC, W
At least one of carbides such as C and TaC can also be mentioned. The content of the conductivity-imparting agent in the conductive zirconia ceramic is desirably 10% by weight or more. If it is less than 10% by weight, the volume resistivity is 1 ×
In some cases, it is difficult to reduce the resistance to 10 ⁹ Ω · cm or less. On the other hand, if a large amount of the conductivity-imparting agent is added, the volume resistivity of the zirconia ceramics decreases, but the strength of the nested body, which is the obtained sintered body, is impaired. Therefore,
It is desirable that the content be 40% by weight or less.

According to the first aspect or the second aspect of the present invention,
Then, by providing the metal layer, such a metal layer
It is possible to process with a general cutting machine, mold
Part (in some cases, nesting parts or nesting cores,
It is easy to fine-tune the nesting on the cover plate).
Can be. Moreover, high scratch resistance and surface hardness can be obtained.
Can be. The metal layer is made of Cr, Cr compound, Cu, Cu
Compound, selected from the group consisting of Ni and Ni compounds
Made of at least one kind of material, the thickness of the metal layer is 3 ×
10^-Fivem to 5 × 10^-Fourm, preferably 5 × 10^-Fivemno
2 × 10^-Fourm is preferable. One metal layer
Or a plurality of layers. C
As the r compound, specifically, a nickel-chromium alloy
Can be mentioned. In addition, as a Cu compound,
Include copper-zinc alloy, copper-cadmium alloy, copper-tin alloy
Can be mentioned. Furthermore, as a Ni compound,
Physically, nickel-iron alloy, nickel-cobalt alloy
Gold, nickel-tin alloy, nickel-phosphorus alloy (Ni-P
System), nickel-iron-phosphorus alloy (Ni-Fe-P system),
Nickel-cobalt-phosphorus alloy (Ni-Co-P)
Can be mentioned. As a method of forming a metal layer,
Dissolution plating and electroless plating can be used.
When high scratch resistance is required for the metal layer, for example,
For example, it is preferable that the metal layer be made of chromium (Cr).
is there. On the other hand, the scratch resistance of the metal layer is not required to the left,
If a thickness is required, for example, the metal layer may be made of copper (C
It is preferred to comprise u). Furthermore, the metal layer
When scratch resistance is required to some extent and thickness is also required.
In this case, for example, the metal layer is made of nickel (Ni).
Preferably. In addition, the metal layer needs to be thick
If surface hardness is required, the metal layer
Has a two-layer structure, for example, the lower layer is made of copper (Cu) or
Nickel (Ni) to achieve the desired thickness and adjust the thickness.
While the upper layer is made of thin chromium (Cr).
Preferably. The thickness of the metal layer is 3 × 10 ^-Fivemno
To 5 × 10^-Fourm so that the metal layer
It can be easily processed with a cutting machine. Moreover,
The molten thermoplastic introduced into the cavity contacts the metal layer.
Even if touched, make sure that the molten thermoplastic
Can be prevented.

In the second aspect of the present invention, the conductive zirconia ceramic may contain a sintering temperature inhibitor in a range of 3% by weight or less. Fe as a conductivity-imparting agent
₂ O ₃ , NiO, Co ₂ O ₄ , Cr ₂ O ₃ , TiO ₂ , TiN
When using, Ca, K, Na,
Oxides such as Mg, Zn, and Sc can be mentioned. When a carbide such as TiC, WC and TaC is used as the conductivity-imparting agent, Al ₂ O ₃ and TiO ₂ can be mentioned as the firing temperature suppressor. 3% by weight of these firing temperature inhibitors
If it is contained in the following range, the firing temperature can be lowered and the grain growth of zirconia and the conductivity imparting agent can be suppressed, so that the mechanical properties such as bending strength and hardness of the nest body can be increased.

In the first embodiment or the second embodiment of the present invention including the above-mentioned various forms (hereinafter, sometimes collectively simply referred to as the present invention), the thickness of the nesting body is
It is desirable that the thickness be 0.1 mm to 10 mm, preferably 0.5 mm to 10 mm, more preferably 1 mm to 7 mm, and still more preferably 2 mm to 5 mm. When the thickness of the nest body is less than 0.1 mm, the heat insulation effect by the nest is reduced, and the molten thermoplastic resin introduced into the cavity is rapidly cooled, and poor appearance such as weld marks and flow marks occurs on the molded product. Easier to do. When the nest is fixed to a metal or alloy mold part constituting the mold assembly, the nest may be bonded to the mold part using, for example, a thermosetting adhesive. The thickness is 0.
When the thickness is less than 1 mm, if the thickness of the adhesive becomes uneven, uneven stress remains in the nest, so that the surface of the molded product may undulate, or the nest may be formed by the pressure of the molten thermoplastic resin introduced into the cavity. May be damaged. On the other hand, when the thickness of the nest body exceeds 10 mm, the heat insulation effect of the nest becomes too large, and if the cooling time of the resin in the cavity is not extended, the molded article may be deformed after the molded article is taken out. Therefore, a problem such as extension of the molding cycle may occur.

The thermal conductivity of zirconia ceramics, conductive zirconia ceramics or partially stabilized zirconia ceramics constituting the nest body is 8.5 J /
(M · s · K) or less [8.5 W / (m · K) or less, or 2 × 10 ⁻² cal / (cm · s · K) or less], specifically, about 3.5 to 6 J / (M · s · K).
When the nest body is manufactured using an inorganic material having a thermal conductivity exceeding 8.5 J / (m · s · K), the nest is provided because the molten thermoplastic resin in the cavity is rapidly cooled by the nest. The same appearance as that of a molded product formed by using a mold assembly made of ordinary carbon steel or the like can be obtained.

When the molded product requires mirror surface properties, it is preferable that the surface roughness _Ry of the cavity surface of the nest or the cavity forming surface of the nest body is 0.03 μm or less. If the surface roughness _Ry exceeds 0.03 μm, the mirror finish may be insufficient, and characteristics required for a molded product, for example, surface smoothness (image clarity) may not be satisfied. For this purpose, for example, diamond lapping may be performed on the cavity forming surface of the nesting body until the surface roughness _Ry becomes 0.03 μm or less, and polishing may be performed as necessary. Lapping can be performed using a lapping machine or the like. It is desirable that the wrapping be performed on the nesting body after it is formed into a desired shape. The measurement of the surface roughness R _y is based on JIS B060
1-1994.

In order to prevent the nest from being broken by the fine cracks generated at the edge of the nesting body coming into contact with the molten thermoplastic resin, the edge of the nesting body may be cut with a diamond grindstone in some cases. It is preferable that polishing is performed so that stress is not concentrated. Alternatively,
In some cases, it is preferable to provide a curvature surface or a C-plane cut having a radius of 0.3 mm or less to avoid stress concentration on the edge of the nesting body.

The mold assembly or the molding method according to the first or second embodiment of the present invention including the above-described various forms (hereinafter, collectively referred to as the mold assembly or the molding method of the present invention) In some cases, the nest is disposed on the first mold part and faces the second mold part in a state where the first mold part and the second mold part are clamped. A thin layer is formed on the surface of the nesting body portion (the thin layer forming surface of the nesting body), and the nesting body faces the nesting in a state where the first mold portion and the second mold portion are clamped. and the opposing surface of the second mold part, be a clearance C ₁₁ between the facing surface and the opposing nesting portion of the second mold section 0.03mm or less (C ₁₁ ≦ 0.03mm) desirable.

Such a configuration is applied to a first configuration of a mold assembly or the like.
Called Naru. In addition, the part of the nesting body facing the second mold part
Nested body other than the surface of the minute (the thin layer forming surface of the nested body)
May be formed with a thin layer. Of the second mold part
The surface of the nested part facing the facing surface is the facing surface of the nesting
It may be called. Mold the first mold part and the second mold part
In the tightened state, the second mold part
Overlap amount ΔS of opposing surfaces ₁₁To be 0.5 mm or more
preferable. The opposing surface of the second mold part is
A kind of notch provided on the surface of the opposing second mold part
(Notch) and extension of the parting surface of the second mold part
And the like. In addition, it faces the opposing surface of the nest.
A notch provided on the surface of the second mold part
) May be referred to as a nested covering. Where
Of molten thermoplastic resin in mold assembly
For example, a direct gate structure
Can be.

Alternatively, the mold assembly of the present invention or
In the molding method, the first or second mold part is used.
And form a part of the cavity, the end face of the nest
A coating plate for coating, wherein the nest is a first mold;
And the first mold part and the second mold part are clamped.
Of the nesting body facing the covering plate in the
A thin layer is formed on the surface of the part (the thin layer forming surface of the nest body).
And the first mold part and the second mold part are clamped.
In the state, the clearer between the nest and the cover plate
C_{twenty one}Is 0.03 mm or less (C_{twenty one}≦ 0.03mm)
And the amount of overlap ΔS of the covering plate with respect to the nesting
_{twenty one}Is 0.5 mm or more (ΔS _{twenty one}≧ 0.5mm)
Is desirable.

Such a configuration is referred to as a second configuration such as a mold assembly. Note that a thin layer may be formed on the nest body other than the surface of the nest body facing the covering plate (the thin layer forming surface of the nest body). The surface of the nest portion facing the cover plate may be referred to as the nest facing surface. Here, examples of the molten thermoplastic resin introduction portion in the mold assembly having such a configuration include a direct gate structure, a side gate structure, and an overlap gate structure. The covering plate overlaps the entire periphery of the nest.

Further, in the mold assembly or molding method of the present invention, the mold assembly or the molding method further includes a coating plate which is attached to the second mold portion, forms a part of the cavity, and covers a part of the end face of the nest. The nest is disposed on the first mold portion, and the surface of the portion of the nest body facing the covering plate when the first mold portion and the second mold portion are clamped (the thin nest body portion). A thin layer is formed on the layer forming surface), and a thin layer is formed on the surface of the nest body facing the second mold portion (the thin layer forming surface of the nest body); In a state where the mold portion and the second mold portion are clamped, the opposing surface of the second mold portion facing the nest, and the nest portion facing the opposing surface of the second mold portion clearance C ₃₁ between the, 0.03 mm or less (C ₃₁ ≦ 0.03
mm), and the overlapping amount ΔS ₃₁ of the facing surface of the second mold portion with respect to the nest is 0.5 mm or more (ΔS ₃₁ ≧ 0.5 m).
m) and the clearance C ₃₂ between the insert and the cover plate is 0.03 mm or less (C ₃₂ ≦ 0.03 m
m) and the amount of overlap Δ of the coated plate with respect to the nesting
S ₃₂ may be configured to be 0.5 mm or more (ΔS ₃₂ ≧ 0.5 mm).

Such a configuration is referred to as a third configuration such as a mold assembly. The nest other than the surface of the nest body facing the covering plate (the thin layer forming surface of the nest body) and the surface of the nest body facing the second mold portion (the thin layer forming surface of the nest body) A thin layer may be formed on the body. The facing surface of the second mold part and the surface of the nest portion facing the covering plate may be referred to as the nesting facing surface. Here, examples of the molten thermoplastic resin introduction portion in the mold assembly having such a configuration include a side gate structure and an overlap gate structure.

Alternatively, in the mold assembly or the molding method of the present invention, the nest is provided in the first nest provided in the first mold portion and the second nest provided in the second mold portion. A first nest, which comprises a second nest, and faces the second nest in a state where the first mold part and the second mold part are clamped.
The surface of the nested body portion of the nest (the thin layer forming surface of the first nested body) and the surface of the second nested body portion of the second nested body facing the first nest (the thin nested body of the second nested body) A thin layer is formed on the layer forming surface, and in a state where the first mold part and the second mold part are clamped, a first nest part facing the second nest, Clearance C ₄₁ between the first nest and the opposing second nest portion
May be configured to be 0.03 mm or less (C ₄₁ ≦ 0.03 mm).

Such a configuration is referred to as a fourth configuration such as a mold assembly. In addition, a thin layer may be formed on a portion of the first nest body other than the thin layer forming surface of the first nest body, or a second layer other than the thin layer forming surface of the second nest body may be formed. A thin layer may be formed in a portion of the nest body of the nest. The surface of the first nest portion facing the second nest is referred to as the first nest facing surface, and the surface of the second nest portion facing the first nest is referred to as the second nest facing surface. May be called. In a state where the first mold portion and the second mold portion are clamped, a first nest portion facing the second nest, a second nest portion facing the first nest, overlapping amount [Delta] S ₄₁ is 0.5mm or more ([Delta] S ₄₁ ≧
0.5 mm). Further, it is disposed between the first nest and the second nest and attached to the first mold part, the second mold part, or the first and second mold parts, It is desirable that the mold assembly further include a coating plate provided with a plastic resin introduction portion. The clearance C ₄₂ between the first nest and the covering plate and the clearance C ₄₃ between the second nest and the covering plate are 0.03 mm or less (C ₄₂ , C ₄₃ ≦ 0.
03 mm), and the overlapping amount ΔS ₄₂ of the covering plate with respect to the first nest and the overlapping amount ΔS ₄₃ of the covering plate with respect to the second nest are 0.5 mm or more (ΔS ₄₂ , Δ
S ₄₃ ≧ 0.5 mm), and the cover plate preferably overlaps only a part of the first and second nests.

In the third structure or the fourth structure of the mold assembly or the like of the present invention, the nest portion in the vicinity of the high-pressure molten thermoplastic resin introduction portion is easily damaged. By covering the end face of the nest with the covering plate with the clearance and the amount of overlap, it is possible to reliably prevent the nest made of zirconia ceramics or conductive zirconia ceramic which is easily broken. In addition, the appearance of the end of the molded product is not impaired, and burrs are not generated at the end of the molded product.

In the first configuration of the mold assembly or the like according to the present invention, the nest is disposed on the mold assembly, particularly when the mold is hardly damaged or burred, etc. It can be performed by bonding to a surface constituting a cavity (a cavity surface of a mold portion). In this case, the mold is placed in the mold portion so that the nest does not contact the cavity surface of the mold portion due to the stress caused by the mold clamping. Alternatively, if the nest can be fixed using bolts, it may be fixed using bolts.

Alternatively, the first mold assembly or the like of the present invention
In the configuration of the second aspect, further, the second aspect of the mold assembly and the like of the present invention
In the configurations of the fourth to fourth configurations, after processing into a predetermined shape by cutting or the like, there is no possibility that the nest will fall from the nest mounting part provided in the mold part when mounting the nest and be damaged, or When the nest can be mounted on the nest mounting portion without using the adhesive, the nest can be directly mounted on the nest mounting portion provided on the mold portion without using the adhesive. Further, the nest may be bonded to the nest mounting portion using a thermosetting adhesive selected from an epoxy-based, silicone-based, urethane-based, acrylic-based, or the like.
Note that a nesting mounting core provided with a nesting mounting portion may be used, the nesting may be fixed to the nesting mounting portion of the nesting mounting core, and the nesting mounting core may be attached to the mold portion. Alternatively, if the nest can be fixed using bolts, it may be fixed using bolts.

In some cases, it is necessary to form holes (through holes or non-through holes) in the molded product. In such a case,
In the mold assembly or the molding method of the present invention, if the slide assembly for forming a hole in a molded product is further provided in the mold assembly, the slide core being arranged in the first or second mold portion. Good.

In this case, the slide core for forming a hole in the molded product is composed of a pair of opposed slide core members and an annular member attached to each slide core member constituting a part of the cavity. The annular member may have a shape in which one end is closed and the other end is open, or a shape in which both ends are open.
Then, the annular member is connected to the first aspect or the second aspect of the present invention.
The configuration may be the same as that of the nest according to the aspect. Note that a thin layer may be formed on at least the opposed surface of the annular member facing the annular member, and a thin layer may be formed on the entire surface of the annular member. It is desirable that the thickness of the annular member be 0.1 mm to 5 mm, preferably 0.5 mm to 5 mm, more preferably 1 mm to 5 mm, and still more preferably 2 mm to 5 mm. When the thickness of the annular member is less than 0.1 mm,
The heat insulating effect of the annular member is reduced, which causes rapid cooling of the molten thermoplastic resin introduced into the cavity, and the appearance defect is likely to occur in the molded product. On the other hand, the thickness of the annular member is 5 m
If it exceeds m, the heat insulating effect of the annular member becomes too large, and unless the cooling time of the resin in the cavity is extended,
The molded product may be deformed after removing the molded product. Therefore, a problem such as extension of the molding cycle may occur.

When the hole to be formed in the molded product is a through hole
When the pair of slide core members face each other,
End of annular member attached to one slide core member
Part and the annular member attached to the other slide core member
Clearance C between the end of ₅₁Is 0.03mm or less
(C₅₁≦ 0.03 mm). Also,
An annular member and nest attached to the slide core member
Clearance C between₅₂Is 0.03 mm or less (C₅₂≤
0.03 mm).

Alternatively, in the case of forming a hole (through hole, non-through hole or concave portion) in the molded product in the mold assembly or the molding method of the present invention, a projection (convex portion) may be provided in the insert. . Alternatively, a core pin (also referred to as a pin or a mold pin) attached to the first mold part and / or the second mold part and occupying the cavity forms a part of the cavity is a mold assembly. Is preferably further provided. The cross-sectional shape of the core pin may be designed according to the desired cross-sectional shape of the hole. Also, the core pin may be tapered toward the tip,
A step may be provided on the side surface of the core pin.

When manufacturing a perforated molded product, the flow of the molten thermoplastic resin introduced into the cavity is branched by the core pin and merges again. In this process, the molten thermoplastic resin is cooled, and the solidified resin joins, so that a weld line is easily generated. In a molded product in which a weld line has occurred, the strength is significantly reduced. Therefore, it is necessary to design a mold so that a weld line is not generated in a portion of a molded product to which stress is applied, and there is a problem that the degree of freedom in designing the molded product is reduced. In addition, the appearance of the molded product in which the weld line is generated becomes ugly.

The core pin may be made of metal or ceramics. In the case of a metal core pin, the molten thermoplastic resin branched by the core pin and cooled in the cavity merges to form a weld mark, and The strength of the product may be reduced. In such a case, the core pin may be configured as described below, and this can suppress the cooling of the resin when the molten thermoplastic resin in the cavity merges. This can be effectively prevented, and a decrease in the strength of the molded article can be prevented. When all the core pins are made of zirconia ceramics, it is preferable that the diameter of the core pin (the diameter when the core pin has a cylindrical diameter and the diameter of a circumscribed circle when the core pin is a polygonal pillar) does not exceed 10 mm. If the diameter of the core pin exceeds 10 mm, the heat insulation effect of the core pin becomes too large, and if the cooling time of the resin in the cavity is not extended, the molded article may be deformed after the molded article is taken out from the mold. Therefore, a problem such as extension of the molding cycle may occur. However, in the case where the nest having good heat insulating properties is provided in the first and / or second mold parts, the molten thermoplastic resin that is branched by the core pins and merges is hard to be cooled. No problem. In this case, the core pin may be attached to a mold portion different from the mold portion provided with the nest, or a through hole may be provided in the nest, and the core pin may be attached to the mold portion through the through hole. It is good also as a form.

When the diameter of the core pin made of zirconia ceramics is 10 mm or less, it is preferable that the core pin has the same configuration as the nest according to the first or second embodiment of the present invention. On the other hand, the core pin diameter is 10m
m, the core pin is attached to (a) the core pin attachment portion attached to the first mold portion and / or the second mold portion, and (b) the core pin attachment portion, and one end is closed. And an annular member having a shape with the other end open or a shape with both ends open, the annular member comprising:
Configure the surface of the core pin portion occupying the cavity,
Preferably, the core pin mounting portion extends from the other end of the annular member to the inside of the annular member. Further, it is preferable that the annular member has the same configuration as the nest according to the first aspect or the second aspect of the present invention. It is necessary to form a thin layer on the surface of at least a portion of the core pin or the annular member facing the cavity surface of the nest.

In the mold assembly or the molding method of the present invention, the clearance (C _c1 ) between the core pin occupying the cavity and the nested cavity surface, or the clearance between the annular member and the nested cavity surface. it is preferable that the clearance (C _c1) a 0.03mm or less (C _c1 ≦ 0.03mm). The lower limit of the clearance (C _c1 ) is
The value may be such that the cavity surface of the nest does not come into contact with the core pin or the annular member due to the thermal expansion of the nest when the mold assembly is heated, and the nest is not damaged. still,
If the clearance (C _c1 ) exceeds 0.03 mm, the molten thermoplastic resin penetrates between the core pin or the annular member and the cavity surface of the nest, causing cracks in the nest or burrs on the molded product. There is a fear. By setting the clearance (C _c1 ) to 0.03 mm or less, it is possible to reliably prevent the molten thermoplastic resin from entering between the core pin or the annular member and the cavity surface of the nest, and furthermore, to the molded product. The hole can be formed reliably.

The core pin or the annular member is used in the first embodiment of the present invention.
By adopting the same configuration as the nest according to the aspect or the second aspect, the metal layer on the surface of the core pin or the annular member can be easily processed. In addition, since the molten thermoplastic resin branched by the core pin and rejoining is not cooled much, a weld line or the like is hardly generated in the molded product. Furthermore, by defining the clearance between the opposing surface and the nested cavity surface in the portion of the core pin occupying the cavity, the core pin and the nest do not come into contact, and the core pin and the nest can be used for a long period of time. It is possible to do. Moreover, the durability of the core pin or the annular member can be improved by making the core pin or the annular member have the same configuration as the nest according to the first or second embodiment of the present invention.

Various clearances (C₁₁, C_{twenty one}, C_{twenty two},
C₃₁, C₃₂, C₄₁, C₄₂, C₄₃, C ₅₁, C₅₂, C_c1) Is
0.03 mm or less, preferably 0 mm or more and 0.025 m
m or less (0 mm ≦ C₁₁, C_{twenty one}, C_{twenty two}, C₃₁, C₃₂,
C₄₁, C₄₂, C₄₃, C₅₁, C₅₂, C_c1≤0.025m
m). Clearance (C₁₁, C_{twenty one}, C_{twenty two}, C₃₁,
C₃₂, C₄₁, C₄₂, C₄₃, C₅₁, C₅₂, C_c1) Is 0.0
If it exceeds 3 mm, the molten thermoplastic resin will
Opposite surface of mold part, coating plate, slide core, core pin
Intrusion may occur, causing cracks in nesting, etc.
Burrs on the molded product,
There are also problems such as nesting damage when taking out
You. However, in the present invention, it occurs at the end of nesting or the like.
Because fine cracks that are easy to cover are covered by the metal layer,
Breakage of nests can be significantly reduced
You.

The overlap amount (ΔS₁₁, ΔS_{twenty one}, ΔS_{twenty two}, ΔS
₃₁, ΔS₃₂, ΔS₄₁, ΔS₄₂, ΔS ₄₃) Is 0.5m
m, the fine cracks generated on the outer
Nests formed as a result of contact between the melt and the thermoplastic resin
Cracks may grow and nesting may be damaged.
However, in the present invention, the end of a nest or an annular member
Fine cracks that are likely to occur are covered by the metal layer
Therefore, nesting etc. is significantly reduced from being damaged
Can be.

As a method for molding a molded article using the mold assembly of the present invention, injection molding, injection compression molding, multicolor molding, gas-assist molding, which are generally used for molding a thermoplastic resin. And a blow molding method.

The mold assembly or the molding method of the present invention further comprises a pressurized fluid injection device for injecting a pressurized fluid into the molten thermoplastic resin introduced into the cavity. be able to. Alternatively, the mold may have a structure capable of making the volume of the cavity variable, such as a structure in which an intaglio structure is formed by the first mold portion and the second mold portion. Another example is a structure in which the mold assembly further includes a movable core in the cavity, which can make the volume of the cavity variable. Further, a pressurized fluid injecting device arranged in the first or second mold portion and for injecting a pressurized fluid into the molten thermoplastic resin introduced into the cavity is further provided, and A mold assembly having a structure capable of changing the volume of the cavity may be used.

In the method of molding a molded article according to the first or second aspect of the present invention, when the apparatus is further provided with a pressurized fluid injection device, it is possible to melt the molten thermoplastic resin into the cavity from the molten thermoplastic resin introduction part. After starting the introduction of the thermoplastic resin, a method of injecting a pressurized fluid from a pressurized fluid injection device into the molten thermoplastic resin in the cavity and thereby forming a hollow portion in the resin in the cavity (gas assist molding method) ).

The mounting position of the pressurized fluid injection device depends on the shape of the molded article to be molded and the like. In the introduction part (for example, in the gate part), or
It may be appropriately selected from a pressurized fluid injection device mounting portion provided in the mold portion and opened in the cavity. The injection of the pressurized fluid into the molten thermoplastic resin introduced into the cavity can be started during, simultaneously with, or after the introduction of the molten thermoplastic resin into the cavity. The injection of the pressurized fluid into the molten thermoplastic resin in the cavity is preferably continued even after the resin in the cavity has cooled and solidified. The amount of the molten thermoplastic resin introduced into the cavity may be an amount necessary to completely fill the inside of the cavity with the molten thermoplastic resin, or depending on a molded product, the amount of the molten thermoplastic resin may be introduced into the cavity. The amount may be insufficient to be completely filled with the resin.

The pressurized fluid suitable for use is a gaseous or liquid fluid at normal temperature and pressure that does not react with or mix with the molten thermoplastic resin when injected into the molten thermoplastic resin. desirable. Specifically, a gaseous substance at normal temperature such as nitrogen gas, carbon dioxide gas, air, and helium gas, a liquid such as water, and a gas liquefied under high pressure can be used. Among them, nitrogen gas and helium gas can be used. And the like. It is more preferable that the pressurized fluid to be injected is an inert pressurized fluid that does not cause burning due to adiabatic compression in the hollow portion of the molded product. When nitrogen gas is used, the pressurized fluid has a purity of 90% or more. It is desirable to use
Further, foamable resin, fiber reinforced resin material, or the like can be used as the pressurized fluid. In this case, the hollow portion is filled with an expandable resin, a fiber-reinforced resin material, and the like.
Such a structure is also included in the concept of a hollow portion in the present invention.

Alternatively, the mold assembly is placed in the cavity.
The product has a variable structure and the volume of the molded product to be molded
(V_M) Rather than the volume of the cavity (V_C) Will be bigger
Thus, the first mold part and the second mold part are clamped, and
Cavity (Volume: V_C) Introduce molten thermoplastic resin
Before, at the same time as the introduction of thermoplastic resin
The cavity volume should be
The volume of the molded product (volume: V _M) To reduce
Compression molding method). The cavity
The volume of the molded product to be molded (V_M)
During or after the introduction of molten thermoplastic resin (introduction
(Including simultaneous with completion). Such mold set
As described above, the first mold part has a three-dimensional structure.
In which an inro structure is formed by the first mold part and the second mold part
Or inside the cavity, which can make the volume of the cavity variable
The structure in which the mold assembly further includes a movable core is given.
be able to. The movement of the core is controlled, for example, by a hydraulic system.
Can be done with a Linder.

[0066] During the above clamping, the relationship of the molded article of the volume to be formed (V _M) and the volume of the cavity (V _C), the thickness of the molded article to be molded and t _0, molding at mold clamping Δt = t ₁ −t where t ₁ is the distance of the cavity in the thickness direction of the product.
_{When 0} is set, the relationship is preferably such that 0.1 mm ≦ Δt ≦ 6 mm. If Δt <0.1 mm, it may be difficult to mold a molded article using a molten thermoplastic resin having poor fluidity, and it is not possible to reduce the stress remaining on the molded article. On the other hand, when Δt> 6 mm,
There is a possibility that air is entrained in the molded article and the quality of the molded article is degraded.

Incidentally, the gas assist molding method and the injection compression molding method can be combined.

As the thermoplastic resin in the present invention, all of the thermoplastic resins which are usually used can be used. Specifically, examples of the amorphous thermoplastic resin include styrene resins such as polystyrene resin, ABS resin, AES resin, and AS resin; methacrylic resin; polycarbonate resin; modified PPE resin; and polyarylate resin. Examples of the crystalline thermoplastic resin include polyolefin resins such as polyethylene resin and polypropylene resin; polyamide 6, polyamide 66, and polyamide M.
Polyamide resins such as XD6; polyoxymethylene (polyacetal) resins; polyethylene terephthalate (P
ET) resin, polybutylene ethylene terephthalate (P
Polyester resins such as BT) resins; polyphenylene sulfide resins; polysulfone resins; polyethersulfone resins; polyetherimide resins; and polyamideimide resins.

The crystalline thermoplastic resin has a higher density and a higher melting point due to crystallization, and the hardness and elastic modulus of the molded product are improved. Further, the crystalline thermoplastic resin has a feature that it is difficult for moisture, a dye, a plasticizer, and the like to enter the crystal structure, and thus has excellent chemical resistance. Normally, when molding a molded article using a crystalline thermoplastic resin, the mold temperature is set to be considerably lower than the load deflection temperature of the crystalline thermoplastic resin, and the molten crystal introduced into the cavity is set. A method of promoting cooling and solidification of a thermoplastic resin is adopted. Since the normal mold part is made of a metal material, it has good thermal conductivity, and when the mold temperature is set significantly lower than the load deflection temperature of the crystalline thermoplastic resin, it is introduced into the cavity. The melted crystalline thermoplastic resin starts cooling instantly when it comes into contact with the cavity surface of the mold part. As a result, an amorphous layer or a fine crystal layer with low crystallinity (skin layer) is formed on the surface of the molded product.
Is formed. In a molded article on which such a skin layer is formed, there is a problem that physical properties related to the surface of the molded article are significantly reduced. For example, abrasion resistance and weather resistance of a molded article molded from a polyoxymethylene (polyacetal) resin as a crystalline thermoplastic resin are significantly reduced. Further, the transferability of the cavity surface of the mold portion to the surface of the molded product is also deteriorated.

In the present invention, since the nest is provided, the molten crystalline thermoplastic resin introduced into the cavity is not rapidly cooled. As a result, even when a crystalline thermoplastic resin is used, the degree of crystallinity of the resin does not decrease, the degree of crystallinity of the resin surface of the molded product is high, and the resin surface such as cracks due to deterioration of the resin is reduced. Can be prevented from deteriorating in physical properties related to.

Further, a thermoplastic resin made of a polymer alloy material can be used. Here, the polymer alloy material is made of a blend of at least two kinds of thermoplastic resins, or a block copolymer or a graft copolymer in which at least two kinds of thermoplastic resins are chemically bonded. Here, as thermoplastic resins constituting a polymer alloy material in which at least two kinds of thermoplastic resins are blended, polystyrene resin, ABS resin, AE
S resin, styrene resin such as AS resin, polyolefin resin such as polyethylene resin and polypropylene resin, methacryl resin, polycarbonate resin, polyamide resin such as polyamide 6, polyamide 66, polyamide MXD6, modified PPE resin, polybutylene terephthalate resin, Polyester resin such as polyethylene terephthalate resin, polyoxymethylene resin, polysulfone resin, polyimide resin, polyphenylene sulfide resin, polyarylate resin, polyether sulfone resin,
Polyether ketone resin, polyether ether ketone resin, polyester carbonate resin, liquid crystal polymer,
Elastomers may be mentioned. As a polymer alloy material obtained by blending two kinds of thermoplastic resins, a polymer alloy material of a polycarbonate resin and an ABS resin can be exemplified. Incidentally, such a combination of resins is referred to as polycarbonate resin / ABS resin. The same applies to the following. Further, as a polymer alloy material blended at least two types of thermoplastic resin,
Polycarbonate resin / PET resin, polycarbonate resin / PBT resin, polycarbonate resin / polyamide resin, polycarbonate resin / PBT resin / PET resin, modified PPE resin / HIPS resin, modified PPE resin /
Polyamide resin, modified PPE resin / PBT resin / PE
Examples include T resin, modified PPE resin / polyamide MXD6 resin, polyoxymethylene resin / polyurethane resin, PBT resin / PET resin, polycarbonate resin / liquid crystal polymer. Further, as a polymer alloy material composed of a block copolymer or a graft copolymer in which at least two kinds of thermoplastic resins are chemically bonded, HIPS resin, ABS resin, AES resin, and AAS resin can be exemplified.

In a molded article molded on the basis of a polymer alloy material, the appearance (particularly, glossiness) of the molded article generally deteriorates, and in particular, poor appearance occurs at a portion where the thickness of the molded article changes or at a weld portion. There is a problem that it is easy. The reason is that the normal mold part is made of a metal material with good thermal conductivity, so the molten polymer alloy material introduced into the cavity instantaneously contacts the cavity surface of the mold part. Start to cool. As a result, a solidified layer is formed on the molten polymer alloy material, resulting in poor transferability and poor gloss. In the present invention, since the molten polymer alloy material introduced into the cavity is not quenched, the gloss of the molded article is extremely improved, and a molded article with excellent mirror finish can be easily obtained. .

It should be noted that stabilizers, ultraviolet absorbers, release agents, dyes and pigments can be added to the various thermoplastic resins described above, and glass beads, mica, kaolin,
An inorganic filler such as calcium carbonate or an organic filler can also be added.

In the method of molding a molded article of the present invention, a thermoplastic resin containing 5% to 80% by weight of inorganic fibers can be used. When importance is placed on the strength of the molded article, the average length of the inorganic fibers is set to 5 μm to 5 mm, preferably 10 μm to 0.4 mm. When the image clarity (mirror property) of the molded article is emphasized, 5 μm to 0.4 m
m, more preferably 5 μm to 0.2 mm, and still more preferably 5 μm to 0.1 mm. In these cases, the average diameter of the inorganic fibers is 0.01 μm.
m to 15 μm, more preferably 0.1 μm to 13 μm
m, more preferably 0.1 μm to 10 μm.

In the prior art, when a molded article is molded using a thermoplastic resin containing inorganic fibers, the appearance of the molded article is deteriorated as a result of the inorganic fibers being precipitated on the surface of the molded article, or The problem that the performance (specularity) is deteriorated is likely to occur. Therefore, it has been difficult to use a thermoplastic resin containing inorganic fibers for a molded article requiring excellent appearance characteristics and image clarity. In addition, the phenomenon of inorganic fiber precipitation on the surface of a molded article can be recognized by, for example, floating of the inorganic fiber on the surface of the molded article. Therefore, in order to solve the problem such as the precipitation of inorganic fibers on the surface of the molded article, in the conventional technology, it is necessary to reduce the viscosity of the thermoplastic resin and improve the fluidity of the molten thermoplastic resin. I was However, when the content of the inorganic fibers is increased, it is difficult to prevent the inorganic fibers from depositing on the surface of the molded article. For this reason, it has been difficult to use a thermoplastic resin containing inorganic fibers in a molded article requiring excellent appearance characteristics, despite having excellent performance. The cause of the inorganic fibers precipitating from the surface of the molded article when the content of the inorganic fibers increases is also related to the material of the mold part. Since the normal mold part is made of a metal material having good thermal conductivity, the molten thermoplastic resin containing the inorganic fibers introduced into the cavity instantaneously contacts the cavity surface of the mold part. Start to cool. As a result, a solidified layer is formed on the molten thermoplastic resin in contact with the cavity surface of the mold portion, and inorganic fibers are deposited.
In addition, there arises a problem that the transferability of the cavity surface of the mold portion to the surface of the molded product is insufficient. In the present invention, since the molten thermoplastic resin introduced into the cavity is not quenched, no solidified layer is formed on the molten thermoplastic resin in contact with the cavity surface of the mold portion,
Precipitation of the inorganic fibers can be reliably prevented.

In this case, the proportion of the inorganic fibers contained in the thermoplastic resin (in other words, the proportion of the inorganic fibers added to the thermoplastic resin) depends on the required flexural modulus (for example, A
The value measured according to STM D790 is 3.0
(GPa or more) as long as it is within a range in which a molded product satisfying (GPa or more) can be molded. The upper limit thereof is difficult to mold because the fluidity of the molten thermoplastic resin in the cavity is reduced, or has an excellent mirror surface property. The value may be a value at which a molded article cannot be molded. Specifically, when a crystalline thermoplastic resin is used, the upper limit is approximately 80% by weight. When an amorphous thermoplastic resin is used, its fluidity is inferior to that of a crystalline thermoplastic resin. Therefore, in some cases, the upper limit is approximately 50% by weight. If the content is less than 5% by weight, the required bending elastic modulus, elastic modulus and linear expansion coefficient of the molded product cannot be obtained, and if it exceeds 80% by weight, the fluidity of the molten thermoplastic resin is reduced, so that the molded product is reduced. Molding may be difficult, or a molded article having excellent mirror surface properties may not be formed.

If the average length of the inorganic fibers is less than 5 μm or the average diameter is less than 0.01 μm, the required bending elastic modulus of the molded product cannot be obtained. On the other hand, if the average length of the inorganic fibers exceeds 5 mm or the average diameter exceeds 15 μm, there arises a problem that the surface of the molded article is not mirror-finished.

The surface of the inorganic fiber having the average length and the average diameter in the above ranges is preferably treated using a silane coupling agent or the like, and then compounded with a thermoplastic resin, and pelletized to obtain a molding material. . By molding a molded article using such a molding material and the mold assembly of the present invention in which the nest of the present invention is incorporated, high rigidity,
A molded product having a high elastic modulus, a low coefficient of linear expansion, a high load deflection temperature (heat resistance), and excellent mirror finish (image clarity) can be obtained.

The inorganic fibers include glass fibers, carbon fibers,
It is preferable to be composed of at least one material selected from the group consisting of wollastonite, aluminum borate whisker fiber, potassium titanate whisker fiber, basic magnesium sulfate whisker fiber, calcium silicate whisker fiber and calcium sulfate whisker fiber. . The number of inorganic fibers contained in the thermoplastic resin is not limited to one, and two or more kinds of inorganic fibers may be contained in the thermoplastic resin.

The average length of the inorganic fibers means the weight average length. The length of the inorganic fiber may be measured by dissolving the resin component by immersing a molding pellet or a molded article containing the inorganic fiber in a liquid in which the resin component of the thermoplastic resin is dissolved, or in the case of glass fiber at 600 ° C. By burning the resin component at the above high temperature, the remaining inorganic fibers can be measured by observation with a microscope or the like. Usually, a person measures the length by taking a photograph of the inorganic fiber, or obtains the length of the inorganic fiber using a dedicated fiber length measuring device. Since the number average length has too great an effect of the finely broken fibers, it is preferable to use the weight average length. In the measurement of the weight average length, the measurement is performed except for fragments of inorganic fibers which are too small and crushed. If the length is shorter than twice the nominal diameter of the inorganic fiber, the measurement becomes difficult. Therefore, for example, an inorganic fiber having a length twice or more the nominal diameter is measured.

In the present invention, since the nest is made of zirconia ceramics or conductive zirconia ceramics, rapid cooling of the molten thermoplastic resin in the cavity can be prevented. It is possible to prevent a solidified layer from being formed on the plastic resin, and prevent appearance defects such as weld marks and flow marks from occurring in the molded product.
Further, even when, for example, a thermoplastic resin containing inorganic fibers is used, it is possible to prevent the inorganic fibers from depositing on the surface of the molded article.

In addition, in the first embodiment of the present invention, if the active metal film is formed by using the active metal solder method, the active metal film can have high adhesion to the surface of the nest body, The metal layer can obtain high adhesion to the nest body. Furthermore, in the first aspect of the present invention, since the active metal film is provided, the surface of the nest body has conductivity, and the metal layer can be formed by, for example, an electrolytic plating method. Become. On the other hand, in the second aspect of the present invention, the metal layer can be directly formed on the thin layer forming surface of the nest body by forming the nest body from conductive zirconia ceramics. Moreover, in the first or second aspect of the present invention, since the metal layer is provided on the outermost surface of the nest, the metal layer on the opposing surface of the nest is processed by a general cutting machine or the like. And high abrasion resistance and surface hardness can be obtained. In addition, since the fine cracks generated on the outer peripheral portion of the nesting body during the processing of the nesting body are surely covered with the metal layer, the nesting does not break because the cracks do not come into contact with the molten thermoplastic resin.

Further, since the fluidity of the molten thermoplastic resin is improved, the pressure at which the molten thermoplastic resin is introduced into the cavity can be set low, and the stress remaining in the molded article can be reduced. As a result, the quality of the molded product is improved. Further, since the introduction pressure can be reduced, the thickness of the mold portion can be reduced, the size of the molding device can be reduced, and the cost of the molded product can be reduced.

[0084]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below with reference to the drawings.

(Embodiment 1) The nesting and mold assembly of the first embodiment relates to the nesting and mold assembly according to the first aspect of the present invention, and further relates to the nesting and mold assembly of the present invention. 1 relates to the configuration. A mold assembly according to the first embodiment whose schematic end view is shown in FIG. 1 includes (A) a first mold section (movable mold section) 10 and a second mold section (fixed mold section) 11. When closing the mold,
A mold for molding a molded article made of a thermoplastic resin, in which a cavity 14 is formed; and (B) a mold for disposing the molten thermoplastic resin in the cavity, which is disposed in the second mold portion 11. A mold set including a thermoplastic resin introduction part (referred to as a molten resin introduction part in the drawing) 13 and (C) a nest 15 provided in the first mold part 10 and constituting a part of the cavity 14. It is three-dimensional. 1A shows a state in which the mold assembly is clamped, and FIG. 1B shows a state in which the mold assembly is opened.

In a state where the first mold part 10 and the second mold part 11 are clamped, the facing surface of the second mold part 11 facing the insert 15 (parting surface in the first embodiment). PL ₂ ) and the clearance C ₁₁ between the portion of the nest 15 facing the opposing surface of the second mold portion 11 (the opposing surface 15B of the nest 15) is 0.03 mm or less (C ₁₁ ≦ 0.03).
3 mm).

The dimensions of the molded article formed in Example 1 were a rectangular parallelepiped having an outer shape of 94 mm × 94 mm × 3 mm (thickness). Cavity 14 in mold assembly of embodiment 1
Was set so that a molded article having such a shape could be formed. The outer shape of the nest 15 is 100 mm × 10
0 mm x 6 mm (height), and the nest 15
mm × 94 mm × 3 mm (depth)). Nesting 1
The thickness of the side wall and the bottom surface of 5 is 3 mm. The surface of the recess corresponds to the cavity surface 15 </ b> A of the insert 15.

In the first embodiment, the nesting body 115 is
It is composed of a partially stabilized zirconia ceramic having a thickness of 3.0 mm. That is, zirconia (ZrO ₂ ) contains a partial stabilizer composed of yttria (Y ₂ O ₃ ), and the partially stabilized zirconia ceramic in Example 1 is
It has a composition of rO ₂ —Y ₂ O ₃ . The ratio of the partial stabilizer contained in the partially stabilized zirconia ceramics was set to 3 mol%. The thermal conductivity of the partially stabilized zirconia ceramics is about 3.8 J / (ms · K). First
In a state where the mold part 10 and the second mold part 11 are clamped, the nest body 115 facing the second mold part 11
The surface of the portion (the thin layer forming surface of the nesting body 115)
An active metal film is formed based on the active metal solder method, and a metal layer is formed on the active metal film. Note that the two-layer structure of the active metal film and the metal layer is collectively simply referred to as a thin layer 16, and is represented by one layer in the figure. The active metal film is made of a 5 μm thick eutectic composition of Ti—Cu—Ag, and the metal layer is made of nickel (Ni).

The nest body 115 was produced by press-molding partially stabilized zirconia and then firing. Thereafter, the cavity forming surface of the nesting body 115 is polished and finished using a diamond grindstone, and the surface roughness _Ry of the cavity forming surface of the nesting body 115 is reduced to 0.0.
It was 2 μm. Next, on the thin layer forming surface of the nest body 115 facing the parting surface PL _{2 of the second} mold portion 11,
An active metal film was formed based on the active metal solder method. Specifically, a paste made of a Ti-Cu-Ag eutectic composition is applied to the thin layer forming surface of the nest body 115 by a screen printing method or the like, and baked in a vacuum at a high temperature of about 800 ° C. An active metal film was formed. After that, the nested body 11 other than the portion where the active metal film is formed
A portion 5 was masked, and a metal layer made of nickel (Ni) was formed on the active metal film on the active metal film by electrolytic plating. The thickness of the metal layer after plating is 100
μm.

On the other hand, the first mold portion (movable mold portion) 10 was made of carbon steel S55C, and was cut to provide a core mounting portion. The core 10A for nesting is made of carbon steel S.
Made from 55C. And core 10A for nesting mounting
After the nest 15 is bonded using an epoxy-based adhesive (not shown), the nesting core 10A is attached to the first mold part 1.
0 was attached to the core mounting part. Then, the metal layer formed on the opposing surface 15B of the nest 15 is cut by about 50 μm using a plane cutting machine for metal processing, and the top surface of the metal layer formed on the opposing surface 15B of the nest 15 and the first of the parting surface PL ₁ of the mold portion 10 has substantially the same level. Since a metal layer made of nickel (Ni) is formed on the opposing surface 15B of the nest 15, the opposing surface 15B of the nest 15 and the parting surface PL1 of the _first mold part 10 can be easily and substantially at the same level. And could be.

On the other hand, a second mold part (fixed mold part) 11 was made of carbon steel S55C. A molten thermoplastic resin introduction part 13 having a direct gate structure with a diameter of 5 mm was provided at the center of the second mold part 11.

The first mold part (movable mold part) 10 and the second mold part (fixed mold part) 11 thus manufactured were assembled to obtain a mold assembly of Example 1. . First mold part 10
With the mold and the second mold part 11 clamped, the opposing surface of the second mold part 11 facing the insert 15 (Example 1)
, The parting plane PL ₂ ) and the second mold part 1
Clearance C ₁₁ is 0mm between the first opposing face and the opposing nesting 15 parts of (opposing surface 15B of the insert 15) (C
₁₁ = 0 mm), and both surfaces were in contact with each other. With such a structure, the facing surface 15B of the insert 15 does not come into contact with the molten thermoplastic resin introduced into the cavity 14. The surface of the nest body 115 does not come into direct contact with the second mold portion 11, and the end of the nest body 115 is protected.

After the completed mold assembly was attached to the molding apparatus, the mold assembly was heated to 130 ° C. using a mold temperature controller, and was rapidly cooled to 40 ° C., but cracked into the nest 15 even if it was rapidly cooled to 40 ° C. No such damage occurred. Also, no damage occurred to the thin layer 16.

As a molding device, IS manufactured by Toshiba Machine Co., Ltd.
The mold assembly was heated to 100 ° C using a -80 injection molding machine. Injection molding was performed using a polycarbonate resin (GS2020M, manufactured by Mitsubishi Engineering-Plastics Corporation) to which 20% by weight of glass fiber having an average length of 200 μm and an average diameter of 13 μm was added as a thermoplastic resin. The molding conditions were as shown in Table 1 below. The molten thermoplastic resin was introduced (injected) into the cavity 14 via the molten thermoplastic resin introduction part (direct gate part) 13. Then, after introducing (injecting) a predetermined amount of the molten thermoplastic resin into the cavity 14 via the molten thermoplastic resin introduction portion 13, the thermoplastic resin in the cavity 14 is cooled,
After 30 seconds, the mold assembly was opened, and the molded product was taken out of the mold assembly.

[Table 1] Mold temperature: 100 ° C Resin temperature: 290 ° C Injection pressure: 8.83 × 10 ⁷ Pa (900 kgf / cm ²⁾
-G)

There was no glass fiber deposition (floating) on the surface of the molded product that was in contact with the cavity surface 15A of the nest 15, and the molded product had very high specularity. Also, no molding defects such as flow marks and jetting were observed. Further, the molding was continuously performed 10,000 times, but no damage occurred to the insert 15 and the thin layer 16 (the active metal film and the metal layer).

(Embodiment 2) The nesting and mold assembly of the second embodiment relates to the nesting and mold assembly according to the second aspect of the present invention, and further relates to the nesting and mold assembly of the present invention. 1 relates to the configuration. In Example 2, the nest 15 was made of partially stabilized conductive zirconia ceramics. Further, the metal layer 17 is formed on the thin layer forming surface of the nest body 115.
Was formed. That is, the nesting body 115 is, specifically,
It is made of partially stabilized zirconia (ZrO ₂ —Y ₂ O ₃ ) ceramic, and contains 8% by weight of Fe ₂ O ₃ as a conductivity-imparting agent.
It is contained. The ratio of Y ₂ O ₃ , which is a partial stabilizer contained in the partially stabilized zirconia ceramics, was set to 3 mol%. The thermal conductivity of such conductive zirconia ceramics is about 3.8 J / (m · s · K), and the volume resistivity is 1 × 10 ⁸ Ω · cm. The metal layer 17 is made of nickel (Ni) having a thickness of 0.5 mm.

The construction and structure of the first mold section 10, the second mold section 11, the insert 15, the mold assembly and the like were the same as those in the first embodiment. FIG. 2A shows a state where the mold assembly is clamped, and FIG. 2B shows a state where the mold assembly is opened. In Example 2, the metal layer 17 was formed on the entire surface of the insert 15 by electrolytic plating. After the nest 15 was bonded to the nesting core 10A using an epoxy-based adhesive (not shown), the nesting core 10A was attached to the core mounting portion of the first mold part 10. . Then, the metal layer 17 formed on the opposing surface 15B of the nest 15 is cut using a metal cutting plane cutting machine, and the top surface of the metal layer 17 formed on the opposing surface 15B of the nest 15 and the first metal are cut. a parting plane PL ₁ of the mold portion 10 has substantially the same level.

In the second embodiment, the first mold part (movable mold part) 10 which is the same as the first embodiment
And the second mold part (fixed mold part) 11 were assembled to obtain a mold assembly. First mold part 10 and second mold part 11
In a state where the mold is clamped, the opposed surface of the second mold portion 11 facing the insert 15 (parting surface PL ₂ in Example ₂ ) and the opposed surface of the second mold portion 11 were opposed. clearance C ₁₁ between the portion of the insert 15 (the opposing surface 15B of the insert 15), 0.02mm (C ₁₁ = 0.0
2 mm). With such a structure, the facing surface 15B of the insert 15 does not come into contact with the molten thermoplastic resin introduced into the second mold portion 11 and the cavity 14.

After the completed mold assembly was attached to the molding apparatus, the mold assembly was heated to 130 ° C. using a mold temperature controller, and then rapidly cooled to 40 ° C., but cracked into the nest 15. No such damage occurred. Further, no damage occurred to the metal layer 17.

Using the same injection molding machine as in Example 1 as the molding apparatus, the mold assembly was heated to 100 ° C. And
Using the same thermoplastic resin as in Example 1, injection molding was performed under the same conditions as in Example 1.

There was no glass fiber deposition (floating) on the surface of the molded product that was in contact with the cavity surface 15A of the nest 15, and the molded product had very high specularity. Also, no molding defects such as flow marks and jetting were observed. Further, the molding was continuously performed 10,000 times, but no damage occurred in the insert 15 and the metal layer 17.

Comparative Example 1 In the mold assembly used in Example 1, the insert 15 was mirror-finished to _Ry 0.02 μm in carbon steel (thermal conductivity about 46 J / (ms · s ·).
K), molding was performed by replacing the nest prepared from 11 × 10 ^-2 cal / cm · sec · deg). In addition, using the same thermoplastic resin as in Example 1, molding was performed under the same molding conditions as in Example 1.

As a result, the fluidity of the molten thermoplastic resin in the cavity 14 was poor, and the cavity 14 could not be completely filled with the molten thermoplastic resin. Therefore, the injection pressure is set to 2 × 10 ⁷ Pa (200 kgf / cm ² −
G) increased to 1.1 × 10 ⁸ Pa (1100 kgf /
cm ² -G). Molding defects such as flow marks and jetting occurred in the obtained molded product. Further, glass fibers were precipitated on the surface of the molded product, and the specularity of the molded product obtained in Comparative Example 1 was remarkably inferior to that of the molded product obtained in Example 1.

Comparative Example 2 In Comparative Example 2, the mold assembly of Example 1 was used. However, the facing surface 1 of the nest 15
No thin layer was formed on 5B. Then, the insert 15 was bonded to the insert core 10A using an adhesive, and the insert insert core 10A was fixed to the insert mounting portion provided in the first mold portion 10. The level difference between the top surface of the facing surface 15B of the nest 15 and the parting surface PL1 of the _first mold part 10 was set to zero in design. However, in practice, the top surface of the opposing surface 15B of the nest 15 is the first mold due to the uneven thickness of the adhesive when the nest 15 is bonded to the nest mounting core 10A with an adhesive. Parting surface P of part 10
L ₁ has a 0.02mm protruding state than, moreover, the parallelism between the parting surfaces PL ₂ of the second mold part 11 is attached in a bad state. Since the opposing surface 15B of the nest 15 is made of partially stabilized zirconia ceramics, the opposing surface 15B of the nest 15 could not be cut by a metal plane cutter and could not be modified. In this state, molding was performed under the same conditions as in Example 1. As a result of the molding, the molded product had a very beautiful appearance. However, when 100 moldings were continuously performed, the facing surface 15B of the nest 15 was tightened with the second mold portion 11 when the mold was clamped. Since it was hit locally, cracks occurred in that part.

(Embodiment 3) The mold assembly of Embodiment 3 also relates to the first configuration of the mold assembly and the like of the present invention. The mold assembly of the third embodiment differs from the mold assembly of the second embodiment in that the shapes of the cavity 14 and the insert 15 are different. In the mold assembly according to the third embodiment, a schematic end view of which is shown in FIG.
mm × 100 mm, a box shape having a thickness of 4 mm and a depth of 15 mm. The dimensions of the cavity 14 in the mold assembly of Example 3 were set so that a molded product having such a shape could be molded.

In the third embodiment, the nest 15 has the same configuration as that of the second embodiment except that the shape is different. The metal layer 17 was formed on the cavity forming surface of the nesting body 115 and the thin layer forming surface of the nesting body 115. The thickness of the nest body 115 was 3.0 mm. Nest mounting part 1
The insert 15 was fixed to OB using an epoxy adhesive (not shown). Then, the metal layer 17 formed on the facing surface 15B of the nest 15 is cut, and the top surface of the metal layer 17 formed on the facing surface 15B of the nest 15 and the first mold part 1 are cut.
0 of the parting plane PL ₁ was substantially the same level.

The first mold section (movable mold section) 10 and the second mold section (fixed mold section) 11 thus manufactured were assembled to obtain a mold assembly of the present invention. In a state where the first mold part 10 and the second mold part 11 are clamped, the facing surface of the second mold part 11 facing the insert 15 (parting surface PL _{2 in the} third embodiment). And the second mold part 11
Clearance C ₁₁ between the facing surface and the opposing nesting 15 parts of (opposing surface 15B of the insert 15), 0.02 m
m (C ₁₁ = 0.02 mm). With such a structure, the facing surface 15 </ b> B of the insert 15 does not come into contact with the molten resin introduced into the second mold portion 11 and the cavity 14.

After the completed mold assembly was attached to the molding apparatus, the mold assembly was heated to 130 ° C. using a mold temperature controller, and then rapidly cooled to 40 ° C., but the partially stabilized zirconia was obtained. No damage such as cracks occurred in the nesting body 115 made of ceramics. Further, no damage occurred to the metal layer 17.

Using the same injection molding machine as in Example 1 as the molding device, the mold assembly was heated to 100 ° C. And
Using the same thermoplastic resin as in Example 1, injection molding was performed under the same conditions as in Example 1.

There was no glass fiber deposition (floating) on the surface of the molded product that was in contact with the cavity surface 15A of the nest 15, and the molded product had very high specularity. Also, no molding defects such as flow marks and jetting were observed. Further, the molding was continuously performed 10,000 times, but no damage occurred in the insert 15 and the metal layer 17.

The nest body 115 is made of, for example, partially stabilized zirconia ceramics, and a thin layer forming surface of the nest body 115 corresponding to the facing surface 15B of the nest 15 is provided.
Similar to the first embodiment, an active metal film and a metal layer may be formed.

(Embodiment 4) The mold assembly of Embodiment 4 also relates to the first structure of the mold assembly and the like of the present invention. The difference between the mold assembly of the fourth embodiment and the mold assembly of the first embodiment is that the mold assembly has a structure in which the volume of the cavity can be changed (an intaglio structure in the fourth embodiment). . That is, even if the mold assembly is not completely clamped, the cavity 1
The first mold part 1 has a slight clearance C ₁₁ (0.01 mm in the fourth embodiment) so that the first mold part 1 is formed.
0 and the opposing surface (parting surface PL ₂ ) of the _second mold part 11 are fitted to the opposing surface 15B of the nest 15 (see FIGS. 4A and 4B). . The components constituting the mold assembly according to the fourth embodiment whose schematic end views are shown in FIG. 4 are basically the same as the components constituting the mold assembly according to the first embodiment. Is omitted.

In Example 4, the dimensions of the molded product were cylindrical with a bottom (outer diameter 50.40 mm, inner diameter 44 mm). The nest body 115 was manufactured by grinding ZrO ₂ —CeO ₂ . The ratio of CeO ₂ , which is a partial stabilizer contained in the partially stabilized zirconia ceramics, was set to 8 mol%. The thermal conductivity of such partially stabilized zirconia ceramics is about 3.8J.
/ (M · s · K). The nesting body 115 has a stepped cylindrical shape, the outer diameter of the stepped portion is 50 mm, the outer diameter of the cylindrical portion above the stepped portion is 44 mm, and the surface to be bonded to the nesting core 10A. Was 38 mm in diameter. The cavity forming surface of the nesting body 115 was polished using a diamond grindstone, and the surface roughness _Ry of the cavity forming surface was set to 0.02 μm.

Next, when the first mold part 10 and the second mold part 11 are clamped, a nest corresponding to the facing surface 15B of the nest 15 facing the facing surface of the second mold part 11. Only on the thin layer forming surface of the main body 115, Ti-Cu-Ag
Paste consisting of about 80
The paste was baked in a vacuum furnace at 0 ° C. for 30 minutes to obtain an active metal film having a thickness of 5 μm. After that, a portion of the obtained nest body 115 other than the portion where the active metal film is formed is masked, and a metal layer of copper (Cu) having a thickness of 0.25 mm is formed on the active metal film by electrolytic plating. Formed.

The second mold part (fixed mold part) 11 was made of carbon steel HPM1. A molten thermoplastic resin introduction part 13 having a direct gate structure with a diameter of 5 mm was provided at the center of the second mold part 11. In addition, the first mold part (movable mold part) 10 was also made of carbon steel HPM1, cut, and provided with a core mounting part in the first mold part 10. The core for nesting was also made of carbon steel HPM1. Then, the insert 15 was bonded to the insert-mounting core 10A using an epoxy-based adhesive (not shown). Next, the nesting core 10 </ b> A was fixed to the core mounting part provided in the first mold part 10. And the opposing surface 15 of the nest 15
The metal layer in B was turned on a lathe for metalworking to about 6
It was cut by 0 μm. As a result, when the first mold part 10 and the second mold part 11 are clamped, the nest 1
5 (parting surface PL ₂ of the second mold portion 11) and a portion of the nest 15 (the nest) facing the opposite surface of the second mold portion 11. clearance C ₁₁ between the facing surface 15B) of 15, 0.01 mm
It became. With such a structure, the opposing surface 15B of the nest 15 is in contact with the second mold portion 11 and the cavity 14.
No longer comes into contact with the molten thermoplastic resin introduced therein.

After the completed mold assembly was attached to the molding apparatus, the mold assembly was heated to 130 ° C. using a mold temperature controller and then rapidly cooled to 40 ° C., but the partially stabilized zirconia was also obtained. No damage such as cracks occurred in the nesting body 115 made of ceramics. Also, no damage occurred to the active metal film or the metal layer.

As a molding device, IS manufactured by Toshiba Machine Co., Ltd.
The mold assembly was heated to 100 ° C. using a −75 Pre-Strol injection compression molding machine. Further, the same thermoplastic resin as in Example 1 was used as the thermoplastic resin. Then, the first mold part 10 and the second mold part 11 are clamped so that the volume (V _C ) of the cavity 14 is larger than the volume (V _M ) of the molded product to be molded ( (See FIG. 4A).
At the time of mold clamping, the relationship between the volume (V _M ) of the molded product to be molded and the volume (V _C ) of the cavity is such that Δt satisfies 0.5 mm.

More specifically, in molding, first, the first
After completely closing the mold part 10 and the second mold part 11 (see FIG. 4B), the first mold part 10 was moved to expand the cavity 14 by 1 mm (FIG. 4). (A)). Then, under the conditions exemplified in Table 2 below, the molten thermoplastic resin was introduced (injected) into the cavity 14 from the injection cylinder (not shown) via the molten thermoplastic resin introduction section (direct gate section) 13. Then, after introducing (injecting) a predetermined amount of the molten thermoplastic resin into the cavity 14 through the molten thermoplastic resin introduction portion 13 (see a schematic end view of the mold assembly in FIG. 5A). Then, the first mold part 10 was moved toward the second mold part 11 (see a schematic end view of the mold assembly in FIG. 5B). 0.5m travel
m. Next, the thermoplastic resin in the cavity 14 was cooled and solidified. After 30 seconds, the mold assembly was opened, and the molded product was taken out of the mold assembly.

[Table 2] Mold temperature: 100 ° C Resin temperature: 290 ° C Injection pressure: 3.92 × 10 ⁷ Pa (400 kgf / cm ²⁾
-G)

There was no glass fiber deposition (floating) on the surface of the molded product that was in contact with the cavity surface 15A of the insert 15A, and the molded product had very high specularity. Also, no molding defects such as flow marks and jetting were observed. Observation of the opposing surface 15B of the nest 15 shows that the metal layer has some traces of contact with the opposing surface (parting surface PL ₂ ) of the _second mold part 11 due to uneven thermal expansion. No damage occurred to the nest 15 because the metal layer absorbed the damage to the nest 15. Although molding was continuously performed for 10,000 shots, no damage such as cracks occurred in the insert 15. Further, the molding was continuously performed 10,000 times, but no damage occurred to the insert 15, the metal layer, and the active metal film.

As described above, when a mold assembly having a structure capable of making the volume of the cavity variable at the time of molding the molded product is used, the surface of the molded product can be uniformly compressed. The occurrence of sink marks on the surface can be suppressed.

FIG. 6 shows a modification of the fourth embodiment. In this modification, the nesting body 115 is made of conductive zirconia ceramics, and the cavity forming surface and the thin layer forming surface (corresponding to the facing surface 15B of the nesting 15) of the nesting body 115 are made of metal made of copper (Cu). Layer 17 is formed. In addition, such a nest 15 is substantially
It can be manufactured in the same manner as in the second embodiment.

Comparative Example 3 In Comparative Example 3, the mold assembly of Example 4 was used. However, no thin layer was formed on the surface of the insert 15. Then, the nest 15 is bonded to the nest mounting core 10A with an adhesive, and
A was fixed to a core mounting part provided in the first mold part 10. In a state where the first mold portion 10 and the second mold portion 11 are clamped, the opposing surface of the second mold portion 11 facing the insert 15 (the cavity of the second mold portion 11). surface)
If, as the clearance C ₁₁ between the facing surface and the opposing nesting 15 portion of the second mold section 11 (opposing surface 15B of the insert 15) is 0.01 mm, designed nest 15, was prepared . Then, molding was performed under the same conditions as in Example 4. As a result of molding, the molded article had a very beautiful appearance. However, when the molding was continuously performed for 20 shots, the portion of the facing surface 15B of the nest 15 suddenly fell due to the uneven thermal expansion. 2 (a parting surface PL)
₂ ) and cracked in that area.

(Embodiment 5) The mold assembly of Embodiment 5 showing a schematic end view in FIG. 7A also relates to the first structure of the mold assembly and the like of the present invention. The mold assembly of the fifth embodiment differs from the mold assembly of the first embodiment in that a pressurized fluid injection device 18 is provided in the mold assembly. The pressurized fluid injection device 18 includes a well-known pressurized fluid injection nozzle, and is disposed in the second mold portion 11 so as to open to the cavity 14. The pressurized fluid injection device 18 is connected to a pressurized fluid source (not shown) via a pipe (not shown).

The components constituting the mold assembly of Embodiment 5 are as follows:
Basically, the components are the same as those constituting the mold assembly according to the first embodiment, and a detailed description thereof will be omitted. In addition, a concave portion of 94 mm × 94 mm × 3 mm (depth) was formed in the second mold portion 11, and the cavity 14 was constituted by the concave portion. The bottom of the recess (the top in FIG. 7)
In addition, a molten thermoplastic resin introduction unit 13 and a pressurized fluid injection device 18 are provided. Then, using the same thermoplastic resin as in Example 1, molding was performed under the same molding conditions as in Example 1. In the fifth embodiment, the molten thermoplastic resin that completely fills the cavity 14 is introduced (injected) into the cavity 14 from the molten thermoplastic resin introduction part 13,
Immediately from the pressurized fluid injection device 18, nitrogen gas as a pressurized fluid (pressure: 7 × 10 ⁶ Pa, 70 kgf / cm ² -G)
Was injected into the molten thermoplastic resin in the cavity 14 to form a hollow portion in the resin in the cavity 14.
This state is schematically shown in FIG. Cavity 1
The hollow portion was pressurized with a pressurized fluid until the resin in 4 was cooled and solidified. After the resin in the cavity 14 was cooled and solidified, the pressurized fluid in the hollow portion was released to the atmosphere via the pressurized fluid injection device 18. Then, the mold assembly was opened, and the molded product was taken out of the mold assembly.

No glass fiber was deposited on the surface of the molded product, and the molded product had very high specularity. In addition, molding defects such as flow marks and jetting were not observed in the molded product, and a desired hollow portion was formed inside the molded product. Moreover, it is possible to reliably prevent the occurrence of sink marks in the molded product, and further, since the cooling and solidification of the molten thermoplastic resin in contact with the nest is delayed, solidification near the cavity surface 15A of the nest 15 has begun. The occurrence of the phenomenon that the resin portion and the internal resin are mixed with each other can be avoided, and the occurrence of color unevenness and poor appearance on the surface of the molded product near the thick portion can be prevented.

The molding was continuously performed 10,000 times, but no damage such as cracks occurred in the insert 15 and no damage occurred to the active metal film and the metal layer.

The nesting body 115 is made of, for example, partially stabilized conductive zirconia ceramics, and the thin layer forming surface of the nesting body 115 corresponding to the facing surface 15B of the nesting 15 (in some cases, the cavity of the nesting body 115). Construction surface and thin layer forming surface or nest body 1
A metal layer may be formed on the entire surface (15) as in the second embodiment.

(Embodiment 6) A schematic end face shown in FIG.
The mold assembly of Embodiment 6 shown in the figure is also a mold assembly of the present invention.
Etc. regarding the first configuration. In the mold assembly of the sixth embodiment
The nest 15 is arranged on the first mold part (movable mold part) 10.
The second mold part (fixed mold part) 11 is provided with a second mold part.
A nested covering portion 11A corresponding to the facing surface of the mold portion 11 is provided.
Have been killed. Then, the first mold part 10 and the second mold
In a state where the portion 11 and the mold 11 are clamped, the nested covering portion 11
A and a portion of the nest 15 facing the nest covering portion 11A
(Clearance C between the nest 15 and the opposing surface 15B)
₁₁Is 0.03 mm or less (C ₁₁≤ 0.03 mm)
And the weight of the nest covering portion 11A with respect to the nest 15
Fake amount ΔS₁₁Is 0.5 mm or more (ΔS₁₁≧ 0.5mm)
It is. In the sixth embodiment, the nested covering portion 11A
Is a second mold portion facing the facing surface 15B of the insert 15
11 parting plane PL_TwoKind of notch provided in
(Notch). Of the molten thermoplastic resin introduction part 13
The structure was a direct gate structure. Example 6 Mold Set
FIG. 8A is a schematic end view when the solid is clamped.
FIG. 9 shows a schematic end view when the mold is opened.
It is shown in (A). Also, the schematic of the mold assembly during assembly
Various end views are shown in FIGS. 8B and 8C.

The size of the cavity 14 in the mold assembly of Example 6 is 100 mm × 100 mm × 4 mm, and the shape is a rectangular parallelepiped. The size of the nest 15 is 10
It is 2.00 mm × 102.00 mm × 3.00 mm. That is, the thickness of the nest body 115 made of partially stabilized zirconia ceramics was set to 2.98 mm. The nesting body 115 is manufactured by grinding, and the nesting body 11 is formed.
Polishing and finishing using a diamond grindstone were performed on the cavity forming surface of No. 5, and the surface roughness _Ry of the cavity forming surface was set to 0.02 μm. Next, an active metal film and a metal layer (thin layer 16) are formed on the surface of the nest body 115 (specifically, the cavity forming surface and the thin layer forming surface of the nest body 115) in the same manner as in the first embodiment. did. As in the second embodiment, a metal layer may be formed by electroplating on the cavity forming surface and the thin layer forming surface of the nest body 115 using conductive zirconia ceramics, for example.

The first mold part (movable mold part) 10 was made of carbon steel S55C. The inner size of the nest mounting portion 10B for the nest 15 is 102.20 mm × 102.20 m
m, and a depth of 3.02 mm is cut to provide a nesting portion 10B (see FIG. 8B), and then the nesting 15 is formed using a silicon-based adhesive (not shown). It was adhered inside the nesting portion 10B (see FIG. 8C). Then, similarly to the first embodiment, the surface of the metal layer is cut and the facing surface 15B of the
The clearance between 1A was adjusted.

On the other hand, a second mold portion (fixed mold portion) 11 was made of carbon steel S55C. A molten thermoplastic resin introduction part 13 having a direct gate structure with a diameter of 5 mm was provided at the center of the second mold part (fixed mold part) 11.

The first mold part (movable mold)
(Mold part) 10 and second mold part (fixed mold part) 11
Thus, a mold assembly of Example 6 was obtained. In this mold assembly
Here, the opposing surface 15B of the nest 15 and the nest covering portion 11
Clearance between A (C ₁₁) Is 0.02 mm (C
₁₁= 0.02 mm). Also, for nest 15
Of the nested covering portion 11A (ΔS₁₁) Is 1.0m
m (ΔS₁₁= 1.0 mm). In such a structure
By doing so, the opposing surface 15B of the nest 15 is
Melt thermoplastic introduced into part 11 and cavity 14
No longer comes into contact with resin.

After the completed mold assembly was attached to the molding apparatus, the mold assembly was heated to 130 ° C. using a mold temperature controller and then rapidly cooled to 40 ° C., but the partially stabilized zirconia was also obtained. No damage such as cracks occurred in the nest 15 made of ceramics. Also, no damage occurred to the thin layer 16.

Using the same molding apparatus and thermoplastic resin as in Example 1, molding was performed under the same molding conditions as in Example 1. FIG. 9B is a schematic end view showing a state where the molten thermoplastic resin is introduced (injected) into the cavity 14. Nesting 1
The surface of the molded product that was in contact with the cavity surface 15A of No. 5 had no glass fiber precipitation (floating), and had very high specularity. Also, there were no molding defects such as flow marks and jetting. The molding was continuously performed 10,000 times, but no damage occurred in the insert 15, the active metal film, and the metal layer.

(Embodiment 7) A mold assembly according to embodiment 7 of which a schematic partial end view is shown in FIG. 10A relates to a second structure such as a mold assembly of the present invention. The mold assembly according to the seventh embodiment further includes a cover plate 12 that is disposed on the first mold portion (fixed mold portion) 10, forms a part of the cavity 14, and covers the end surface of the insert 15. Provided. Nesting 1
5 is provided on the first mold part 10. First mold part (fixed mold part) 10 and second mold part (movable mold part) 11
When the mold is clamped, the clearance C ₂₁ between the nest 15 and the covering plate 12 is 0.03 mm or less (C ₂₁ ≦ 0.03 mm), and the amount of overlap ΔS ₂₁ of the covering plate 12 with respect to the nest 15. Is 0.5 mm or more (ΔS ₂₁ ≧ 0.5 mm). Incidentally, FIG.
The schematic end view during the assembly of the mold assembly shown in
These are shown in FIGS. 10B and 10C.

The insert 15 was manufactured in substantially the same manner as in Example 1. That is, a thin layer (active metal film and metal layer) 16 was formed on the cavity forming surface and the thin layer forming surface of the nest body 115 made of partially stabilized zirconia ceramics. The first mold part (fixed mold part) 10 was made of carbon steel S55C. Carbon steel S55C was cut to provide a nested mounting portion 10B. Then nest 15
Was adhered to the nesting portion 10B using a two-component curing type epoxy adhesive (not shown) (FIG. 10B).
reference). On the other hand, the second mold part (movable mold part) 11 was made of carbon steel S55C.

The coating plate 12 was made from carbon steel S55C. After cutting the cover plate 12, it was fixed to the first mold part 10 using screws (not shown) (FIG. 10).
(C)). The cover plate 12 forms a part of the cavity 14, and the cover plate 12
It covers all around. The cover plate 12 is provided with a molten thermoplastic resin introduction portion 13 having a side gate structure. In FIG. 10C, the illustration of the molten thermoplastic resin introduction part 13 is omitted. Nest 15 and cover plate 12
Between the nest 15 and the cover plate 12 so that the clearance (C ₂₁ ) between
So that the amount of overlap (ΔS ₂₁ ) is 0.5 mm or more,
The metal layer on the facing surface 15B of the cover plate 12 and the insert 15 was cut.

Alternatively, as shown in FIG. 11A, which is a schematic partial end view of the mold assembly, a nest 15 having a curved surface can be used depending on the shape of a molded product to be molded. . In this case, the first mold part 10 is made of carbon steel S5
5C, the nesting portion 10B is cut, and the nesting portion 10B provided on the first mold portion 10 is cut.
The radius of curvature at the bottom of the nest 1
It is preferable to match the radius of curvature of the back surface of 5 (the surface opposite to the cavity surface). The coating plate 12 is made of carbon steel S55.
C. It is preferable to make the radius of curvature of the surface of the cover plate 12 facing the nest 15 coincide with the radius of curvature of the cavity surface 15A of the nest 15. After cutting the facing surface 15B of the cover plate 12 and the insert 15, it may be fixed to the first mold part 10. Also,
The second mold part 11 may be made of carbon steel S55C. Alternatively, as shown in a schematic partial end view of FIG.
May be constituted by a nesting core 10A mounted on the first mold part 10. In this case, a nest mounting portion is provided on the nest mounting core 10A.

Further, instead of providing the cover plate 12 with the molten thermoplastic resin introduction portion 13 having a side gate structure,
As shown in FIG. 12, the coating plate 12 is not provided with a molten thermoplastic resin introduction portion, and the molten thermoplastic resin introduction portion 1 having a direct gate structure is provided at the center of the second mold portion 11.
3 may be provided.

The molding method of the molded article using the mold assembly of the seventh embodiment can be substantially the same as the molding method of the molded article described in the first embodiment. Omitted.

As in the case of the second embodiment, a partially stabilized conductive zirconia ceramic
For example, a metal layer may be formed on the cavity forming surface and the thin layer forming surface of the fifteen by electroplating. Example 7
The mold assembly may be configured so that the volume of the cavity can be made variable similarly to the mold assembly described in the fourth embodiment. Further, the pressurized fluid injection device 18 may be provided in the mold assembly of the seventh embodiment as in the fifth embodiment.

(Eighth Embodiment) A mold assembly according to an eighth embodiment relates to a third structure such as the mold assembly of the present invention. FIG. 13 is a schematic end view when the mold assembly of Example 8 is clamped.
(A) and (B), and a schematic end view when the mold is opened is shown in FIG. In addition, FIGS. 14A, 14B, and 14C show schematic end views of the mold assembly being assembled. 13 (A) and FIG. 14 (A) to FIG.
(C) and FIG. 15 are views when the area of the mold assembly including the coating plate is cut in a vertical plane, and FIG. 13 (B) includes the coating plate in a vertical plane parallel to the vertical plane. FIG. 3 is a view when an area of a mold assembly is cut off.

In the mold assembly according to the eighth embodiment, the first mold section (fixed mold section) is disposed between the nest 25 and the second mold section (movable mold section) 21. 20 attached,
The second mold part 21 further includes a coating plate 22 provided with a molten thermoplastic resin introduction part 23.
1A is provided, and in a state where the first mold part 20 and the second mold part 21 are clamped, a nesting covering part which is a facing surface of the second mold part 11 facing the nest 25. 21
A and the clearance C between the portion of the nest 25 facing the nest covering portion 21A (the facing surface 25B of the nest 25)
₃₁ is 0.03 mm or less (C ₃₁ ≦ 0.03 mm),
Overlap amount ΔS of nest covering portion 21A with respect to nest 25
₃₁ is 0.5 mm or more (ΔS ₃₁ ≧ 0.5 mm), and the clearance C ₃₂ between the nest 25 and the covering plate 22
Is 0.03 mm or less (C ₃₂ ≦ 0.03 mm), and the overlapping amount ΔS ₃₂ of the covering plate 22 with respect to the nest 25 is 0.5 mm or more (ΔS ₃₂ ≧ 0.5 mm). FIG.
(A) and (B), the cover plate 22 overlaps only a part of the nest 25.
The molten thermoplastic resin introduction portion 23 in the mold assembly according to the eighth embodiment has a side gate structure. In addition, the nesting cover 21
A is a kind of notch (notch) provided on the parting surface of the second mold portion 21 facing the opposing surface 25B of the insert 25.

The size of the cavity 24 in the mold assembly of Example 8 is 100 mm × 100 mm × 4 mm, and the shape is a rectangular parallelepiped. The size of the nest 25 is 10
It is 2.00 mm × 102.00 mm × 3.00 mm. A nest body 125 made of partially stabilized zirconia ceramics or partially stabilized conductive zirconia ceramics is formed by grinding, and the nest body 1 is formed.
Polishing and finishing using a diamond grindstone were performed on 25 cavity forming surfaces, and the surface roughness _Ry of the cavity forming surface was set to 0.02 μm. Then nest 25
Was produced substantially in the same manner as in Example 2. In addition, using partially stabilized zirconia ceramics,
May be manufactured substantially in the same manner as in the first embodiment.
An active metal film and a metal layer formed on the nest body 215;
Alternatively, the metal layer is hereinafter generally referred to as a thin layer 26.

The first mold part (fixed mold part) 20 was made of carbon steel S55C. The inner size of the nest mounting portion 20B for the nest 25 is 102.20 mm × 102.20 m
m, and a depth of 3.02 mm is cut to provide a nesting portion 20B (see FIG. 14A), and then the nesting 25 is formed using a silicon-based adhesive (not shown). It was adhered inside the nesting portion 20B (see FIG. 14B). Then, the surface of the thin layer 26 (specifically, the surface of the metal layer) on the facing surface 25B of the insert 25 was cut.

The coating plate 22 was made of carbon steel, and attached to the first mold part 20 at a predetermined position with a bolt (not shown) (see FIG. 14C). In addition, coating plate 2
2 is provided with a molten thermoplastic resin introduction section (gate section) 23. Surface 2 facing nesting of cover plate 22
The clearance (C ₃₂ ) between 2A and the facing surface 25B of the nest 25 is 0.02 mm (C ₃₂ = 0.02 mm), and the overlapping amount (ΔS ₃₂ ) of the coating plate 22 with the nest 25 is 1.0 mm. (ΔS ₃₂ = 1.0 mm).

On the other hand, the second mold part (movable mold part) 21 was made of carbon steel S55C.

The first mold part (fixed mold)
(Mold part) 20 and a second mold part (movable mold part) 21
Thus, a mold assembly of Example 8 was obtained. In this mold assembly
Here, the opposing surface 25B of the nest 25 and the nest covering portion 21
Clearance between A (C ₃₁) Is 0.02 mm (C₃₁
= 0.02 mm). Also, for nest 25
The amount of overlap of the nested covering portions 21A (ΔS₃₁) Is 1.0mm
(ΔS₃₁= 1.0 mm). As mentioned above, put
The melt introduced into the cavity 24 and the opposing surface 25B of the
The structure was such that there was no contact with the molten thermoplastic resin.

After the completed mold assembly was attached to the molding apparatus, the mold assembly was heated to 130 ° C. using a mold temperature controller, and then rapidly cooled to 40 ° C., but cracked into the nest 25. No such damage occurred.

Using the same molding apparatus and thermoplastic resin as in Example 1, molding was performed under the same molding conditions as in Example 1. There was no glass fiber precipitation (floating) on the surface of the molded product that was in contact with the cavity surface 25A of the nest 25, and the molded product had very high specularity. Also, there were no molding defects such as flow marks and jetting. Continuous molding 1
0000 times, no damage occurred to the nest 25 and the thin layer (the active metal film and the metal layer, or the metal layer) 26.

(Embodiment 9) Embodiment 9 relates to a fourth structure such as a mold assembly of the present invention. FIG. 16 is a schematic end view of the mold assembly according to the ninth embodiment. 17 to 19 show schematic end views of the mold assembly during assembly. 16 (A), (A) and (C) of FIG. 17, (A) and (C) of FIG. 18, and (A) and (B) of FIG.
FIG. 17B is a view when a region of the mold assembly including the coating plate is cut on a vertical plane, and FIG. 16B, FIG.
(D) and FIGS. 18 (B) and (D) are views when the area of the mold assembly not including the coating plate is cut along a vertical plane parallel to the vertical plane.

In the mold assembly according to the ninth embodiment, the inserts are arranged in both the first and second mold portions. That is, the first nest 3 is inserted into the first mold portion (fixed mold portion) 30.
5, a second mold part (movable mold part) 40
The second nest 45 is disposed at the bottom. Further, the cover plates 33 and 43 provided with the molten thermoplastic resin introduction section (gate section) 39 are composed of the first nest 35 and the second nest 4.
5 and is attached to the first mold part 30 and the second mold part 40. Then, the first mold part 3
In a state where the mold 0 and the second mold part 40 are clamped, a portion of the first nest 35 facing the second nest 45 (a facing surface of the first nest) and the first nest 35 are opposed to each other. The clearance C ₄₁ between the portion of the second nest 45 (the opposing surface of the second nest) is 0.03 mm (C ₄₁ ≦ 0.03).
mm) or less, the overlap amount ΔS ₄₁ between the facing surface of the first nest 35 and the facing surface of the second nest 45 is 0.5 mm or more (ΔS ₄₁ ≧ 0.5 mm). a clearance C ₄₂ between the cover plate 33, the clearance C ₄₃ between the second nest 45 and the cover plate 43 is 0.03mm or less (C _42, C ₄₃ ≦ 0.03m
m) and the coating plate 3 for the first nest 35
3 overlapping amount [Delta] S _42, and the overlap amount [Delta] S ₄₃ of the cover plate 43 with respect to the second nest 45 is above _{0.5mm (ΔS 42, ΔS 43 ≧} 0.5mm), coated plates 33 and 43 first And only a part of the second nests 35 and 45 overlap.

The size of the cavity 38 in the mold assembly of Example 9 is 100 mm × 100 mm × 3 mm, and the shape is a rectangular parallelepiped. In the ninth embodiment, the thickness of the first nest body 135 constituting the first nest 35 is 3.00 mm, and the thickness of the second nest body 145 constituting the second nest 45 is 2.00 mm. These nests were made from the partially stabilized conductive zirconia ceramics as in Example 2. The size of the first nesting body 135 is 102.00 mm × 102.00 m
mx 3.00 mm. The first made by grinding
The surface of the cavity constituting surface of the nested body 135 was polished and finished using a diamond grindstone, and the surface roughness _Ry of the cavity constituting surface was set to 0.02 μm. Next, in the same manner as in the second embodiment, the first nested main body 135 is formed.
The metal layer 37 was formed on the cavity forming surface and the thin layer forming surface. In addition, using partially stabilized zirconia ceramics,
An active metal film and a metal layer may be formed on at least the thin layer forming surface of the first nest body 135 in the same manner as in the first embodiment.

A first mold part (fixed mold part) 30 was made of carbon steel S55C. The inner size of the nest mounting portion 31 for the first nest 35 is 102.20 mm × 102.
Cutting was performed so that the depth was 20 mm and the depth was 3.02 mm, and the nest mounting portion 31 was provided in the first mold portion 30 (see FIGS. 17C and 17D). The reference number 32
Is a first covering plate mounting portion. Next, the first nest 35 was bonded into the nest mounting portion 31 using a silicon-based adhesive (not shown) (see FIGS. 18C and 18D). Then, the opposing surface 3 of the first nest 35
The metal layer 37 constituting 5B was cut.

The partially stabilized conductive zirconia was press-formed so that the cavity surface became concave, and then fired to produce a second nest body 145 constituting the second nest 45. This second nested body 145
Is provided with a concave portion. The outer dimensions of the second nest body 145 are 106.00 mm × 106.00 mm. The dimensions of the recess are 100.00 mm × 100.0
0 mm, and the thickness of the bottom surface 45B of the recess is 2.00 mm.
And the thickness (height) of the rising portion 45C from the bottom surface
Is 5.00 mm. Therefore, the height (thickness) of the portion forming the cavity 38 is 3.00 mm. The bottom surface 45B of the concave portion and the inner side surface 45A of the rising portion 45C (these surfaces are cavity forming surfaces) are polished and finished using a diamond grindstone, and the surface roughness _Ry of these cavity forming surfaces is _reduced . It was set to 0.02 μm. Further, the bottom surface 45 of the concave portion of the second nest body 145 is formed.
The boundary between B and the rising portion 45C was a curved surface having a radius of 0.1 mm. In order to attach the second covering plate 43 to the second mold part 40, a part of the rising part 45C of the second insert 45 is removed (see FIG. 18A and FIG. 18A). (B)). Next, the metal layer 47 was formed on the cavity forming surface and the thin layer forming surface of the second nest body 145 in the same manner as in Example 2. In the same manner as in the first embodiment, the active metal film and the metal layer may be formed on at least the thin layer forming surface of the second nest body 145 by using partially stabilized zirconia ceramics.

The second mold part (movable mold part) 40 was made of carbon steel S55C. Then, the inner size of the nest mounting portion 41 for the second nest 45 is 106.20 mm ×
Cutting was performed to 106.20 mm and the depth to 5.02 mm, and the nesting portion 41 was provided in the second mold portion 40 (see FIGS. 17A and 17B). Reference numeral 42 is a second covering plate mounting portion. Then
The second nest 45 was adhered to the nest mounting portion 41 using a silicon-based adhesive (not shown) (see FIGS. 18A and 18B). Then, the metal layer 47 forming the facing surface 45D of the second insert 45 was cut.

The first coating plate 33 is made of carbon steel, and is fixed at a predetermined position with bolts (not shown).
0 (see FIG. 19B). The first cover plate 33 has a portion 39 of the molten thermoplastic resin introduction portion.
A is formed. Further, a second cover plate 43 was made of carbon steel, and was fixed to a second mold portion 40 at predetermined positions by bolts (not shown) (see FIG. 19A).
The second cover plate 43 has a portion 39B of the molten thermoplastic resin introduction portion. In a state where the first mold part and the second mold part are clamped, the first covering plate 33 and the second covering plate 43 form a molten thermoplastic resin introduction part 39.

The thus-fabricated first mold part (fixed mold part) 30 and second mold part (movable mold part) 40 were assembled to obtain a mold assembly of Example 9. In this mold assembly, in a state where the first mold part 30 and the second mold part 40 are clamped, a portion of the first nest 35 facing the second nest 45 (the first nest 35). The clearance (C ₄₁ ) between the opposed surface 35B of the second insert 35 and the portion of the second insert 45 facing the first insert 35 (the opposed surface 45D of the second insert 45) was 0.01 mm. . Also, the clearance (C ₄₂ ) between the surface 34 of the first covering plate 33 facing the first nest and the first nest 35, the surface of the second covering plate 43 facing the second nest. 44 and the second
The clearance (C ₄₃ ) between the nests 45 was 0.01 mm. Further, the overlapping amount (ΔS ₄₁ ) between the facing surface 35B of the first nest 35 and the facing surface 45D of the second nest 45 is 1.0 mm, and the first coating plate 33 for the first nest 35 is formed. (ΔS
₄₂ ) was 1.0 mm. On the other hand, the amount of overlap (ΔS ₄₃ ) of the second cover plate 43 with respect to the second insert 45 was 3.0 mm. The first and second cover plates 33, 43 overlap only with a part of the first and second inserts 35, 45.

After attaching the completed mold assembly to the molding apparatus, the mold assembly is heated to 130 ° C. using a mold temperature controller and then rapidly cooled to 40 ° C. No damage such as cracks occurred in the nests 35, 45 of No. 2, and no damage occurred to the metal layers 37, 47.

Using the same molding apparatus and thermoplastic resin as in Example 1, molding was performed under the same molding conditions as in Example 1. There was no glass fiber deposition (floating) on the surface of the molded product in contact with the cavity surfaces 35A, 45A of the nests 35, 45,
The molded article had very high specularity. Also, there were no molding defects such as flow marks and jetting. Continuous molding was performed 10,000 times.
Also, no damage occurred to the metal layers 37 and 47.

In the ninth embodiment, the covering plate 3 provided with the molten thermoplastic resin introduction portion (gate portion) 39 is provided.
The third and fourth embodiments have the structure in which the cover plate is attached to either the first mold unit 30 or the second mold unit 40. It can also be.

(Embodiment 10) The mold assembly of the tenth embodiment is a modification of the mold assembly of the eighth embodiment. As shown in a schematic end view of FIG. 20A, the mold assembly of the tenth embodiment has a structure that allows the volume of the cavity to be variable when molding a molded product. In the tenth embodiment, a core 27 that can be moved by, for example, a hydraulic cylinder (not shown) is provided in the cavity 24 of the mold assembly. In molding the molded product, the first mold portion 20 and the second mold portion 20 are formed such that the volume (V _C ) of the cavity 24 is larger than the volume (V _M ) of the molded product to be molded at the time of mold clamping. Of the core 21 and the position of the core 27 in the cavity is controlled. And
A molten thermoplastic resin is introduced into the cavity (volume: V _C ) 24, and is not shown before, simultaneously with, during, or after the introduction of the thermoplastic resin (including simultaneous with the completion of the introduction). The core 27 is moved by the operation of the hydraulic cylinder, and the volume of the cavity 24 is reduced to the volume (V _M ) of the molded product to be molded. This state is shown in FIG.
This is schematically shown in FIG. As described above, when a mold assembly having a structure capable of making the volume of the cavity 24 variable at the time of molding the molded product is used, the surface of the molded product can be uniformly compressed. The occurrence of sink marks can be suppressed.

Using the same molding apparatus and thermoplastic resin as in Example 1, molding was performed under the same molding conditions as in Example 1. There was no glass fiber precipitation (floating) on the surface of the molded product that was in contact with the cavity surface 25A of the nest 25, and the molded product had very high specularity. Also, there were no molding defects such as flow marks and jetting. Continuous molding 1
0000 times, but no damage occurred to the nest 25 and the thin layer (the active metal film and the metal layer or the metal layer) 26 manufactured by the substantially same method as the example 1 or the example 2. .

(Embodiment 11) The mold assembly of the eleventh embodiment is also a modification of the mold assembly of the eighth embodiment. As shown in a schematic end view of FIG. 21A, the mold assembly according to the eleventh embodiment further includes a pressurized fluid injection device. In the example shown in FIG.
The mounting position of the pressurized fluid injection device 28 was a mounting portion of the pressurized fluid injection device which was provided in the mold portion and opened to the cavity. Then, a pressurized fluid is injected from the pressurized fluid injection device 28 into the molten thermoplastic resin introduced into the cavity 24, whereby a hollow portion is formed inside the thermoplastic resin in the cavity 24. FIG. 21B schematically shows a state when the introduction of the molten thermoplastic resin into the cavity 24 is completed, and FIG. 22 schematically shows a state when the injection of the pressurized fluid into the molten thermoplastic resin is completed. Is shown. As described above, if the pressurized fluid is injected into the molten thermoplastic resin in the cavity 24, the resin in the cavity 24 is pressed toward the cavity surface of the mold part and the cavity surface 25A of the nest 25, The occurrence of sink marks in the molded product can be reliably prevented. Moreover, since the cooling and solidification of the molten thermoplastic resin that comes into contact with the nest 25 is delayed, the phenomenon that the part of the resin that has started to solidify near the cavity surface 25A of the nest 25 and the internal resin are mixed with each other. Generation can be avoided, and color unevenness and poor appearance can be prevented from occurring on the surface of the molded product near the thick portion.

Using the same molding apparatus and thermoplastic resin as in Example 1, molding was performed under the same molding conditions as in Example 1. There was no glass fiber precipitation (floating) on the surface of the molded product that was in contact with the cavity surface 25A of the nest 25, and the molded product had very high specularity. Also, there were no molding defects such as flow marks and jetting. Also, a desired hollow portion was surely formed inside the molded product. Although the molding was continuously performed 10,000 times, the nest 25 and the thin layer (the active metal film and the metal layer or the metal layer) 26 manufactured by the method substantially the same as that of the first or second embodiment were damaged. Did not occur.

(Embodiment 12) In Embodiment 12, in order to form a hole in a molded product, the cavity is attached to the first mold part and / or the second mold part, and the portion occupying the cavity is formed by the cavity. The present invention relates to a mold assembly further including a core pin constituting a part. Hereinafter, various forms of core pins will be described with reference to the drawings.

In a mold assembly whose schematic partial cross-sectional views are shown in FIGS.
Has the same configuration as the nesting in the first or second embodiment, and is attached to the second mold portion 11 by a known method. In the structure shown in FIG. 23A, the clearance between the tip surface 103 of the core pin 101 and the cavity surface 15A of the insert 15 is sufficiently large. Thereby, a non-through hole can be formed in the molded product. still,
On the surface of the core pin 101, a thin layer 16A (formed of an active metal film and a metal layer or a metal layer) is formed. On the other hand, the tip surface of the core pin 101 in FIG. 23B corresponds to the facing surface 102, and the leading surface (facing surface 102).
(C _c1 ) is less than or equal to 0.03 mm (C _c1 ≦ 0.03 m).
m), preferably 0.001 mm to 0.03 mm
(0.001 mm ≦ C _c1 ≦ 0.03 mm), more preferably 0.003 mm to 0.03 mm (0.003 mm
≦ C _c1 ≦ 0.03 mm). A thin layer 16A (formed of an active metal film and a metal layer or a metal layer) is formed on the surface of the core pin 101. Here, the thin layer 16A only needs to be formed at least on the facing surface 102. Thereby, a through hole can be formed in the molded product without the molten thermoplastic resin entering between the facing surface 102 and the cavity surface 15A of the insert 15. In the structure shown in FIGS. 23A and 23B, the opposing surface 102 of the core pin due to the concentrated stress is used.
Alternatively, in order to prevent breakage of the distal end surface 103, the opposing surface 1 of the core pin before forming a thin layer with a diamond grindstone is used.
02 or 0.2m at the outer corner of the tip surface 103
It is preferable to provide a curvature of at least mR or to perform a C-plane process (a process of chamfering a corner at an angle of 45 degrees).

Alternatively, as shown in a schematic partial cross-sectional view of FIG. 24A, a through hole is provided in the insert 15 so that the tip of the core pin 101 can be closed when the mold assembly is clamped. Portion 104 extends into the through hole. In this case, the clearance (C _c2 ) between the tip 104 of the core pin and the through hole provided in the insert 15 is preferably 0.1 mm or more. If the clearance (C _c2 ) is less than 0.1 mm, the core pin and the nest come into contact due to expansion and contraction due to heat, and the nest and the core pin may be damaged. A step is provided in a portion of the core pin 101 occupying the cavity 14, and a facing surface 102 facing the cavity surface 15 </ b> A of the insert 15 is provided. It is desirable that the clearance (C _c1 ) between the cavity surface 15A of the nest 15 and the opposing surface 102 be as described above. With such a structure, the molten thermoplastic resin does not intrude between the opposing surface 102 and the nested cavity surface 15A, and the through-hole can be reliably formed at an accurate position in the molded product, In addition, it is possible to prevent the distal end portion 104 of the core pin and the insert 15 from being damaged. A thin layer 16A (formed of an active metal film and a metal layer or a metal layer) is formed on the surface of the core pin 101. Here, the thin layer 16A only needs to be formed on at least the distal end portion 104 and the facing surface 102.

Alternatively, as shown in FIGS. 24B and 25A, the core pin 1
Numeral 11 has the same configuration as the nest in the first or second embodiment. The nest 15 is provided with a through-hole, and the core pin 111 can be connected to the first mold part through the through-hole by a known method. 10 is attached. Core pin 1
11, a thin layer 16A (active metal film and metal layer,
Alternatively, a metal layer is formed. In these cases, the portion of the core pin 111 occupying the cavity 14 has an opposing surface 112 facing the cavity surface 15A of the insert 15 and a clearance (C _c1 ) between the opposing surface 112 and the cavity surface 15A of the insert 15. Is desirably as described above. Also, the clearance (C) between the core pin 111 and the through hole provided in the insert 15
_c2 ) is preferably 0.1 mm or more.

In the structure shown in FIG. 24B, the clearance between the tip surface 113 of the core pin 111 and the cavity surface 11B of the second mold portion 11 is sufficiently large. Thereby, a non-through hole can be formed in the molded product. On the other hand, the clearance (C _c3 ) between the tip surface 113 of the core pin 111 and the cavity surface 11B of the second mold part 11 in FIG. 25A is determined when the cavity surface 11B is made of metal. It can be 0 mm. When a nest (not shown) is provided in the second mold part 11, the cavity surface of the nest and the core pin 11
The clearance (C _c3 ) between the front end surface 113 of FIG.
03 mm or less (C _c3 ≦ 0.03 mm), preferably 0.1 mm or less.
001 mm to 0.03 mm (0.001 mm ≦ C _c3 ≦
0.03 mm), more preferably 0.003 mm to 0.03 mm (0.003 mm ≦ C _c3 ≦ 0.03 mm)
It is desirable that Thereby, the core pin 111
The through hole can be formed in the molded product without the molten thermoplastic resin entering between the front end surface 113 of the second mold portion 11 and the cavity surface (nested cavity surface) of the second mold portion 11. 24 (A), (B), FIG. 25 (A),
In the structure shown in (B), in order to prevent breakage of the core pin due to concentrated stress, a diamond grindstone is used to form 0.2 mmR or more on the outer corners of the tip surfaces 112 and 113 of the core pin before forming a thin layer. It is preferable to provide a curvature or perform C-plane processing.

In the example shown in FIG. 25 (B), which is a schematic partial cross-sectional view, a through hole is provided in the insert 15 and the core pin 111 passes through the through hole to allow the first mold part 10 to pass through.
In a known manner. Second mold part 11
Is provided with a hole 11C, and the tip 114 of the core pin 111 extends into the hole 11C when the mold assembly is clamped. On the surface of the core pin 111, a thin layer 16A (formed of an active metal film and a metal layer or a metal layer) is formed. Tip portion 114 of core pin 111 and hole portion 11C
Between 0.01 and 0.03 (C _c4 )
mm. With such a structure, a through hole can be reliably formed in a molded product.

In the example shown in FIG. 26 (A) which is a schematic partial cross-sectional view, the core pin includes a core pin mounting portion 120 mounted on the second mold portion 11 by a known method, and a core pin mounting portion. An annular member 121 attached to the end 120 and closed at one end and open at the other end. Annular member 1
Reference numeral 21 is a cap. The annular member 121 is similar to the first embodiment.
Or it has the same configuration as the nesting in Example 2,
On its surface, a thin layer 16A (made of an active metal film and a metal layer or a metal layer) is formed. The annular member 121 constitutes a surface of a portion of the core pin occupying the cavity 14. The core pin mounting portion 120 is a ring member 1
The other end 21 extends into the annular member. The thickness of the annular member 121 (1/2 of the difference between the outer diameter and the inner diameter when the sectional shape is annular) is preferably 0.5 to 4 mm. The core pin mounting section 120 may be made of metal.
In the structure shown in FIG.
The clearance between the tip surface 123 of the nest and the nested cavity surface 15A is sufficiently large. Thereby, a non-through hole can be formed in the molded product. 26B, the clearance (C _c1 ) between the tip surface corresponding to the facing surface 122 of the annular member 121 and the cavity surface 15A of the insert 15 is as described above. It is desirable to do as it did. Thereby, the annular member 1
Through holes can be formed in the molded product without intrusion of the molten thermoplastic resin between the distal end surface corresponding to the opposing surface 122 and the nested cavity surface 15A. FIG.
In the example shown in (B), the thin layer 16A may be formed at least on the distal end surface corresponding to the facing surface 122 of the annular member 121. In the structure shown in FIGS. 26A and 26B, in order to prevent the annular member from being damaged by concentrated stress, the outer corner portion of the annular member 121 before forming a thin layer with a diamond grindstone. It is preferable to give a curvature of 0.2 mmR or more or to perform a C-plane treatment.

In the examples shown in FIGS. 27A and 27B, which are schematic partial cross-sectional views, the core pin is attached to the first mold portion 10 by a known method.
0, and an annular member 131 attached to the core pin attaching portion 130 and having one end opened and the other end closed.
The annular member 131 has a cap shape. Annular member 131
Has a configuration similar to that of the nesting in the first or second embodiment, and has a thin layer 16A (made of an active metal film and a metal layer or a metal layer) formed on the surface thereof. The annular member 131 forms a surface of a portion of the core pin occupying the cavity 14. The surface forming one end of the annular member 131 corresponds to the facing surface 132, and the core pin mounting portion 1
30 penetrates through holes provided in the insert 15 and extends from one end of the annular member 131 to the inside of the annular member. The thickness of the annular member 131 (when the sectional shape is annular,
(1/2) of the difference between the outer diameter and the inner diameter is preferably 0.5 to 4 mm. The core pin mounting portion 130 may be made of metal. In addition, the core pin mounting portion 130 and the nest 15
It is preferable that the clearance (C _c2 ) between the through hole and the through hole provided is 0.1 mm or more. If the clearance (C _c2 ) is less than 0.1 mm, the core pin and the nest come into contact due to expansion and contraction due to heat, and the nest and the core pin may be damaged.

In the structure shown in FIG. 27A, the clearance between the end surface 133 of the annular member 131 and the cavity surface 11B of the second mold portion 11 is sufficiently large. Thereby, a non-through hole can be formed in the molded product. In this case, at least the annular member 13
What is necessary is just to be formed in the opposing surface 132 which comprises one end of 1. On the other hand, the surface (tip surface) 133 at the other end of the annular member and the cavity surface 1 of the second mold portion 11 in FIG.
1B, the clearance (C _c3 ) between the cavity surface 1
When 1B is made of metal, it can be 0 mm. When a nest (not shown) is provided in the second mold part 11, the clearance (C _c3 ) between the cavity surface of the nest and the other end surface (tip surface) 133 of the annular member is Desirably, it is as described above. Thereby, the surface (tip surface) 133 at the other end of the annular member and the second
The through hole can be formed in the molded product without the molten thermoplastic resin penetrating between the mold portion 11 and the cavity surface 11B. In this case, the thin layer 16A only needs to be formed on at least the opposing surface 132 forming one end of the annular member 131 and the surface (tip surface) 133 at the other end of the annular member. The clearance (C _c1 ) between the opposing surface 132 of the annular member 131 and the nested cavity surface 15A is desirably set as described above. In the structure shown in FIGS. 27A and 27B, in order to prevent breakage of the annular member due to concentrated stress, a diamond grindstone is applied to the outer corner portion of the annular member 131 before forming a thin layer. .
It is preferable to provide a curvature of 2 mmR or more or to perform a C-plane treatment.

In the example shown in FIG. 28 (A) which is a schematic partial cross-sectional view, the core pin includes a core pin mounting portion 120A mounted on the second mold portion 11 by a known method, and a core pin mounting portion. An annular member 121A attached to 120A and open at both ends. The annular member 121A has a ring shape. The annular member 121A has a configuration similar to that of the nest in the first or second embodiment, and has a thin layer 16A (made of an active metal film and a metal layer or a metal layer) formed on the surface thereof. . The thin layer 16A is
What is necessary is just to be formed in at least the opposing surface 122A. The annular member 121A forms a surface of a portion of the core pin occupying the cavity 14. The surface forming one end of the annular member 121A corresponds to the facing surface 122A, and the core pin mounting portion 1
20A is an annular member 121A from the other end of the annular member 121A.
A. In this example, the distal end surface 123A of the core pin mounting portion 120A is located within a plane occupied by the opposing surface 122A. The thickness (1/2 of the difference between the outer diameter and the inner diameter when the sectional shape is annular) of the annular member 121A is
Preferably, it is 0.5 to 4 mm. The core pin mounting portion 120A may be made of metal. Incidentally, a surface at one end of the annular member 121A (opposing surface) in FIG.
It is desirable that the clearance (C _c1 ) between 122A and the nested cavity surface 15A be as described above. Thereby, a through hole can be formed in the molded product without the molten thermoplastic resin entering between the end surface (opposing surface) 122A of the annular member 121A and the nested cavity surface 15A.

In the example shown in FIG. 28 (B), which is a schematic partial sectional view, a through hole is provided in the insert 15 so that the tip of the core pin attaching portion 120A can be closed when the mold assembly is clamped. The portion 124A extends from one end of the annular member 121A into the through hole. Tip portion 124A of core pin mounting portion 120A
(C _c2 ) between the hole and the through hole is 0.1 mm or more. With such a structure, a through hole can be reliably formed in a molded product.

In the example shown in FIG. 29A, which is a schematic partial cross-sectional view, the distal end portion 12 of the core pin mounting portion 120A is shown.
5A stops inside the annular member 121. The nest 15 is provided with a through hole, and the first mold part 10 is provided with a protruding portion 10C protruding from the through hole. And
The clearance (C _c2 ) between the protrusion 10C and the through hole is 0.1 mm or more. When the mold assembly is clamped, the protrusion 10C fits inside the annular member 121A. More specifically, when the mold assembly is clamped, the protruding portion 10C is fitted with the distal end portion 125A of the core pin mounting portion 120A. With such a structure, a through hole can be reliably formed in a molded product. Further, the fitting accuracy can be improved. Note that the distal end surfaces of the distal end portion 125A of the core pin mounting portion 120A and the protruding portion 10C may be smooth. When the mold assembly is clamped, the side wall of the tip of the protrusion 10C and the annular member 1
The protrusions 10C are provided so that the inner surfaces of the
Is preferably 0.1 mm or more between the side wall of the distal end and the inner surface of the annular member 121A.

In the structures shown in FIGS. 28A and 28B and FIG. 29A, in order to prevent breakage of the annular member due to concentrated stress, a diamond grindstone is used to form a thin layer. It is preferable to give a curvature of 0.2 mmR or more to the outer corner portion of the annular member 121A, or to perform C-plane processing.

In the example shown in FIG. 29 (B), which is a schematic partial cross-sectional view, the core pin includes a core pin mounting portion 130A mounted on the first mold portion 10 by a known method, and a core pin mounting portion. An annular member 131A attached to 130A and having both ends opened. The annular member 131A has a ring shape. The annular member 131A has a configuration similar to that of the nest in the first or second embodiment, and a thin layer 16A (made of an active metal film and a metal layer or a metal layer) is formed on the surface thereof. . The thin layer 16A is
What is necessary is just to form at least the facing surface 132A and the surface 136A facing the second mold part 11. The annular member 131A constitutes the surface of the portion of the core pin occupying the cavity 14. A surface forming one end of the annular member 131A corresponds to the facing surface 132A, a through hole is provided in the nest 15, the core pin mounting portion 130A penetrates the through hole, and the annular member 131A is connected to the annular member 131A from one end. Extends inside. In this case, the core pin mounting portion 130
The clearance (C _c2 ) between A and the through hole is 0.1 mm
It is preferable that it is above. The surface corresponding to the facing surface 132A of the annular member 131A and the nested cavity surface 15
It is desirable that the clearance (C _c1 ) from A is as described above. Further, the clearance (C _c3 ) between the surface 136A constituting the other end of the annular member 131A and the cavity surface 11B of the second mold portion 11 is 0 mm when the cavity surface 11B is made of metal. It can be. When a nest (not shown) is provided in the second mold part 11, the clearance (C _c3 ) between the cavity surface of the nest and the surface 136A forming the other end of the annular member 131A is as described above. It is desirable to do as it did. In this example, the distal end surface 133A of the core pin mounting portion 130A is located within the plane occupied by the surface 136A, but when the cavity surface 11B is made of metal, the distal end surface 133A of the core pin mounting portion 130A is It may project from the plane occupied by the surface 136A.

In the example shown in FIG. 30 (A), which is a schematic partial cross-sectional view, a hole 11C is provided in the second mold portion 11 so that when the mold assembly is clamped, The distal end portion 134A of the core pin attachment portion 130A extends into the hole 11C. Clearance (C _c4 ) between annular member 131A and hole 11C at distal end 134A of core pin mounting portion 130A.
Is preferably 0.01 to 0.03 mm.

In the example shown in FIG. 30 (B), which is a schematic partial sectional view, the distal end 13 of the core pin mounting portion 130A is shown.
5A stops inside the annular member 131A, and the second mold portion 11 is provided with a protrusion 11D. When the mold assembly is closed, the protrusion 11D fits inside the annular member 131A. It can be in the form. More specifically, when the mold assembly is clamped, the protrusion 11D is
It fits with the leading end 135A of 0A. With such a structure, a through hole can be reliably formed in a molded product. Further, the fitting accuracy can be improved. The tip 135A of the core pin mounting portion 130A and the protrusion 11D
May be smooth. When the mold assembly is clamped, the clearance between the tip side wall of the protrusion 11D and the inner surface of the annular member 131A is set so that the tip side wall of the protrusion 11D does not contact the inner surface of the annular member 131A. It is preferably at least 0.1 mm.

In the structures shown in FIGS. 29B, 30A and 30B, a thin layer is formed with a diamond grindstone in order to prevent damage to the annular member due to concentrated stress. It is preferable to give a curvature of 0.2 mmR or more to the outer corner portion of the annular member 131A before performing, or to perform a C-plane treatment.

In the example shown in FIG. 31A and FIG. 32A which is a schematic partial cross-sectional view, the core pin occupies at least the inside of the cavity 14 instead of being made of, for example, partially stabilized zirconia ceramics. Core pin 14
Thermal sprayed layers 141 and 151 formed by spraying, for example, partially stabilized zirconia are formed on the surface of the portion 0,150. On the surface of the thermal spray layers 141 and 151, for example, a thin layer 16B composed of an active metal film and a metal layer is formed.
The core pins 140 and 150 may be made of metal.

In the structure shown in FIG.
The core pin 140 is attached to the second mold part 11, and the clearance between the tip surface 143 of the core pin 140 and the cavity surface 15A of the insert 15 is sufficiently large. In the structure shown in FIG. 32A, a through hole is provided in the insert 15 and the core pin 150 is attached to the first mold part 10 through the through hole. The clearance between 153 and the cavity surface 11B of the second mold part 11 is sufficiently large. Thereby, a non-through hole can be formed in the molded product.
In the example shown in FIG. 32A, the portion of the core pin 150 occupying the cavity 14 has a facing surface 152 facing the cavity surface 15A of the nest 15, and the facing surface 152 and the cavity of the nest 15 It is desirable that the clearance (C _c1 ) from the surface 15A be as described above.

Alternatively, in the example shown in FIG. 31 (B) which is a schematic partial cross-sectional view, the core pin 140 is attached to the second mold portion 11 and the core pin 140 occupying the cavity 14 is formed. The portion has an opposing surface 142 that opposes the cavity surface 15A of the nest 15. Opposite surface 1
The clearance (C _c1 ) between the cavity 42 and the cavity surface 15A of the insert 15 is desirably set as described above. In the structure shown in FIG. 31B, a through hole can be formed in a molded product.

Further, in the example shown in FIG. 32 (B), which is a schematic partial cross-sectional view, a through hole is provided in the insert 15, and the core pin 150 passes through the first hole through the through hole.
The portion of the core pin 150 occupying the cavity 14 has a facing surface 152 facing the cavity surface 15A of the nest 15, and the facing surface 1
It is desirable that the clearance (C _c1 ) between the cavity 52 and the cavity surface 15A of the insert 15 be as described above. Moreover, the clearance (C _c3 ) between the tip surface 153 of the core pin 150 and the cavity surface 11B of the second mold part 11 can be set to 0 mm when the cavity surface 11B is made of metal. Second mold part 1
In the case where a nest (not shown) is provided in the nest 1, it is desirable that the clearance (C _c3 ) between the cavity surface of the nest and the tip end surface 153 of the core pin 150 be as described above. Thereby, a through hole can be formed in the molded product. In FIGS. 32A and 32B, the clearance (C _c2 ) between the core pin 150 and the through hole provided in the insert 15 is preferably 0.1 mm or more.

Alternatively, in the example shown in FIG. 33 (A) which is a schematic partial cross-sectional view, the core pin 140 is attached to the second mold portion 11 and the insert 15 is provided with a through hole. When the mold assembly is clamped, the tip 144 of the core pin 140 extends into the through hole. The clearance (C _c2 ) between the tip 144 of the core pin 140 and the through hole may be 0.1 mm or more.

On the other hand, as shown in a schematic partial cross-sectional view in FIG. 33B, a through hole is provided in the insert 15, and the core pin 150 passes through the through hole to allow the first mold part 10 to pass through.
Can be cited. In this case, the second mold part 11 is provided with a hole 11C, and when the mold assembly is clamped, the tip part 1 of the core pin 150 is closed.
54 extends into the hole 11C. The clearance (C _c4 ) between the thermal spray layer 151 and the hole 11C at the tip 154 of the core pin 150 is preferably 0.01 to 0.03 mm.

The structure shown in FIG. 34A is a structure substantially combining the examples of the core pins shown in FIGS. 23B and 24B. That is, the first core pin 1
Numeral 10 has the same configuration as the nest in the first or second embodiment, and a nest 15 is provided with a through-hole. The first core pin 110 is provided with the first core pin 110 through the through-hole by a known method. It is attached to the mold part 10. Further, the second core pin 100 also has the same configuration as the nesting in the first or second embodiment, and
1 in a known manner. The distal end surfaces of the first core pin 110 and the second core pin 100 have a structure that can fit each other. The first core pin 110 has an opposing surface 112.

The structure shown in FIG. 34B is a structure in which the examples of the core pins shown in FIGS. 28A and 29B are combined. That is, the first core pin includes a core pin attachment portion 130B attached to the first mold portion 10 by a known method, and an annular member 131B attached to the core pin attachment portion 130B and having both ends opened. The annular member 131B has a ring shape, and the configuration can be similar to that of the annular member 131. Core pin mounting part 13
0B is an annular member 131B from the other end of the annular member 131B.
Extends inside. On the other hand, the second core pin
A core pin attaching portion 120B attached to the mold portion 11 by a known method, and an annular member 121B attached to the core pin attaching portion 120B and having both ends opened. The annular member 121B has a ring shape, and the configuration can be similar to that of the annular member 121. Core pin mounting part 12
OB is the annular member 121B from the other end of the annular member 121B.
Extends inside. These annular members 121B, 1
31B constitutes the surface of the portion of the core pin occupying the cavity 14. A surface forming one end of the annular member 131B corresponds to the facing surface 132B, a through hole is provided in the nest 15, the core pin mounting portion 130B penetrates the through hole, and the annular member 131B extends from one end of the annular member 131B. Extends inside. In this case, the core pin mounting portion 130B
The clearance (C _c2 ) between the hole and the through hole is preferably 0.1 mm or more. Core pin mounting portion 120B, 1
30B has a structure that can fit each other. 0.003 to 0.03 mm between one end surface (tip surface) of the annular member 121B and the other end surface (tip surface) of the annular member 131B.
Is preferable in order to prevent breakage of the annular member 121B and the annular member 131B.

The structure shown in FIG. 35A is a structure in which the examples of the core pins shown in FIGS. 31B and 32B are combined. That is, the nest 15 is provided with a through-hole, and the core pin includes a first core pin 150 attached to the first mold part 10 through a through-hole provided in the nest 15, and a second mold part. 11 and the second core pin 140 is attached to the first core pin 150 so that the front end 154 of the first core pin 150 and the front end 144 of the second core pin 140 are fitted when the mold assembly is clamped. There may be a clearance of 0.003 to 0.03 mm between the distal end surface of the thermal spray layer 151 formed on the first core pin 150 and the distal end surface of the thermal spray layer 141 formed on the second core pin 140. It is preferable to prevent the thermal sprayed layers 141 and 151 from being damaged.

The structure shown in FIG. 35 (B) is a modification of the structure shown in FIG. 34 (A), and a nest 151 is attached to the _first mold part 10 and a second mold part is provided. nest 15 ₂ is attached to the 11. The nest 15 ₁ has a through hole, the first core pin 110 having a configuration similar to the nest in Example 1 or Example 2,
It is attached to the first mold part 10 through this through hole by a known method. The first core pin 110 has the facing surface 11
2 The second core pin 100 also Example 1 or has the same configuration as nested in Example 2, the nest 15 ₂ has a through hole, a second core pin 1
00 is attached to the second mold part 11 through the through hole by a known method. The second core pin 100 has an opposing surface 102. The distal end surfaces of the first core pin 110 and the second core pin 100 have a structure that can fit each other. Clearance between the cavity surface 15A ₁ of the facing surfaces 112 and nest 15 ₁ in the first core pin 110 (C _c1), and the opposing surface 1 of the second core pin 100
02 and the clearance between the cavity surface 15A ₂ of the insert 15 ₂ (C _c1), it is desirable to be as described above. Further, the clearance between the first core pin 110 and nest 15 ₁ of the through hole (C _c2), and the clearance between the second core pin 100 and nest ₁₅₂ of the through-hole (C _c2) is 0. It is preferably 1 mm or more.

(Example 13) As a mold assembly for manufacturing a perforated molded product in Example 13, a mold assembly having a core pin shown in FIG. 28B was used. With reference to FIGS. 36 and 37, the assembly of the mold assembly for manufacturing a perforated molded product in the thirteenth embodiment will be described below. still,
The basic structure of the mold assembly was the same as the mold assembly described in the seventh embodiment.

In the thirteenth embodiment, the nest 15 is formed of a disc-shaped ZrO ₂ —Y ₂ O _{3 having} a thickness of 3.00 mm and a diameter of 100.00 mm having a through hole 15C having a diameter of 27.00 mm at the center. Nesting was used. A thin layer 16 (comprising an active metal film and a metal layer) is formed on the cavity surface 15A of the nest 15. The formation of the thin layer 16 can be the same as in the first embodiment. The inner size of the nesting portion 10B of the first mold portion (fixed mold portion) 10 is 100.2 mm in outer diameter and 3.02 mm in depth, and the nesting portion 10B is cut by cutting carbon steel S55C. First
(Fixed mold part) 10. Then, the insert 15 was fixed to the insert mounting portion 10B in the first mold portion (fixed mold portion) 10 using an epoxy-based adhesive (not shown) (see FIG. 37A). Then, the surface of the metal layer was cut.

A coating plate 12 for coating the end of the insert 15 was made of carbon steel S55C. The inner dimension was 99.00 mm. The cover plate 12 was fixed to a first mold portion (fixed mold portion) 10 using screws (not shown) (see FIG. 37B). The clearance (C ₂₁ ) between the nest 15 and the coating plate 12 was on average 0.01 mm. The amount of overlap (ΔS ₂₁ ) of the cover plate 12 with respect to the insert 15 was 0.5 mm.

FIGS. 36A and 36B show the state of the mold after clamping and the state of opening the mold after assembling the mold assembly for manufacturing a perforated molded product of Example 13. FIG. Show.
A core pin for forming a hole in a molded product includes a metal core pin attachment portion 120A attached to the second mold portion (movable mold portion) 11 by a known method, and a core pin attachment portion 120.
A is composed of an annular member 121A attached using an adhesive (not shown) to A. Both ends of the annular member 121A are open. The annular member 121A is made of Z
It was made of rO ₂ —Y ₂ O ₃ , had an inner diameter of 26.00 mm and an outer diameter of 32.00 mm. The outer corner portion of the annular member 121A is polished to 0.5 mmR. Annular member 121
A thin layer 16A (comprising an active metal film and a metal layer) is formed on the surface of A. The formation of the thin layer 16A can be the same as in the first embodiment. The diameter of the portion where the annular member 121A of the core pin mounting portion 120A made of carbon steel S55C was mounted was 25.90 mm. The surface forming one end of the annular member 121A corresponds to the facing surface 122A, and the core pin mounting portion 120A extends from the other end of the annular member 121A into the inside of the annular member. The cavity surface 15A of the nest 15 and the facing surface 122 of the annular member 121A
A is not in surface contact. When closing the mold, insert 15
Cavity surface 15A and opposed surface 1 of annular member 121A
The clearance (C _c1 ) between 22A and 0.01 mm is 0.01 mm.
Met. When the mold is clamped, the distal end portion 124A of the core pin mounting portion 120A is inserted into the through hole 1 from one end of the annular member 121A.
Extends into 5C. Tip part 1 of core pin attachment part 120A
The clearance (C _c2 ) between 24A and the through hole 15C was 0.55 mm. With such a structure,
Breakage of the nest 15 and the core pin, or occurrence of burrs on the molded product can be prevented.

Then, using the same thermoplastic resin as in Example 1, molding was performed under the same molding conditions as in Example 1. There was no glass fiber precipitation on the surface of the molded product, and the molded product had very high specularity. In addition, molding defects such as flow mark and jetting were not observed in the molded product, and a through-hole was formed in the molded product. Continuous molding 100
Although the test was performed 00 times, no damage such as a crack occurred in the insert 15 and no damage occurred in the thin layer 16. Also, no damage occurred to the annular member 121A or the thin layer 16A.

It is to be noted that a nest or an annular member can be produced in the same manner as in Example 2 using partially stabilized conductive zirconia ceramics.

(Example 14) As a mold assembly for manufacturing a perforated molded product in Example 14, a mold assembly having a core pin shown in FIG. 29A was used. The basic structure of the mold assembly was the same as that of the mold assembly described in the seventh embodiment.

The nest 15 is made of partially stabilized zirconia (Zr
O ₂ -Y ₂ O ₃₎ were made from ceramics. Then, the cavity forming surface of the nesting body is polished and finished using a diamond grindstone to reduce the surface roughness _Ry to 0.
02 μm. The size of the nest 15 is 4.00 m in thickness.
m, outer diameter 100.00 mm, inner diameter 30.00 mm. Next, a thin layer 16 composed of an active metal film and a metal layer was formed on the nest body in the same manner as in Example 1, and the thin layer was ground and polished. First mold part (fixed mold part)
The inner dimension of the ten nested mounting parts 10B is set to an outer diameter of 100.2.
mm and a depth of 4.02 mm, the nesting portion 10B was manufactured by cutting from carbon steel S55C. Also,
The nested mounting portion 10B was provided with a columnar protruding portion 10C fitted with the core pin mounting portion 120A. Next, the insert 15 was fixed in the insert mounting portion 10B with an epoxy-based adhesive (not shown).

The covering plate 12 for suppressing the end of the nest 15 is made of carbon steel S55C, and has an inner dimension of 9 mm.
It was 9.00 mm. The cover plate 12 was fixed to a first mold part (fixed mold part) 10 using screws (not shown).

The clearance (C ₂₁ ) between the insert 15 and the coating plate 12 was 0.01 mm on average.
The amount of overlap (ΔS ₂₁ ) of the cover plate 12 with respect to the insert 15 was 0.5 mm.

A core pin mounting portion 120A was mounted in the second die portion (movable die portion) 11. The diameter of the portion where the annular member 121A of the core pin mounting portion 120A made of carbon steel S55C was mounted was 25.9 mm. The annular member 121A is manufactured by cutting from ZrO ₂ —Y ₂ O ₃ ,
The outer corners of the annular member are coated with a diamond grindstone.
After finishing to 5 mmR, a thin layer 16A composed of an active metal film and a metal layer was formed on the surface in the same manner as in Example 1. The outer diameter of the annular member 121A was 32.00 mm and the inner diameter was 26.00 mm. Then, the core pin mounting portion 120
The annular member 121A was fixed to the portion to which the annular member A was attached using an adhesive. When the mold assembly is clamped, the clearance (C _c1 ) between the cavity surface 15A of the insert 15 and the facing surface 122A of the annular member 121A is 0.01.
mm. The clearance (C _c2 ) between the protrusion 10C and the through hole provided in the insert 15 was 2.1 mm. Also, the tip side wall of the protrusion 10C and the annular member 12
The clearance between the inner surface of 1A was 0.1 mm. The molded product is a donut type having an outer diameter of 99 mm, an inner diameter of 32 mm, and a thickness of 2 mm. FIGS. 38A and 38B show the state of the mold after clamping and the state of opening the mold after assembling the mold assembly for manufacturing a perforated molded product of Example 14. FIG.
Are shown below.

After attaching the completed mold assembly to a molding apparatus, the mold assembly was heated to 130 ° C. using a mold temperature controller.
Even when quenched to 40 ° C., no problems such as cracks occurred in the insert 15 made of zirconia ceramics. Also, no damage occurred to the annular member 121A or the thin layers 16, 16A.

A molding apparatus manufactured by Mitsubishi Heavy Industries, Ltd., 15
The mold assembly was heated to 80 ° C. using a 0MST injection molding machine. Black polycarbonate resin (S3 made by Mitsubishi Engineering-Plastics Corporation) as a molding material
000), resin temperature 280 ° C., injection pressure 6.8
After injecting the molten thermoplastic resin into the cavity 14 from the molten thermoplastic resin introduction part 13 under the condition of 6 × 10 ⁷ Pa (700 kgf / cm ² -G) (see FIG. 39), the molded product is molded after 20 seconds. Removed from the assembly.

The surface of the molded product in contact with the cavity surface 15A of the nest 15 had excellent gloss up to the end of the molded product, and no weld line was generated. No molding defects such as flow marks and jetting were observed in the molded product, and the molded product had through holes.
No damage was found in the insert 15, the annular member 121 </ b> A, and the thin layers 16 and 16 </ b> A even after molding 10,000 times.

It is to be noted that a nest or an annular member can be produced in the same manner as in Example 2 using partially stabilized conductive zirconia ceramics.

Although the present invention has been described based on the preferred embodiments, the present invention is not limited to these embodiments.
The conditions of the structure of the mold assembly, the structure of the nest, the method of manufacturing the same, and the method of forming the molded product described in the examples are merely examples and can be changed as appropriate.

FIG. 40 shows a tab forming portion 24 communicating with the cavity 24 in order to remove a molded product from the mold assembly.
A illustrates a structure in which A is provided on the covering plate 22A. The cover plate 22A is attached to the first mold part 20. Incidentally, the clearance C ₃₃ during this case also, the nesting 25 and the cover plate 22A is 0.03m
m or less. This mold assembly has substantially the same structure as the mold assembly described in the eighth embodiment. The coating plate 22A is also provided at two places in the direction perpendicular to the paper surface of FIG. Incidentally, FIG.
And (A) of FIG. 41 shows the covering plates 22 and 2 in a vertical plane.
FIG. 40 (B) and FIG. 41 (B) are views when the area of the mold assembly including 9A is cut, and the vertical planes parallel to such vertical planes do not include the coating plates 22 and 29A. It is a figure when cutting the area | region of a metal mold assembly. By forming the mold assembly in such a structure, a tab portion is formed on the molded product. After opening the mold assembly (see FIGS. 41A and 41B), a protruding pin (not shown) provided on the second mold portion 21 is applied to the tab portion to form a molded product. , And the molded product may be taken out of the mold assembly. Note that the tab portion formed on the molded product may be deleted in a later step.

[0212]

According to the present invention, since the metal layer is formed on the surface of the nest, it is possible to process the metal layer on the opposing surface of the nest and the like when mounting the nest on the mold. Adjustment becomes relatively easy, the manufacturing cost of the mold assembly can be reduced, and the occurrence of breakage at the end or edge of the insert can be reliably prevented, and long-term molding can be endured. That is, in the mold assembly of the present invention,
The nesting is performed by a predetermined clearance (C) or an overlapping amount (Δ
Within the range of S), it is possible to easily incorporate the molded product into the mold part, and even if the molding is performed for a long period of time, the molded product excellent in appearance is easily and inexpensively formed without causing damage to the nest. It becomes possible.

Further, not only is the transferability of the nested cavity surface to the molded product surface excellent, but also the rapid cooling of the molten thermoplastic resin filled in the cavity can be suppressed, resulting in jetting, flow marks, etc. Can effectively prevent the occurrence of poor appearance and ensure that the inorganic fibers precipitate (float) on the surface of the molded product even when a thermoplastic resin containing inorganic fibers is used. Can be prevented. Moreover, continuous molding is easy, the quality of the molded product is stable, and molding can be performed for a long time. In addition, the appearance of the molded article is not impaired, the occurrence of burrs at the end of the molded article can be prevented, the defective rate of the molded article can be reduced, and the homogenized and high quality of the molded article can be achieved. Cost can be reduced.

Further, since the flowability of the molten thermoplastic resin in the cavity is improved, the pressure at which the molten thermoplastic resin is introduced into the cavity can be set low, so that the stress remaining in the molded article can be reduced. The quality of molded products is improved. Further, since the introduction pressure can be reduced, the thickness of the mold portion can be reduced, the size of the molding device can be reduced, and the cost of the molded product can be reduced.

In the present invention, by using a mold assembly having a slide core or a core pin, transferability deterioration due to rapid cooling of the molten thermoplastic resin can be prevented.
Deterioration of gloss can be prevented, and generation of weld lines can be suppressed. In addition, a perforated molded product can be easily and reliably molded.

[Brief description of the drawings]

FIG. 1 is a schematic end view showing a mold-clamped state and a mold-opened state of a mold assembly according to a first embodiment.

FIG. 2 is a schematic end view showing a mold assembly and a mold open state of a mold assembly according to a second embodiment.

FIG. 3 is a schematic end view showing a mold assembly of a third embodiment in a mold-clamped state and a mold-opened state.

FIG. 4 is a schematic end view showing a mold assembly of a fourth embodiment in a mold-clamped state.

FIG. 5 is a schematic end view showing a state where a molten thermoplastic resin is being introduced into a cavity and after the molten thermoplastic resin is introduced into the cavity using the mold assembly of Example 4.

FIG. 6 is a schematic end view showing a mold clamping state of a modified example of the mold assembly according to the fourth embodiment.

FIG. 7 is a schematic end view showing a mold-clamped state of the mold assembly of Example 5, and a schematic end-face showing a state in which a hollow portion is formed after a molten thermoplastic resin is introduced into a cavity. FIG.

FIGS. 8A and 8B are a schematic end view showing a mold assembly of a sixth embodiment in a mold-clamped state, and a schematic end view of the mold assembly of the sixth embodiment during assembly.

FIG. 9 is a schematic end view showing a mold opening state of the mold assembly of Example 6, and a schematic end view showing a state in which a molten thermoplastic resin is introduced into a cavity.

FIG. 10 is a schematic end view showing a mold clamping state of the mold assembly according to the seventh embodiment, and a schematic end view during assembling of the mold assembly according to the seventh embodiment.

FIG. 11 is a schematic end view showing a modification of the mold assembly according to the seventh embodiment.

FIG. 12 is a schematic end view showing a modification of the mold assembly according to the seventh embodiment.

FIG. 13 is a schematic end view when the mold assembly of Example 8 is clamped.

FIG. 14 is a schematic end view of the mold assembly of Example 8 during assembly.

FIG. 15 is a schematic end view when the mold assembly of Example 8 is opened.

FIG. 16 is a schematic end view when the mold assembly of Embodiment 9 is clamped.

FIG. 17 is a schematic end view of the mold assembly of Example 9 during assembly.

FIG. 18 is a schematic end view of the mold assembly of Example 9 during assembly.

FIG. 19 is a schematic end view when the mold assembly of Embodiment 9 is opened.

FIG. 20 is a schematic end view of a mold assembly according to a tenth embodiment having a structure capable of making a volume of a cavity variable when molding a molded product.

FIG. 21 is a schematic end view of a mold assembly of Example 11 provided with a pressurized fluid injection device, and a schematic end view showing a state during molding of a molded product.

FIG. 22 is a schematic end view showing a state during molding of the molded article, following FIG. 21;

FIG. 23 is a schematic partial cross-sectional view of a mold assembly of the present invention including a core pin.

FIG. 24 is a schematic partial cross-sectional view of a mold assembly of the present invention including a core pin.

FIG. 25 is a schematic partial cross-sectional view of a mold assembly of the present invention including a core pin.

FIG. 26 is a schematic partial sectional view of a mold assembly of the present invention including a core pin.

FIG. 27 is a schematic partial cross-sectional view of a mold assembly of the present invention including a core pin.

FIG. 28 is a schematic partial sectional view of a mold assembly of the present invention including a core pin.

FIG. 29 is a schematic partial cross-sectional view of a mold assembly of the present invention including a core pin.

FIG. 30 is a schematic partial cross-sectional view of a mold assembly of the present invention including a core pin.

FIG. 31 is a schematic partial cross-sectional view of a mold assembly of the present invention including a core pin.

FIG. 32 is a schematic partial cross-sectional view of a mold assembly of the present invention including a core pin.

FIG. 33 is a schematic partial cross-sectional view of a mold assembly of the present invention including a core pin.

FIG. 34 is a schematic partial sectional view of a mold assembly of the present invention including a core pin.

FIG. 35 is a schematic partial cross-sectional view of a mold assembly of the present invention including a core pin.

FIG. 36 is a schematic partial end view of a mold assembly for producing a perforated molded product in Example 13.

FIG. 37 is a schematic partial end view during assembling of a mold assembly for manufacturing a perforated molded product in Example 13.

FIG. 38 is a schematic partial end view of a mold assembly for producing a perforated molded product in Example 14.

FIG. 39 is a schematic partial end view showing a state in which a molten thermoplastic resin is introduced into a cavity of a mold assembly for producing a perforated molded product in Example 14.

FIG. 40 is a schematic end view of a mold assembly having a structure in which a cover forming plate is provided with a tab forming portion communicating with a cavity for removing a molded product from the mold assembly.

FIG. 41 is a view schematically showing a second mold portion and a molded product after the mold assembly is opened.

[Explanation of symbols]

10 1st mold part (movable mold part), 10A ...
Core for nesting, 10B ... nesting part, 11.
..Second mold part (fixed mold part), 11A ... nested covering part, 12 ... covering plate, 13 ... molten thermoplastic resin introduction part, 14 ... cavity, 15 ...・ Nesting, 15A ・ ・ ・ Nesting cavity surface, 15B ・ ・
· Opposing surface of nest, 115 ··· Nest body, 16 ···
.Thin layer (two-layer structure of active metal film and metal layer), 17.
・ Metal layer, 18 ・ ・ ・ Pressurized fluid injection device, 20 ・ ・ ・ First mold part, 20A ・ ・ ・ Nested mounting part, 21 ・ ・ ・ Second mold part, 21A ・ ・ ・ Nested coating Part, 22 ... coating plate, 23 ... molten thermoplastic resin introduction part, 24
... Cavity, 24A ... Tab forming part, 25 ...
Nesting, 25A: Nesting cavity surface, 25B
... Opposite surfaces of the nest, 26... Thin layer (active metal film and metal layer or metal layer), 27.
... Pressurized fluid injection device, 30 ... First mold part, 3
DESCRIPTION OF SYMBOLS 1 ... Nest mounting part, 32 ... 1st coating plate attachment part, 33, 43 ... Coating plate, 35 ... 1st nest, 35A ... 1st nest cavity surface, 35B... Opposing surface of the first nest, 135.
The first nested body, 37, 47 ... metal layer, 38 ...
・ Cavity, 39 ・ ・ ・ Molten thermoplastic resin introduction part, 4
0: second mold part, 41: nested mounting part, 42
... Second cover plate mounting portion, 45 ... Second nest, 45A ... Cavity surface of second nest, 14
Reference numeral 5: second nest body, 45D: opposing surface of second nest, 50: roof rail for vehicle, 51 ...
Rail: 52: Leg, 53: Trace of molten thermoplastic resin introduction part, 54: Hollow part, 55: Through hole, 6
0 ... first mold part, 61 ... second mold part, 62
... Nesting coating part, 63 ... coating plate, 64
..Coating plate, 65 ... Melt thermoplastic resin introduction part, 66 ... Pressurized fluid injection device, 66A ... Pressurized fluid injection nozzle, 66B ... Check valve, 67 ... Cavity, 68A, 68B ... slide core member, 70
..Nesting, 70B ... Opposing surfaces of nesting, 71 ...
End face of nest, 72 ... hole, 73 ... cavity face of nest, 80A, 80B, 81A, 81B ... annular member, 101, 111, 140, 150 ... core pin, 102, 112, 122, 122A, 132, 13
2A, 142, 152 ... facing surface, 103, 113,
123, 123A, 133, 133A, 143, 153
... End face, 104, 114, 124A, 125A,
134A, 135A, 144, 154... Tip of core pin, 120, 120A, 130, 130A... Core pin mounting portion, 121, 121A, 131, 131A.
..Annular members, 141,151... Sprayed layer

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Akimasa Kaneishi 5-6-2 Higashi-Hachiman, Hiratsuka-shi, Kanagawa Pref. Mitsui Engineering Plastics Co., Ltd. Technology Center (72) Inventor Tsutomu Maeda Gamo-cho, Gamo-gun, Shiga Prefecture 10th Kawai 1 Kyocera Corporation Shiga Plant F term (reference) 4F202 AA28 AJ02 AJ06 AJ09 AM36 CA11 CA15 CB01 CK17 CK43

Claims (36)

[Claims] 1. A nest that is disposed inside a mold used for molding a molded article made of a thermoplastic resin and constitutes a part of a cavity provided in the mold, and is made of zirconia ceramics. A nest comprising: a nest body; an active metal film formed on a surface of at least a part of the nest body; and a metal layer formed on the active metal film. 2. The active metal film comprises a metal selected from the group consisting of Ti, Zr and Be, Ni, Cu, Ag and Fe.
The eutectic composition with a metal selected from the group consisting of: wherein the active metal film has a thickness of 1 × 10 ⁻⁶ m to 1 × 10 ⁻⁵ m. Nesting. 3. The metal layer is made of Cr, Cr compound, Cu, Cu.
The metal layer is made of at least one material selected from the group consisting of a compound, Ni and a Ni compound, and a thickness of the metal layer is 3 × 10 ⁻⁵ m to 5 × 10 ⁻⁴ m. Or a nest according to claim 2. 4. The nest according to claim 1, wherein the zirconia ceramic is made of partially stabilized zirconia ceramic. 5. The partially stabilized zirconia ceramic has a partial stabilizer of calcia (CaO), yttria (Y ₂ O ₃ ), magnesia (MgO), silica (Si).
O ₂₎ and ceria (nesting of claim 4, characterized in that it consists of at least one material selected from the group consisting of CeO _2). 6. A nest that is disposed inside a mold used for molding a molded article made of a thermoplastic resin and constitutes a part of a cavity provided in the mold, wherein the conductive zirconia ceramics is provided. And a metal layer formed on a surface of at least a part of the nest body. 7. The nest according to claim 6, wherein the volume resistivity of the conductive zirconia ceramic is 1 × 10 ⁹ Ω · cm or less. 8. The metal layer is made of Cr, Cr compound, Cu, Cu.
7. The method according to claim 6, wherein the metal layer is made of at least one material selected from the group consisting of a compound, Ni, and a Ni compound, and has a thickness of 3 × 10 ⁻⁵ m to 5 × 10 ⁻⁴ m. Or a nest according to claim 7. 9. The nest according to claim 6, wherein the conductive zirconia ceramic is made of partially stabilized zirconia ceramic. 10. The partial stabilizer in the partially stabilized zirconia ceramics includes calcia (CaO), yttria (Y ₂ O ₃ ), magnesia (MgO), and silica (Si).
O ₂₎ and ceria (nesting of claim 9, characterized in that it consists of at least one material selected from the group consisting of CeO _2). 11. The nest according to claim 6, wherein a conductivity-imparting agent is added to the conductive zirconia ceramics. 12. The conductive agent is made of Fe ₂ O ₃ , NiO, C
_{o 3 O 4, Cr 2 O} 3, TiC, WC, TaC, nested according to claim 11, characterized in that it consists of at least one material selected from the group consisting of TiO ₂ and TiN. (A) a mold for molding a thermoplastic resin molded product, comprising a first mold portion and a second mold portion, wherein a cavity is formed at the time of mold clamping; (B) a molten thermoplastic resin introduction part arranged in the first mold part or the second mold part for introducing the molten thermoplastic resin into the cavity; and (C) a first mold part and And / or a nest disposed in the second mold portion and constituting a part of the cavity, wherein the nest comprises a nest body made of zirconia ceramics, and at least a part of the nest body. A mold assembly comprising: an active metal film formed on a surface; and a metal layer formed on the active metal film. 14. An active metal film comprising a metal selected from the group consisting of Ti, Zr and Be, Ni, Cu, Ag and F.
14. The eutectic composition with a metal selected from the group consisting of: e, wherein the active metal film has a thickness of 1 × 10 ⁻⁶ m to 1 × 10 ⁻⁵ m. Mold assembly. 15. The metal layer is made of Cr, Cr compound, Cu, C
The metal layer is made of at least one material selected from the group consisting of a u compound, Ni and a Ni compound, and has a thickness of 3 × 10 ⁻⁵ m to 5 × 10 ⁻⁴ m. A mold assembly according to claim 13 or claim 14. 16. The mold assembly according to claim 13, wherein the zirconia ceramic is made of partially stabilized zirconia ceramic. 17. The partially stabilized zirconia ceramics may include, for example, calcia (CaO), yttria (Y ₂ O ₃ ), magnesia (MgO), and silica (Si).
O ₂₎ and ceria (mold assembly according to claim 16, characterized in that it consists of at least one material selected from the group consisting of CeO _2). 18. The nest is disposed on the first mold part, and
An active metal film and a metal layer are formed on a surface of a portion of the nesting body facing the second mold portion in a state where the mold portion and the second mold portion are clamped; In a state in which the mold portion and the second mold portion are clamped, the opposing surface of the second mold portion facing the nest, and the nest portion facing the opposing surface of the second mold portion. The mold assembly according to any one of claims 13 to 17, wherein a clearance therebetween is equal to or less than 0.03 mm. 19. A coating plate attached to the first or second mold part, forming a part of the cavity, and covering the end face of the nest, wherein the nest is disposed on the first mold part. A surface of a portion of the nesting body facing the covering plate in a state where the first mold portion and the second mold portion are clamped,
An active metal film and a metal layer are formed, and in a state where the first mold part and the second mold part are clamped, the clearance between the nest and the cover plate is 0.1 mm.
The mold assembly according to any one of claims 13 to 17, wherein the overlap length of the cover plate with respect to the nest is 0.5 mm or more. 20. A cover plate attached to the second mold part, forming a part of the cavity, and covering a part of the end face of the nest, wherein the nest is disposed on the first mold part, On the surface of the portion of the nest body facing the cover plate in a state where the first mold portion and the second mold portion are clamped,
An active metal film and a metal layer are formed, and an active metal film and a metal layer are formed on a surface of a portion of the nesting body facing the second mold portion. In a state in which the second mold portion is clamped, the clearance between the facing surface of the second mold portion facing the nest and the portion of the nest facing the facing surface of the second mold portion is , 0.03 mm or less, the amount of overlap of the opposing surface of the second mold portion with the nest is 0.5 mm or more, and the clearance between the nest and the cover plate is 0.03 mm or less. The mold assembly according to any one of claims 13 to 17, wherein the amount of overlap of the coating plate with respect to (i) is 0.5 mm or more. 21. The nest comprises a first nest disposed on the first mold part and a second nest disposed on the second mold part, wherein the first mold is provided. The surface of the portion of the first nest body facing the second nest when the part and the second mold part are clamped, and the second nest body facing the first nest. An active metal film and a metal layer are formed on the surface of the first part, and the first mold part and the second mold part are closed with the first mold part facing the second nest. The clearance between the nested portion and a second nested portion facing the first nest is less than or equal to 0.03 mm. Mold assembly. 22. (A) a mold for molding a thermoplastic resin molded product, comprising a first mold part and a second mold part, wherein a cavity is formed at the time of mold clamping; (B) a molten thermoplastic resin introduction part arranged in the first mold part or the second mold part for introducing the molten thermoplastic resin into the cavity; and (C) a first mold part and And / or a nest provided in the second mold part and constituting a part of the cavity, wherein the nest comprises a nest body made of conductive zirconia ceramics, and at least the nest body. A mold assembly comprising a metal layer formed on a part of the surface. 23. Volumetric solidification of conductive zirconia ceramics.
Resistive value is 1 × 10 ⁹Ω · cm or less
23. The mold assembly of claim 22, wherein: 24. The metal layer is made of Cr, Cr compound, Cu, C
The metal layer is made of at least one material selected from the group consisting of a u compound, Ni and a Ni compound, and has a thickness of 3 × 10 ⁻⁵ m to 5 × 10 ⁻⁴ m. A mold assembly according to claim 22 or claim 23. 25. The mold assembly according to claim 22, wherein the conductive zirconia ceramic is made of partially stabilized zirconia ceramic. 26. Partially stabilized zirconia ceramics include partial stabilizers such as calcia (CaO), yttria (Y ₂ O ₃ ), magnesia (MgO) and silica (Si).
O ₂₎ and ceria (mold assembly of claim 25, characterized in that it consists of at least one material selected from the group consisting of CeO _2). 27. A conductive zirconia ceramic to which a conductivity imparting agent is added.
The mold assembly according to any one of claims 26 to 26. 28. The conductivity-imparting agent is Fe ₂ O ₃ , NiO, C
_{o 3 O 4, Cr 2 O} 3, TiC, WC, TaC, mold assembly according to claim 27, characterized in that it consists of at least one material selected from the group consisting of TiO ₂ and TiN. 29. A nest body which is disposed on a first mold part and faces the second mold part in a state where the first mold part and the second mold part are clamped. On the surface of the part,
A metal layer is formed, and in a state where the first mold part and the second mold part are clamped, an opposing surface of the second mold part facing the nest, and a second mold part The mold assembly according to any one of claims 22 to 28, wherein a clearance between the opposing surface and the opposing nest portion is 0.03 mm or less. 30. A coating plate attached to the first or second mold part, forming a part of the cavity, and covering the end face of the nest, wherein the nest is disposed on the first mold part. A surface of a portion of the nesting body facing the covering plate in a state where the first mold portion and the second mold portion are clamped,
When the metal layer is formed and the first mold part and the second mold part are clamped, the clearance between the nest and the cover plate is 0.1 mm.
The mold assembly according to any one of claims 22 to 28, wherein the die is not more than 03 mm, and the amount of overlap of the covering plate with respect to the nest is not less than 0.5 mm. 31. A cover plate attached to the second mold part, forming a part of the cavity, and covering a part of an end face of the nest, wherein the nest is disposed on the first mold part, On the surface of the portion of the nest body facing the cover plate in a state where the first mold portion and the second mold portion are clamped,
A metal layer is formed, and a metal layer is formed on a surface of a portion of the nesting body facing the second mold portion, and the first mold portion and the second mold portion are separated from each other. In the mold-clamped state, the clearance between the opposing surface of the second mold portion facing the nest and the nest portion opposing the opposing surface of the second mold portion is 0.03 mm or less, The amount of overlap of the facing surface of the second mold part with respect to the nest is 0.5 mm or more, the clearance between the nest and the cover plate is 0.03 mm or less, and the amount of overlap of the cover plate with respect to the nest is 0 mm. The mold assembly according to any one of claims 22 to 28, wherein the length is not less than 0.5 mm. 32. The nest comprises a first nest disposed on the first mold part and a second nest disposed on the second mold part, wherein the first mold is provided. The surface of the portion of the first nest body facing the second nest when the part and the second mold part are clamped, and the second nest body facing the first nest. A metal layer is formed on the surface of the first mold part. In a state where the first mold part and the second mold part are clamped, a first nest part facing the second nest is formed. The mold set according to any one of claims 22 to 28, wherein a clearance between the first nest and a portion of the second nest opposite to the first nest is 0.03 mm or less. Three-dimensional. 33. The apparatus according to claim 13, further comprising a pressurized fluid injection device for injecting a pressurized fluid into the molten thermoplastic resin introduced into the cavity. The mold assembly according to claim 1. 34. The mold assembly according to claim 13, wherein the mold has a structure capable of changing the volume of the cavity. 35. (A) a mold comprising a first mold part and a second mold part, wherein a cavity is formed at the time of mold clamping; and (B) a first mold part or a second mold part. A molten thermoplastic resin introduction unit for introducing the molten thermoplastic resin into the cavity, which is disposed in the mold unit, and (C) disposed in the first mold unit and / or the second mold unit; A nest constituting a part of the cavity, wherein the nest comprises a nest body made of zirconia ceramics, an active metal film formed on at least a part of the surface of the nest body, and a metal layer formed on the active metal film. A method of molding a molded article made of a thermoplastic resin using a mold assembly composed of: a first mold part and a second mold part are clamped, and a molten heat is formed in a cavity. After introducing the molten thermoplastic resin from the thermoplastic resin introduction section, the heat A method for molding a molded article made of a thermoplastic resin, comprising cooling and solidifying a plastic resin, opening the mold, and taking out the molded article from a mold. 36. (A) a mold comprising a first mold part and a second mold part, wherein a cavity is formed at the time of mold clamping; and (B) a first mold part or a second mold part. A molten thermoplastic resin introduction unit for introducing the molten thermoplastic resin into the cavity, which is disposed in the mold unit, and (C) disposed in the first mold unit and / or the second mold unit; A nest constituting a part of the cavity, wherein the nest uses a mold assembly composed of a nest body made of conductive zirconia ceramics and a metal layer formed on a surface of at least a part of the nest body. A method of molding a molded article made of a thermoplastic resin, wherein a first mold part and a second mold part are clamped, and a molten thermoplastic resin is introduced into a cavity from a molten thermoplastic resin introduction part. Later, the thermoplastic resin in the cavity is cooled and solidified, and then Performs opening, thermoplastic molding method of the resin-made molded article characterized by taking out the molded product from the mold.