JP2002225080A - Molding method for resin product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method to advantageously mold a resin product constitut ed in such a manner that a plurality of primary molded articles are bonded through a secondary molded article made of a fiber reinforced resin with an excellent strength. SOLUTION: A first cavity to provide the secondary molded article is formed at the assembled area of the plurality of primary molded articles which are arranged while being assembled with each other. At the same time, a second cavity which communicates with the first cavity is formed. Under this state, a second resin material comprising a fiber reinforced resin material is injected into the first cavity in such a manner that the second resin material may be branched in the first cavity. In the meantime, at the communicated area of the first cavity with the second cavity, the second resin material which is branched in the first cavity is merged. Then, at the merged area of the second resin material in the first cavity, the flowing direction of the second resin material is changed in such a manner that the second resin material may flow from the inside of the first cavity to the inside of the second cavity.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of molding a resin product, and more particularly to a method of forming a secondary molded fiber reinforced resin in a state where a plurality of primary molded products are assembled to each other. The present invention relates to a method for advantageously molding a resin product integrally joined via a molded product.

[0002]

BACKGROUND ART Conventionally, resin products having a hollow shape, etc.
When molding a resin product that is difficult to mold by a single injection molding operation by using an injection molding method, for example, the following molding method is employed. That is, first, a plurality of primary molded products having a divided body form of a target hollow resin product are molded by predetermined primary molding by mold molding using the first resin material, and then the injection molded mold is formed. In the mold, at least a part of the cavity surface is formed by the surfaces of the assembly portions of the plurality of primary molded products assembled together, while setting the plurality of primary molded products together. The formed cavity is formed so as to surround the assembly site of the plurality of primary molded products. Then
Into such a cavity, a second resin material is injected through a plurality of gates, for example, to divide the inside of the cavity, and to divide the second resin material in the cavity at a predetermined position in the cavity. By joining, the cavity is filled with the second resin material to form a secondary molded product having a shape corresponding to the cavity, and to be fused to a plurality of primary molded product assembly sites, respectively. By letting it through, through the secondary molded article,
A plurality of primary molded articles are integrally joined to obtain a target hollow resin product.

In general, when obtaining a resin product having excellent strength, it is effective to use a fiber-reinforced resin material capable of forming a high-strength molded product. Therefore, even in the resin molding method as described above, by using a fiber-reinforced resin material as the second resin material that gives the secondary molded product, a plurality of primary moldings that can be joined via a high-strength secondary molded product are used. It is expected that the strength of the joining portion of the product, and further, the strength of the target resin product as a whole can be increased.

However, in the conventional method of molding a resin molded article as described above, a general resin molding is used to reliably fuse a secondary molded article to a plurality of mutually assembled primary molded articles. Compared to the case of performing an injection molding operation adopted when molding a product, a second resin material that gives a secondary molded product is injected at a high temperature, and the second resin material is compared in the cavity. In practice, even if a fiber-reinforced resin material is used as the material for forming the secondary molded product, the strength of the joints of multiple primary molded products and the overall resin product Was not able to be increased to the extent that it was sufficiently satisfactory.

[0005] That is, when the above-described method for molding a resin molded article is performed using a fiber reinforced resin as the second resin material for providing the secondary molded article, the fiber reinforced resin material injected into the cavity is large. When the fiber-reinforced resin materials are separated from each other, they are strongly collided with each other when the separated fiber-reinforced resin materials merge, and a large number of reinforcing fibers scattered inside the vicinity of the confluence interface of the fiber-reinforced resin materials. On the other hand, the large flow pressure of the fiber-reinforced resin material is applied intensively, so that the large number of reinforcing fibers do not intersect and become entangled with each other.
Orientation in the upright direction, as a result, in a secondary molded article molded with such a fiber reinforced resin material, the strength of the portion given at the confluence of the fiber reinforced resin material,
It will be significantly reduced as compared with other parts.

For this reason, in the conventional resin product molding method, even if a secondary molded product is molded from a fiber-reinforced resin material,
Variations inevitably occur in the strength of the joining portions of a plurality of primary molded articles joined via such secondary molded articles, and therefore, it is extremely difficult to mold a resin product having excellent strength. It was.

[0007]

The present invention has been made in view of the circumstances described above, and a problem to be solved is a state in which a plurality of primary molded products are assembled together. Below, the fiber-reinforced resin material is injected into the cavity in which at least a part of the cavity surface is formed on the surface of the assembly site of the plurality of primary molded articles so as to be diverted in the cavity, By filling the fiber reinforced resin material into the cavity, the fiber reinforced resin material is filled into the cavity to form a secondary molded product, and a plurality of primary products are formed through the secondary molded product. By integrally joining the molded articles, when molding the desired resin product, the fiber reinforced resin material, which divides the first cavity, merges with the fiber reinforced resin material. By a number of reinforcing fibers interspersed within the vicinity of the confluence interface of the resin material, it relaxes eliminated or is to be oriented in an upright direction, in the secondary molded article,
It is possible to sufficiently secure the strength of the portion composed of the merging portions of the fiber reinforced resin material, and further, the strength of the entire joining portion of the plurality of primary molded products joined via such a secondary molded product, Another object of the present invention is to provide a method capable of reliably forming a resin molded product having excellent strength.

[0008]

According to the present invention, in order to solve such a problem, after forming a plurality of primary molded articles using a first resin material, the plurality of primary molded articles are assembled with each other. Forming a first cavity in which at least a part of the cavity surface is constituted by the surface of each of the assembly sites in the plurality of primary molded articles, and thereafter, the first cavity is formed of a fiber-reinforced resin material. A second resin material is injected so as to be diverted in the first cavity, and the second resin material diverted in the first cavity is joined at a predetermined position in the first cavity. By causing the first cavity to be filled with the second resin material, and forming a secondary molded product having a shape corresponding to the first cavity,
A method for molding a resin product in which the plurality of primary molded products are integrally joined via the secondary molded product by fusing to the respective assembly sites in the plurality of primary molded products, Forming a second cavity communicating with the junction of the second resin material in the first cavity, the second resin material diverting in the first cavity, in the first cavity After merging at the merging site, the flow direction of the second resin material is changed at the merging site in the first cavity so as to flow from the first cavity toward the second cavity. The gist of the present invention is a method of molding a resin product characterized by being changed.

In short, in the method of molding a resin product according to the present invention, when molding a resin product obtained by integrally joining a plurality of primary molded products via a secondary molded product, Injected into a first cavity having a shape corresponding to the first cavity, the fiber resin material that gives a secondary molded product that divides the inside of the first cavity, joins at a joining portion in the first cavity, Since the flow direction is changed so that it is allowed to flow into the second cavity communicating with the confluence site in the first cavity, the fiber-reinforced resin material that gives the secondary molded product is Even if the fiber is injected so as to be diverted at a high speed into the first cavity, immediately after the fiber-reinforced resin material that diverges in the first cavity merges, the diverted fiber Each flow tip of the plasticized resin material is caused to flow into the second cavity, so that a large flow pressure of the fiber-reinforced resin material is dispersed in a large number in the vicinity of the confluence interface of the fiber-reinforced resin material. Can be advantageously prevented from acting intensively on the reinforcing fibers.

Therefore, according to the method of the present invention, when the fiber-reinforced resin materials diverging in the first cavity merge, a large number of reinforcing fibers scattered inside the vicinity of the confluence interface of the fiber-reinforced resin materials are mutually connected. In a secondary molded article molded with such a fiber reinforced resin material, which is oriented in an upright direction without being entangled with and entangled with the fiber reinforced resin material, the strength of the portion given at the confluence of the fiber reinforced resin material is It can be effectively prevented that the temperature is significantly reduced as compared with the site.

Therefore, according to the method for molding a resin product according to the present invention as described above, it is possible to effectively and sufficiently improve the strength of the secondary molded product by using the fiber reinforced resin material, and to form the secondary molded product. It is possible to stably increase the overall strength of the joining portions of the plurality of primary molded articles joined via the same, and it is possible to reliably mold a resin product having excellent strength.

According to one preferred embodiment of the method for molding a resin product according to the present invention, after the molding of the secondary molded product, the second molded product which has flowed into the second cavity is formed. The molded body molded from the resin material is removed. As a result, unnecessary portions are removed from the intended resin product, and the appearance of the resin molded product can be advantageously enhanced.

According to another advantageous aspect of the method for molding a resin product according to the present invention, a first mold and a first mold are opposed to each other and are perpendicular to the facing direction. A first mold and a second mold that are displaceable from each other in different directions, and at each of the first and second positions, a second mold that is moldable with the first mold is used. Having the second mold positioned in the first position, the first mold and the second mold are matched to form the plurality of primary molded articles. The first mold and the second mold are matched while the second mold is positioned at the second position while the primary molding cavity is formed. By this means, a state in which the plurality of primary molded products molded in the primary molded product molding cavity are assembled to each other. In conjunction with the set, said first cavity to provide the secondary molded article, it configured mold so that said second cavity communicating are formed is used.

By employing such a configuration, it is possible to mold the primary molded article and the secondary molded article using the same molding die, thereby improving the efficiency of the molding operation of the intended resin product. Therefore, the reduction of the molding cost can be advantageously achieved.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, in order to clarify the present invention more specifically, the configuration of a method for molding a resin product according to the present invention will be described in detail with reference to the drawings.

First, FIG. 1 schematically shows an example of a resin product molded in accordance with the method of the present invention in a longitudinal sectional form. As is apparent from FIG. 1, the resin product 10 is assembled by assembling a left casing 12 and a right casing 14 as primary molded articles, which are opened in one direction, at their opening end faces. Body 16 as a secondary molded product in a frame state
, And are integrally joined.

More specifically, the left casing 12 and the right casing 14 constituting the resin product 10 are formed of the same olefin resin material and have the same rectangular shape. On the other hand, the joined body 16 is formed of a matrix of an olefin-based resin material that provides the left and right housings 12 and 14, and is fused to the left and right housings 12 and 14 in which a large number of glass fibers are dispersed. Left and right housings 1 made of a glass fiber reinforced resin material that can be attached
With a rectangular frame shape slightly larger than 2,14,
It is configured.

In the left housing 12 and the right housing 14 made of such a resin material, a concave groove 18 having a predetermined depth is continuously formed in the opening end surface of the left housing 12 in the circumferential direction. On the other hand, on the open end face of the right housing 14,
A ridge 20 having a size that can be fitted into the concave groove 18 provided on the opening end surface of the left housing 12 is integrally formed so as to extend continuously in the circumferential direction. Further, outer flange portions 22 and 24 having a predetermined height are integrally provided around the outer peripheral surfaces of the openings of the left and right housings 12 and 14, respectively.

Then, the ridge 20 of the right housing 14 is fitted into the concave groove 18 of the left housing 12 so that the left housing 1
2 and the respective open end surfaces of the right housing 14 and the outer flange portions 22 and 24 of the left and right housings 12 and 14 are opposed to each other. With the joined body interposed between the opposing surfaces of the outer flange portions 24, the left housing 12 and the right housing 14
6 are fused and joined to both side surfaces in the thickness direction. Also, here, the left and right housings 12,
At the joint surface of the outer flange portions 22 and 24 to the joined body 16 at 14, two ridges 26 are provided respectively, and the joined body 16 of each of the flange portions 22 and 24 is provided.
The bonding strength of each of the outer flange portions 22 and 24 to the bonded body 16 is sufficiently increased by increasing the bonding area of the outer flange portions 22 and 24.

Thus, in the present embodiment, the left and right housings 12 and 14 assembled with the resin products 10 butted against each other, and the joined body 1 for joining them together.
6 as a whole, and is constituted by a hollow article having a rectangular cylindrical shape with bottoms on both sides in the vertical direction.

By the way, the resin product 10 having such a structure is advantageously molded according to a procedure described later. In this case, for example, an injection molding having a structure as shown below is used. A mold is used.

That is, as is clear from FIGS. 2 and 3, the injection mold 28 used in the present embodiment is
Provided in a fixed position with respect to the immovable fixed plate 30;
The fixed die 32 as the first die and the fixed plate 30 are opposed to each other, and can be moved toward and away from the fixed plate 30 in the left-right direction, which is the opposite direction to the fixed plate 30, by a known driving mechanism (not shown). And a movable die 36 as a second die attached to the movable plate 34 thus mounted. A slide base 38 in the shape of a housing is interposed between the movable die 36 and the movable plate 34. Further, a lower side wall of the slide base 38 is provided by a known hydraulic mechanism (not shown). A cylinder 40 that is extended and contracted in the up-down direction is mounted in a state where the cylinder 40 is fixed to the lower surface of the movable die 36 at the tip.

Thus, in the injection mold 28, the movable mold 36 is moved toward and away from the fixed mold 32 in the left-right direction as the movable board 34 moves toward and away from the fixed board 30. The mold is opened / closed, and the expansion and contraction operation of the cylinder 40
The upper and lower side walls of the slide base 38 can be vertically slid between the opposing surfaces (see FIG. 8).

A movable mold side cavity forming recess 42 is provided at a lower portion of the surface of the injection mold 28 opposite to the fixed mold 32 of the movable mold 36, while an upper portion thereof is provided. Is provided with a movable mold side cavity forming projection 44.

The movable mold side cavity forming recess 42 is
A shallow bottom outer concave portion 46 having a shape corresponding to the shape of the outer flange portion 22 of the left housing 12 of the resin product 10 on the side opposite to the joining surface; And an inner concave portion 48 having a shape corresponding to the outer shape of the main body portion.
And has a shape corresponding to the outer surface shape of. In addition, the movable mold side cavity forming convex portion 44 is
An outer ridge 50 having a shape corresponding to the shape of the joining surface of the outer flange portion 24 of the right housing 14 of the right housing 14, and a main body portion of the right housing 14 protruding inside the outer ridge 50. Inner convex portion 52 having a shape corresponding to the inner surface shape
And is formed in a shape corresponding to the inner surface shape of the right housing 14 as a whole.

Further, in the movable die 36, a shallow portion having a predetermined length is provided on both upper and lower sides of a portion where the movable die side cavity forming concave portion 42 is provided on a surface facing the fixed die 32. A bottom cavity forming groove 54 is provided one by one so as to cut out a portion of the outer concave portion 46 of the movable mold side cavity forming concave portion 42 which faces the opening peripheral portion in the vertical direction, and extend in the vertical direction. ing. In other words, these two cavity forming grooves 54, 5
Reference numeral 4 denotes a state in which one end in the longitudinal direction is open toward the inside of the outer concave portion 46 of the movable mold side cavity forming concave portion 42, and extends vertically upward and vertically downward from the outer concave portion 46, respectively. It is being done. Also,
In such a cavity forming groove 54, the depth of the opening side end of the movable mold side cavity forming concave portion 42 into the outer concave portion 46 gradually becomes shallower as approaching the opening portion. I have.

On the other hand, a fixed mold-side cavity forming convex portion 56 is provided at a lower portion of the surface of the fixed mold 32 facing the movable mold 36, and a fixed mold side cavity-forming concave portion is provided at an upper portion thereof. 58 are provided. The fixed mold side cavity forming protrusion 56 and the fixed mold side cavity forming recess 58 also correspond to the inner shape of the left housing 12 and the outer shape of the right housing 14 of the target resin product 10 as a whole, respectively. It is formed with a shape. That is,
The fixed mold-side cavity forming protrusion 56 has, like the movable mold-side cavity forming protrusion 44, an outer protrusion 50 having a shape corresponding to the shape of the joining surface in the outer flange portion 22 of the left housing 12, An inner protrusion 52 projecting inside the outer protrusion 50 and having a shape corresponding to the inner surface shape of the main body portion of the left housing 12; and forming a fixed mold side cavity. The concave portion 58 has a shape corresponding to the shape of the surface of the outer flange portion 24 of the right housing 14 opposite to the joining surface, similarly to the movable mold side cavity forming concave portion 42, and has a shallow bottom outer concave portion 46. And an inner concave portion 48 having a shape corresponding to the outer shape of the main body portion of the right housing 14.

2 and 3, reference numeral 60 denotes a resin material injected from a nozzle 62 of an injection molding machine (not shown).
The sprue 64 leads to the surface of the fixed mold 32 facing the movable mold 36, and the sprue 64 extends in a direction perpendicular to the paper surface of FIGS. 2 and 3 with respect to the surface of the fixed mold 32 facing the movable mold 36. It is a runner formed so as to extend toward it. Further, although not shown, a gap between the outer convex portion 50 and the inner convex portion 52 of the fixed mold side cavity forming convex portion 56 is provided on a surface of the fixed mold 32 opposed to the movable mold 36. The runner 6 extends into the outer recess 46 of the side cavity forming recess 58.
4 and the outer convex portion 50 and the inner convex portion 52 thereof.
2 and the inside of the outer concave portion 46 are provided with gates that open at two positions in a direction perpendicular to the paper surface of FIGS. 2 and 3, respectively.

The movable mold 3 having such a structure is
In the injection mold 28 having the fixed mold 6 and the fixed mold 32, as shown in FIG. 3, the tip of the cylinder 40 attached to the lower surface of the movable mold 36 is shrunk to move the movable mold 36. The movable plate 34 is moved closer to the fixed plate 30 in a state where the movable plate 34 is brought into contact with the lower side wall portion of the slide base 38 and is located at the slide movement lower limit position as the first position. By matching the fixed mold 32 with the movable mold side cavity forming concave portion 42 and the fixed mold side cavity forming convex portion 56, the desired resin product 1 is formed.
A left housing molding cavity 66 as a primary molded product molding cavity having a shape corresponding to the left housing 12 is formed while the movable mold side cavity forming protrusion 44 and the fixed mold side cavity forming recess 58 are formed. A right housing molding cavity 68 serving as another primary molded product molding cavity having a shape corresponding to the right housing 14 of the resin product therebetween.
Is formed.

The left and right housing molding cavities 6
6 and 68, the cavity forming grooves 5 of the movable mold 36 are provided above and below the left housing molding cavity 66, respectively.
4 and 54 and the opposing surface of the stationary mold 32 opposed thereto, spaces 70 and 70 are formed. As shown in FIG. 4, the outer projection 5 of the stationary mold side cavity forming projection 56 is formed.
0 protrudes into the outer concave portion 46 of the movable mold side cavity forming concave portion 42, and the left housing forming cavity 6
6, the opening of the cavity forming groove 54 to the outer concave portion 46 is closed at the side surface of the outer convex portion 50, and the space 70 has a closed state without any opening. It is supposed to be.

In the injection molding die 28, as shown in FIG. 5, the cylinder 40 is extended and the movable die 36 is brought into contact with the upper side wall of the slide base 38. The movable mold 36 and the fixed mold 3 are positioned in the slide movement upper limit position as the second position.
2 by molding, between the movable mold side cavity forming recess 42 and the fixed mold side cavity forming recess 58,
A resin product accommodating cavity 72 corresponding to the overall outer shape of the target resin product 10 is formed. When such a resin product accommodation cavity 72 is formed, the fixed mold-side cavity forming recess 58 is provided with respect to the outer recess 46 of the movable mold-side cavity forming recess 42.
Of the movable mold 3 because the outer concave portion 46 of the
6, the spaces 70, 70 surrounded by the cavity forming grooves 54, 54 and the opposing surface of the fixed mold 32 opposed thereto are opened into the outer concave portion 46 of the movable mold side cavity forming concave portion 42. Become.

7 and 8, the left housing 12 and the right housing 14 molded in the left and right housing molding cavities 66, 68 are moved to the movable mold side in accordance with the procedure described later. The movable product 36 and the fixed mold 32 are combined as described above to form the resin product accommodating cavity 72 in a state where the resin product accommodation cavity 72 is formed in the cavity forming recess 42 and the fixed mold side cavity forming recess 58, respectively. The left housing 12 and the right housing 14 abut their respective open end faces, and the left and right housings 12,
14 with the outer flange portions 22 and 24 facing each other and assembled in the resin product accommodating cavity 7.
2 to be set.

Further, since the left housing 12 and the right housing 14 are housed in the resin product housing cavity 72 in this manner, the left and right housings 12, A bonded body forming cavity 74 as a first cavity having a shape corresponding to the bonded body 16 is formed between the facing surfaces of the outer flange portions 22 and 24 of the respective 14.
Further, the movable mold 36 is surrounded by the cavity forming grooves 54 and 54 and the opposing surface of the fixed mold 32 opposed thereto, and is opened toward the inside of the outer concave portion 46 of the movable mold side cavity forming concave portion 42. , Communicating spaces 70, 70
Are formed as tab portion forming cavities 76, 76 as second cavities, which are formed at the time of molding the joined body 16 and provide a tab portion described later.

When the intended resin product 10 is molded by using the injection mold 28 having the above-described structure, first, as shown in FIG. The movable mold 36 and the fixed mold 32 that have been pressed are combined to form a left housing molding cavity 66 and a right housing molding cavity 68.

Next, as shown in FIG. 6, an olefin resin material 78 as a first resin material in a molten state is injected from a nozzle of an injection machine, and the resin material is passed through a sprue 60, a runner 64, and a gate (not shown). 78,
It is introduced and filled into the left housing molding cavity 66 and the right housing molding cavity 68, respectively. At this time, as described above, since the spaces 70 and 70 provided above and below the left housing molding cavity 66 are in a sealed state, the olefin resin material 78 enters the spaces 70 and 70. Is stopped.

Subsequently, the olefin resin material 78 filled in the left housing molding cavity 66 and the right housing molding cavity 68 is solidified, and the left housing 12 and the right housing 14 are combined with the molding cavities 66. , 68, the molded left casing 12 is held in the movable mold cavity forming recess 42, while the right casing 14 is fixed in the fixed mold cavity molding recess, as shown in FIG. 58
The movable mold 36 and the fixed mold 32 are
Once open the mold.

Next, as shown in FIG.
The movable mold 36 and the fixed mold 32 are matched in a state where the movable mold 36 is slid to the slide movement upper limit position, and the movable mold side cavity forming recesses 42 of the movable mold 36 and
By forming the resin product accommodating cavity 72 between the fixed mold 32 and the fixed mold cavity forming recess 58, the left casing held in the movable mold side and the fixed mold cavity forming recesses 42 and 58, respectively. 12 and the right housing 14
The resin product accommodating cavity 72 is abutted against each other at the opening end faces thereof and assembled so that the outer flange portions 22 and 24 face each other.
Set so that it is housed inside. This also gives
As described above, in the resin product accommodating cavity 72, the joined body molding cavity 74 is provided between the outer flange portions 22 and 24 facing surfaces of the left and right housings 12 and 14b.
And a tab portion forming cavity 76 communicating with the joined body forming cavity 74 is formed above and below the resin product accommodating cavity 72, respectively.

Thereafter, as shown in FIG. 9, an olefin-based fiber-reinforced resin material 80 as a second resin material in a molten state is injected from a nozzle 60 of the injection machine, and is injected through a sprue 60, a runner 64, and a gate (not shown). Then, the fiber reinforced resin material 80 is introduced into the joined body forming cavity 74.

As described in detail above, in the mold 28 for the injection molding machine used in the present embodiment, the gate as the entrance of the fiber reinforced resin material 80 into the joined body molding cavity 74 is shown in FIG. In FIG. 9, since two portions are formed in a direction perpendicular to the paper surface, in this step, the fiber-reinforced resin material 80 introduced into the joined body forming cavity 74 through such two gates is used. In this case, the flow is diverted from the arrangement portions of the two gates to the communication portion with the tub forming cavities 76, 76 shown in FIG.

When the fiber reinforced resin material 80 diverted in the joined body molding cavity 74 reaches the portion of the joined body molding cavity 74 which communicates with the tab molding cavities 76, 76, the diverted fibers are separated. The respective flow fronts of the reinforced resin material 80 are joined at such a communicating portion, whereby the inside of the joined body forming cavity 74 is filled with the fiber reinforced resin material 80. Also, on the other hand, the bonded body molding cavity 74
As shown in FIG. 10, the flow direction of the fiber-reinforced resin material that has been merged at the communication portion with the tab portion forming cavities 76 and 76 is changed toward the inside of the tab portion forming cavity 76. Flows into the tab portion forming cavity 76 through the opening of the cavity forming groove 54 forming the tab portion forming cavity 76 to the outer concave portion 46 of the movable mold side forming cavity forming concave portion 42 forming the joined body forming cavity 74. I'm sullen.

At this time, the bonded body forming cavity 7
As will be described later, the fiber reinforced resin material 80 diverted in the inside 4 is compared with the outer flange portions 22 and 24 of the left and right housings 12 and 14 which have been molded earlier so as to be reliably fused. From the point where the high temperature state is maintained, the respective flow front ends are caused to collide with each other at a large speed at the communication part with the tab part forming cavity 76 in the joined body forming cavity 74, As described above, the flow direction of each of these flow tips is
Since it is changed in the direction toward the inside of the tab portion molding cavity 76, as shown in FIG.
Of the many reinforcing fibers 82 included in the fiber reinforced resin material 80, it is possible to prevent the reinforcing fibers 82 scattered inside the vicinity of the confluence interface 84 from acting intensively. The reinforcing fibers 82 in the vicinity of the confluence interface 84 in the fiber-reinforced resin material 80 are interspersed and entangled with each other without being oriented upright, and are scattered.

Subsequently, as described above, the fiber reinforced resin material 80 filled in the bonded body forming cavity 74 and the tab portion forming cavities 76, 76 is solidified, respectively, as shown in FIG. A molded body 16 having a shape corresponding to the molded body forming cavity 74 is formed, and the bonded body 16 is fused to the left housing 12 and the right housing 14 at their contact surfaces.
The left and right housings 12 and 14 are integrally joined via the joining body 16, while having a shape corresponding to each tab portion forming cavity 76 and being thinner than other portions. Tab portion 8 joined to joined body 16 at the site
6 are each molded to obtain an intermediate product 88. And
Thereafter, the movable mold 36 and the fixed mold 32 are opened to release the intermediate product 88 from the injection molding mold 28, and then the tab portion 8 integrally formed with the intermediate product 88 is opened.
6 is removed from the joined body 16 at the thin joint portion by cutting or the like, thereby obtaining the desired resin product 10.

As described above, in the present embodiment, the joint molded cavity 74 formed between the opposing surfaces of the outer flange portions 22 and 24 of the left casing 12 and the right casing 14 formed earlier. By injecting the fiber reinforced resin material 80 at a high speed so as to diverge, and joining the diverted fiber reinforced resin material 80 at the communicating portion of the bonded body forming cavity 74 with the tab portion forming cavities 76, 76, the joining is performed. When the inside of the body molding cavity 74 is filled with the fiber reinforced resin material 80 and the joined body 16 that integrally joins the outer flange portions 22 and 24 is formed, when the divided fiber reinforced resin material 80 merges, The flow direction of the material 80 is changed from the inside of the joined body forming cavity 74 to the inside of the tab portion forming cavities 76, 76, so that the separated fibers are separated. Reinforced resin material 80 even though caused to collide at high speed, such fiber-reinforced resin material 80
Are scattered in such a manner that the reinforcing fibers 82 in the vicinity of the confluent interface 84 are interlaced and entangled with each other without being oriented upright, so that the fiber-reinforced resin material 80 in the molded joined body 16 is formed. It can be effectively prevented that the strength of the part provided at the confluence part becomes lower than that of the other parts.

Therefore, according to the present embodiment, the strength of the entire joined body 16 made of the fiber-reinforced resin material 80 can be sufficiently increased, and the left housing joined via such a high-strength joined body 16. It is possible to stably increase the bonding strength between the housing 12 and the right housing 14, and thus it is possible to reliably obtain the resin product 10 having excellent strength.

In the present embodiment, after the injection molding operation using the injection mold 28, the joining portion of the tabs 86, 86, which are removed from the intermediate product 88, with the joined body 16 is a thin portion. The unnecessary tab portions 86, 86 can be easily removed from the portion, and the desired external shape of the resin product 10 can be more easily and reliably adjusted. It is.

Further, in this embodiment, after the left housing 12 and the right housing 14 are formed between the movable mold 36 and the fixed mold 32, the left and right housings 12, 14 are held. In this state, by merely sliding the movable mold 36 in the vertical direction, a bonded body molding cavity 74 for providing a bonded body 16 for bonding them can be formed between the left housing 12 and the right housing 14. Since the configured injection molding die 28 is used, the left and right casings 12 and 14 formed first and the joined body 16 formed after the molding are formed in the same molding die 28. Thus, both the efficiency of the molding operation of the intended resin product 10 and the reduction of the molding cost can be advantageously achieved.

In the above-described embodiment, since the joined body forming cavity 74 is communicated with the tab portion forming cavities 76 at the site where the fiber reinforced resin material 80 joins, The residual gas in the cavity 74 and the gas generated from the fiber reinforced resin material 80 entangled in the respective flow front ends of the fiber reinforced resin material 80 that separates The gas is discharged from the cavity 74 into the tab portion forming cavities 76 and 76, whereby insufficient joining of the fiber reinforced resin material 80 due to entrainment of gas into the joining interface 84 of the fiber reinforced resin material 80 can be advantageously avoided or prevented. The fiber reinforced resin material 80 which can be suppressed
Can be more sufficiently fused to the left and right housings 12 and 14. As a result, the joining strength between the left housing 12 and the right housing 14 is more sufficiently increased, and the resin product 10 exhibiting more excellent strength can be reliably molded.

Although the specific configuration of the present invention has been described in detail above, this is merely an example, and the present invention is not limited by the above description.

For example, the resin material for providing the left housing 12 and the right housing 14 is not limited to those shown in the above-described embodiment, and any olefin resin may be used as long as it has compatibility. A thermoplastic resin material or a thermosetting resin material of the same type other than the materials or different types from each other can be appropriately used as a material for forming the left and right housings 12 and 14.

Further, the fiber-reinforced resin material forming the joined body 16 is not particularly limited to the one shown in the above embodiment, but is fused to the resin material that provides the left and right housings 12 and 14. Any possible fiber reinforced resin material can be used, and furthermore, various known reinforced fibers, such as glass fiber and carbon fiber, are also used in such fiber reinforced resin material. It can be done.

Further, in the above embodiment, the movable mold 36
Are slid to two positions, and are matched with the fixed mold 32 at one of the two slid positions to form the left and right housing molding cavities 66, 68. While holding the molded left and right housings 12, 14, the outer flanges of the left and right housings 12, 14 are formed by being matched with the fixed mold 32 at another sliding position. Between the opposing surfaces of the portions 22 and 24, the joined body molding cavity 7 is provided.
4 is used, and the left and right housings 12 and 14 and the joined body 16 are used.
Are molded in the same molding die 28. For example, the left and right housings 12, 14 and the joined body 16 are separated from each other by using different molding dies. It is also possible to mold by a molding operation.

In this case, the left and right housings 1
Although the joints 2 and 14 may be formed by a method other than the injection molding method, the joined body 16 is injected so that the fiber-reinforced resin material forming the joined body 16 is branched into a molding cavity for providing the joined body. Injection molding technique will be adopted. And, as such, the left and right housings 12, 1
Even when the joined body 16 is injection-molded separately from 4,
After the fiber-reinforced resin material diverted in the molding cavity providing the joined body 16 is merged, it is necessary to change the flow direction from inside the molding cavity to another cavity communicating therewith. That goes without saying.

Even when the left and right housings 12 and 14 and the joined body 16 are molded using the same molding die, the structure of the molding die is the same as that of the above-described embodiment. It is by no means limited to what is shown in the form.

That is, for example, while only one gate is provided to be connected to the joint-forming cavity 74, the fiber-reinforced resin material 80 introduced from the one gate is divided into two in the joint-forming cavity 74. It is also possible to provide an appropriate branching section for allowing the fiber-reinforced resin material 80 injected into the bonded body forming cavity 74 to be separated in the bonded body forming cavity 74.

Further, the positions at which the cavity forming concave portions 42, 58 and the cavity forming convex portions 44, 56 formed on the opposing surfaces of the movable mold 36 and the fixed mold 32 are changed, or according to the formation positions. Alternatively, the sliding direction of the movable mold 36 may be changed.

The arrangement position and the number of the tab portion forming cavities 76 communicated with the joined body forming cavity 74 are determined by the fiber reinforced resin material 80 diverted in the joined body forming cavity 74. It can be changed appropriately depending on the merging point in 74 and the number thereof. In addition, such a tab portion forming cavity 7
If the shape and size of 6 are designed so as not to reduce the flow rate of the fiber-reinforced resin material 80 at the confluence in the joined body molding cavity 74, they are not limited to those shown in the above embodiment. It is not.

In addition, in the above-described embodiment, the present invention relates to a case where the left casing and the right casing made of a resin material are integrally joined via a joint made of a fiber-reinforced resin material. Although a specific example of a method applied to a method of forming a hollow resin product having a rectangular cylindrical shape with a bottom portion on both sides in the vertical direction has been described, the present invention provides a method in which a plurality of primary molded products are interposed through secondary molded products. It can be advantageously applied to any of the resin product molding methods that are integrally joined together.
Of course.

In addition, although not enumerated one by one, the present invention
Based on the knowledge of those skilled in the art, various changes, modifications, improvements and the like can be performed in embodiments, and unless such embodiments depart from the spirit of the present invention.
Both are included in the scope of the present invention,
Needless to say.

[0059]

As is apparent from the above description, according to the resin product molding method according to the present invention, the strength of the secondary molded product can be effectively and sufficiently improved by using the fiber reinforced resin material. It is possible to stably increase the overall strength of the joining portion of a plurality of primary molded products joined via such a secondary molded product, thereby reliably molding a resin product having excellent strength. It is possible.

[Brief description of the drawings]

FIG. 1 is an explanatory longitudinal sectional view showing an example of a resin product molded according to the method of the present invention.

FIG. 2 is an explanatory longitudinal sectional view showing an example of an injection mold used when molding the resin product shown in FIG. 1 according to the method of the present invention.

FIG. 3 is a view for explaining an example of a use state of the injection mold shown in FIG. 2, in which the movable mold and the fixed mold are moved in a state where the movable mold is positioned at a lower limit position of slide movement. This shows a state where the types have been matched.

4 is an enlarged sectional explanatory view of a main part in FIG. 2;

5 is a view for explaining another example of a use state of the injection mold shown in FIG. 2, wherein the movable mold and the fixed mold are arranged in a state where the movable mold is positioned at a slide movement upper limit position. 2 shows a state in which is matched.

FIG. 6 is an explanatory view showing an example of a step of molding a resin product according to the method of the present invention, wherein a left housing molding cavity and a right housing molding cavity formed between a movable die and a fixed die are provided; This shows a state where the resin material is injected and filled.

FIG. 7 is an explanatory view showing another example of a step of molding a resin product according to the method of the present invention, in a state where the molded left housing and right housing are held by a movable mold and a fixed mold, respectively. Shows the state in which the movable mold and the fixed mold are opened.

FIG. 8 is an explanatory view showing still another example of a step of molding a resin product according to the method of the present invention, wherein a molded left casing and a right casing are mutually assembled in a resin product accommodating cavity. The joint body is formed in a state, and a joined body forming cavity is formed between the facing surfaces of the outer flange portions of the left and right housings. Further, a tab part forming cavity communicating with the joined body forming cavity is formed above and below the joined body forming cavity. FIG.

FIG. 9 is an explanatory view showing another example of a step of molding a resin product according to the method of the present invention, in which a fiber-reinforced resin material is injected into a joined body molding cavity, and the inside of the joined body molding cavity and a tab portion are formed. The figure shows a state in which a fiber reinforced resin material is filled in the molding cavity.

FIG. 10 is an enlarged sectional explanatory view of a main part in FIG. 9;

FIG. 11 is an explanatory view taken along the line XX in FIG. 10;

FIG. 12 is an explanatory view showing still another example of the step of molding a resin product according to the method of the present invention, in which a movable mold and a fixed mold are opened, and a molded intermediate product is injected into a mold for injection molding. 2 shows a state taken out of the apparatus.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 Resin product 12 Left housing 14 Right housing 16 Joined body 28 Injection molding die 32 Fixed mold 36 Movable mold 66 Left casing molding cavity 68 Right casing molding cavity 72 Resin product accommodating cavity 74 Joint molding cavity 76 Tab Part molding cavity 78 Olefin resin material 80 Fiber reinforced resin material 82 Reinforcing fiber

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F202 AB25 AG07 AH55 AH56 AH58 CA11 CB21 CC01 CK06 CK17 CK42 CK52 CL09 4F206 AB25 AG07 AH55 AH56 AH58 JA07 JB21 JC01 JC09 JF02 JL02 JN12 JN22 JN25 JN33 J81

Claims (3)

[Claims] After molding a plurality of primary molded products using a first resin material, the plurality of primary molded products are assembled with each other, while the plurality of primary molded products are assembled with each other at a surface of each assembly site in the plurality of primary molded products. Forming a first cavity in which at least a part of the cavity surface is formed, and then diverting a second resin material made of a fiber-reinforced resin material into the first cavity in the first cavity; And the second resin material, which diverges in the first cavity, is allowed to join at a predetermined position in the first cavity, so that the second resin material flows into the first cavity. Filling the material to form a secondary molded product having a shape corresponding to the first cavity,
A method of molding a resin product in which the plurality of primary molded products are integrally joined via the secondary molded product by fusing to the respective assembly sites in the plurality of primary molded products, Forming a second cavity communicating with the confluence site of the second resin material in the first cavity, the second resin material diverting in the first cavity, in the first cavity After flowing at the merging point in the first cavity, the flow direction of the second resin material is changed so as to flow from the inside of the first cavity toward the inside of the second cavity. A method for molding a resin product, wherein 2. The method according to claim 1, wherein after the molding of the secondary molded article, a molded article molded with the second resin material that has flowed into the second cavity is removed. Molding method for resin products. 3. A first mold and a first mold, which are opposed to the first mold, and are displaceable to mutually different first and second positions in a direction perpendicular to the facing direction. In each of the first and second positions, having the first mold and a second mold that is moldable, wherein the second mold is positioned at the first position. Below, the first mold and the second mold are matched to form a primary molding cavity for providing the plurality of primary moldings, while the second mold is formed by the second molding. The first mold and the second mold are matched under the state where they are located at the second position, so that a plurality of primary molded articles molded in the primary molded article molding cavity are interconnected. The first cavity which is set in an assembled state and which gives the secondary molded product, 3. The method for molding a resin product according to claim 1, wherein a molding die configured to form the second cavity communicating with the resin is used.