JP2011177935A - Core-back type foamed resin molding mold, core-back type foamed resin molding method, and container-like foamed molding - Google Patents
Core-back type foamed resin molding mold, core-back type foamed resin molding method, and container-like foamed molding Download PDFInfo
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- JP2011177935A JP2011177935A JP2010042241A JP2010042241A JP2011177935A JP 2011177935 A JP2011177935 A JP 2011177935A JP 2010042241 A JP2010042241 A JP 2010042241A JP 2010042241 A JP2010042241 A JP 2010042241A JP 2011177935 A JP2011177935 A JP 2011177935A
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- 238000000465 moulding Methods 0.000 title claims abstract description 76
- 239000011347 resin Substances 0.000 title claims abstract description 62
- 229920005989 resin Polymers 0.000 title claims abstract description 62
- 238000000034 method Methods 0.000 title claims abstract description 13
- 239000011324 bead Substances 0.000 claims abstract description 24
- 239000006260 foam Substances 0.000 claims description 16
- 238000005187 foaming Methods 0.000 claims description 11
- 238000010097 foam moulding Methods 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 abstract description 9
- 230000008719 thickening Effects 0.000 abstract 2
- 239000011342 resin composition Substances 0.000 description 11
- 230000015572 biosynthetic process Effects 0.000 description 7
- 239000002994 raw material Substances 0.000 description 4
- 238000002474 experimental method Methods 0.000 description 3
- 239000008188 pellet Substances 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 239000000654 additive Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 235000013372 meat Nutrition 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Landscapes
- Injection Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
Description
本発明は、成形型のコアバックにより溶融樹脂を発泡させて成形を行うコアバック式発泡樹脂成形型及びコアバック式発泡樹脂成形方法並びに容器状発泡成形品に関する。 The present invention relates to a core-back type foamed resin mold, a core-back type foamed resin molding method, and a container-shaped foam-molded article that are molded by foaming a molten resin with a core back of a mold.
例えば、射出成形品であるエンジンカバー(特許文献1参照)や、樹脂トレイ、樹脂キャップなどの容器状の樹脂成形品は、一般に、側壁の先端縁に尖ったエッジが形成されることを防止するために、側壁の先端面に丸みを帯びた突条である玉縁が形成される。 For example, an engine cover (see Patent Document 1) that is an injection-molded product, a container-shaped resin molded product such as a resin tray or a resin cap, generally prevents a sharp edge from being formed at the leading edge of the side wall. Therefore, a bead that is a rounded protrusion is formed on the front end surface of the side wall.
しかしながら、玉縁を従来の射出成形により形成する場合には、図12に示すように成形型1のうち、側壁の先端面を成形する部分に円弧面を有した玉縁用の溝2を加工する必要があり、型製作費が高価になるという問題があった。 However, when the ball edge is formed by conventional injection molding, as shown in FIG. 12, a groove 2 for the ball edge having an arc surface in the portion of the mold 1 where the front end surface of the side wall is formed is processed. There is a problem that the mold manufacturing cost becomes expensive.
本発明は、上記事情に鑑みてなされたもので、型製作費を抑えつつ容器状発泡成形品の側壁の先端面に玉縁を設けることが可能なコアバック式発泡樹脂成形型及びコアバック式発泡樹脂成形方法並びに容器状発泡成形品の提供を目的とする。 The present invention has been made in view of the above circumstances, and a core back type foamed resin mold and a core back type mold capable of providing a bead on the front end surface of a side wall of a container-like foam molded product while suppressing mold production costs. An object is to provide a foamed resin molding method and a container-like foam molded product.
上記目的を達成するためになされた請求項1の発明に係る容器状発泡成形品(50)は、コアバック式発泡成形法により発泡成形される容器状発泡成形品(50)であって、側壁(52)における先端縁全体に、先端縁以外の部分より厚肉の先端厚肉部(53)を設け、先端厚肉部(53)の端面でもある側壁(52)の先端面に丸みを帯びた突条である玉縁(55)を形成したところに特徴を有する。 A container-like foam molded article (50) according to the invention of claim 1 made to achieve the above object is a container-like foam molded article (50) molded by a core back type foam molding method, and has a side wall. The entire tip edge in (52) is provided with a tip thick part (53) that is thicker than the part other than the tip edge, and the tip face of the side wall (52) that is also the end face of the tip thick part (53) is rounded. It is characterized by the formation of a bead (55) which is a protruding ridge.
請求項2の発明は、請求項1に記載の容器状発泡成形品(50)において、側壁(52)の先端縁を内側に増肉して先端厚肉部(53)を形成したところに特徴を有する。 The invention of claim 2 is characterized in that, in the container-like foam molded article (50) of claim 1, the tip edge of the side wall (52) is increased inwardly to form the tip thick part (53). Have
請求項3の発明は、請求項1又は2に記載の容器状発泡成形品(50)において、側壁(52)の先端寄り位置から先端に向かって徐々に肉厚が増すように増肉して先端厚肉部(53)を形成したところに特徴を有する。 According to a third aspect of the present invention, in the container-like foamed molded product (50) according to the first or second aspect, the thickness is increased so that the thickness gradually increases from the position closer to the tip of the side wall (52) toward the tip. It is characterized in that the tip thick part (53) is formed.
請求項4の発明は、請求項1乃至3の何れか1の請求項に記載の容器状発泡成形品(50)において、側壁(52)のうち先端縁以外の部分の肉厚(t2)は、1.5〜3.0[mm]であり、先端厚肉部(53)の肉厚(t3)は、2.2〜3.0[mm]であるところに特徴を有する。 According to a fourth aspect of the present invention, in the container-like foamed molded article (50) according to any one of the first to third aspects, the wall thickness (t2) of the portion other than the tip edge of the side wall (52) is 1.5 to 3.0 [mm], and the thickness (t3) of the tip thick portion (53) is 2.2 to 3.0 [mm].
上記目的を達成するためになされた請求項5の発明に係るコアバック式発泡樹脂成形型(21)は、容器状発泡成形品(50)を発泡成形するためのコアバック式発泡樹脂成形型(21)であって、容器状発泡成形品(50)における側壁(52)の先端縁全体に先端縁以外の部分より厚肉の先端厚肉部(53)を成形するための厚肉成形部(24B)を設けると共に、コアバックにより、先端厚肉部(53)の端面でもある側壁(52)の先端面に丸みを帯びた突条である玉縁(55)を形成可能であるところに特徴を有する。 A core back type foamed resin mold (21) according to the invention of claim 5 made to achieve the above object is a core back type foamed resin mold for foam molding of a container-like foam molded product (50). 21), a thick molded portion (53) for forming a thick tip portion (53) thicker than a portion other than the tip edge on the entire tip edge of the side wall (52) of the container-like foam molded product (50). 24B) and a ball back (55), which is a rounded protrusion, can be formed on the front end surface of the side wall (52) which is also the end surface of the thick end portion (53) by the core back. Have
請求項6の発明は、請求項5に記載のコアバック式発泡樹脂成形型(21)において、厚肉成形部(24B)のうち側壁(52)の外面を成形するための外側成形面(23S)は、コアバック式発泡樹脂成形型(21)の開閉方向に対して傾斜する一方、厚肉成形部(24B)のうち側壁(52)の内面を成形するための内側成形面(22S)は、コアバック式発泡樹脂成形型(21)の開閉方向と平行であるところに特徴を有する。 According to a sixth aspect of the present invention, in the core back type foamed resin mold (21) of the fifth aspect, the outer molding surface (23S) for molding the outer surface of the side wall (52) in the thick molded portion (24B). ) Is inclined with respect to the opening / closing direction of the core back type foamed resin molding die (21), while the inner molding surface (22S) for molding the inner surface of the side wall (52) of the thick molding portion (24B) is The core back type foamed resin mold (21) is characterized by being parallel to the opening and closing direction.
請求項7の発明は、請求項5又は6に記載のコアバック式発泡樹脂成形型(21)において、側壁(52)の先端縁以外の部分を成形するための側壁主体成形部(24A)におけるキャビティ(24)の幅(c2)をコアバック前の状態で2.0[mm]未満としかつ、厚肉成形部(24B)の端面におけるキャビティ(24)の幅(c3)をコアバック前の状態で2.2[mm]以上となるように構成したところに特徴を有する。 The invention according to claim 7 is the core back type foamed resin mold (21) according to claim 5 or 6, wherein the side wall main molding part (24A) for molding a part other than the tip edge of the side wall (52). The width (c2) of the cavity (24) is less than 2.0 [mm] before the core back, and the width (c3) of the cavity (24) at the end face of the thick molded part (24B) is the same as that before the core back. It is characterized by being configured to be 2.2 [mm] or more in the state.
上記目的を達成するためになされた請求項8の発明に係るコアバック式発泡樹脂成形法は、コアバック式発泡樹脂成形型(21)のキャビティ(24)に溶融樹脂を充填した後でコアバックを行うことで容器状発泡成形品(50)を発泡成形するコアバック式発泡樹脂成形法において、容器状発泡成形品(50)の側壁(52)における先端縁全体に先端縁以外の部分より厚肉の先端厚肉部(53)を成形するための厚肉成形部(24B)を、キャビティ(24)に設けておき、コアバックにより、先端厚肉部(53)の端面でもある側壁(52)の先端面に丸みを帯びた突条である玉縁(55)を形成するところに特徴を有する。 In order to achieve the above object, the core back type foamed resin molding method according to the invention of claim 8 is the core back type foamed resin molding die (21) filled with the molten resin after filling the cavity (24). In the core back type foamed resin molding method in which the container-like foamed molded product (50) is foam-molded, the entire tip edge of the side wall (52) of the container-shaped foamed molded product (50) is thicker than the portion other than the tip edge. A thick-walled molded part (24B) for molding the thick-walled tip thick part (53) is provided in the cavity (24), and the side wall (52 which is also the end face of the thick-walled part (53) is provided by the core back. ) Has a feature in that a ball edge (55), which is a rounded protrusion, is formed on the front end surface of ().
請求項9の発明は、請求項8に記載のコアバック式発泡樹脂成形法において、側壁(52)の先端縁以外の部分を成形するための側壁主体成形部(24A)におけるキャビティ(24)の幅(c2)を2.0[mm]未満としかつ、厚肉成形部(24B)の端面におけるキャビティ(24)の幅(c3)を2.2[mm]以上としておき、そのキャビティ(24)に溶融樹脂を充填するようにしたところに特徴を有する。 According to a ninth aspect of the present invention, in the core back type foamed resin molding method according to the eighth aspect, the cavity (24) in the side wall main molding portion (24A) for molding a portion other than the tip edge of the side wall (52). The width (c2) is set to less than 2.0 [mm], and the width (c3) of the cavity (24) at the end face of the thick molded portion (24B) is set to 2.2 [mm] or more, and the cavity (24) It is characterized in that it is filled with molten resin.
[請求項1,2,3及び4の発明]
本発明の構成によれば、容器状発泡成形品(50)を成形するための発泡成形型のうち容器状発泡成形品(50)の側壁(52)の先端面を成形する部分を平坦にしておいても、発泡成形型をコアバックしたときに、先端厚肉部(53)の端面が隆起して玉縁(55)を形成することができる。即ち、発泡成形型に玉縁用の溝を形成しなくても玉縁(55)を形成することができ、発泡成形型の型製作費を抑えることができる。また、側壁(52)の先端縁以外の部分を先端縁に比べて薄肉にすることで、容器状発泡成形品(50)の軽量化及び原材料である樹脂の削減を図ることができる。具体的には、請求項4の発明のように、側壁(52)のうち先端縁以外の部分の肉厚(t2)を1.5〜3.0[mm](好ましくは、2.0[mm])とし、先端厚肉部(53)の肉厚(t3)を2.2〜3.0[mm](好ましくは、2.4[mm])とすることで、所定の強度を維持しつつ良好な玉縁を形成することができる。
[Inventions of Claims 1, 2, 3 and 4]
According to the structure of this invention, the part which shape | molds the front end surface of the side wall (52) of a container-like foaming molded product (50) among the foaming molds for shape | molding a container-like foaming molded product (50) is made flat. However, when the foaming mold is core-backed, the end face of the thick end portion (53) is raised to form the bead (55). That is, the ball edge (55) can be formed without forming the groove for the bead on the foaming mold, and the mold production cost of the foam mold can be suppressed. Further, by making the portion other than the front end edge of the side wall (52) thinner than the front end edge, it is possible to reduce the weight of the container-like foamed molded product (50) and reduce the resin as the raw material. Specifically, as in the invention of claim 4, the thickness (t2) of the side wall (52) other than the tip edge is 1.5 to 3.0 [mm] (preferably 2.0 [ mm]), and the thickness (t3) of the tip thick part (53) is 2.2 to 3.0 [mm] (preferably 2.4 [mm]), thereby maintaining a predetermined strength. However, a good bead can be formed.
ここで、先端厚肉部(53)は、側壁(52)の先端縁を外側に増肉して形成してもよいし、請求項2の発明のように、側壁(52)の先端縁を内側に増肉して形成してもよい。請求項2の発明によれば、先端厚肉部(53)を目立たなくすることができる。 Here, the distal end thick portion (53) may be formed by increasing the distal end edge of the side wall (52) outward, or the distal end edge of the side wall (52) may be formed as in the invention of claim 2. You may increase the thickness on the inner side. According to invention of Claim 2, a front-end | tip thick part (53) can be made not conspicuous.
また、先端厚肉部(53)は、側壁(52)の先端寄り位置で段付き状に肉厚が増すように増肉して形成してもよいし、請求項3の発明のように側壁(52)の先端寄り位置から先端に向かって徐々に肉厚が増すように増肉して形成してもよい。請求項3の発明によれば、増肉による段差形成を回避することがができ、先端厚肉部(53)における引っ掛かりを防止することができる。 Further, the tip thick part (53) may be formed by increasing the thickness so that the thickness increases in a stepped manner near the tip of the side wall (52), or the side wall as in the invention of claim 3. It may be formed by increasing the thickness so that the thickness gradually increases from the position closer to the tip of (52) toward the tip. According to the third aspect of the present invention, it is possible to avoid the formation of a step due to the increase in thickness, and it is possible to prevent the tip thick portion (53) from being caught.
[請求項5及び8の発明]
請求項5及び8の発明によれば、コアバック式発泡樹脂成形型(21)のうち、容器状発泡成形品(50)の側壁(52)の先端面を成形する部分を平坦にしておいても、コアバック式発泡樹脂成形型(21)をコアバックしたときに、先端厚肉部(53)の端面が隆起して玉縁(55)を形成することができる。即ち、コアバック式発泡樹脂成形型(21)に玉縁用の溝を形成しなくても玉縁(55)を形成することができ、型製作費を抑えることができる。また、本発明のコアバック式発泡樹脂成形型(21)により成形された容器状発泡成形品(50)は、側壁(52)の先端縁だけが厚肉であり、側壁(52)の先端縁以外の部分が先端縁に比べて薄肉になるので、容器状発泡成形品(50)の軽量化及び原材料である樹脂の削減を図ることができる。
[Inventions of Claims 5 and 8]
According to invention of Claim 5 and 8, the part which shape | molds the front end surface of the side wall (52) of a container-like foaming molding product (50) among the core back type foaming resin molding dies (21) is made flat. In addition, when the core-back type foamed resin mold (21) is core-backed, the end surface of the thick-walled portion (53) is raised to form the bead (55). That is, the ball edge (55) can be formed without forming the groove for the ball edge in the core-back type foamed resin mold (21), and the mold manufacturing cost can be suppressed. Further, in the container-like foamed molded article (50) molded by the core back type foamed resin mold (21) of the present invention, only the leading edge of the side wall (52) is thick, and the leading edge of the side wall (52). Since the other portions are thinner than the leading edge, it is possible to reduce the weight of the container-like foamed molded product (50) and to reduce the resin as the raw material.
[請求項6の発明]
請求項6のコアバック式発泡樹脂成形型(21)により成形された容器状発泡成形品(50)は、側壁(52)の先端縁を内側に増肉して先端厚肉部(53)が形成されるので、先端厚肉部(53)を目立たなくすることができる。さらに、先端厚肉部(53)は、側壁(52)の先端寄り位置から先端に向かって徐々に肉厚が増すように増肉して形成されるので、増肉によるに段差形成を回避することができ、先端厚肉部(53)における引っ掛かりを防止することができる。
[Invention of claim 6]
The container-like foamed molded product (50) molded by the core-back type foamed resin mold (21) according to claim 6 has an increased thickness on the leading edge of the side wall (52) so that the thickened tip (53) Since it is formed, the tip thick part (53) can be made inconspicuous. Further, the thick-walled portion (53) is formed by increasing the thickness so that the thickness gradually increases from the position closer to the tip of the side wall (52) toward the tip, so that the formation of a step due to the increased thickness is avoided. It is possible to prevent the tip thick portion (53) from being caught.
[請求項7及び9の発明]
本発明者は、側壁(52)の先端面(先端厚肉部(53)の端面)をコアバック前の状態で2.0[mm]未満とした場合に玉縁(55)が形成されず、2.2[mm]以上にした場合に玉縁(55)が形成されることを実験により確認した。そして、請求項7及び9の発明によれば、側壁(52)の先端縁以外の部分を成形するための側壁主体成形部(24A)におけるキャビティ(24)の幅(c2)をコアバック前の状態で2.0[mm]未満としかつ、厚肉成形部(24B)の端面(側壁(52)の先端面)におけるキャビティ(24)の幅(c3)をコアバック前の状態で2.2[mm]以上となるようにしたので、側壁(52)の先端縁以外の部分を薄肉にして容器状発泡成形品(50)の軽量化及び原材料である樹脂の削減を図りつつ、玉縁(55)を形成することができる。
[Inventions of Claims 7 and 9]
The inventor does not form a bead (55) when the front end surface of the side wall (52) (the end surface of the front end thick portion (53)) is less than 2.0 [mm] in the state before the core back. , 2.2 [mm] or more, it was confirmed by experiments that a bead (55) was formed. According to the inventions of claims 7 and 9, the width (c2) of the cavity (24) in the side wall main molding part (24A) for molding a part other than the tip edge of the side wall (52) is set to the value before the core back. The width (c3) of the cavity (24) on the end face (tip face of the side wall (52)) of the thick molded part (24B) is set to less than 2.0 [mm] in the state and 2.2 in the state before the core back. [Mm] or more, so that the portion other than the tip edge of the side wall (52) is thinned to reduce the weight of the container-like foamed molded product (50) and reduce the resin as a raw material, 55) can be formed.
以下、本発明に係るの容器状発泡成形品及びコアバック式発泡樹脂成形型並びにコアバック式発泡樹脂成形方法の一実施形態を、図1〜図9に基づいて説明する。図1(A)には、本発明に係る「容器状発泡成形品」の一例としての自動車のエンジンカバー50が示されている。エンジンカバー50は、図示しないエンジンに上方から対向する主板壁51と、主板壁51の外縁から下方に垂れた側壁52とを有した扁平容器状をなしており、側壁52は主板壁51から離れる(先端に向かう)に従って拡開するように傾斜している。 Hereinafter, an embodiment of a container-like foamed molded article, a core back type foamed resin mold, and a core back type foamed resin molding method according to the present invention will be described with reference to FIGS. FIG. 1A shows an engine cover 50 for an automobile as an example of a “container-like foamed product” according to the present invention. The engine cover 50 has a flat container shape having a main plate wall 51 facing an engine (not shown) from above and a side wall 52 hanging downward from the outer edge of the main plate wall 51, and the side wall 52 is separated from the main plate wall 51. It is inclined so as to expand (toward the tip).
側壁52のうち先端から先端寄り位置までの先端縁は、側壁52における先端縁以外の部分(以下、「側壁主体部54」という)に比べて厚肉な先端厚肉部53になっている。具体的には、側壁主体部54は、主板壁51から先端厚肉部53との境界部にかけて略一定の肉厚であるのに対し、先端厚肉部53は側壁主体部54から離れるに従って徐々に肉厚が増すように増肉されている。より詳細には、図1(B)に示すように、先端厚肉部53は、側壁52の先端縁を内側に増肉して形成されている。そして、先端厚肉部53の端面でもある側壁52の先端面には、丸みを帯びて側壁52の全体に亘って連続した突条である玉縁55が設けられている。この玉縁55を設けたことにより、側壁52の先端縁のエッジが無くなり、例えば、エンジンカバー50の着脱時に側壁52の先端縁に手を掛けた際の角張った感触を無くす或いは和らげることができる。 A tip edge of the side wall 52 from the tip to the position near the tip is a thick tip portion 53 that is thicker than a portion of the side wall 52 other than the tip edge (hereinafter referred to as “side wall main portion 54”). Specifically, the side wall main portion 54 has a substantially constant thickness from the main plate wall 51 to the boundary portion between the front end thick portion 53 and the front end thick portion 53 gradually increases as it moves away from the side wall main portion 54. The thickness is increased to increase the thickness. More specifically, as shown in FIG. 1B, the distal end thick portion 53 is formed by increasing the distal end edge of the side wall 52 inward. A bevel 55 is provided on the front end surface of the side wall 52, which is also the end surface of the front end thick portion 53, which is a rounded and continuous ridge over the entire side wall 52. By providing this bead 55, the edge of the leading edge of the side wall 52 is eliminated, and for example, the angular feel when the hand is put on the leading edge of the side wall 52 when the engine cover 50 is attached or detached can be eliminated or alleviated. .
ここで、完成品のエンジンカバー50の各部の寸法は、例えば、以下のようになっている。即ち、主板壁51の肉厚(図2の「t1」参照)は2.7[mm]であり、側壁主体部54の肉厚(図2の「t2」参照)は2.0[mm]であり、先端厚肉部53の端面における肉厚(図2の「t3」参照)は2.4[mm]である。また、玉縁55の隆起量(図2の「t4」参照)は、例えば、1.0[mm]である。 Here, the dimensions of each part of the finished engine cover 50 are, for example, as follows. That is, the thickness of the main plate wall 51 (see “t1” in FIG. 2) is 2.7 [mm], and the thickness of the side wall main portion 54 (see “t2” in FIG. 2) is 2.0 [mm]. And the thickness (see “t3” in FIG. 2) at the end face of the tip thick portion 53 is 2.4 [mm]. Further, the amount of protrusion of the ball edge 55 (see “t4” in FIG. 2) is, for example, 1.0 [mm].
なお、エンジンカバー50のうちエンジンとの対向面には、主板壁51を覆うように図示しないスポンジ構造の発泡吸音部材が固着されている。 A foam sound absorbing member having a sponge structure (not shown) is fixed to the surface of the engine cover 50 facing the engine so as to cover the main plate wall 51.
本実施形態のエンジンカバー50の構造に関する説明は以上である。次に、このエンジンカバー50の製造方法について説明する。図3(A)には、エンジンカバー50を成形するためのコアバック式発泡樹脂成形機20に備えたコアバック式発泡樹脂成形型21(以下、「成形型21」という)が示されている。この成形型21は、例えば、水平方向に型開き可能な固定型22と可動型23とからなる。その可動型23には、エンジンカバー50の平面形状と同形状の開口を有したメイン凹部23Aが備えられ、固定型22にはそのメイン凹部23A内に嵌合可能なメイン突部22Aが設けられている。そして、メイン凹部23Aにメイン突部22Aを突入させて固定型22と可動型23とが型閉じされ、その型閉じ状態で、メイン凹部23Aの奥面及び内側面と、メイン突部22Aの先端面及び外側面との間にエンジンカバー50を成形するためのキャビティ24が形成される。 This completes the description of the structure of the engine cover 50 of the present embodiment. Next, a method for manufacturing the engine cover 50 will be described. 3A shows a core back type foamed resin molding die 21 (hereinafter referred to as “molding die 21”) provided in the core back type foamed resin molding machine 20 for molding the engine cover 50. FIG. . The mold 21 includes, for example, a fixed mold 22 and a movable mold 23 that can be opened in the horizontal direction. The movable mold 23 is provided with a main recess 23A having an opening having the same shape as the planar shape of the engine cover 50, and the fixed mold 22 is provided with a main projection 22A that can be fitted into the main recess 23A. ing. The main protrusion 22A is inserted into the main recess 23A, and the fixed mold 22 and the movable mold 23 are closed. With the mold closed, the back and inner surfaces of the main recess 23A and the tip of the main protrusion 22A are closed. A cavity 24 for forming the engine cover 50 is formed between the surface and the outer surface.
より具体的には、固定型22と可動型23のうち開閉方向(水平方向)で対向する対向面22T,23Tの間でエンジンカバー50の主板壁51が成形され、メイン凹部23Aの内側面23Sと、メイン突部22Aの外側面22Sとの間でエンジンカバー50の側壁52が成形される。そして、固定型22には、コアバック式発泡樹脂成形機20のシリンダー(図示せず)に連通したライナー25が形成され、そのライナー25からキャビティ24内に溶融状態の樹脂組成物が充填される。 More specifically, the main plate wall 51 of the engine cover 50 is formed between the opposed surfaces 22T and 23T facing each other in the opening / closing direction (horizontal direction) of the fixed die 22 and the movable die 23, and the inner side surface 23S of the main recess 23A. And the side wall 52 of the engine cover 50 is formed between the outer surface 22S of the main projection 22A. The fixed mold 22 is formed with a liner 25 communicating with a cylinder (not shown) of the core back type foamed resin molding machine 20, and the melted resin composition is filled into the cavity 24 from the liner 25. .
ここで、キャビティ24のうち側壁52を成形する部分は、側壁主体部54を成形するための側壁主体成形部24Aと、先端厚肉部53を成形するための厚肉成形部24Bとから構成されている。側壁主体成形部24Aにおけるキャビティ幅は略一定であるのに対し、厚肉成形部24Bにおけるキャビティ幅は、側壁主体成形部24Aから離れるに従って幅広となっている。 Here, the portion of the cavity 24 where the side wall 52 is formed is composed of a side wall main body forming portion 24A for forming the side wall main body portion 54 and a thick wall forming portion 24B for forming the distal end thick portion 53. ing. While the cavity width in the side wall main molded part 24A is substantially constant, the cavity width in the thick wall molded part 24B becomes wider as the distance from the side wall main molded part 24A increases.
詳細には、図5に示すように、側壁52の外側面を成形するメイン凹部23Aの内側面23Sは、メイン凹部23Aの奥面から開口端に向かって拡開するように成形型21の開閉方向に対して傾斜している。これに対し、側壁52の内側面を成形するメイン突部22Aの外側面22Sは、側壁主体成形部24Aに対応する部分でメイン凹部23Aの内側面23Sと平行でありかつ、厚肉成形部24Bに対応する部分で成形型21の開閉方向と平行(即ち、水平)になっている。 Specifically, as shown in FIG. 5, the inner surface 23S of the main recess 23A for molding the outer surface of the side wall 52 opens and closes the mold 21 so as to expand from the inner surface of the main recess 23A toward the opening end. Inclined with respect to direction. On the other hand, the outer side surface 22S of the main projection 22A that molds the inner side surface of the side wall 52 is parallel to the inner side surface 23S of the main recess 23A at a portion corresponding to the side wall main molding portion 24A, and the thick molding portion 24B. Is parallel to the opening / closing direction of the mold 21 (ie, horizontal).
さて、成形型21は、型閉じ状態になると、図3(A)に示すように、可動型23が固定型22の所定箇所に当接して全閉位置に位置決めされる。そして、図3(B)に示すように、全閉位置から可動型23を所定量b1だけ固定型22から離脱する側に後退させたコアバック位置に保持可能となっている。その可動型23が全閉位置からコアバック位置に移動するコアバック動作により、キャビティ24の各部で幅が広がる。 Now, when the mold 21 is in the mold closed state, as shown in FIG. 3A, the movable mold 23 comes into contact with a predetermined portion of the fixed mold 22 and is positioned at the fully closed position. As shown in FIG. 3B, the movable mold 23 can be held at the core back position where the movable mold 23 is moved backward from the fixed mold 22 by a predetermined amount b1 from the fully closed position. Due to the core back operation in which the movable mold 23 moves from the fully closed position to the core back position, the width of each part of the cavity 24 increases.
コアバック動作前(図3(A)参照)のキャビティ24の各部の幅は以下のようになっている。即ち、キャビティ24のうち主板壁51を成形する部分である固定型22及び可動型23の対向面22T,23Tの間の幅は、1.5[mm](図5の「c1」参照)になっており、側壁主体成形部24Aの幅は、1.5[mm](図5の「c2」参照)となっている。また、厚肉成形部24Bの幅は、上述したように側壁主体成形部24Aから離れるに従って幅広となっており、厚肉成形部24Bの端面(側壁52の先端面)における幅が、2.4[mm](図5の「c3」参照)になっている。そして、コアバック動作では、可動型23が、例えば、1.2[mm](図3(B)の「b1」参照)だけ固定型22から離脱する側に後退し、コアバック動作後のキャビティ24の各部の幅が、上述したエンジンカバー50の完成品の肉厚となる。 The width of each part of the cavity 24 before the core back operation (see FIG. 3A) is as follows. That is, the width between the opposed surfaces 22T and 23T of the fixed mold 22 and the movable mold 23, which are the portions of the cavity 24 where the main plate wall 51 is molded, is 1.5 [mm] (see “c1” in FIG. 5). Thus, the width of the side wall main molded portion 24A is 1.5 [mm] (see “c2” in FIG. 5). Further, as described above, the thickness of the thick molded portion 24B becomes wider as the distance from the side wall main molded portion 24A increases, and the width of the end surface of the thick molded portion 24B (the front end surface of the side wall 52) is 2.4. [Mm] (see “c3” in FIG. 5). In the core back operation, the movable mold 23 moves backward to the side away from the fixed mold 22 by, for example, 1.2 [mm] (see “b1” in FIG. 3B), and the cavity after the core back operation is performed. The width of each part 24 is the thickness of the finished product of the engine cover 50 described above.
コアバック式発泡樹脂成形機20に投入する樹脂組成物は、エンジンカバー50の主成分となるベース樹脂に、化学発泡剤及びその他の添加材を、所定の割合で含んだものである。この樹脂組成物は、例えば、上記した材料を溶融混練したものを予めペレットに成形しておき、そのペレットをコアバック式発泡樹脂成形機20の図示しないシリンダに投入する。 The resin composition to be charged into the core back type foamed resin molding machine 20 includes a base resin as a main component of the engine cover 50 and a chemical foaming agent and other additives in a predetermined ratio. For example, the resin composition obtained by melting and kneading the above-mentioned materials is formed into pellets in advance, and the pellets are put into a cylinder (not shown) of the core back type foamed resin molding machine 20.
次いで、可動型23を全閉位置に配置した状態で(図3(A)、図4(A)及び図5参照)、溶融状態の樹脂組成物をライナー25からキャビティ24に充填する(図4(B)及び図6(A)参照)。すると、溶融状態の樹脂組成物が、キャビティ24内に充填される。そして、樹脂組成物がキャビティ24全体に行き渡ったら、図4(B)及び図6(A)に示すように、樹脂組成物の表面部分のみが固化して内部が溶融状態になっている間に可動型23を全閉位置からコアバック位置(図3(B)、図4(C)及び図6(B)参照)に移動する。これにより、上記したキャビティ24の隙間が広げられて、溶融状態の樹脂組成物が発泡する。この結果、エンジンカバー50は、図4(C)及び図6(B)に示すように、表面近傍が非発泡樹脂層50Aで構成され、内部が発泡樹脂層50Bで構成された内部発泡構造になる。 Next, in a state where the movable mold 23 is disposed at the fully closed position (see FIGS. 3A, 4A, and 5), the resin composition in a molten state is filled into the cavity 24 from the liner 25 (FIG. 4). (See (B) and FIG. 6 (A)). Then, the molten resin composition is filled in the cavity 24. When the resin composition has spread over the entire cavity 24, as shown in FIGS. 4B and 6A, only the surface portion of the resin composition is solidified and the inside is in a molten state. The movable mold 23 is moved from the fully closed position to the core back position (see FIGS. 3B, 4C, and 6B). Thereby, the clearance gap of the above-mentioned cavity 24 is expanded, and the resin composition in a molten state foams. As a result, as shown in FIGS. 4 (C) and 6 (B), the engine cover 50 has an internal foam structure in which the vicinity of the surface is constituted by the non-foamed resin layer 50A and the inside is constituted by the foamed resin layer 50B. Become.
ここで、可動型23を全閉位置にしてキャビティ24内に樹脂組成物を充填した段階で、側壁52の先端面(先端厚肉部53の端面)は、固定型22のうちメイン突部22Aの外側面に形成された段差面22Dによって平坦面に成形される(図6(A)参照)。ところが、可動型23をコアバック動作させて固定型22の段差面22Dがコアバック動作前の位置より所定量b1だけ後退すると、樹脂組成物の発泡により、平坦面であった側壁52の先端面が隆起して、丸みを帯びた玉縁55が形成される。 Here, at the stage where the movable mold 23 is in the fully closed position and the resin composition is filled into the cavity 24, the front end surface of the side wall 52 (the end surface of the front end thick portion 53) is the main protrusion 22 A of the fixed mold 22. Is formed into a flat surface by a step surface 22D formed on the outer surface (see FIG. 6A). However, when the movable mold 23 is core-backed and the stepped surface 22D of the fixed mold 22 is retracted by a predetermined amount b1 from the position before the core-back operation, the front end surface of the side wall 52 that was a flat surface is caused by foaming of the resin composition. Is raised to form a rounded bead 55.
キャビティ24内の樹脂全体が固化したら、可動型23を固定型22から離間させて成形型21からエンジンカバー50を取り出す。その後、エンジンカバー50を図示しない金型にインサートして、図示しないスポンジ構造の吸音発泡部材を成形し、エンジンカバー50の全ての製造工程が完了する。 When the entire resin in the cavity 24 is solidified, the movable mold 23 is separated from the fixed mold 22 and the engine cover 50 is taken out from the mold 21. Thereafter, the engine cover 50 is inserted into a mold (not shown) to form a sound absorbing foam member having a sponge structure (not shown), and all manufacturing steps of the engine cover 50 are completed.
このように本実施形態によれば、容器状発泡成形品としてのエンジンカバー50を成形するための成形型21のうち、エンジンカバー50の側壁52の先端面を成形する部分(段差面22D)を平坦にしておいても、成形型21をコアバックしたときに、先端厚肉部53の端面が隆起して玉縁55を形成することができる。即ち、成形型21に玉縁用の溝を形成しなくても玉縁55を形成することができ、成形型21の型製作費を抑えることができる。また、側壁52における先端縁以外の部分(側壁主体部54)を先端縁(先端厚肉部53)に比べて薄肉にすることで、エンジンカバー50の軽量化及び原材料である樹脂組成物の削減を図ることができる。 Thus, according to this embodiment, the part (step surface 22D) which shape | molds the front end surface of the side wall 52 of the engine cover 50 among the shaping | molding die 21 for shape | molding the engine cover 50 as a container-like foaming molded product. Even if it is flat, when the mold 21 is core-backed, the end face of the tip thick portion 53 can be raised to form the bead 55. That is, the bead 55 can be formed without forming the bead groove in the forming die 21, and the mold manufacturing cost of the forming die 21 can be suppressed. Further, by reducing the portion of the side wall 52 other than the front end edge (side wall main portion 54) thinner than the front end edge (front end thick portion 53), the engine cover 50 is reduced in weight and the resin composition as a raw material is reduced. Can be achieved.
また、本実施形態のエンジンカバー50は、先端厚肉部53を側壁52の内側に増肉して形成したので、側壁52の外側に増肉して形成した場合に比べて先端厚肉部53を目立たなくすることができる。さらに、先端厚肉部53は、側壁52の先端寄り位置から先端に向かって徐々に肉厚が増すように増肉して形成したので、増肉による段差形成を回避することができ、先端厚肉部53における物品や手触りの引っ掛かりを防止することができる。 Further, the engine cover 50 according to the present embodiment is formed by increasing the thickness of the tip thick portion 53 on the inside of the side wall 52, so that the tip thick portion 53 is increased as compared with the case of increasing the thickness on the outside of the side wall 52. Can be made inconspicuous. Furthermore, since the tip thick portion 53 is formed by increasing the thickness so that the thickness gradually increases from the position closer to the tip of the side wall 52 toward the tip, formation of a step due to the increase in thickness can be avoided. It is possible to prevent the meat part 53 from being caught on the article or the touch.
[成形実験]
成形型21をコアバックさせる前の側壁52の先端面の幅(図5の「c3」参照)と、コアバック後に形成される玉縁55との関係を調べるべく、成形実験を行った。具体的には、コアバック前の側壁52の先端面の幅が2.0[mm]、2.2[mm]、2.4[mm]となるキャビティ24を有した成形型21を用意し、各成形型21を用いて上述したコアバック式発泡樹脂成形方法によりエンジンカバー50の成形を行った。そして、成形後のエンジンカバー50における側壁52の先端面を観察した。図7〜図9は成形後の側壁52の先端縁の拡大写真であり、図10は側壁52の先端縁を対比するための概念図である。
[Molding experiment]
A molding experiment was conducted in order to examine the relationship between the width of the front end surface of the side wall 52 before the mold 21 was core-backed (see “c3” in FIG. 5) and the bead 55 formed after the core back. Specifically, a mold 21 having a cavity 24 in which the width of the front end surface of the side wall 52 before the core back is 2.0 [mm], 2.2 [mm], and 2.4 [mm] is prepared. The engine cover 50 was molded by the core back type foamed resin molding method described above using each mold 21. And the front end surface of the side wall 52 in the engine cover 50 after shaping | molding was observed. 7 to 9 are enlarged photographs of the leading edge of the side wall 52 after molding, and FIG. 10 is a conceptual diagram for comparing the leading edge of the side wall 52.
図7の写真及び図10の実線で示すように、コアバック前の側壁52の先端面の幅を2.0[mm]とした場合、成形後の側壁52の先端面に玉縁の形成は認められなかった。図8の写真及び図10の点線で示すように、コアバック前の側壁52の先端面の幅を2.2[mm]とした場合、成形後の側壁52の先端面の一部に玉縁55の形成が認められた。さらに、図9の写真及び図10の二点鎖線で示すように、コアバック前の側壁52の先端面の幅を2.4[mm]とした場合、成形後の側壁52の先端面の全体に比較的大きく隆起した玉縁55の形成が認めらた。 As shown by the photograph in FIG. 7 and the solid line in FIG. 10, when the width of the front end surface of the side wall 52 before the core back is 2.0 [mm], the formation of the bead on the front end surface of the side wall 52 after molding is as follows. I was not able to admit. As shown by the photograph in FIG. 8 and the dotted line in FIG. 10, when the width of the front end surface of the side wall 52 before core back is 2.2 [mm], a bead is formed on a part of the front end surface of the side wall 52 after molding. Formation of 55 was observed. Further, as shown by the photograph in FIG. 9 and the two-dot chain line in FIG. 10, when the width of the front end surface of the side wall 52 before core back is 2.4 [mm], the entire front end surface of the side wall 52 after molding is formed. The formation of a rim 55 having a relatively large protrusion was observed.
この実験結果から明らかなように、コアバック前の側壁52の先端面の幅(図5の「c3」参照)を2.2[mm]以上、好ましくは2.4[mm]以上にすると、成形型21に玉縁用の溝を形成しなくても玉縁55が形成可能であることが分かった。 As is apparent from the experimental results, when the width of the front end face of the side wall 52 before the core back (see “c3” in FIG. 5) is 2.2 [mm] or more, preferably 2.4 [mm] or more, It has been found that the bead 55 can be formed without forming a bead groove in the mold 21.
[他の実施形態]
本発明は、前記実施形態に限定されるものではなく、例えば、以下に説明するような実施形態も本発明の技術的範囲に含まれ、さらに、下記以外にも要旨を逸脱しない範囲内で種々変更して実施することができる。
[Other Embodiments]
The present invention is not limited to the above-described embodiment. For example, the embodiments described below are also included in the technical scope of the present invention, and various other than the following can be made without departing from the scope of the invention. It can be changed and implemented.
(1)前記実施形態では、本発明に係る「容器状発泡成形品」として、エンジンの上面を覆うエンジンカバー50を例示したが、エンジンの下面を覆うエンジンアンダーカバー、タイミングベルトカバー、オイルパン、内装パネル、その他、自動車部品に限定されないカバー、トレイ、キャップ、筐体等でもよい。 (1) In the above-described embodiment, the engine cover 50 covering the upper surface of the engine is exemplified as the “container-like foamed product” according to the present invention, but the engine undercover, the timing belt cover, the oil pan, which covers the lower surface of the engine, A cover, a tray, a cap, a housing, and the like that are not limited to interior panels and other automobile parts may be used.
(2)前記実施形態では、側壁52の先端縁を内側に増肉して先端厚肉部53を形成していたが、図10(A)〜同図(C)に示すように、側壁52の先端縁を外側に増肉して先端厚肉部53を形成してもよい。この場合、先端厚肉部53は、図10(A)及び同図(B)に示すように、側壁52の先端寄り位置から先端に向かって徐々に肉厚が増すように増肉して形成してもよいし、同図(C)に示すように、側壁52の先端寄り位置で段付き状に肉厚が増すように増肉して形成してもよい。 (2) In the above-described embodiment, the distal end edge of the side wall 52 is increased inward to form the distal end thick portion 53. However, as shown in FIGS. The distal end edge may be thickened outward to form the distal end thick portion 53. In this case, as shown in FIGS. 10A and 10B, the distal end thick portion 53 is formed by increasing the thickness so that the thickness gradually increases from the position closer to the distal end of the side wall 52 toward the distal end. Alternatively, as shown in FIG. 5C, the thickness may be increased so that the thickness increases stepwise at a position near the tip of the side wall 52.
(3)前記実施形態では、側壁52が主板壁51から先端縁に向かって拡開するように成形型21の開閉方向に対して傾斜していたが、図10(B)及び同図(C)に示すように、側壁52が成形型21の開閉方向と平行になっていてもよい。さらに、側壁52は、主板壁51と先端縁との間で湾曲又は屈曲していてもよい。 (3) In the above-described embodiment, the side wall 52 is inclined with respect to the opening / closing direction of the mold 21 so as to expand from the main plate wall 51 toward the leading edge, but FIG. 10B and FIG. ), The side wall 52 may be parallel to the opening / closing direction of the mold 21. Further, the side wall 52 may be curved or bent between the main plate wall 51 and the leading edge.
20 コアバック式発泡樹脂成形機
21 コアバック式発泡樹脂成形型
22D 段差面
24 キャビティ
24A 側壁主体成形部
24B 厚肉成形部
50 エンジンカバー(容器状発泡成形品)
52 側壁
53 先端厚肉部
54 側壁主体部
55 玉縁
20 Core Back Type Foamed Resin Molding Machine 21 Core Back Type Foamed Resin Mold 22D Stepped Surface 24 Cavity 24A Side Wall Main Molded Part 24B Thick Molded Part 50 Engine Cover (Container Foam Molded Product)
52 Side Wall 53 Tip Thick Part 54 Side Wall Main Part 55 Ball Edge
Claims (9)
側壁(52)における先端縁全体に、前記先端縁以外の部分より厚肉の先端厚肉部(53)を設け、前記先端厚肉部(53)の端面でもある前記側壁(52)の先端面に丸みを帯びた突条である玉縁(55)を形成したことを特徴とする容器状発泡成形品(50)。 A container-like foam molded article (50) that is foam-molded by a core-back foam molding method,
The tip end surface of the side wall (52) is provided on the entire tip edge of the side wall (52) with a tip thick part (53) that is thicker than the portion other than the tip edge, and is also the end face of the tip thick part (53). A container-like foamed molded article (50), characterized in that a rim (55), which is a rounded protrusion, is formed.
前記容器状発泡成形品(50)における側壁(52)の先端縁全体に前記先端縁以外の部分より厚肉の先端厚肉部(53)を成形するための厚肉成形部(24B)を設けると共に、
コアバックにより、前記先端厚肉部(53)の端面でもある前記側壁(52)の先端面に丸みを帯びた突条である玉縁(55)を形成可能なことを特徴とするコアバック式発泡樹脂成形型(21)。 A core-back type foamed resin mold (21) for foam-molding a container-like foam-molded product (50),
A thick molded part (24B) for forming a thick tip part (53) thicker than a part other than the tip edge is provided on the entire tip edge of the side wall (52) of the container-like foam molded product (50). With
A core back type characterized in that a ball edge (55), which is a rounded protrusion, can be formed on the front end surface of the side wall (52) which is also an end surface of the thick end portion (53) by the core back. Foamed resin mold (21).
前記厚肉成形部(24B)のうち前記側壁(52)の内面を成形するための内側成形面(22S)は、前記コアバック式発泡樹脂成形型(21)の開閉方向と平行であることを特徴とする請求項5に記載のコアバック式発泡樹脂成形型(21)。 The outer molding surface (23S) for molding the outer surface of the side wall (52) in the thick molded portion (24B) is inclined with respect to the opening / closing direction of the core back type foamed resin molding die (21). ,
The inner molding surface (22S) for molding the inner surface of the side wall (52) in the thick molded portion (24B) is parallel to the opening / closing direction of the core back type foamed resin molding die (21). The core back type foaming resin mold (21) according to claim 5, characterized by the above.
前記容器状発泡成形品(50)の側壁(52)における先端縁全体に前記先端縁以外の部分より厚肉の先端厚肉部(53)を成形するための厚肉成形部(24B)を、前記キャビティ(24)に設けておき、前記コアバックにより、前記先端厚肉部(53)の端面でもある前記側壁(52)の先端面に丸みを帯びた突条である玉縁(55)を形成することを特徴とするコアバック式発泡樹脂成形法。 In the core-back type foamed resin molding method in which the container-like foamed molded article (50) is foam-molded by filling the cavity (24) of the core-back-type foamed resin mold (21) with the molten resin and then performing the core back. ,
A thick molding part (24B) for molding a tip thick part (53) thicker than a part other than the tip edge over the entire tip edge of the side wall (52) of the container-like foam molded product (50), Provided in the cavity (24), by means of the core back, a bead (55) which is a rounded protrusion on the front end surface of the side wall (52) which is also an end surface of the thick end portion (53). A core back type foamed resin molding method characterized by forming.
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Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
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JPH11509490A (en) * | 1995-07-18 | 1999-08-24 | コーラルテック リミテッド | Molding |
JP2001502617A (en) * | 1996-10-17 | 2001-02-27 | コーラルテック リミテッド | Injection foam molding |
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JPH11509490A (en) * | 1995-07-18 | 1999-08-24 | コーラルテック リミテッド | Molding |
JP2001502617A (en) * | 1996-10-17 | 2001-02-27 | コーラルテック リミテッド | Injection foam molding |
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