JP2019098654A - 樹脂成形装置及び樹脂成形方法 - Google Patents
樹脂成形装置及び樹脂成形方法 Download PDFInfo
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Abstract
Description
図1は、本発明の実施形態に係る樹脂成形装置30(図2に示す)を使用した樹脂成形方法によって成形された樹脂製品1の断面図である。樹脂製品1は、例えば自動車の内装材、各種建築材等として使用することができる部材であり、樹脂製の基材10と、樹脂製の表皮材20とを備えている。基材10は、後述する発泡剤を含んだ基材成形用樹脂によって形成されたものであり、表皮材20によって覆われる被覆部11と、表皮材20によって覆われていない部位、即ち表皮材20から露出した露出部12とを有している。被覆部11及び露出部12は共に板状をなしている。尚、表皮材20は必須の部材ではなく、表皮材20を省略してもよい。
次に、図2に示す樹脂成形装置30の構成について説明する。樹脂成形装置30は、上述した図1に示す発泡層13を有する樹脂製の基材10と、該基材10に積層されて一体化された樹脂製の表皮材20とを備えた樹脂製品1を成形するための装置であり、固定金型(第2金型)31と、可動金型(第1金型)32と、型駆動装置33と、樹脂供給装置34とを備えている。
次に、上記のように構成された樹脂成形装置30を用いて樹脂製品1を成形する樹脂成形方法について説明する。樹脂成形方法は、発泡層24を有する樹脂製の基材10と、該基材10に積層されて一体化された樹脂製の表皮材20とを備えた樹脂製品1を成形する方法であり、大きく分けて、表皮材セット工程、樹脂供給工程、基材成形工程、基材発泡工程及び脱型工程を備えている。
以上説明したように、この実施形態によれば、可動金型32及び固定金型31を型開き状態にしてから、可動金型32の表皮材セット面40aに表皮材20をセットした後、この表皮材20と固定金型31の基材成形面31aとの間に樹脂供給装置34によって発泡剤を含んだ基材成形用樹脂Cを供給し、その後、型駆動装置33によって可動金型32及び固定金型31を型閉じ状態にすることで、基材成形用樹脂を可動金型32及び固定金型31によって成形することができる。そして、型閉じ状態にある可動金型32及び固定金型31を型駆動装置33によって型開き方向に相対移動させることで基材成形用樹脂C
に含まれている発泡剤の作用によって基材10を発泡させて発泡層13を形成することができる。
10 基材
13 発泡層
20 表皮材
30 樹脂成形装置
31 固定金型(第2金型)
32 可動金型(第1金型)
33 型駆動装置
34 樹脂供給装置
40 本体金型部
41 別体金型部
42 相対移動機構
Claims (8)
- 発泡層を有する樹脂製の基材を備えた樹脂製品を成形する樹脂成形装置において、
第1金型と、
上記基材における上記第1金型とは反対側の面を成形する基材成形面を有する第2金型と、
上記第1金型及び上記第2金型の一方を他方に接離する方向に駆動して上記第1金型と上記第2金型とを型開き状態と型閉じ状態とに切り替える型駆動装置と、
上記基材を形成する発泡剤を含んだ基材成形用樹脂を供給する樹脂供給装置とを備え、
上記第1金型及び上記第2金型の一方は、本体金型部と、該本体金型部とは別体に構成された別体金型部と、上記別体金型部を上記本体金型部に対して上記型駆動装置の駆動方向に相対移動させる相対移動機構とを有していることを特徴とする樹脂成形装置。 - 請求項1に記載の樹脂成形装置において、
上記相対移動機構は、型閉じ状態にある上記第1金型及び上記第2金型を型開きするときに上記別体金型部を上記本体金型部よりも遅い移動速度で型開き方向に移動させるように構成されていることを特徴とする樹脂成形装置。 - 請求項1に記載の樹脂成形装置において、
上記相対移動機構は、型閉じ状態にある上記第1金型及び上記第2金型を型開きするときに上記別体金型部を上記本体金型部よりも速い移動速度で型開き方向に移動させるように構成されていることを特徴とする樹脂成形装置。 - 請求項1から3のいずれか1つに記載の樹脂成形装置において、
上記第1金型には、上記本体金型部と、上記別体金型部と、上記相対移動機構とが設けられ、
上記本体金型部は、上記樹脂製品が有する表皮材をセットするための表皮材セット面を有し、
上記別体金型部は、上記基材における上記表皮材から露出した露出部を成形する露出部成形面を有していることを特徴とする樹脂成形装置。 - 請求項4に記載の樹脂成形装置において、
上記表皮材セット面には、弾性材からなる発泡層を有する表皮材がセットされることを特徴とする樹脂成形装置。 - 請求項4または5に記載の樹脂成形装置において、
上記型駆動装置は、上記第1金型を駆動することを特徴とする樹脂成形装置。 - 発泡層を有する樹脂製の基材を備えた樹脂製品を成形する樹脂成形方法において、
第1金型及び第2金型を用意し、
上記第2金型が有する基材成形面に、上記基材を形成する発泡剤を含んだ基材成形用樹脂を供給する樹脂供給工程と、
上記樹脂供給工程の後、上記第1金型及び上記第2金型を型締めして上記基材を成形する基材成形工程と、
上記基材成形工程の後、上記第1金型及び上記第2金型を型開きして上記基材を発泡させる際に、上記第1金型及び上記第2金型の一方を構成している本体金型部と該本体金型部とは別体に構成された別体金型部とを型駆動装置の駆動方向に相対移動させる基材発泡工程とを備えていることを特徴とする樹脂成形方法。 - 請求項7に記載の樹脂成形方法において、
上記基材に積層されて一体化される表皮材を上記第1金型の表皮材セット面にセットする表皮材セット工程を備えていることを特徴とする樹脂成形方法。
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