JP2019142086A - Manufacturing method of composite molded body, molding die used in manufacturing method, and composite molded body - Google Patents

Abstract

To provide a manufacturing method of a composite molded body that can reliably prevent generation of burrs that are formed on an exposed part and keep the manufacturing cost low, and a molding die that can be easily changed, can handle a protrusion with a complex shape, and has excellent maintainability of a concavity of a molding die, and a composite molded body that does not generate burrs in the exposed part.SOLUTION: In a manufacturing method of a composite molded body, the composite molded body 7 comprises an integral molded body of a foamed particle molded body 8 and a rigid member 5 embedded in the foamed particle molded body, and has an exposed part 50 in which a part of the rigid member is exposed from the foamed particle molded body. Using a mold 1 provided with an opening/closing door 2 which is provided with a concavity 10 capable of accommodating the exposed part, and is connected to an opening part 11 of the concavity via a door rotation member 23, and has an opening/closing changeover part 21 and a door part 22 that closes the opening part. When storing the exposed part, the exposed part is brought into contact with the opening/closing changeover part, the opening/closing door is rotated to store the exposed part in the concavity, and the opening part of the concavity is closed by the door part. Then, in-mold molding is performed by filling the mold with foamed particles.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for producing a composite molded body, a mold used for the production method, and a composite molded body.

  In recent years, a composite molded body of a foamed particle molded body and a rigid member embedded in the foamed particle molded body has been manufactured. As such a composite molded body, for example, as shown in FIG. 6, by embedding a rigid member 5 made of metal or the like inside the foamed particle molded body 8 as a sheet core material 7 of an automobile seat sheet, A composite molded body in which the foamed particle molded body 8 and the rigid member 5 are integrated is exemplified. The rigid member 5 in the sheet core member 7 is embedded in the foamed particle molded body 8 as a reinforcing member at the time of an automobile collision, a member for attachment to the vehicle body, a locking member for joining to the skin, or the like. When the member is to be attached to the vehicle body, it is designed such that a part of the rigid member 5 is exposed in a hook shape from the foamed particle molded body 8.

A sheet core 7 in which such a rigid member 5 is embedded in the foamed particle molded body 8 and a part of the rigid member 5 is exposed from the foamed particle molded body 8 in a hook shape is generally used. It is manufactured as follows.
First, the rigid member 5 is disposed at a predetermined position in the mold. At this time, a part of the rigid member 5 that protrudes in a hook shape is accommodated and disposed in a recess formed in the mold. Next, after the raw material foam particles are filled in the mold in that state, the foam particles are fused together to be integrally molded in the mold.

  In the sheet core material 7 of the composite molded body molded by the above method, since the foamed particles of the raw material enter from the opening of the concave portion of the molding die that accommodates the hook-shaped protrusion during molding in the mold, In some cases, burrs are formed in the gap 9 surrounded by the rigid member 5 and the foamed particle molded body 8 in the hook-shaped protrusion. And since the post-process which removes the burr | flash formed in the space | gap part 9 completely is needed, there existed a problem that production efficiency fell remarkably.

  Various methods have been proposed for such problems. For example, in the method described in Patent Document 1, an opening / closing body provided with a biasing means is provided in a concave portion of a mold, and a protrusion is sandwiched by the opening / closing body, or a protrusion is sandwiched by an elastic body to generate a burr. I try not to let you.

International Publication No. WO2015 / 159691

  According to the proposal of the above-mentioned patent document 1, since the opening of the recess can be closed while the protrusion is housed in the recess of the mold, it is possible to prevent the invasion of the foamed particles as a raw material and to generate burrs. Can be suppressed.

  However, the proposal of Patent Document 1 basically has a structure in which the protrusion is sandwiched by using the biasing means, so that the structure of the mold apparatus itself is complicated, and the cleaning and maintenance in the mold recess are complicated. There was a problem. In addition, since the occupied volume of the switchgear in the concave portion of the mold is large, there is a problem that it is difficult to cope with a projecting portion having a complicated shape.

  The present invention has been made to solve the above-described problems, and can be applied to a method of manufacturing a composite molded body that can prevent the formation of burrs formed on an exposed portion, and a protrusion having a complicated shape. It is an object of the present invention to provide a molding die that is excellent in maintainability of the molding die recess and handleability such as arrangement change, and a composite molded body that does not generate burrs in the protruding portion.

The present invention provides a method for producing a composite molded body described below, a molding die used in the production method, and a composite molded body.
<1> A composite molding comprising an integral molded body of a foamed particle molded body and a rigid member embedded in the foamed particle molded body, and comprising an exposed portion in which a part of the rigid member is exposed from the foamed particle molded body. A body manufacturing method, wherein a recess capable of accommodating the exposed portion is provided, and the opening / closing switching portion connected to the opening of the recess via a door rotation member and the door for closing the opening. When the exposure part is stored, the exposure part is brought into contact with the opening / closing switching part and the opening / closing door is rotated so that the exposure part is A method for producing a composite molded body, comprising: housing in a recess, closing the opening of the recess with the door, and then performing in-mold molding by filling the molding die with foamed particles.
<2> The composite molding according to <1>, wherein the opening / closing door has a substantially L-shaped connection between the opening / closing switching portion and the door portion in a cross-section of the rotation axis of the door rotation member. Body manufacturing method.
<3> The method for producing a composite molded body according to <1> or <2>, wherein a magnet for holding the open / close position of the open / close door is provided in the mold.
<4> A composite molding comprising an integral molded body of a foamed particle molded body and a rigid member embedded in the foamed particle molded body, and comprising an exposed portion in which a part of the rigid member is exposed from the foamed particle molded body. A molding die for molding a body in a mold, wherein the molding die is provided with a recess capable of accommodating the exposed portion, and the opening of the recess is connected via a door rotation member An opening / closing door having an opening / closing switching portion and a door portion for closing the opening portion is provided, and the opening / closing door is rotated so that the concave portion can be closed by the door portion.
<5> A composite molded body obtained by in-mold molding using the mold according to <4>, wherein the composite molded body includes a foamed particle molded body and a rigidity embedded in the foamed particle molded body. The composite molded body includes an exposed portion where a part of the rigid member is exposed from the foamed particle molded body, and the rigid member constituting the exposed portion is substantially U-shaped. And the composite molded body has no burr in a region surrounded by the foamed particle molded body and a substantially U-shaped rigid member constituting the exposed portion.

  According to the method for manufacturing a composite molded body according to the present invention, it is possible to reliably prevent the occurrence of burrs formed on the exposed portion. In addition, the mold of the present invention used in the method for producing a composite molded body can be applied to an exposed portion of a rigid member having a complicated shape, and is excellent in maintainability of the mold mold recess and handleability such as arrangement change. Yes. Furthermore, the composite molded body manufactured by the molding die and the manufacturing method of the present invention is a composite molded body in which burrs are not generated in the exposed portion of the rigid member in a state of being taken out from the mold after molding.

It is the fragmentary perspective view which showed the recessed part opening part in the shaping | molding die of this invention. It is operation | movement explanatory sectional drawing of the door in the shaping | molding die shown in FIG. 1, (A) is before a rigid member mounting, (B) is a schematic sectional drawing which showed the rigid member mounting, (C) is from a back side. FIG. (A) is the fragmentary perspective view which showed the recessed part opening part of the shaping | molding die of embodiment which provided the top-plate part. (B) is a perspective view showing an embodiment in which recess openings are provided on both sides of an opening / closing door. It is operation | movement explanatory sectional drawing of the opening / closing door in the shaping | molding die shown in FIG. 3, (A) is a schematic sectional drawing which showed before rigid member mounting, (B) was after rigid member mounting. (A)-(C) are schematic perspective views which show embodiment of the opening / closing door unit with which a shaping | molding die is mounted | worn. It is a schematic perspective view which shows the composite molded object of this invention as a sheet | seat core material for motor vehicles, and has the exposed part 50 attached to a vehicle body. (A)-(C) are schematic which shows the aspect of the space | gap part in which a burr | flash is formed. It is operation | movement explanatory sectional drawing of embodiment which temporarily fixes rotation of a door rotation member with a ball plunger, (A) is a schematic sectional drawing which showed before rigid member mounting, (B) was after rigid member mounting. It is.

  Below, the manufacturing method of the composite molded object of this invention and the shaping | molding die used for this are demonstrated.

  First, a mold used in the method for producing a composite molded body of the present invention will be described with reference to the drawings. FIG. 1 is a partial perspective view showing a recess opening in the mold of the present invention. The mold 1 of the present invention is an integral molded body of a foamed particle molded body 8 and a rigid member 5 embedded in the foamed particle molded body 8, and an exposed portion from which the rigid member 5 is exposed. The composite molded body 7 including the portion 50 is for in-mold molding. The integral molded body only needs to include the foamed particle molded body 8 and the rigid member 5 embedded in the foamed particle molded body 8, and other members may be integrally molded together.

  The molding die 1 can accommodate an exposed portion 50 that can be a portion exposed from the composite molded body 7, and is provided with a concave portion 10 that is recessed from the cavity surface. The cavity-side opening 11 of the recess 10 is provided with an opening / closing door 2 having an opening / closing switching portion 21 and a door portion 22 connected via a door rotation member 23. As shown in FIG. 1, FIG. 2 (A), (B), the opening / closing switching portion 21 and the door portion 22 constituting the opening / closing door 2 are connected to each other at one end side with a predetermined cross-sectional angle. The connecting portion is provided with a door turning member 23, and the opening / closing door 2 is attached to the edge of the cavity side opening 11 of the mold 1 through the door turning member 23.

  The area of the opening / closing switching unit 21 is set to be equal to or smaller than the area of the cavity-side opening 11. At least the opening / closing switching unit 21 may be formed so that the rigid member 5 can come into contact therewith. The opening / closing door 2 rotates around the door rotation member 23 so that the opening / closing switching portion 21 moves into the recess 10 and the cavity portion 11 is closed by the door portion 22. In addition, the angle formed by the opening / closing switching portion 21 and the door portion 22 in the opening / closing door 2 in the sectional view of the rotation axis of the door rotation member 23 is not particularly limited as long as the exposed portion 50 of the rigid member 5 can be accommodated. The shape is preferably substantially L-shaped, and is preferably 70 to 100 ° and more preferably 80 to 90 ° in consideration of storage workability. When the opening / closing switching unit 21 is formed in accordance with the area of the cavity-side opening 11, the opening / closing switching unit 21 can function as an inner door and the door 22 can function as an outer door. In this case, the opening 11 can be closed by the inner door formed by the opening / closing switching unit 21 even when the door 22 is open. If the opening / closing switching part 21 and the door part 22 function as an opening / closing door, it is preferable that at least a part of the opening / closing switching part 21 and the door part 22 is connected to the door rotation member 23 at the above angle.

  In the mold 1 of the present invention, it is preferable to provide a holding means for holding the open / close state of the open / close door 2 near the cavity-side opening 11. Examples of the holding means include a means for temporarily holding the open / close state of the open / close door 2 by the magnet 3 and a means for temporarily stopping the rotation of the door rotation member 23 by pressing or the like.

  When the magnet 3 is used, it is possible to temporarily hold the open / close state of the open / close switching portion 21 and the door portion 22 by making the material of the open / close door 2 a material that can be attracted to the magnet 3. It becomes possible to efficiently store the exposed portion 50 in the recess 10.

  The specific arrangement position of the magnet 3 can be appropriately determined according to the shape of the composite molded body to be molded, that is, the design of the mold 1, and can be provided, for example, in the vicinity of the cavity-side opening 11. . Thereby, the opening / closing switching part 21 or the door part 22 can be attracted by the magnetic force of the magnet 3, and the opened / closed state can be temporarily maintained. For example, when the magnet 3 is embedded on the back side of the open / close door 2 as shown in FIGS. 1 and 2A to 2C, it protrudes about 0.5 mm from the mold surface. It is desirable to provide it. By projecting the magnet 3 from the surface of the mold, the door portion 22 can be held and stabilized when the door 2 is opened. In addition, by embedding the magnet 3 in the mold 1, when the door 2 is closed, the opening / closing switching portion 21 can be attracted to the inner wall of the recess 10 and stabilized. Moreover, by providing the long magnet 3 or a plurality of the magnets 3 along the opening 11, the door 2 can be held more stably.

  In the case where the rotation of the door rotation member 23 is temporarily fixed by pressing or the like, for example, as shown in FIG. It is preferable to hold the open / closed state of the door portion 22. Furthermore, a notch 26 may be provided in the door rotation member 23 in accordance with the opening / closing position of the door portion 22, and the ball plunger 25 or the like may be used to hold the notch 26.

  According to the mold 1 having the above-described structure, when the rigid member 5 is placed, the door rotating member is attached to the door portion 22 from the state where the door portion 22 is positioned outside the opening portion 11 and opened. The opening / closing switching portion 21 existing near the opening 11 is brought into contact with the exposed portion 50 of the rigid member 5 and the rigid member 5 is pushed into the recess 10 from the opening side, whereby the opening / closing door 2 is rotated. The recessed portion 10 can be closed by the door portion 22 in a state where the exposed portion 50 of the rigid member 5 is housed in the recessed portion 10.

  Moreover, when the exposed part 50 formed in the rigid member 5 is U-shaped or the like, the rigid member 5 is provided on the edge of one end side of the door part 22 opposite to the joint part of the door rotation member 23. Can be provided. As shown in FIG. 1, by inserting the rigid member 5 through the insertion portion 24, the rigid member 5 is reliably accommodated and closed in the recess 10 even when the cavity-side opening 11 is closed by the door portion 22. be able to. In these cases, it is preferable that the door portion 22 closes the opening portion 11 and closes the foamed particles used for molding so as not to enter the concave portion 10, and is generally a space of 5 mm or less, more preferably 3 mm or less. It is preferable that In addition, the recessed part 10 is formed in the direction where the exposed part 10 protrudes, and it is preferable to form so that the depth direction of the recessed part 10 may be the opening / closing direction of the mold.

  In the mold 1 of the present invention, the top plate portion 4 as shown in FIGS. 3A, 4A, and 4B can be provided in the cavity-side opening 11. In this case, the top plate portion 4 is provided so as to cover a part of the cavity side opening portion 11, and the opening / closing door 2 is provided in a portion not covered by the top plate portion 4. In addition, two open / close doors 2 may be provided at each of the opposing edge portions of the opening portion 11 so as to face each other toward the center of the opening portion 11 so as to have the shape of both doors. Further, as shown in FIG. 3B, the opening 11 is provided with portions not covered with the opening / closing door 2 at both ends so that only the gap 9 inside the exposed portion 50 of the rigid member 5 is covered with the opening / closing door 11. It may be. When the gap 9 is formed, the rigid member 5 that forms the gap 9 is caught in the door 22 when the exposed portion 50 accommodated in the recess 10 is taken out, and the door 22 is It can be opened.

  An insertion portion 24 into which the rigid member 5 can be inserted can be provided at the edge of one end side of the top plate portion 4. In this case, it is not necessary to provide the insertion portion 24 at the edge of the one end side of the opening / closing door 2 door portion 22, but, for example, when the rigid member 5 has a circular cross-sectional shape, FIG. As shown in (A) and (B), when the semicircular insertion portion 24 is provided at each edge of the top plate portion 4 and the door portion 22 and the recess portion 10 is closed by the door portion 22, the rigid member 5. It can also be provided so as to have a circular shape equivalent to the cross-sectional shape.

  The top plate part 4 is provided to adjust the position of the insertion part 24 in the top view of the cavity side opening 11. For example, the insertion part 24 is provided near the center part in the top view of the cavity side opening 11. It can be arranged. In this manner, the protrusion 10 projects in an oblique direction with respect to the opening 11 by arranging the concave portion 10 in consideration of the positional relationship between the top plate portion 4 and the open / close door 2, that is, the insertion position of the rigid member 5. The rigid member 5 and the rigid member 5 having a complicated shape can be accommodated in the recess 10.

  In the mold 1 described above, the open / close door 2 is provided directly to the cavity-side opening 11 of the mold 1 and the top plate 4 is further provided. For example, FIG. As shown in (C), the opening / closing door 2 including the opening / closing switching portion 21 and the door portion 22 is attached to the opening portion 61 of the case portion 60 having an opening portion on the upper portion via the door rotation member 23 so as to be opened and closed. It is also possible to use the molding die 1 in which the opening / closing door unit 6 having the above structure is provided in the recess 10 of the molding die 1.

  Also in the open / close door unit 6, the insertion portion 24 can be provided at the edge of one end side of the door portion 22 of the open / close door 2. Furthermore, the top plate portion 4 is provided so as to cover a part of the opening 61 of the case portion 60, and the insertion portion 24 through which the rigid member 5 can be inserted is provided at a predetermined position on the edge of one end side of the top plate portion 4. You can also.

  Furthermore, the magnet 3 for holding the opening / closing position of the opening / closing door 2 can be provided in the opening 61 of the case portion 60. The position at which the magnet 3 is disposed with respect to the open / close door unit 6 is not particularly limited. For example, the opening 61 of the case portion 60, the vicinity of the edge of the top plate portion 4, and FIG. Can be provided at the rising portion 62 of the opening 61 of the case portion 60 of the door unit 6 as shown in FIG. Thereby, holding | maintenance of the door part 22 before rigid member 5 mounting is attained.

  In addition, the opening / closing door unit 6 is internally provided in the recess 1 of the molding die 1 through a screw hole provided in the case portion 60 of the opening / closing unit and the bottom of the recess 10 of the molding die 1 or the like. Can be fixed. By using a door unit that can be attached to and detached from the recess 10 of the mold 1, it is possible to easily perform design changes and maintenance such as changing the position of the recess 10 of the mold 1.

  Below, the manufacturing method of a composite molded object using the shaping | molding die 1 of this invention is explained in full detail. In the following, the core material 7 for automobiles is taken as an example, but the manufacturing method of the present invention is applicable to any composite molded body having an exposed portion 50 where a part of the rigid member 5 is exposed from the foamed particle molded body 8. can do. As shown in FIG. 6, the composite molded body as the sheet core 7 is an integral molded body of the foamed particle molded body 8 and the rigid member 5 embedded in the foamed particle molded body 8. From the above, it is a composite molded body having an exposed portion 50 where a part of the rigid member 5 is exposed. The exposed portion 50 is attached to the automobile frame. Therefore, when the vehicle body is attached, the exposed portion side in FIG. 6 is the lower surface side.

  The manufacturing method of the said composite molded object is obtained by insert-molding the rigid member 5. FIG. First, the rigid member 5 is placed at a predetermined position in the cavity of a metal mold as the mold 1. At this time, a portion to be the exposed portion 50 where a part of the rigid member 5 is exposed is accommodated in the concave portion 10 of the mold 1 of the present invention. Specifically, the opening / closing switching portion of the opening / closing door 2 provided in the opening portion 11 of the recess 10 from the state where the door portion 22 does not block the opening portion 11 and the opening / closing switching portion 21 is positioned in the opening portion 11. 21, the exposed portion of the rigid member 5 is brought into contact. Then, by pushing the rigid member 5 into the recess 10, the open / close door 2 is rotated via the door rotation member 23, and the exposed portion 50 of the rigid member 5 is introduced into the recess 10. As the opening / closing switching unit 21 rotates, the recess 10 is closed by the door 22, and the exposed portion of the rigid member 5 is set in the recess 10 in a closed state. In addition, the door part 22 should just block | close the opening part 11 of the recessed part 10 to such an extent that a foamed particle does not enter into the recessed part 10 at the time of in-mold shaping | molding. Due to the above, since the foamed particles are prevented from entering the gap 9 surrounded by the rigid member 5 and the foamed particle molded body 8, the generation of burrs is effectively prevented.

  For example, as the portion where the rigid member 5 is exposed, as shown in FIG. 7A, the portion protrudes from the end of the foamed particle molded body 8 and is exposed, and the rigid member 5 is formed in a substantially U shape. The aspect made is mentioned. In this case, it comprises a column portion extending outward of the foamed particle molded body, and a latching portion extending from the column portion and projecting outward from the foamed particle molded body, and connecting a tip portion of the column portion. It is preferable. Moreover, it is preferable to have a base part embedded in the foamed particle molded body and connected to the column part. In addition, it becomes easy to generate | occur | produce the burr | flash which a foamed particle fills in the space | gap part 9 enclosed by the rigid member of the substantially U-shaped exposed part, and the edge part of the foamed particle molded object 8, and is shape | molded. Therefore, in the composite molded body formed by in-molding using the molding die of the present invention, the composite molded body is an integral molded body of a foamed particle molded body and a rigid member embedded in the foamed particle molded body. The composite molded body includes an exposed portion in which a part of the rigid member is exposed from the foamed particle molded body, and when the rigid member constituting the exposed portion is substantially U-shaped, The composite molded body does not have burrs in a region surrounded by the foamed particle molded body and the substantially U-shaped rigid member.

  As another aspect of the exposed portion, as shown in FIG. 7 (b), a concave portion is formed in the foamed particle molded body 8, and the rigid member 5 crosses the concave portion. Can be mentioned. In this case, burrs are likely to occur in the gap 9 surrounded by the rigid member 5 and the recessed portion of the foamed particle molded body 8. In addition, in this invention, if the rigid member 5 is exposed from the foaming particle molded object 8, it can apply even if it is other than said aspect. The gap 9 does not necessarily need to be completely closed and surrounded by the rigid member 5 and the foamed particle molded body 8.

  The shape of the exposed portion 50 in the rigid member 5 is appropriately determined according to the design of the composite molded body, and is not particularly limited. For example, the shape is oblique with respect to the mold 1 cavity side opening 11. It may protrude in the direction or may have a complicated shape. According to the mold 1 of the present invention, since there is no need to provide an extra structure in the recess 10, a wide space can be secured, and the exposed portion 50 having the complicated shape as described above can be secured. Applicable.

  Examples of the material of the rigid member 5 include metals such as iron, aluminum, and copper, and resins. In addition, from the viewpoint of improving the strength of the composite molded body as the sheet core material 7, metal is preferable, and steel is particularly preferable. In addition, the rigid member 5 can be of any shape such as a wire member, a pipe member, a plate-like member, a linear member, a tubular member, or a rod-like member. For example, when used as the sheet core 7, it is preferable to use a rod-like or linear rigid member 5 having a diameter of 2 to 20 mm. The diameter of the rigid member 5 is more preferably 3 to 10 mm, and further preferably 4 to 7 mm. Moreover, the cross-sectional shape of the rigid member 5 is not limited to a circle, and may be, for example, a polygon.

Further, the rigid member 5 preferably has a tensile strength of 200 N / mm ² or more, and more preferably 250 to 1300 N / mm ² from the viewpoint of improving the strength of the sheet core material 7. The yield point of the rigid member 5 is preferably 400 N / mm ² or more, and more preferably 440 N / mm ² or more. The physical properties of the rigid member 5 can be measured based on JIS G3532.

  Next, after the rigid member 5 is disposed in the cavity and the mold 1 is closed, the foam particles are filled in the cavity and the foamed particle molded body 8 is molded in the mold. When the foam particles are introduced into the cavity, the opening of the recess 10 in which the exposed portion 50 is accommodated is closed by the door portion 22, so that the foam particles are prevented from entering the exposed portion 50 portion. The

  The foamed particles to be filled can be used as long as they are for producing this kind of foamed particle molded body. The foamed particle molded body 8 can be molded from thermoplastic resin foam particles. Examples of the thermoplastic resin constituting the expanded particle molded body 8 include polystyrene resins, polyethylene resins, polyolefin resins such as polypropylene resins, polybutylene succinates, polyester resins such as polyethylene terephthalate, polylactic acid, and polycarbonates. Resin, thermoplastic elastomer, thermoplastic polyurethane and the like. Moreover, the composite resin of polystyrene resin and polyolefin resin, the mixture of 2 or more types of said resin, etc. can be mentioned. Among these, from the viewpoints of lightness and strength, polyolefin resins and composite resins of polystyrene resins and polyolefin resins are preferable. Of these, polyethylene resins and polypropylene resins are preferable, and polypropylene resins are more preferable. In addition, as an additive to the above resin, a foam regulator such as zinc borate, an antistatic agent, a conductivity imparting agent, a lubricant, an antioxidant, an ultraviolet absorber, a flame retardant, a metal deactivator, a pigment, a dye, Various additives such as a crystal nucleating agent or an inorganic filler can be added.

  And these foamed particles can be normally manufactured by a well-known method. For example, the propylene-based resin expanded particles may be added to a required amount of a dispersion medium (usually water) in a pressurizable closed container such as an autoclave, and a surfactant may be added as needed to disperse the resin particles, Press-fit and stir under heating to impregnate the foaming agent into the resin particles. After a predetermined time, the resin particles impregnated with the foaming agent together with the dispersion medium from inside the container under high temperature and high pressure conditions are in the low pressure range (normally under atmospheric pressure) It is manufactured by a method such as a method of discharging to a foam and obtaining foamed particles by foaming.

  After filling the above-mentioned foamed particles into the cavity, heated steam is introduced into the mold 1 to heat the foamed particles for secondary foaming, and the foamed particles are fused together to form the foamed particle compact 8. At the same time, it is integrated with the rigid member 5. Thereafter, it is removed from the mold 1 to produce a composite molded body. The heating conditions in the mold 1 can be appropriately set in consideration of the physical properties of the foamed particle molded body 8 after molding. The method for adhering the foamed particles constituting the foamed particle molded body is not limited to fusion of the foamed particles with a heating medium such as steam, and the foamed particle molded body is filled with the foamed particles. If it can form, other methods are also applicable, for example, you may adhere | attach foamed particles using an adhesive agent.

The molded body density of the foamed particle molded body 8 after molding is preferably 0.015 to 0.5 g / cm ³ . From the viewpoint of making the sheet core material 7 excellent in strength and lightness, the molded body density of the foamed particle molded body 8 is more preferably 0.025 to 0.3 g / cm ³ , and 0.03 to 0.3 mm. More preferably, it is 1 g / cm ³ . In the case of the foamed particle molded body 8 made of polyolefin resin, the molded body density is preferably 0.018 to 0.07 g / cm ³ and the molded body density is 0.020 to 0.06 g / cm ^{3. 3} is more preferable.

  A plurality of expanded particle molded bodies 8 having different molded body densities can be combined into a single expanded particle molded body 8. In this case, the average molded body density of the entire foamed particle molded body 8 may be within the above numerical range. In addition, the molded object density used here can be calculated | required by the submerging method which immerses and measures the foamed particle molded object 8.

  In the composite molded body with the rigid member 5 embedded in the foamed particle molded body 8 in the present invention, the “embedding” means that at least a part of the rigid member 5 is integrated in the foamed particle molded body 8. For example, not only when the rigid member 5 is tightly surrounded by the foamed particle molded body 8, but also through the space formed partially or entirely around the rigid member 5. Is included in the foamed particle molded body 8.

  For example, when the composite molded body of the present invention is used as a core material of an automobile seat as shown in FIG. 6, the rigid member 5 in the sheet core material 7 is placed inside the expanded particle molded body 8 as a frame member. The sheet core 7 is embedded and integrated, and the strength of the sheet core member 7 and a part thereof function as an attachment member to the vehicle body. Further, the rigid member 5 does not have to be embedded in the foamed particle molded body 8 in the entire axial direction, and a part of the rigid member 5 may be exposed to the outside from the foamed particle molded body 8. From the viewpoint of the strength of the sheet core member 7, the exposed portion 50 of the rigid member 5 is preferably 50% or less of the entire length of the rigid member 5.

When the composite molded body molded in the mold under the above conditions is removed from the mold 1, the composite molded body is pulled out so that the exposed portion 50 of the rigid member 5 is pulled out from the concave portion 10 of the mold 1, and the rigid member 5 is removed. It is easily taken out by sliding it to the opening side, rotating the opening / closing door 2 by bringing the rigid member 5 and the door portion 22 into contact, and opening the door portion 22 toward the outside of the opening portion 11. Can do. Specifically, when the rigid member 5 includes the pillar portion and the latching portion, the latching portion is caught by the door portion 22 and the door portion 22 can be opened.
Further, if the magnet 3 is provided so as to keep the door 22 open, the door 22 is kept open until the next molding, and the exposed portion 50 of the rigid member 5 is stored in the recess 10. In addition, the operation can be performed without opening the door portion 22 again. Then, the rigid member 5 of the exposed portion 50 and the open / close switching portion 21 come into contact with each other, and the exposed portion 50 is pushed in with a force more than the magnet 3 holds. The open state is released, and the door 22 is closed.

  According to the method for manufacturing a composite molded body using the mold 1 of the present invention, the portion that becomes the exposed portion 50 of the rigid member 5 is accommodated in the recess 10, and is formed in the cavity-side opening 11 of the mold 1. Since the provided opening / closing door 2 prevents the foamed particles used for molding from entering the recess, for example, the foamed particles are surrounded by a part of the rigid member 5 and the foamed particle molded body 8 and protruded into a hook shape. Even in the case of a composite molded body having the gap 9, the occurrence of burrs in the gap 9 can be reliably prevented. Moreover, since the attachment structure of the opening / closing door 2 with respect to the recess 10 of the mold 1 is very simple with only the connection of the door rotation member 23, it is excellent in maintainability of the mold 1 and the manufacturing cost can be kept low. It becomes.

DESCRIPTION OF SYMBOLS 1 Mold 10 Recessed part 11 Cavity side opening part 2 Opening / closing door 21 Opening / closing switching part 22 Door part 23 Door rotation member 24 Insertion part 25 Ball plunger 26 Notch 3 Magnet 4 Top plate part 5 Rigid member 50 Exposed part 6 Opening / closing Door unit 60 Case part 61 Opening part 7 Sheet core material (composite molding)
8 Foamed particle molded body 9 Cavity

Claims (5)

A composite molded body comprising an integral molded body of a foamed particle molded body and a rigid member embedded in the foamed particle molded body, and comprising an exposed portion in which a part of the rigid member is exposed from the foamed particle molded body. A manufacturing method comprising:
An opening / closing door provided with a recess capable of accommodating the exposed portion and having an opening / closing switching portion and a door portion for closing the opening portion connected to the opening portion of the recess via a door rotation member. Use the mold that is
When the exposed portion is stored, the exposed portion is brought into contact with the open / close switching portion, the open / close door is rotated to store the exposed portion in the concave portion, and the opening portion of the concave portion is accommodated by the door portion. A method for producing a composite molded body, comprising: sealing the foamed mold, filling the mold with foamed particles, and performing in-mold molding.   2. The composite molded body according to claim 1, wherein the opening / closing door is connected to the opening / closing switching portion and the door portion in a substantially L shape in a cross-section of a rotation axis of the door rotating member. Method.   The method for manufacturing a composite molded body according to claim 1 or 2, wherein a magnet for holding an open / close position of the open / close door is provided in the mold. A composite molded body comprising an integral molded body of a foamed particle molded body and a rigid member embedded in the foamed particle molded body, and comprising an exposed portion where a part of the rigid member is exposed from the foamed particle molded body. A mold for in-mold molding,
The molding die is provided with a recess capable of accommodating the exposed portion,
An opening / closing door having an opening / closing switching portion and a door portion for closing the opening portion, which are connected via a door rotation member, is provided at the opening portion of the concave portion,
The mold is characterized in that the opening / closing door is rotated, and the concave portion can be closed by the door portion.   A composite molded body obtained by in-mold molding using the molding die according to claim 4, wherein the composite molded body includes a foamed particle molded body and a rigid member embedded in the foamed particle molded body. The composite molded body includes an exposed portion in which a part of the rigid member is exposed from the foamed particle molded body, and the rigid member constituting the exposed portion is substantially U-shaped, The composite molded body has no burrs in a region surrounded by the foamed particle molded body and a substantially U-shaped rigid member constituting the exposed portion.

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