JP2021070271A - Molded body and its manufacturing method - Google Patents

Abstract

To provide a molded body and a method for manufacturing the molded body that is less prone to molding defects.SOLUTION: According to one aspect of the present invention, there is provided a molded body, having a shape that is approximately the same as a space defined by a pair of molds used during molding, a resin molded body, and a skin member, the resin molded body is made of foamed resin and has a bending portion, the wall thickness in the bending portion is configured to be thinner than the wall thickness of the resin molded body other than the bending portion according to the shape of the space, and the skin member is disposed on one side of the resin molded body that is a valley of the bending portion.SELECTED DRAWING: Figure 1

Description

The present invention relates to a molded product and a method for producing the same.

In Patent Document 1, a foamed resin sheet that has been heated and softened is placed in a cavity (space) of a split mold, and then the cavity is sucked under reduced pressure to cause secondary foaming of the foamed resin sheet to foam resin. A method of inflating the sheet has been proposed. By such a method, a molded product having a space shape defined by a pair of molds can be manufactured.

Japanese Unexamined Patent Publication No. 2001-310380

However, the molded body in recent years has become complicated, and the cavity may require a complicated shape. In such a case, the resin does not wrap around sufficiently, especially in a bent portion, and molding defects that are not shaped into the shape of the space occur. Further, when another resin sheet is welded to the foamed resin sheet, there is a problem that the resin sheet is not properly welded.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a molded product in which molding defects are unlikely to occur and a method for producing the same.

According to one aspect of the present invention, the molded body has substantially the same shape as the space defined by the pair of molds used at the time of molding, includes the resin molded body and the skin member, and the resin. The molded body is made of a foamed resin and includes a bent portion, wherein the wall thickness at the bent portion is thinner than the wall thickness of the resin molded body other than the bent portion according to the shape of the space. The skin member is provided on one side of the resin molded product, which is a valley of the bent portion.

A molded body having the above configuration can suppress the occurrence of molding defects. It has the above-mentioned advantageous effects.

The front side perspective view of the molded body 1 is shown. The back side perspective view of the molded body 1 is shown. The end view for explaining the wall thickness of the molded body 1 is shown. The perspective view of the molded body 1 before bending the hinge part 33 is shown. The end view of the molded body 1 before bending the hinge portion 33 is shown. The end view for explaining the structure of the molds 71 and 72 is shown. The aspect of the molding machine 2 for manufacturing a molded body 1 is shown. In the production of the molded body 1, the molds 71 and 72 are opened. In the production of the molded body 1, the foamed resin sheet 21 and the non-foamed resin sheet 22 are shaped into the shape of the mold 72 by suction of the mold 72 under reduced pressure. In the production of the molded body 1, the molds 71 and 72 are closed, and in particular, FIG. 10A shows the whole, and FIG. 10B shows an enlarged view of a portion surrounded by a dotted line in FIG. 10A. 10C shows a mode in which the foamed resin sheet 21 is expanded from the state shown in FIG. 10B. The perspective view which shows the molded body 1 which concerns on a modification is shown. The end view which shows the molded body 1 which concerns on a modification is shown.

Hereinafter, embodiments of the present invention will be described. The various features shown in the embodiments shown below can be combined with each other. In addition, the invention is independently established for each feature.

1. 1. Overall Configuration Section 1 describes the configuration of the molded body 1 according to the present embodiment. FIG. 1 shows a front perspective view of the molded body 1. FIG. 2 shows a rear perspective view of the molded body 1. FIG. 3 shows an end view for explaining the wall thickness of the molded body 1. FIG. 4 shows a perspective view of the molded body 1 before bending the hinge portion 33. FIG. 5 shows an end view of the molded body 1 before bending the hinge portion 33. FIG. 6 shows an end view for explaining the configuration of the molds 71 and 72.

1.1 Basic configuration First, the basic configuration of the molded product 1 will be outlined. The molded body 1 has substantially the same shape as the space S defined by the pair of molds 71 and 72 used at the time of molding (see FIGS. 5 and 6). As shown in FIGS. 1 to 3, the molded body 1 includes a resin molded body 11 and a skin member 12. Specifically, the molded body 1 has a two-layer structure. That is, the molded body 1 includes a resin molded body 11 as a first layer and a skin member 12 as a second layer.

(Resin molded body 11 and bent portion 13)
The resin molded body 11 is a molded body made of foamed resin M2 (see FIG. 7). The foaming ratio of the resin molded product 11 is not particularly limited, but is, for example, 1.5 to 6 times. Further, the resin molded body 11 includes a bent portion 13. It should be noted that, in relation to the bent portion 13, the molded body 1 includes at least one having a radius of curvature r of the bent portion 13 of 100 mm or less. Further, at least those having an angle θ formed by the two tangent planes P1 and P2 at both ends of the bent portion 13 of 150 degrees or less are included. Further, the angle θ may be 90 degrees or less. Such a short radius of curvature r and an angle θ forming an acute angle mean a sharp bending. When such a sharp bending is included, molding defects are generally likely to occur during molding.

Therefore, as shown in FIGS. 3 and 5, in the present embodiment, the wall thickness t1 at the bent portion 13 is made of resin according to the shape of the space S defined by the pair of molds 71 and 72 used at the time of molding. It has been devised so that the thickness of the molded body 11 is thinner than the wall thickness t2 other than the bent portion 13. Preferably, the wall thickness t1 in the bent portion 13 is configured to be continuously thinned from the wall thickness t2 other than the bent portion 13 of the resin molded body 11. Specifically, the wall thickness t2 is continuously changed to the wall thickness t1 as the bending portion 13 approaches the center.

Regarding the radius of curvature r, specifically, for example, r = 100,98,96,94,92,90,88,86,84,82,80,78,76,74,72,70,68, 66,64,62,60,58,56,54,52,50,48,46,44,42,40,38,36,34,32,30,28,26,24,22,20,18, It is 16, 14, 12, 10, 8, 6, 4, 2, 1 mm, and may be within the range between any two of the numerical values exemplified here.

Regarding the angle θ, specifically, for example, θ = 150, 147.5, 145, 142.5, 140, 137.5, 135, 132.5, 130, 127.5, 125, 122.5. , 120, 117.5, 115, 112.5, 110, 107.5, 105, 102.5, 100, 97.5, 95, 92.5, 90, 87.5, 85, 82.5, 80 , 77.5,75,72.5,70,67.5,65,62.5,60,57.5,55,52.5,50,47.5,45,42.5,40,37 .5,35,32.5,30,27.5,25,22.5,20,17.5,15,12.5,10 degrees, between any two of the values illustrated here. It may be within the range.

Further, regarding the wall thicknesses t1 and t2, specifically, for example, (t1 / t2) = 0.9,0.89,0.88,0.87,0.86,0.85,0.84. 0.83, 0.82, 0.81, 0.8, 0.79, 0.78, 0.77, 0.76, 0.75, 0.74, 0.73, 0.72, 0. 71,0.7,0.69,0.68,0.67,0.66,0.65,0.64,0.63,0.62,0.61,0.6,0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47, 0. 46, 0.45, 0.44, 0.43, 0.42, 0.41, 0.4, 0.39, 0.38, 0.37, 0.36, 0.35, 0.34 It is 0.33, 0.32, 0.31, 0.3, and may be within the range between any two of the numerical values exemplified here.

(Skin member 12)
As shown in FIG. 1, the skin member 12 is arranged on one side of the resin molded body 11 which is a valley (recess) of the bent portion 13. In one example, the skin member 12 is made of a breathable non-woven fabric, and specific examples thereof include nylon fibers, cellulose fibers, and aramid fibers, but the present invention is not limited to these examples.

1.2 Functional configuration Next, the functional configuration of the molded product 1 will be described. The molded body 1 is an interior part of an automobile, and a front surface 34 is formed on the molded body 1, and a passenger of the automobile can place an article such as a drink container on the front surface 34. As described above, since the front surface 34 is a portion to which the load of the article is applied, the molded body 1 includes a reinforcing portion 32 that reinforces the forming region of the front surface 34 of the molded body 1.

That is, the molded body 1 includes a base portion 31, a reinforcing portion 32, and a hinge portion 33. Further, a protruding portion 35 is formed on the molded body 1. The protrusion 35 divides the concave space of the molded body 1 into two regions.

(Base 31)
As shown in FIGS. 1 and 2, the base 31 includes a base body 311 and a flange wall 312. The base body 311 is formed in a concave shape, and a flange wall 312 is connected to the edge of the base body 311. The base body 311 includes a base wall 315 and an erection wall 316. The base wall 315 is a plate-shaped member. Although the base wall 315 is a flat plate in FIGS. 1 and 2, it may be curved.

The base wall 315 is supported by the reinforcing portion 32, and when a load is applied to the base wall 315, the deformation of the base wall 315 is suppressed. The base wall 315 has a first edge portion 313, a second edge portion 314, a front surface 34, and a back surface 36. A flange wall 312 is connected to the first edge portion 313. The front surface 34 is formed on the opposite side of the back surface 36, and the back surface 36 faces the reinforcing portion 32 at intervals. The back surface 36 is a surface supported by the reinforcing portion 32.

The erection wall 316 is a plate-shaped member, and the erection wall 316 extends so as to rise from the base wall 315. In this embodiment, the erection wall 316 is connected to the second edge 314. The erection wall 316 has a protrusion 35. A flange wall 312 is connected to the edge of the erection wall 316.

The flange wall 312 is a plate-shaped member, and in the present embodiment, the flange wall 312 is formed in an annular shape. The inner edge of the flange wall 312 is connected to the base wall 315 and the erection wall 316. A hinge portion 33 is formed on the outer edge of the flange wall 312, and the outer edge of the flange wall 312 is connected to the reinforcing portion 32 via the hinge portion 33. An opening 317 is formed in the flange wall 312, and a fixing member (for example, a bolt) for fixing the molded body 1 to an in-vehicle part of an automobile is inserted into the opening 317.

(Reinforcing part 32 and hinge part 33)
The reinforcing portion 32 is rotatably connected to the base portion 31 via a hinge portion 33. In the present embodiment, the molded body 1 is provided with two reinforcing portions 32 and two hinge portions 33, but the number is not limited to two, and may be one or three or more. There may be.

The hinge portion 33 is formed to be thin. Specifically, the wall thickness of the hinge portion 33 is thinner than the wall thickness of the reinforcing portion 32 and the wall thickness of the base portion 31. Therefore, the hinge portion 33 is configured so that the reinforcing portion 32 can be bent so that the manufacturer or the manufacturing apparatus can tilt the reinforcing portion 32 toward the back surface 36 of the base wall 315.

The reinforcing portion 32 is a plate-shaped member formed in a concave shape. The reinforcing portion 32 has a reinforcing rib 321 and a fixing portion 322. When the reinforcing portion 32 is bent, the reinforcing rib 321 is formed so as to project toward the back surface 36 of the base wall 315. The reinforcing portion 32 is provided to reinforce the base portion 31. Although the reinforcing rib 321 also has a bent portion 14, it does not have a design surface, so unlike the bent portion 13, the wall thickness is not reduced. Of course, this is just an example, and the bent portion 14 may be replaced with the configuration of the bent portion 13.

Specifically, in the present embodiment, the reinforcing rib 321 is in contact with the back surface 36 of the base wall 315, whereby the base wall 315 is supported by the reinforcing portion 32, and as a result, the base portion 31 is reinforced by the reinforcing portion 32. Will be done. In the present embodiment, the reinforcing rib 321 is in contact with the base wall 315, but the present invention is not limited thereto. An intervening member may be provided between the reinforcing rib 321 and the base wall 315, and the reinforcing rib 321 may not be in contact with the base wall 315. The reinforcing rib 321 is welded to the back surface 36 of the base wall 315. An opening 323 is formed in the fixing portion 322, and a fixing member (for example, a bolt) for fixing the molded body 1 to an in-vehicle part of an automobile is inserted into the opening 323.

2. Manufacturing Method of Molded Body 1 Section 2 describes a manufacturing method of the molded body 1. FIG. 7 shows an aspect of the molding machine 2 for manufacturing the molded body 1.

2.1 Configuration of Molding Machine 2 The molding machine 2 includes a resin supply device 4, a T-die 5, a mold 71, and a mold 72. The resin supply device 4 includes a hopper 41, an extruder 42, an injector 44, and an accumulator 45. The extruder 42 and the accumulator 45 are connected via a connecting pipe 61. The accumulator 45 and the T-die 5 are connected via a connecting pipe 62.

(Hopper 41 and extruder 42)
The hopper 41 is used to put the raw material resin M1 into the cylinder 43 of the extruder 42. The form of the raw material resin M1 is not particularly limited, but is usually in the form of pellets. The raw material resin M1 is, for example, a thermoplastic resin such as polyolefin, and examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-propylene copolymer and a mixture thereof. The raw material resin M1 is charged into the cylinder 43 from the hopper 41 and then heated in the cylinder 43 to be melted into a molten resin. Further, it is conveyed toward the tip of the cylinder 43 by the rotation of the screw arranged in the cylinder 43. The screw is arranged in the cylinder 43, and the molten resin is kneaded and conveyed by its rotation. A gear device is provided at the base end of the screw, and the screw is rotationally driven by the gear device.

(Injector 44)
The cylinder 43 is provided with an injector 44 for injecting a foaming agent into the cylinder 43. Examples of the foaming agent injected from the injector 44 include a physical foaming agent, a chemical foaming agent, and a mixture thereof, and a physical foaming agent is preferable. As the physical foaming agent, inorganic physical foaming agents such as air, carbon dioxide, nitrogen gas, and water, organic physical foaming agents such as butane, pentane, hexane, dichloromethane, and dichloroethane, and their supercritical fluids are used. be able to. As the supercritical fluid, it is preferable to use carbon dioxide, nitrogen, etc., for nitrogen, the critical temperature is -149.1 ° C, the critical pressure is 3.4 MPa or more, and for carbon dioxide, the critical temperature is 31 ° C, the critical pressure. It is obtained by setting the pressure to 7.4 MPa or more. Examples of the chemical foaming agent include those that generate carbon dioxide gas by a chemical reaction between an acid (eg, citric acid or a salt thereof) and a base (eg, baking soda). The chemical foaming agent may be injected from the hopper 41 instead of being injected from the injector 44.

(Accumulator 45 and T-die 5)
The foamed resin M2 formed by melt-kneading the raw material resin M1 and the foaming agent is extruded from the resin extrusion port of the cylinder 43 and injected into the accumulator 45 through the connecting pipe 61. The accumulator 45 includes a cylinder 46 and a piston 47 slidable inside the cylinder 46, and the foamed resin M2 can be stored in the cylinder 46. Then, by moving the piston 47 after a predetermined amount of the foamed resin M2 is stored in the cylinder 46, the foamed resin M2 is pushed out from the slit provided in the T die 5 through the connecting pipe 62 and hung down to be a foamed resin sheet. 21 is formed.

(Molds 71 and 72)
The foamed resin sheet 21 is guided between the molds 71 and 72. A concave cavity 711 is formed in the mold 71. A convex core 721 is formed on the mold 72. The molds 71 and 72 are provided with a large number of decompression suction holes (not shown). Further, the molds 71 and 72 are formed with pinch-off portions 712 and 722 so as to surround the cavity 711.

2.2 Flow of manufacturing method FIG. 8 shows a mode in which the molds 71 and 72 are opened in the manufacturing of the molded product 1. FIG. 9 shows an embodiment in which the foamed resin sheet 21 and the non-foamed resin sheet 22 are shaped into the shape of the mold 72 by vacuum suction of the mold 72 in the production of the molded body 1. FIG. 10 shows a mode in which the molds 71 and 72 are closed in the production of the molded body 1, and in particular, FIG. 10A shows the whole, and FIG. 10B is an enlarged view of a portion surrounded by a dotted line in FIG. 10A. 10C shows a mode in which the foamed resin sheet 21 is expanded from the state of FIG. 10B. The manufacturing method of the molded body 1 includes a placement step, a molding step, a cutting step, a rotation step, and a welding step.

(Placement process)
In the arranging step, the foamed resin sheet 21 and the non-foamed resin sheet 22 are arranged between the pair of molds 71 and 72. More specifically, as shown in FIGS. 7 and 8, in the arranging step, one foamed resin sheet 21 formed by extruding the molten foam resin M2 from the slit of the T die 5 is formed into a mold 71. , 72. A non-foamed resin sheet 22 is arranged between the foamed resin sheet 21 and the mold 72.

(Molding process)
Subsequently, in the molding step, the pair of molds 71 and 72 are closed and sucked from both sides, and then opened, so that the foamed resin sheet 21 is more foamed to become a resin molded body 11 and a non-foamed resin. The molded body 1 is manufactured by forming the sheet 22 as the skin member 12. Specifically, the molding step includes a suction step, a mold closing step, and an expansion step. In the suction step, the foamed resin sheet 21 and the non-foamed resin sheet 22 are sucked from the decompression suction holes of the mold 72. As a result, the foamed resin sheet 21 and the non-foamed resin sheet 22 are shaped along the core 721 of the mold 72 (see FIG. 9).

In the mold closing step, as shown in FIG. 10A, the molds 71 and 72 are brought close to each other to close the mold. As a result, the pinch-off portion 712 and the pinch-off portion 722 come into contact with each other, and the space S is formed by the molds 71 and 72. Here, the space S defined by the pair of molds 71 and 72 includes the bending space S1, and the thickness d1 of the bending space S1 is thinner than the thickness d2 other than the bending space S1 of the space S. Please note. Preferably, the thickness in the bending space S1 is configured to be continuously thinner than the thickness of the space S other than the bending space S1.

With such a configuration, the wall thickness t1 in the bent portion 13 will be reprinted, but the bent portion 13 of the resin molded body 11 has a wall thickness t1 according to the shape of the space S defined by the pair of molds 71 and 72 used at the time of molding. It will be configured to be thinner than the wall thickness t2 other than the above. Further, at least those having a radius of curvature R of 100 mm or less in the bending space S1 are included, and at least those having an angle φ formed by the two tangent planes Q1 and Q2 at both ends of the bending space S1 of 150 degrees or less are included. Further, the angle φ may be 90 degrees or less. That is, the thicknesses d1 and d2 correspond to the wall thicknesses t1 and t2, the radius of curvature R corresponds to the radius of curvature r, and the angle φ corresponds to the angle θ.

That is, by such a step, the foamed resin sheet 21 and the non-foamed resin sheet 22 are appropriately wrapped around the bent space S1 and shaped along the shapes of the molds 71 and 72. Then, the non-foamed resin sheet 22 can be appropriately welded to the foamed resin sheet 21. As a result, molding defects are suppressed.

In the state where the mold closing step is completed, the distance between the molds 71 and 72 is very narrow in the portion where the hinge portion 33 is formed, and the foamed resin sheet 21 and the non-foamed resin sheet 22 are crushed. There is. As a result, the thinned hinge portion 33 is formed on the molded body 1. Further, the portion of the foamed resin sheet 21 and the non-foamed resin sheet 22 outside the space S becomes a burr 25. Further, in the expansion step, the space S is depressurized from the decompression suction holes of the molds 71 and 72. As a result, the foamed resin sheet 21 is expanded. When the space S is depressurized, the foaming of the foamed resin sheet 21 is promoted and the foamed resin sheet 21 expands (see FIGS. 10B and 10C).

(Excision process)
Subsequently, the molds 71 and 72 are opened, and the molded body 1 is taken out from the molds 71 and 72. The foamed resin sheet 21 and the non-foamed resin sheet 22 are welded to form the resin molded body 11 and the skin member 12 in the molded body 1, respectively. In the excision step, the burr 25 formed on the molded body 1 is excised.

(Rotation process)
Subsequently, in the rotation step, the entire reinforcing portion 32 of the molded body 1 is rotated around the hinge portion 33 of the molded body 1. Specifically, the reinforcing portion 32 of the molded body 1 is bent so as to tilt the reinforcing portion 32 of the molded body 1 toward the back surface 36 of the base wall 315. The rotation step may be carried out by the manufacturer or may be carried out by the manufacturing apparatus.

(Welding process)
In the welding step, the back surface 36 of the base wall 315 of the molded body 1 and the reinforcing rib 321 of the reinforcing portion 32 of the molded body 1 are welded. As a result, it is possible to prevent the bent reinforcing portion 32 from returning to the original state, that is, the state before the bent portion due to the elastic force of the hinge portion 33. Ultrasonic welding is used in the welding process.

By such a manufacturing method, it is possible to manufacture a molded body 1 having a complicated shape including a bent portion while suppressing the occurrence of molding defects.

3. 3. Modification Example Section 3 describes a modification of the molded body 1. That is, the molded body 1 or the molded body 1 may be carried out according to the following aspects.

(1) The wall thickness of the bent portion 13 may be changed discretely as compared with a portion other than the bent portion 13. FIG. 11 shows a perspective view showing a molded body 1 according to a modified example. FIG. 12 shows an end view showing a molded body 1 according to a modified example. As described above, it is preferable that the region 131 including the bent portion 13 is formed substantially uniformly with a wall thickness t1.
(2) In the embodiment, if the two-layer molded body 1 having the bent portion 13 is formed so that the wall thickness t1 of the bent portion 13 is thinner than the wall thickness t2 of the other portion. It is not limited to the molded body 1 described.
(3) Since it is costly to newly process the dies 71 and 72, the conventional dies 71 and 72 having the same thicknesses d1 and d2 may be used in the production of the molded body 1. In such a case, the wall thickness of the molded body 1 can be adjusted by incorporating another member into the molds 71 and 72 at the time of molding.
(4) The skin member 12 is arranged on one side of the resin molded body 11 which is a valley (concave portion) of the bent portion 13, but in addition to this, the other side which is a mountain (convex portion) of the bent portion 13. May also be placed in.

4. Conclusion As described above, it is possible to provide a molded product in which molding defects are unlikely to occur and a method for producing the molded product.

It may be provided in each of the following aspects.
In the molded body, the radius of curvature of the bent portion is 100 mm or less.
In the molded body, the angle formed by the two tangent planes at both ends of the bent portion is 150 degrees or less.
In the molded body, the angle is 90 degrees or less.
In the molded body, the wall thickness at the bent portion is configured to be continuously thinner than the wall thickness of the resin molded body other than the bent portion.
A method for manufacturing a molded body having a resin molded body and a skin member, which comprises an arranging step and a molding step. In the arranging step, a foamed resin sheet and a non-foamed resin sheet are arranged between a pair of molds. Here, the space defined by the pair of molds includes a bending space, and the thickness of the bending space is configured to be thinner than the thickness of the space other than the bending space. By closing the pair of molds, sucking them from both sides, and then opening them, the foamed resin sheet becomes more foamed to become the resin molded product, and the non-foamed resin sheet becomes the skin member. , A method for producing the molded product.
In the method for manufacturing a molded product, the radius of curvature of the bent space is 100 mm or less.
In the method for manufacturing a molded product, the angle formed by the two tangent planes at both ends of the bent space is 150 degrees or less.
In the method for producing a molded product, the angle is 90 degrees or less.
In the method for manufacturing a molded product, the thickness in the bent space is configured to be continuously thinner than the thickness of the space other than the bent space.
Of course, this is not the case.

Finally, various embodiments of the present invention have been described, but these are presented as examples and are not intended to limit the scope of the invention. The novel embodiment can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the gist of the invention. The embodiment and its modifications are included in the scope and gist of the invention, and are included in the scope of the invention described in the claims and the equivalent scope thereof.

1: Molded body 11: Resin molded body 12: Skin member 13: Bent part 131: Region 14: Bending part 2: Molding machine 21: Foamed resin sheet 22: Non-foamed resin sheet 25: Burr 31: Base 311: Base body 312 : Flange wall 313: First edge 314: Second edge 315: Base wall 316: Standing wall 317: Opening 32: Reinforcing part 321: Reinforcing rib 322: Fixed part 323: Opening 33: Hinging part 34: Front surface 35: Protruding portion 36: Back surface 4: Resin supply device 41: Hopper 42: Extruder 43: Cylinder 44: Injector 45: Accumulator 46: Cylinder 47: Piston 5: T-die 61: Connecting pipe 62: Connecting tube 71: Mold 711: Cavity 712: Pinch-off part 72: Mold 721: Core 722: Pinch-off part M1: Raw material resin M2: Foamed resin P1: Contact plane P2: Contact plane Q1: Contact plane Q2: Contact plane R: Radius of curvature S: Space S1: Bending space d1: Thickness d2: Thickness r: Radius of curvature t1: Wall thickness t2: Wall thickness θ: Angle φ: Corner

Claims (10)

It is a molded product
It has almost the same shape as the space defined by the pair of molds used during molding,
A resin molded body and a skin member are provided,
The resin molded body is
Made of foamed resin
A bent portion is provided, and here, the wall thickness at the bent portion is configured to be thinner than the wall thickness other than the bent portion of the resin molded body according to the shape of the space.
The skin member is arranged on one side of the resin molded product, which is a valley of the bent portion. In the molded product according to claim 1,
The bent portion has a radius of curvature of 100 mm or less. In the molded product according to claim 1 or 2.
The angle formed by the two tangent planes at both ends of the bent portion is 150 degrees or less. In the molded product according to claim 3,
The angle is 90 degrees or less. In the molded product according to any one of claims 1 to 4.
The wall thickness at the bent portion is configured to be continuously thinner than the wall thickness of the resin molded product other than the bent portion. A method for manufacturing a molded body having a resin molded body and a skin member.
It has a placement process and a molding process.
In the arrangement step, the foamed resin sheet and the non-foamed resin sheet are arranged between the pair of molds, and the space defined by the pair of molds includes a bending space and the thickness of the bending space. Is configured to be thinner than the thickness of the space other than the bent space.
In the molding step, the pair of molds are closed, sucked from both sides, and then opened to further foam the foamed resin sheet to become the resin molded body, and the non-foamed resin sheet becomes the non-foamed resin sheet. A method of manufacturing the molded product by becoming a skin member. In the method for producing a molded product according to claim 6,
The radius of curvature of the bent space is 100 mm or less. In the method for producing a molded product according to claim 6 or 7.
The angle formed by the two tangent planes at both ends of the bent space is 150 degrees or less. In the method for producing a molded product according to claim 8,
The angle is 90 degrees or less. The method for producing a molded product according to any one of claims 6 to 9.
The thickness in the bent space is configured to be continuously thinner than the thickness of the space other than the bent space.

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