JP3443594B2 - Forming method of foam board - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for molding a foamed plate in which foamed plastic is formed into a plate shape, and more particularly to a method for molding a foamed plate suitable for molding a service hole cover or the like arranged in an automobile door. Regarding

[0002]

2. Description of the Related Art Conventionally, inside an automobile door,
A service hole cover is provided for waterproofing or soundproofing. This service hole cover is usually formed of a soft plastic sheet, and a recess (a projection when viewed from the opposite side) is formed in the seat at a location corresponding to a pocket or a speaker attached to the interior side of an automobile door and a speaker. ,
Felt is adhered to almost the entire sheet.

[0003]

However, since the recesses corresponding to the door pockets and the speaker portion in the service hole cover are relatively large and have a deep depth, only the recessed members are separately formed by vacuum forming, and the recesses are previously formed. A recessed member is adhered by heat sealing or the like so as to cover the hole on a plastic sheet which is cut by forming a hole at a predetermined position, and further, a felt is adhered on the sheet to manufacture.

However, according to this type of conventional method, when a plastic sheet is three-dimensionally molded, vacuum molding is used. Therefore, it is necessary to install an expensive vacuum molding die or a heating device for heating the sheet. In addition, many steps such as a step of cutting the sheet into a predetermined shape, a step of forming the concave member by vacuum forming, a step of adhering the concave member to a hole on the sheet, a step of sticking felt, etc. are required,
There is a problem that the manufacturing cost increases.

The present invention has been made in view of the above points, and it is possible to easily form a relatively large concave portion or convex portion on a foam plate, and to easily manufacture a service hole cover and the like with a small number of steps. An object of the present invention is to provide a method for molding a foam plate that can be manufactured.

[0006]

In order to achieve the above-mentioned object, the molding method of the present invention is a molding method in which a foamed plate in which foamed plastic is formed into a plate shape is three-dimensionally molded to form a concave portion or a convex portion. In, in the part corresponding to the concave or convex part on the foam plate, the annular groove formed as a flat mold
Characterized in that a plurality of contour-shaped annular grooves are formed on the foam plate by pressing the rib for use and crushing the foam plate portion, and the recesses or protrusions are formed by extending the annular groove and the vicinity thereof. .

[0007]

According to the method of molding a foam plate having such a structure, a part of the foam plate is crushed into contour lines by press working to form an annular groove, whereby the annular groove and its vicinity are formed. Since the material is expanded and the concave portion or the convex portion is formed therein, it is not necessary to preheat the foam plate which is the material as in the conventional vacuum forming, and the material heating device is not necessary. Further, it is only necessary to form an annular groove in a contour line shape at a portion corresponding to the concave portion or the convex portion on the foam plate, and these grooves are formed by pressing the end portion of the strip-shaped steel plate or the like on the foam plate, and press working. Since it can be easily formed, it is not necessary to make an expensive vacuum forming mold as in the case of performing vacuum forming, and for example, use a simple flat plate mold in which a strip steel plate is erected in a contour line on a wooden board. You can Therefore, the equipment cost for molding can be made very low.

Further, if a Thomson blade is provided on the peripheral edge of the plate-shaped die, it can be cut into a predetermined shape during press working. In one working step, cutting can be performed from the processing of the concave portion or the convex portion. Can be completed and processing man-hours can be reduced.

Furthermore, if the present invention is applied to the manufacture of a service hole cover disposed inside an automobile door, the conventional steps of vacuum forming and cutting a sheet,
It is possible to eliminate the step of adhering the separately formed concave member to the predetermined hole portion of the sheet and the step of attaching the felt to the back surface of the sheet, and it is possible to manufacture the service hole cover very easily with a small number of steps. In addition, the service hole cover can be manufactured at low cost because it has a soundproofing effect without attaching the felt.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. The foam plate 1 used for molding is shown in FIG.
As shown in (1), a sheet-like material is formed by forming foamed plastic (for example, polyethylene foam) to a thickness of about 4 mm and adhering the soft film 1a to the back surface thereof. This foam board 1
Then, using a simple groove forming die 3 for press working, a concave portion 2 (a mountain-shaped convex portion when viewed from the opposite side) as shown in FIG. 6 is formed.

As shown in FIG. 2, the groove forming die 3 has a contoured annular groove forming rib 5 corresponding to the three-dimensional shape of the concave portion 2 to be formed on a substrate 4 such as a wooden board. Flat plate
And a cutting blade 6 for cutting the foam plate of the material into a predetermined shape is provided on the peripheral portion of the substrate 4 in a protruding manner. The annular groove forming rib 5 is formed by projecting the strip-shaped steel plate having a thickness of about 1 mm on the substrate 4 in a standing manner, and the ellipses are arranged in order in a contour line, that is, with the deepest part of the recess 2 as the center. Thus, a plurality of annular groove forming ribs 5 are formed in contour lines (FIG. 5).

By pressing the annular groove forming rib 5 against the foam plate 1 and forming the annular groove 8 therein, the groove and its vicinity are extended to form the concave portion 2, so that the tip has a rectangular cross section. ing. Further, when it is desired to increase the depth of the concave portion 2 (height of the convex portion), the number of annular groove forming ribs 5 is increased. Further, transverse ribs 7 are arranged between the curved portions of the annular groove forming rib 5 so as to radially divide the transverse ribs 7 so as to traverse the curved portions. The height of the annular groove forming rib 5 and the transverse rib 7 on the substrate 4 is slightly higher than the thickness of the foam plate 1.

As shown in FIG. 3, for example, such a groove forming die 3 is fixed on a bolster 10 of a press machine, and a pad plate 9 such as a wood plate is attached to a lower portion of a ram 11.

When the recess 2 is formed in the foam plate 1, as shown in FIG. 3, the foam plate 1 is placed on the upper surface of the groove forming die 3 using a press machine.
It can be easily molded simply by pressing to press.

That is, by the stroke operation of the ram of the pressing machine, the foam plate 1 is placed on the surface of the groove forming die 3 (for example, about 6 mm).
When pressed with a force of 0 kgf), the tips of the annular groove forming ribs 5 and the transverse ribs 7 of the groove forming die 3 are moved to the foam plate 1 as shown in FIG.
And the annular groove 8 and the transverse groove 18 are formed therein. At this time, the foamed portions of the bottom portions of the grooves 8 and 18 are crushed, so that the portions extend in the width direction and the longitudinal direction.

The annular groove 8 and the transverse groove 18 are formed on the plane of the foam plate 1 in the same shape as the planes of the annular groove forming rib 5 and the transverse rib 7 of the groove forming die 3 shown in FIG. Foaming due to the formation of multiple annular or contour lines around the site
When the plate 1 is removed, as shown in FIGS. 6 and 7, the portion surrounded by the annular groove projects upward or downward by the amount of extension. Therefore, the recessed portion (projection when viewed from the opposite side) 2 is formed on the foam plate 1.

Simultaneously with the press working, the foam plate 1 is cut into a predetermined shape by the cutting blade 6 arranged around the groove forming die 3. Since the tips of the annular groove forming rib 5 and the transverse rib 7 have a rectangular cross section, the foam plate 1 is not cut by the ribs, and the film 1 is formed on the back surface of the foam plate 1.
It is not broken even when a is bonded.

As described above, only by pressing, a part of the foam plate 1 is crushed into contour lines to form grooves, and the annular groove 8, the transverse groove 18 and the vicinity thereof are elongated, and the concave portion is formed therein. Alternatively, since the convex portion is formed, it is not necessary to preheat the foam plate, which is a material, unlike the conventional vacuum forming, and a preheating process and equipment such as a heating device are unnecessary.

Further, it suffices to form the annular groove 8 and the transverse groove 18 in a contour line shape in a portion corresponding to the concave portion or the convex portion on the foam plate 1, and these grooves form the end portion of the strip-shaped steel plate and the like on the foam plate. It can be easily formed by pressing just by pressing it on top. Therefore, unlike the case of performing conventional vacuum forming, it is not necessary to make an expensive vacuum forming die, and for example, a simple flat plate die in which a strip-shaped steel plate is erected in a contour line on a wooden board can be used. . Therefore, the equipment cost for molding can be made very low.

Further, since the Thomson blade 6 is provided on the peripheral edge of the groove forming die 3, the foam plate 1 can be cut into a predetermined shape during press working, and in a single working step, a concave portion or a convex portion can be formed. From processing to cutting can be completed,
The number of processing steps can be reduced.

Such a foam plate 1 can be used as a service hole cover arranged inside an automobile door, and if a service hole cover is manufactured from this foam plate 1, a seat which has been conventionally used can be obtained. It is possible to eliminate the steps of vacuum forming and cutting, the step of adhering a separately formed concave member to the predetermined hole portion of the sheet, and the step of attaching felt to the back surface of the sheet, and it is very easy to open the service hole cover in a few steps. It can be manufactured. In addition, the service hole cover can be manufactured at low cost because it has a soundproofing effect without attaching the felt.

In the above embodiment, the annular groove 8 is formed in a contour line at a predetermined position of the foam plate, and the transverse groove 18 is formed so as to traverse the annular groove 8. However, depending on the shape, the transverse groove may be formed. It is possible to form the concave portion or the convex portion only by the annular groove 8 without making it.

[Brief description of drawings]

FIG. 1 is a partial perspective view of a foam plate used in an embodiment of a molding method of the present invention.

FIG. 2 is a perspective view of a groove forming die used in an embodiment of a forming method of the present invention.

FIG. 3 is a schematic front view of a state of being pressed.

FIG. 4 is a partially enlarged view of a groove formed by press working.

FIG. 5 is a plan view of a groove forming die.

FIG. 6 is a perspective view of a molded foam plate.

FIG. 7 is an enlarged sectional view taken along line VII-VII of FIG.

[Explanation of symbols]

1-foam board 2-recess 3-grooving mold 8-annular groove 18-cross groove

Claims (4)

(57) [Claims] 1. A molding method of three-dimensionally molding a foamed plate formed by molding foamed plastic into a plate shape to form a concave portion or a convex portion, in a portion corresponding to the concave portion or the convex portion on the foam plate,
Press the annular groove forming rib formed as a flat plate mold
By crushing a part of the foam plate, a plurality of contour-shaped annular grooves are formed on the foam plate, and the annular groove and the vicinity thereof are elongated to form a concave portion or a convex portion. Forming method of foam plate. 2. The method for molding a foam plate according to claim 1, wherein a film is adhered to the back surface of the foam plate. 3. The method for molding a foam plate according to claim 2, wherein a cavities or protrusions are molded on the foam plate to manufacture a circulator hole cover used in an automobile door. 4. The method for molding a foam plate according to claim 1, wherein the foam plate is cut into a predetermined shape during the pressing.