JP3839135B2 - Resin molded body, method for manufacturing the same, and manufacturing apparatus therefor - Google Patents

Resin molded body, method for manufacturing the same, and manufacturing apparatus therefor Download PDF

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Publication number
JP3839135B2
JP3839135B2 JP15699097A JP15699097A JP3839135B2 JP 3839135 B2 JP3839135 B2 JP 3839135B2 JP 15699097 A JP15699097 A JP 15699097A JP 15699097 A JP15699097 A JP 15699097A JP 3839135 B2 JP3839135 B2 JP 3839135B2
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movable mold
mold
resin
pressure
molten resin
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JPH11941A (en
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充 渡
村 孝 志 木
崎 尚 行 矢
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Prime Polymer Co Ltd
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Prime Polymer Co Ltd
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Priority to PCT/JP1998/002527 priority patent/WO1998056556A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/72—Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/361—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/361—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons
    • B29C2043/3615—Forming elements, e.g. mandrels or rams or stampers or pistons or plungers or punching devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/58—Measuring, controlling or regulating
    • B29C2043/5833—Measuring, controlling or regulating movement of moulds or mould parts, e.g. opening or closing, actuating
    • B29C2043/5841—Measuring, controlling or regulating movement of moulds or mould parts, e.g. opening or closing, actuating for accommodating variation in mould spacing or cavity volume during moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/58—Measuring, controlling or regulating
    • B29C2043/5875—Measuring, controlling or regulating the material feed to the moulds or mould parts, e.g. controlling feed flow, velocity, weight, doses
    • B29C2043/5883—Measuring, controlling or regulating the material feed to the moulds or mould parts, e.g. controlling feed flow, velocity, weight, doses ensuring cavity filling, e.g. providing overflow means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/12—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels
    • B29C33/14—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels against the mould wall

Description

【０００１】
【発明の属する技術分野】
本発明は、樹脂基材の少なくとも一部分にメッシュ形状の小径多孔部が形設された樹脂成形体、およびそのための製造方法ならびに製造装置に関し、より詳細には、一対の固定金型と可動金型との間に溶融樹脂を供給して、可動金型を固定金型に対して閉止することによって、溶融樹脂をプレス成形する樹脂成形体の製造方法及びそのための製造装置に関する。
【０００２】
【従来の技術】
近年、自動車に対するニーズの多様化に伴って、例えば、自動車内の音響システムのスピーカを自動車のドアに埋設することが行われている。
【０００３】
このため、従来より、図１３に示したように、アームレスト６１の下方などのスピーカー埋設部分に相当する部分にメッシュ形状の小径の複数の孔部が形成された円形状の小径多孔部（スピーカグリル）６２を備えた樹脂製のドアトリム６０が使われ、これを金属製のドアの内側に取り付けて内装部材とすることが行われている。特に、最近では、このドアトリム６０の一部分に、高級感を付与するために、部分的に塩化ビニル、ポリエチレン、ポリプロピレン、合成ゴム等から製造された合成皮革などの表皮部材６３を貼着することが行われている。
【０００４】
このようなドアトリムを製造する方法としては、射出成形によって、メッシュ形状の小径の複数の孔部が形成された小径多孔部を備えた樹脂成形体を製造した後、または樹脂成形体と小径多孔部とを別々に製造してから組み合わせた後、この樹脂成形体の表面に接着剤を介して部分的に皮革などの表皮部材を貼着して、ドアトリムを製造する方法がある。
【０００５】
【発明が解決しようとする課題】
ところで、昨今では、一対の固定金型と可動金型との間に溶融樹脂を供給して、可動金型を固定金型に対して閉止することによって、溶融樹脂をプレス成形する射出プレス成形方法（スタンピング成形と呼ぶこともある）（以下、これらの方法を総称して「射出プレス」と言う）が開発されてきている。
【０００６】
すなわち、このような射出プレスでは、わずかに開いた固定金型と可動金型との間に低圧で供給された溶融樹脂を型締め圧力によって均一に流動させて成形するので、通常の射出成形法に比較して残留歪が少なくかつ成型品の変形が小さい等のメリットがあることから現在広範に用いられている。
【０００７】
また、この射出プレスでは、固定金型と可動金型との間に表皮部材を予め装着しておき、樹脂成形体の表面に表皮層を溶着によって同時に形成できる。しかし、この方法は、上記したようなメッシュ形状の小径の複数の孔部が形成された小径多孔部を備えた樹脂成形体を製造する方法としては、適していない。
【０００８】
従来方法によれば、図１４に示したように、可動金型１１３の一部分に固定金型１１１側に突設する複数の小径柱状体１１２を一定間隔離間して設けておき、可動金型１１３を固定金型１１１に対して降下（閉止）させて、両金型の間に空隙１１９を形成した後、押出機１０２などから、ホットランナーブロック１１６の通路１１７を介して、固定金型の上面に開口したゲート部１１５より溶融樹脂Ｂを両金型の間の空隙１１９に射出して、さらに可動金型を閉止することによって、溶融樹脂を型締め圧力によって均一に流動させて成形することが考えられる。
【０００９】
しかしながら、このような方法では、射出された溶融樹脂Ｂが、可動金型１１３の降下にともなって、図１５に示したように、可動金型１１３の小径柱状体１１２の下端と固定金型１１１の上面１１４との間に溶融樹脂Ｂ’が流延してしまう（入り込む）ので、その部分が平面的ないわゆるバリとなってしまい、成形後にメッシュ形状の小径の複数の孔部が閉塞してしまうおそれがあり、このような方法で孔部を形成することは困難であった。
【００１０】
従って、現状では、このようなドアトリムを製造する方法としては、スピーカー埋設部分に相当する部分を欠落部分とした樹脂成形体本体を射出プレスによりあらかじめ成形するとともに、別途メッシュ形状の小径の複数の孔部が形成された小径多孔部を射出成形で成形して、両者を組み合わせて（取り付けて）、ドアトリムを製造するのが通常である。このような方法では、工程が煩雑で手間がかかり、製造コストが高くなっていた。
【００１１】
さらに、ドアトリムを製造する方法として、射出成形によって一体又は別々に成形して、メッシュ形状の小径の複数の孔部が形成された小径多孔部を備えた樹脂成形体を製造した後、この樹脂成形体の表面に接着剤を介して部分的に皮革などの表皮部材を貼着する方法では、接着剤塗布作業、表皮部材貼着作業が必要であり、工程が煩雑で手間がかかり、製造コストが高くなっていた。
【００１２】
本発明は、このような現状に鑑みて、樹脂基材の少なくとも一部分にメッシュ形状の小径多孔部が形設された樹脂成形体を、小径多孔部において平面的なバリが発生せず、射出プレスにより一体的に簡単に成形することが可能な樹脂成形体の製造方法およびそのための製造装置を提供することを目的とする。
【００１３】
また、本発明は、このような製造方法および製造装置を用いて製造した、樹脂基材の少なくとも一部分にメッシュ形状の小径多孔部が形設された樹脂成形体の表面に、合成皮革などの表面部材が接着剤などを用いることなく、直接貼着された樹脂成形体を提供することを目的とする。
【００１４】
【課題を解決するための手段】
本発明は、前述したような従来技術における課題及び目的を達成するために発明されたものであって、本発明の樹脂成形体の製造方法は、一対の固定金型と可動金型との間に溶融樹脂を供給して、可動金型を固定金型に対して閉止することによって、溶融樹脂をプレス成形する樹脂成形体の製造方法であって、前記固定金型の一部分に形成され、加圧シリンダーによって可動金型側に突出動可能なコア部材と前記可動金型との間の、前記可動金型側に一定間隔離間して配設した複数の小径柱状部材を介在させつつ、前記加圧シリンダーで前記コア部材を可動金型側に突出させることによって、前記小径柱状部材に前記コア部材の上面を密着させる工程と、前記固定金型と可動金型の間に形成される空隙に溶融樹脂を供給する工程と、前記可動金型を固定金型に対して閉止するとともに、前記可動金型のプレス圧により前記コア部材を後退させて溶融樹脂をプレス成形する工程と、からなり、前記小径柱状部材に前記コア部材の上面を密着させる工程における前記加圧シリンダーの圧力は、前記溶融樹脂を供給する工程での溶融樹脂圧よりも大であり、前記プレス成形する工程における前記加圧シリンダーの圧力は、前記プレス成形する工程での前記プレス圧よりも小であり、これによって部分的にメッシュ形状の小径多孔部が形設された樹脂成形体を得ることを特徴とする。
さらに、本発明の樹脂成形体の製造方法は、一対の固定金型と可動金型との間に溶融樹脂を供給して、可動金型を固定金型に対して閉止することによって、溶融樹脂をプレス成形する樹脂成形体の製造方法であって、前記固定金型の一部分に形成され、加圧シリンダーによって可動金型側に突出動可能なコア部材と前記可動金型との間の、前記コア部材側に一定間隔離間して配設した複数の小径柱状部材を介在させつつ、前記加圧シリンダーで前記コア部材を可動金型側に突出させることによって、前記小径柱状部材に前記可動金型の下面を密着させる工程と、前記固定金型と可動金型の間に形成される空隙に溶融樹脂を供給する工程と、前記可動金型を固定金型に対して閉止するとともに、前記可動金型のプレス圧により前記コア部材を後退させて溶融樹脂をプレス成形する工程と、からなり、前記小径柱状部材に前記可動金型の下面を密着させる工程における前記加圧シリンダーの圧力は、前記溶融樹脂を供給する工程での溶融樹脂圧よりも大であり、前記プレス成形する工程における前記加圧シリンダーの圧力は、前記プレス成形する工程での前記プレス圧よりも小であり、これによって部分的にメッシュ形状の小径多孔部が形設された樹脂成形体を得ることを特徴とする。
【００１５】
また、本発明の樹脂成形体の製造装置は、一対の固定金型と可動金型と、両金型の間に形成される金型空隙に溶融樹脂を供給する溶融樹脂供給手段と、前記固定金型に嵌着され、加圧シリンダーによって前記可動金型方向に突出動可能なコア部材と、前記可動金型の下面に装着され、一定間隔離間して配設された複数の小径柱状部材と、から構成された樹脂成形体の製造装置であって、前記コア部材は、溶融樹脂の供給時には、前記加圧シリン
ダーによって可動金型方向に移動して、前記小径柱状部材に前記コア部材の上面を密着させ、溶融樹脂のプレス成形時には、前記可動金型を固定金型に対して閉止するとともに前記可動金型のプレス圧によって前記コア部材を後退するように構成し、前記小径柱状部材に前記コア部材の上面を密着させる際の前記加圧シリンダーの圧力は、前記溶融樹脂を供給する際の溶融樹脂圧よりも大となるように設定され、前記プレス成形する際の前記加圧シリンダーの圧力は、前記プレス成形する際の前記プレス圧よりも小となるように設定されていることを特徴とする。
さらに、本発明の樹脂成形体の製造装置は、一対の固定金型と可動金型と、両金型の間に形成される金型空隙に溶融樹脂を供給する溶融樹脂供給手段と、前記固定金型に嵌着され、加圧シリンダーによって前記可動金型方向に突出動可能なコア部材と、前記コア部材の上面に装着され、一定間隔離間して配設された複数の小径柱状部材と、から構成された樹脂成形体の製造装置であって、前記コア部材は、溶融樹脂の供給時には、前記加圧シリンダーによって可動金型方向に移動して、前記小径柱状部材に前記可動金型の下面を密着させ、溶融樹脂のプレス成形時には、前記可動金型を固定金型に対して閉止するとともに前記可動金型のプレス圧によって前記コア部材を後退するように構成し、前記小径柱状部材に前記可動金型の下面を密着させる際の前記加圧シリンダーの圧力は、前記溶融樹脂を供給する際の溶融樹脂圧よりも大となるように設定され、前記プレス成形する際の前記加圧シリンダーの圧力は、前記プレス成形する際の前記プレス圧よりも小となるように設定されていることを特徴とする。
【００１６】
このように構成することによって、固定金型と可動金型の間に形成される空隙に供給された溶融樹脂が、金型の閉止にともなって、空隙全体に流延してプレスされ、このプレスの際に、コア部材がプレス圧によって後退するので、溶融樹脂をプレスできるとともに、コア部材と可動金型の間に介在する複数の小径柱状部材によって、部分的にメッシュ形状の小径多孔部が形設された樹脂成形体が一体的に得られる。しかも、コア部材を可動金型側に突出させて、溶融樹脂を供給するので、小径柱状部材と固定金型または可動金型の間に空隙が形成されないので、このような空隙に溶融樹脂が入り込み、平面的なバリが発生して成形後にメッシュ形状の小径の複数の孔部が閉塞することがなく、確実にメッシュ形状の小径多孔部が形設される。さらに、成型品の外観も良好であり、しかも十分な機械的強度を保持することができる。
【００１７】
この場合、前記小径柱状部材が、可動金型の固定金型側表面に形成されていてもよく、また、コア部材の可動金型側表面に形成されていても良いが、小径柱状部材の磨耗などによって、万一メッシュ形状の小径多孔部の周囲にバリが発生したとしても、バリが樹脂成形体の表面に発生せず、樹脂成形体の裏面に発生することになるので、可動金型の固定金型側表面に形成されているのが好ましい。
【００１８】
また、前記固定金型と可動金型との間に、メッシュ形状の小径多孔部予定部分以外の箇所に、予め表皮材を挟装して成形を行うことによって、部分的に二層ないし多層の成形体を得ることができ、例えば、スピーカグリルを備えたドアトリムなど自動車用内装材など種々の用途に使用可能である。
【００１９】
さらに、本発明の樹脂成形体は、上述した樹脂成形体の製造方法および製造装置によって製造できるものであって、前記樹脂成形体は、樹脂基材の一部分に厚さ方向に欠切した空洞部が形成され、前記空洞部の樹脂基材表面側に、前記樹脂基材と一体的に形成されたメッシュ形状の小径多孔部が形設されるとともに、前記樹脂基材の前記小径多孔部を除いた表面の少なくとも一部分に、表皮層部材が前記樹脂基材との溶着により一体的に固着されていることを特徴とする。
【００２０】
このように、樹脂基材の溶着により表皮層が樹脂基材に一体的に固着されているので、接着剤塗布作業、表皮部材貼着作業が不要で、工程が簡単であり、製造コストも安価となる。
【００２１】
【発明の実施の形態】
以下、図面を参照しながら本発明の実施の形態（実施例）について説明する。
図１は、本発明の樹脂成形体の製造装置を具備した製造装置の全体の概略図、図２は、本発明の樹脂成形体の製造装置の第１の実施例を示す断面図である。
【００２２】
図１において、１は全体で本発明の樹脂成形体の製造装置３を具備した製造装置を示している。製造装置１は、溶融樹脂を樹脂成形体の製造装置３に射出供給するための射出機を備えた射出ユニット部２と、射出ユニット部２より射出供給された溶融樹脂を成形するための樹脂成形体の製造装置３とを備えている。
【００２３】
図１および図２に示したように、樹脂成形体の製造装置３は、下方に固定的に配置された下金型を構成する固定金型１１と、固定金型１１の上方に配置され、プレス機１２のプラテン１２ａの作動によって上下動自在に構成されて、固定金型１１に対して閉止可能となっている上金型を構成する可動金型１３を備えている。
【００２４】
すなわち、可動金型１３は、その周縁部が下方に突設した周縁部１３ａが形成されており、この周縁部１３ａで囲撓されて内部空間１３ｂが形成され、この内部空間１３ｂ内に固定金型１１が嵌合するようになっている。なお、図中、２７は、表皮層部材３０を使用する必要がある場合に、表皮部材を保持するための表皮部材保持装置である。
【００２５】
固定金型１１の可動金型側１３側の表面である上面１４には、溶融樹脂を固定金型１１の上面に射出するためのゲート部１５が開設され、このゲート部１５には、固定金型１１内に設けられたホットランナーブロック１６の通路１７と連通されており、ホットランナーブロック１６の通路１７は、射出ユニット部２に接続されている。これにより、射出ユニット部２から、一定量の溶融樹脂が、ホットランナーブロック１６の通路１７、およびゲート部１５を介して、固定金型１１の上面１４と可動金型１３の下面１８の間の空隙１９に射出されるようになっている。
【００２６】
なお、図示しないが、ゲート部１５には、一定量の溶融樹脂を供給した後に自動的にゲート部１５を閉じるための開閉部材が備えられているのが望ましい。このような開閉部材としては、例えば、特公平４−６９０４６号公報に開示されているような開閉部材を備えたホットノズルを、ホットランナーブロック１６のゲート部１５側の端部に設けてもよい。
【００２７】
一方、可動金型１３の固定金型１１側の表面である下面１８には、樹脂成形品として、例えば、図１３に示したような、メッシュ形状の小径の複数の孔部が形成された円形状の小径多孔部（スピーカグリル）６２を備えたドアトリム６０を成形する場合に、小径多孔部に該当する部分２１に、一定間隔離間して配設され且つ固定金型１１側に突設する複数の小径の円柱部材である小径柱状部材２２、２２が、円形状に配置されて形成されている。
【００２８】
なお、この実施例では、小径柱状部材２２、２２を小径の円柱部材とし、円形状に配置するように形成したが、小径柱状部材２２、２２は、メッシュ形状の小径の複数の孔部の形状に応じて、例えば、四角柱状とするなど適宜変更可能であり、そのサイズ、配置状態、孔部の大きさも目的とする小径多孔部の形状に応じて適宜変更可能である。
【００２９】
また、この場合、小径柱状部材２２、２２を可動金型１３の下面１８に形成する方法としては、可動金型１３の下面に小径柱状部材２２、２２を直接刻設あるいは植設して形成しても良いが、図３に示したように、小径柱状部材２２、２２を突設した円盤状の小径多孔部用部材２０を、可動金型１３の下面１８に形成した円柱形状の凹部２９に嵌着して固定するようにすれば、種々の形態の小径多孔部を形成できるとともに、小径柱状部材２２、２２が磨耗損傷しても取り替えることができるので、バリの発生を防止することができる。
【００３０】
そして、固定金型１１には、この小径柱状部材２２が形成された箇所に対応する位置に、コア部材用ガイド孔２３が設けられており、このコア部材用ガイド孔２３内に、略円柱形状のコア部材２４が固定金型１１の上面１４より突出動可能に配設されている。また、コア部材２４の下端には、外周側に突設する鍔部２４ｂが形成されており、この鍔部２４ｂがガイド孔２３の上端に形成されたストッパ部２３ａに当接して、一定寸法以上にコア部材２４が固定金型１１の上面１４より突出しないように構成されている。この構成により、コア部材はピストンとして作動するようになっている。
【００３１】
さらに、このガイド孔２３の下方には、ピストン室２５が形成されており、このピストン室２５に加圧シリンダー２８が配設されている。この加圧シリンダー２８のピストンロッド２８Ａの先端部２８Ｂが、コア部材２４の後端側２４ｃに固着されており、圧油供給源（図示せず）から管路２６を介して圧油を加圧シリンダー２８に供給することにより、ピストンロッド２８Ａを突出させて、コア部材２４を固定金型１１の上面１４より突出するように構成されている。
【００３２】
この場合、圧油供給源から供給された圧油がピストンロッド２８Ａを突出させて、コア部材２４を押圧する圧力は、射出ユニット部２から固定金型１１の上面１４と可動金型１３の下面１８の間の空隙１９に射出される溶融樹脂の樹脂圧力よりも大きく、固定金型１１の上面１４と可動金型１３の下面１８の間の空隙１９に溶融樹脂が射出された後、可動金型１３が固定金型１１側に下降して、溶融樹脂をプレスする際のプレス圧力よりも小さくする必要がある。
【００３３】
これによって、コア部材２４が固定金型１１の上面１４より突出して、コア部材２４の上端２４ｄが可動金型１３の下面１８に形成された小径柱状部材２２、２２に当接し、固定金型１１の上面１４と可動金型１３の下面１８の間の空隙１９に溶融樹脂が射出された場合に、溶融樹脂の樹脂圧によって、コア部材２４が下方に移動することがない。従って、小径柱状部材２２、２２の下端２２ａとコア部材２４の上端２４ｄとの間に間隙ができないので、このような間隙に溶融樹脂が入り込むことがなく、平面的なバリが発生せず、成形後にメッシュ形状の小径の複数の孔部が閉塞することがなく、確実にメッシュ形状の小径多孔部を形設することができる。また、可動金型１３が固定金型１１側に下降して、溶融樹脂をプレスする際に、プレス圧力によって、可動金型１３の下降に追随して、コア部材１４が後退することができるので、溶融樹脂をプレスするとともに、所定の部位にメッシュ形状の小径の複数の孔部を形成することができる。
【００３５】
さらに、本実施例の場合、下方に固定金型１１を配置し、その上方に可動金型１３を上下動自在に配置した構成、すなわち、成型機を縦型で示したが、固定金型１１と可動金型１３を左右に配置して、可動金型１３を固定金型に対して左右方向（横方向）に移動可能として閉止できるような構成、すなわち、横型の成型機を用いてもよい。
【００３６】
このように構成される本発明の樹脂成形体の製造装置を用いて、樹脂成形体を製造する方法について、図４〜図８に基づいて説明する。
図４に示したように、プラテンを下降することによって、可動金型１３を固定金型１１から一定間隔離間した位置まで下降し待機させる。この際、図９に示したように、例えば、塩化ビニル、ポリエチレン、ポリプロピレン、合成ゴムなどで作製された合成皮革などの表皮部材３１とその下方に貼着したポリエチレ、ポリプロピレンなどの発泡合成樹脂層３２からなる表皮層部材３０を、固定金型１１と可動金型１３との間に、メッシュ形状の小径多孔部予定部分以外の箇所に、部分的に予め、表皮部材保持装置２７にその両端を保持して（図４の紙面に対して垂直方向の両端部を保持して）挟装しておく。
【００３７】
そして、圧油供給源から管路２６を介して圧油を加圧シリンダー２８に供給することにより、ピストンロッド２８Ａを突出させて、コア部材２４を固定金型１１の上面１４より突出させる（図５参照）。その後、コア部材２４の上端２４ｄが可動金型１３の下面１８に形成された小径柱状部材２２、２２に当接する位置まで可動金型１３を降下させる。
【００３８】
この状態で、射出ユニット部２より一定量の溶融樹脂Ａを、ホットランナーブロック１６の通路１７、およびゲート部１５を介して、固定金型１１の上面１４と可動金型１３の下面１８の間の空隙１９に射出する（図６参照）。射出された溶融樹脂は、ゲート部１５の周囲に塊状となり盛り上がるが、溶融樹脂Ａは流延（流動）して、固定金型１１の上面１４と可動金型１３の下面１８の間の空隙１９全体に流動して、小径柱状部材２２、２２の間の間隙にも流動していく（図７参照）。
【００３９】
この場合、圧油供給源から供給された圧油がピストンロッド２８Ａを突出させて、コア部材２４を押圧する圧力が、射出ユニット部２から固定金型１１の上面１４と可動金型１３の下面１８の間の空隙１９に射出される溶融樹脂の樹脂圧力よりも大きく設定されているので、溶融樹脂の樹脂圧によって、コア部材２４が下方に移動することがない。従って、小径柱状部材２２、２２の下端２２ａとコア部材２４の上端２４ｄとの間に間隙ができないので、このような間隙に溶融樹脂が入り込むことがなく、平面的なバリが発生せず、成形後にメッシュ形状の小径の複数の孔部が閉塞することがなく、確実にメッシュ形状の小径多孔部を形設することができる。
【００４０】
次に、ゲート部１５を介して固定金型１１と可動金型１３との間で一定量の溶融樹脂の射出が完了する少し前に、プラテンを下降することによって、可動金型１３を固定金型１１方向にさらに下降させ、両金型の閉止を開始すれば、可動金型１３の下面１８によって溶融樹脂が押圧されて成形が開始される（図８参照）。
【００４１】
この際、圧油供給源から供給された圧油がピストンロッド２８Ａを突出させて、コア部材２４を押圧する圧力が、可動金型１３が固定金型１１側に下降して、溶融樹脂をプレスする際のプレス圧力よりも小さく設定されているので、プレス圧力によって、可動金型１３の下降に追随して、コア部材２４が後退することができるので、溶融樹脂をプレスするとともに、所定の部位にメッシュ形状の小径の複数の孔部を形成することができる。
【００４２】
その後、可動金型１３を固定金型１１に対して完全に閉止することによって、プレス成形が完了する。
プレス成形の完了後に、プラテンを上昇させて可動金型１３を最初の待機位置まで上昇させることにより、両金型を離間させて、樹脂成形体４０を取り出す。
【００４３】
以上のサイクルを繰り返すことによって、本発明の樹脂成形体の製造方法が実施される。
このようにして得られた樹脂成形体４０は、図１０に示したように、樹脂基材４１の一部分に厚さ方向に欠切した空洞部４２が形成され、この空洞部４２の樹脂基材表面側に、樹脂基材４１と一体的に形成されたメッシュ形状の小径の孔４４が設けられた小径多孔部４３が形設されている。また、樹脂基材４１の小径多孔部４３を除いた表面の少なくとも一部分に、表皮層部材３０が樹脂基材４１との溶着により一体的に固着されている。また、小径多孔部４３において、平面的なバリが発生せず、成形後にメッシュ形状の小径の複数の孔部が閉塞することがなく、確実にメッシュ形状の小径多孔部４３が形設されている。
【００４４】
さらに、樹脂基材４１の溶着により表皮層部材３０が樹脂基材に一体的に固着されているので、接着剤塗布作業、表皮部材貼着作業が不要で、工程が簡単であり、製造コストも安価となる。
【００４５】
なお、本実施例の場合には、部分的に表皮層部材が固着された樹脂成形体を得る方法について説明したが、本発明の樹脂成形体の製造方法およびそのための製造装置は、表皮部材が固着されていない部分的にメッシュ形状の小径多孔部が形設された単層の樹脂成形体を得る場合にも適用可能である。
【００４６】
また、表皮層部材３０としては、本実施例では、二層のものを用いたが、三層以上の多層のもの又は単層のものも使用可能である。
さらに、本実施例の場合には、射出ユニット部２から、一定量の溶融樹脂が、ホットランナーブロック１６の通路１７、およびゲート部１５を介して、固定金型１１の上面１４と可動金型１３の下面１８の間の空隙１９に射出されるように構成したが、図１１に示したように、ホットランナーブロック１６の通路１７、およびゲート部１５を設けずに、射出ユニット２の代わりに、押出機５１を備えた注型ユニット５０として、注型ユニット５０にＸ−Ｙ方向に移動可能な移動機構５２を備えるようにして、注型ユニット５０の先端に配置したダイ５３を介して、固体金型１１の上面１４に溶融樹脂を注湯するようにすることも可能である。
【００４７】
図１２は、本発明の樹脂成形体の製造装置のさらに別の実施例を示す断面図である。
この実施例の樹脂成形体の製造装置３は、可動金型１３の下面１８に固定金型１１側に突設する小径柱状部材２２、２２を突設する代わりに、コア部材２４の上端２４ｄに一定間隔離間して配設され且つ可動金型１３側に突設する複数の小径柱状部材２２’、２２’が形成されている点が、前述した第１の実施例と相違する。従って、その他の構成は、第１の実施例と同様であるので、同一構成部材には同一の参照番号を付し、その説明は省略する。
【００４８】
このような構成を有する樹脂成形体の製造装置を用いて樹脂成形体を得る方法についても、コア部材１４を可動金型１３側に突出させて、コア部材２４の上端２４ｄに形成された小径柱状部材２２ '、２２'を可動金型１３の下面に当接させた後、固定金型１１と可動金型１３の間に形成される空隙１９に溶融樹脂を供給する以外は、前述した第１の実施例と同様であるので、その説明は省略する。
【００４９】
【発明の効果】
以上説明したように、本発明の樹脂成形体の製造方法及びそのための製造装置によれば、固定金型と可動金型の間に形成される空隙に供給された溶融樹脂が、金型の閉止にともなって、空隙全体に流延してプレスされ、このプレスの際に、コア部材がプレス圧によって後退するので、溶融樹脂をプレスできるとともに、コア部材と可動金型の間に介在する複数の小径柱状部材によって、部分的にメッシュ形状の小径多孔部が形設された樹脂成形体が一体的に得られる。
【００５０】
しかも、コア部材を可動金型側に突出させて、溶融樹脂を供給するので、小径柱状部材と固定金型または可動金型の間に空隙が形成されないので、このような空隙に溶融樹脂が入り込み、平面的なバリが発生して成形後にメッシュ形状の小径の複数の孔部が閉塞することがなく、確実にメッシュ形状の小径多孔部が形設される。さらに、成型品の外観も良好であり、しかも十分な機械的強度を保持することができる。
【００５１】
また、前記固定金型と可動金型との間に、メッシュ形状の小径多孔部予定部分以外の箇所に、予め表皮材を挟装して成形を行うことによって、部分的に二層ないし多層の成形体を得ることができ、例えば、スピーカグリルを備えたドアトリムなど自動車用内装材など種々の用途に使用可能である。
【００５２】
さらに、本発明の樹脂成形体は、上述した本発明の樹脂成形体の製造方法および製造装置によって製造できるものであって、樹脂基材の溶着により表皮層が樹脂基材に一体的に固着されているので、接着剤塗布作業、表皮部材貼着作業が不要で、工程が簡単であり、製造コストも安価となる。
【００５３】
従って、本発明によれば、部分的にメッシュ形状の小径多孔部が形成された樹脂成型品、例えば、スピーカグリルを備えたドアトリムなど自動車用内装材、換気口を有する天井材、冷暖房のパネル部材など種々の用途に使用可能である。
【図面の簡単な説明】
【図１】図１は、本発明の樹脂成形体の製造装置を具備した製造装置の全体の概略図である。
【図２】図２は、本発明の樹脂成形体の製造装置の第１の実施例を示す断面図である。
【図３】図３は、本発明の樹脂成形体の製造装置の小径柱状部材を設ける別の実施例を説明する断面図である。
【図４】図４は、本発明の樹脂成形体の製造装置を用いた樹脂成形体の製造方法を説明する概略図である。
【図５】図５は、本発明の樹脂成形体の製造装置を用いた樹脂成形体の製造方法を説明する概略図である。
【図６】図６は、本発明の樹脂成形体の製造装置を用いた樹脂成形体の製造方法を説明する概略図である。
【図７】図７は、本発明の樹脂成形体の製造装置を用いた樹脂成形体の製造方法を説明する概略図である。
【図８】図８は、本発明の樹脂成形体の製造装置を用いた樹脂成形体の製造方法を説明する概略図である。
【図９】図９は、本発明に用いる表皮層部材の一例を示す部分拡大断面図である。
【図１０】図１０は、本発明で得られる樹脂成形体の部分拡大断面図である。
【図１１】図１１は、本発明の別の実施例の樹脂成形体の製造装置を具備した製造装置全体の概略図である。
【図１２】図１２は、本発明の樹脂成形体の製造装置のさらに別の実施例の断面図である。
【図１３】図１３は、本発明で得られる樹脂成型品の一例を示すドアトリムの斜視図である。
【図１４】図１４は、従来の射出プレスを用いて小径多孔部を備えた樹脂製の樹脂成形体を製造する場合の方法を説明する断面図である。
【図１５】図１５は、従来の射出プレスを用いて小径多孔部を備えた樹脂製の樹脂成形体を製造する場合の方法を説明する断面図である。
【符号の説明】
１・・・・製造装置
２・・・・射出ユニット部
３・・・・樹脂成形体の製造装置
４・・・・搬出装置
１１・・・・固定金型
１３・・・・可動金型
１５・・・・ゲート部
１６・・・・ホットランナーブロック
２２・・・・小径柱状部材
２３・・・・コア部材用ガイド孔
２４・・・・コア部材
２５・・・・ピストン室[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a resin molded body in which a mesh-shaped small-diameter porous portion is formed in at least a part of a resin base material, and a manufacturing method and manufacturing apparatus therefor, and more specifically, a pair of a fixed mold and a movable mold The present invention relates to a method for manufacturing a resin molded body that press-molds a molten resin by supplying a molten resin between the two and closing a movable mold with respect to a fixed mold, and a manufacturing apparatus therefor.
[0002]
[Prior art]
In recent years, with the diversification of needs for automobiles, for example, a speaker of an acoustic system in an automobile is embedded in the door of the automobile.
[0003]
For this reason, conventionally, as shown in FIG. 13, a circular small-diameter porous portion (speaker grille) in which a plurality of mesh-shaped small-diameter holes are formed in a portion corresponding to the speaker embedding portion such as below the armrest 61. ) 62 is used, and a resin door trim 60 is used, and this is attached to the inside of a metal door to form an interior member. In particular, recently, a skin member 63 such as synthetic leather manufactured partially from vinyl chloride, polyethylene, polypropylene, synthetic rubber or the like may be attached to a part of the door trim 60 in order to give a high-class feeling. Has been done.
[0004]
As a method of manufacturing such a door trim, after manufacturing a resin molded body having a small-diameter porous portion in which a plurality of mesh-shaped small-diameter holes are formed by injection molding, or the resin molded body and the small-diameter porous portion There is a method of manufacturing a door trim by separately attaching a skin member such as leather to the surface of the resin molded body through an adhesive.
[0005]
[Problems to be solved by the invention]
By the way, in recent years, an injection press molding method in which molten resin is supplied between a pair of fixed molds and a movable mold, and the molten resin is press-molded by closing the movable mold with respect to the fixed mold. (Sometimes referred to as stamping) (hereinafter, these methods are collectively referred to as “injection press”) have been developed.
[0006]
That is, in such an injection press, since the molten resin supplied at a low pressure is made to flow uniformly by a clamping pressure between a slightly opened stationary mold and a movable mold, a normal injection molding method is used. Compared to the above, there are advantages such as less residual strain and small deformation of the molded product.
[0007]
Moreover, in this injection press, a skin member can be mounted in advance between the fixed mold and the movable mold, and a skin layer can be simultaneously formed on the surface of the resin molded body by welding. However, this method is not suitable as a method for producing a resin molded body having a small-diameter porous portion in which a plurality of mesh-shaped small-diameter holes are formed as described above.
[0008]
According to the conventional method, as shown in FIG. 14, a plurality of small-diameter columnar bodies 112 protruding from the fixed mold 111 are provided at a part of the movable mold 113 so as to be spaced apart from each other. Is lowered (closed) with respect to the fixed mold 111 to form a gap 119 between the two molds, and then the upper surface of the fixed mold is passed through the passage 117 of the hot runner block 116 from the extruder 102 or the like. By injecting the molten resin B into the gap 119 between the two molds from the gate portion 115 opened to the mold, and further closing the movable mold, the molten resin can be uniformly flowed by the clamping pressure to be molded. Conceivable.
[0009]
However, in such a method, the injected molten resin B is moved by the lowering of the movable mold 113 and the lower end of the small-diameter columnar body 112 of the movable mold 113 and the fixed mold 111 as shown in FIG. Since the molten resin B ′ is cast (enters) between the upper surface 114 of the metal and the portion becomes a flat so-called burr, and a plurality of mesh-shaped small-diameter holes are blocked after molding. It was difficult to form the hole by such a method.
[0010]
Therefore, at present, as a method of manufacturing such a door trim, a resin molded body having a portion corresponding to a speaker embedded portion as a missing portion is molded in advance by an injection press, and a plurality of mesh-shaped small holes are separately provided. Usually, a small-diameter porous portion having a portion formed is molded by injection molding, and both are combined (attached) to produce a door trim. In such a method, the process is complicated and time-consuming, and the manufacturing cost is high.
[0011]
Furthermore, as a method of manufacturing the door trim, after molding a resin molded body having a small-diameter porous portion in which a plurality of mesh-shaped small-diameter holes are formed by injection molding or separately, this resin molding is performed. In the method of partially attaching the skin member such as leather to the surface of the body through the adhesive, the adhesive application work and the skin member sticking work are required, the process is complicated and time-consuming, and the manufacturing cost is low. It was high.
[0012]
In view of the present situation, the present invention provides a resin molded body in which a mesh-shaped small-diameter porous portion is formed on at least a part of a resin base material, and does not generate planar burrs in the small-diameter porous portion. It is an object of the present invention to provide a method for manufacturing a resin molded body that can be easily and integrally molded and a manufacturing apparatus therefor.
[0013]
In addition, the present invention provides a surface of a synthetic leather or the like on the surface of a resin molded body having a mesh-shaped small-diameter porous portion formed on at least a part of a resin base material manufactured using such a manufacturing method and manufacturing apparatus. It is an object to provide a resin molded body in which a member is directly attached without using an adhesive or the like.
[0014]
[Means for Solving the Problems]
  The present invention has been invented in order to achieve the above-described problems and objects in the prior art, and a method for producing a resin molded body of the present invention is provided between a pair of fixed molds and a movable mold. The molten resin is supplied to the mold, and the molten resin is press-molded by closing the movable mold with respect to the fixed mold.A method for producing a resin molded body, comprising:Formed in a part of the fixed moldBy pressure cylinderBetween the movable mold and the core member which can move to the movable mold sideOn the movable mold sideWhile interposing a plurality of small-diameter columnar members arranged at regular intervals,With the pressure cylinderThe core member protrudes toward the movable moldA step of bringing the upper surface of the core member into close contact with the small-diameter columnar member,Supplying molten resin to the gap formed between the fixed mold and movable moldAnd a process ofClose the movable mold with respect to the fixed moldAnd press-molding the molten resin by retreating the core member with the pressing pressure of the movable mold, and the pressure cylinder in the step of bringing the upper surface of the core member into close contact with the small-diameter columnar member The pressure is larger than the molten resin pressure in the step of supplying the molten resin, and the pressure of the pressure cylinder in the press molding step is smaller than the press pressure in the press molding step. Thus, a resin molded body in which a mesh-shaped small-diameter porous portion is partially formed is obtained.
  Furthermore, the method for producing a resin molded body of the present invention provides a molten resin by supplying a molten resin between a pair of fixed molds and a movable mold and closing the movable mold with respect to the fixed mold. Press moldingA method for producing a resin molded body, comprising:Formed in a part of the fixed moldBy pressure cylinderBetween the movable mold and the core member which can move to the movable mold sideOn the core member sideWhile interposing a plurality of small-diameter columnar members arranged at regular intervals,With the pressure cylinderThe core member protrudes toward the movable moldA step of bringing the lower surface of the movable mold into close contact with the small diameter columnar member;Supplying molten resin to the gap formed between the fixed mold and movable moldAnd a process ofClose the movable mold with respect to the fixed moldAnd press-molding the molten resin by retreating the core member with the pressing pressure of the movable mold, and the pressure cylinder in the step of bringing the lower surface of the movable mold into close contact with the small-diameter columnar member The pressure of the pressure cylinder is larger than the molten resin pressure in the step of supplying the molten resin, and the pressure of the pressure cylinder in the step of press molding is smaller than the press pressure in the step of press molding. In this way, a resin molded body in which a mesh-shaped small-diameter porous portion is partially formed is obtained.
[0015]
  Further, the resin molded body manufacturing apparatus of the present invention includes a pair of fixed mold and movable mold, and a molten resin supply means for supplying a molten resin to a mold gap formed between both molds.A core member that is fitted to the fixed mold and is movable in the direction of the movable mold by a pressure cylinder, and a plurality of small diameters that are mounted on the lower surface of the movable mold and spaced apart from each other A columnar member, and a resin molded body manufacturing apparatus comprising:When the molten resin is supplied, the core memberThe pressurized syringe
By daMove in the direction of the movable mold,Adhering the upper surface of the core member to the small diameter columnar member,During press molding of molten resin,The movable mold is closed with respect to the fixed mold and theDepending on the press pressure of the movable moldThe core memberConfigured to retreat,The pressure of the pressure cylinder when bringing the upper surface of the core member into close contact with the small-diameter columnar member is set to be larger than the molten resin pressure when supplying the molten resin, and when the press molding is performed The pressure of the pressure cylinder is set to be smaller than the press pressure at the time of the press molding.It is characterized by.
  Further, the resin molded body manufacturing apparatus of the present invention comprises a pair of fixed mold and movable mold, and a molten resin supply means for supplying molten resin to a mold gap formed between both molds.A core member that is fitted to the fixed mold and is movable in the direction of the movable mold by a pressure cylinder, and a plurality of small-diameter columnar shapes that are mounted on the upper surface of the core member and spaced apart from each other An apparatus for producing a resin molded body comprising a member,When the molten resin is supplied, the core memberBy the pressure cylinderMove in the direction of the movable mold,The lower surface of the movable mold is brought into close contact with the small diameter columnar member,During press molding of molten resin,The movable mold is closed with respect to the fixed mold and theThe core member is configured to retract by the pressing pressure of the movable mold,The pressure of the pressure cylinder when the lower surface of the movable mold is brought into close contact with the small-diameter columnar member is set to be larger than the molten resin pressure when the molten resin is supplied. The pressure of the pressure cylinder is set to be smaller than the press pressure at the time of the press molding.It is characterized by.
[0016]
With this configuration, the molten resin supplied to the gap formed between the fixed mold and the movable mold is cast and pressed over the entire gap as the mold is closed. At this time, since the core member is retracted by the pressing pressure, the molten resin can be pressed, and a plurality of small-diameter columnar members interposed between the core member and the movable mold form a partially mesh-shaped small-diameter porous portion. The provided resin molding can be obtained integrally. Moreover, since the molten resin is supplied by projecting the core member to the movable mold side, no gap is formed between the small-diameter columnar member and the fixed mold or the movable mold. Therefore, the molten resin enters the gap. A plurality of mesh-shaped small-diameter holes are not clogged after molding due to the occurrence of planar burrs, and the mesh-shaped small-diameter porous portion is reliably formed. Further, the appearance of the molded product is good, and sufficient mechanical strength can be maintained.
[0017]
In this case, the small-diameter columnar member may be formed on the surface of the movable mold on the fixed mold side, or may be formed on the movable mold-side surface of the core member. Even if burrs are generated around the small-diameter porous part of the mesh shape, the burrs are not generated on the surface of the resin molded body, but are generated on the back surface of the resin molded body. It is preferably formed on the surface of the fixed mold.
[0018]
In addition, by sandwiching a skin material in advance at a place other than the mesh-shaped small-diameter porous portion planned portion between the fixed mold and the movable mold, a two-layer or multi-layer partially A molded body can be obtained and can be used for various applications such as automobile interior materials such as a door trim provided with a speaker grille.
[0019]
  Furthermore, the resin molded body of the present invention can be manufactured by the above-described method and apparatus for manufacturing a resin molded body,The resin molding isA hollow part cut out in the thickness direction is formed in a part of the resin base material,SaidA mesh-shaped small-diameter porous portion formed integrally with the resin base material is formed on the resin base material surface side of the cavity, and at least a part of the surface excluding the small-diameter porous portion of the resin base material Further, the skin layer member is integrally fixed by welding with the resin base material.
[0020]
As described above, the skin layer is integrally fixed to the resin base material by welding the resin base material, so there is no need for adhesive application work and skin member sticking work, the process is simple, and the manufacturing cost is low. It becomes.
[0021]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments (examples) of the present invention will be described with reference to the drawings.
FIG. 1 is an overall schematic view of a manufacturing apparatus equipped with a resin molded body manufacturing apparatus of the present invention, and FIG. 2 is a cross-sectional view showing a first embodiment of the resin molded body manufacturing apparatus of the present invention.
[0022]
In FIG. 1, reference numeral 1 denotes a manufacturing apparatus provided with a resin molded body manufacturing apparatus 3 of the present invention as a whole. The manufacturing apparatus 1 includes an injection unit 2 having an injection machine for injecting and supplying molten resin to the resin molded body manufacturing apparatus 3, and resin molding for forming the molten resin injected and supplied from the injection unit 2. And a body manufacturing apparatus 3.
[0023]
As shown in FIG. 1 and FIG. 2, the resin molded body manufacturing apparatus 3 is disposed above the fixed mold 11 and the fixed mold 11 constituting the lower mold fixedly disposed below. A movable mold 13 is provided that constitutes an upper mold that can be moved up and down by the operation of the platen 12 a of the press machine 12 and can be closed with respect to the fixed mold 11.
[0024]
That is, the movable mold 13 is formed with a peripheral portion 13a having a peripheral portion protruding downward, and is surrounded by the peripheral portion 13a to form an internal space 13b, and a fixed mold is formed in the internal space 13b. The mold 11 is fitted. In the figure, reference numeral 27 denotes a skin member holding device for holding the skin member when the skin layer member 30 needs to be used.
[0025]
A gate portion 15 for injecting molten resin onto the upper surface of the fixed mold 11 is opened on the upper surface 14 which is the surface of the fixed mold 11 on the movable mold side 13 side. The passage 17 of the hot runner block 16 provided in the mold 11 communicates with the passage 17 of the hot runner block 16 and is connected to the injection unit 2. As a result, a certain amount of molten resin flows from the injection unit portion 2 between the upper surface 14 of the fixed mold 11 and the lower surface 18 of the movable mold 13 via the passage 17 of the hot runner block 16 and the gate portion 15. It is injected into the gap 19.
[0026]
Although not shown, it is desirable that the gate portion 15 is provided with an opening / closing member for automatically closing the gate portion 15 after supplying a certain amount of molten resin. As such an opening / closing member, for example, a hot nozzle provided with an opening / closing member as disclosed in Japanese Patent Publication No. 4-69046 may be provided at the end of the hot runner block 16 on the gate portion 15 side. .
[0027]
  On the other hand, on the lower surface 18 that is the surface of the movable mold 13 on the fixed mold 11 side, as a resin molded product, for example,FIG.When the door trim 60 including the circular small-diameter porous portion (speaker grill) 62 in which a plurality of mesh-shaped small-diameter holes are formed is formed, the portion 21 corresponding to the small-diameter porous portion is formed. A plurality of small-diameter columnar members 22 and 22 which are arranged at regular intervals and project from the fixed mold 11 are arranged in a circular shape.
[0028]
In this embodiment, the small-diameter columnar members 22 and 22 are formed as small-diameter columnar members and arranged in a circular shape. However, the small-diameter columnar members 22 and 22 are formed in a plurality of mesh-shaped small-diameter hole portions. Depending on the shape, for example, it can be appropriately changed to a quadrangular prism shape, and the size, the arrangement state, and the size of the hole can be appropriately changed according to the shape of the target small-diameter porous portion.
[0029]
In this case, as a method of forming the small diameter columnar members 22 and 22 on the lower surface 18 of the movable mold 13, the small diameter columnar members 22 and 22 are directly engraved or implanted on the lower surface of the movable mold 13. However, as shown in FIG. 3, the disk-shaped member for small-diameter porous portion 20 with the small-diameter columnar members 22, 22 projectingly is formed in a cylindrical recess 29 formed on the lower surface 18 of the movable mold 13. If fitted and fixed, various forms of small-diameter porous portions can be formed, and the small-diameter columnar members 22 and 22 can be replaced even if they are worn and damaged, so that the generation of burrs can be prevented. .
[0030]
The fixed mold 11 is provided with a core member guide hole 23 at a position corresponding to the portion where the small diameter columnar member 22 is formed, and the core member guide hole 23 has a substantially cylindrical shape. The core member 24 is disposed so as to be able to protrude from the upper surface 14 of the fixed mold 11. Further, a flange portion 24b is formed at the lower end of the core member 24 so as to protrude on the outer peripheral side. The flange portion 24b abuts on a stopper portion 23a formed at the upper end of the guide hole 23, and exceeds a certain dimension. Further, the core member 24 is configured so as not to protrude from the upper surface 14 of the fixed mold 11. With this configuration, the core member operates as a piston.
[0031]
Further, a piston chamber 25 is formed below the guide hole 23, and a pressure cylinder 28 is disposed in the piston chamber 25. The front end portion 28B of the piston rod 28A of the pressure cylinder 28 is fixed to the rear end side 24c of the core member 24, and pressurizes the pressure oil from the pressure oil supply source (not shown) through the pipe line 26. By supplying to the cylinder 28, the piston rod 28 </ b> A is protruded, and the core member 24 is protruded from the upper surface 14 of the fixed mold 11.
[0032]
In this case, the pressure oil supplied from the pressure oil supply source causes the piston rod 28 </ b> A to protrude and presses the core member 24 from the injection unit portion 2 to the upper surface 14 of the fixed mold 11 and the lower surface of the movable mold 13. After the molten resin is injected into the gap 19 between the upper surface 14 of the fixed mold 11 and the lower surface 18 of the movable mold 13, it is larger than the resin pressure of the molten resin injected into the gap 19 between the movable molds 18. It is necessary to make the mold 13 lower than the pressing pressure when the molten resin is lowered to the fixed mold 11 side and the molten resin is pressed.
[0033]
As a result, the core member 24 protrudes from the upper surface 14 of the fixed mold 11, and the upper end 24 d of the core member 24 comes into contact with the small-diameter columnar members 22, 22 formed on the lower surface 18 of the movable mold 13. When the molten resin is injected into the gap 19 between the upper surface 14 and the lower surface 18 of the movable mold 13, the core member 24 does not move downward due to the resin pressure of the molten resin. Accordingly, there is no gap between the lower end 22a of the small-diameter columnar members 22 and 22 and the upper end 24d of the core member 24. Therefore, molten resin does not enter the gap, flat burrs are not generated, and molding is performed. A plurality of mesh-shaped small-diameter holes are not blocked later, and the mesh-shaped small-diameter porous portion can be reliably formed. Further, when the movable mold 13 is lowered to the fixed mold 11 side and the molten resin is pressed, the core member 14 can be retracted following the lowering of the movable mold 13 by the pressing pressure. In addition to pressing the molten resin, a plurality of mesh-shaped small-diameter holes can be formed at a predetermined site.
[0035]
Further, in the case of the present embodiment, the fixed mold 11 is disposed below, and the movable mold 13 is disposed above and below the movable mold 13, that is, the molding machine is shown as a vertical mold. The movable mold 13 may be arranged on the left and right, and the movable mold 13 may be closed so that it can be moved in the left-right direction (lateral direction) with respect to the fixed mold, that is, a horizontal molding machine may be used. .
[0036]
A method for producing a resin molded article using the resin molded article production apparatus of the present invention configured as described above will be described with reference to FIGS.
As shown in FIG. 4, by lowering the platen, the movable mold 13 is lowered to a position separated from the fixed mold 11 by a predetermined interval and is put on standby. At this time, as shown in FIG. 9, for example, an outer skin member 31 such as synthetic leather made of vinyl chloride, polyethylene, polypropylene, synthetic rubber and the like, and a foamed synthetic resin layer such as polyethylene and polypropylene stuck below the skin member 31 The skin layer member 30 made of 32 is partially sandwiched between the fixed mold 11 and the movable mold 13 at portions other than the mesh-shaped small-diameter porous portion planned portion in advance on both ends of the skin member holding device 27. It is held and held (holding both ends in the direction perpendicular to the paper surface of FIG. 4).
[0037]
Then, by supplying the pressure oil from the pressure oil supply source to the pressurizing cylinder 28 via the conduit 26, the piston rod 28A is protruded, and the core member 24 is protruded from the upper surface 14 of the fixed mold 11 (FIG. 5). Thereafter, the movable mold 13 is lowered to a position where the upper end 24 d of the core member 24 contacts the small-diameter columnar members 22, 22 formed on the lower surface 18 of the movable mold 13.
[0038]
In this state, a certain amount of molten resin A is injected from the injection unit 2 between the upper surface 14 of the fixed mold 11 and the lower surface 18 of the movable mold 13 through the passage 17 and the gate portion 15 of the hot runner block 16. Is injected into the gap 19 (see FIG. 6). The injected molten resin lumps up around the gate portion 15, but the molten resin A is cast (flowed), and a gap 19 between the upper surface 14 of the fixed mold 11 and the lower surface 18 of the movable mold 13. It flows as a whole and also flows into the gap between the small-diameter columnar members 22 and 22 (see FIG. 7).
[0039]
In this case, the pressure oil supplied from the pressure oil supply source causes the piston rod 28 </ b> A to protrude and presses the core member 24, so that the upper surface 14 of the fixed mold 11 and the lower surface of the movable mold 13 are pressed from the injection unit 2. Since the pressure is set higher than the resin pressure of the molten resin injected into the gap 19 between 18, the core member 24 does not move downward due to the resin pressure of the molten resin. Accordingly, there is no gap between the lower end 22a of the small-diameter columnar members 22 and 22 and the upper end 24d of the core member 24. Therefore, molten resin does not enter the gap, flat burrs are not generated, and molding is performed. A plurality of mesh-shaped small-diameter holes are not blocked later, and the mesh-shaped small-diameter porous portion can be reliably formed.
[0040]
Next, shortly before the injection of a fixed amount of molten resin between the fixed mold 11 and the movable mold 13 is completed via the gate portion 15, the movable mold 13 is fixed by lowering the platen. When the mold 11 is further lowered in the direction of the mold 11 and the closing of both molds is started, the molten resin is pressed by the lower surface 18 of the movable mold 13 to start molding (see FIG. 8).
[0041]
  At this time, the pressure oil supplied from the pressure oil supply source causes the piston rod 28A to protrude, and the pressure for pressing the core member 24 is lowered by the movable mold 13 toward the fixed mold 11 to press the molten resin. Since the pressing pressure is set to be smaller than the pressing pressure, the core member follows the lowering of the movable mold 13 by the pressing pressure.24Therefore, the molten resin can be pressed and a plurality of mesh-shaped small-diameter holes can be formed at a predetermined site.
[0042]
  Thereafter, the movable mold 13 is fixed to the fixed mold.11Is completely closed, press forming is completed.
  After press molding is completed, the platen is raised to move the movable mold13Is raised to the initial standby position to separate the two molds and take out the resin molded body 40.
[0043]
By repeating the above cycle, the method for producing a resin molded body of the present invention is carried out.
In the resin molded body 40 thus obtained, as shown in FIG. 10, a cavity 42 is formed in a part of the resin base material 41 and is notched in the thickness direction. A small-diameter porous portion 43 provided with a mesh-shaped small-diameter hole 44 formed integrally with the resin base material 41 is formed on the surface side. The skin layer member 30 is integrally fixed to at least a part of the surface of the resin base material 41 excluding the small-diameter porous portion 43 by welding with the resin base material 41. Further, in the small-diameter porous portion 43, planar burrs are not generated, and a plurality of mesh-shaped small-diameter holes are not blocked after molding, and the mesh-shaped small-diameter porous portion 43 is reliably formed. .
[0044]
Furthermore, since the skin layer member 30 is integrally fixed to the resin base material by welding the resin base material 41, the adhesive application work and the skin member sticking work are unnecessary, the process is simple, and the manufacturing cost is also low. It will be cheap.
[0045]
In the case of the present embodiment, the method for obtaining the resin molded body in which the skin layer member is partially fixed has been described. However, the method for manufacturing the resin molded body of the present invention and the manufacturing apparatus therefor include a skin member. The present invention can also be applied to the case of obtaining a single-layer resin molded body in which a mesh-shaped small-diameter porous portion is partially formed that is not fixed.
[0046]
Further, as the skin layer member 30, a two-layer member is used in this embodiment, but a multilayer member having three or more layers or a single-layer member can also be used.
Furthermore, in the case of the present embodiment, a fixed amount of molten resin is injected from the injection unit portion 2 via the passage 17 and the gate portion 15 of the hot runner block 16 and the movable die. 13 is configured to be injected into the gap 19 between the lower surfaces 18 of the hot runner block 16 without the passage 17 and the gate portion 15 as shown in FIG. As the casting unit 50 provided with the extruder 51, the casting unit 50 is provided with a moving mechanism 52 that is movable in the XY direction, and through a die 53 disposed at the tip of the casting unit 50, It is also possible to pour molten resin onto the upper surface 14 of the solid mold 11.
[0047]
FIG. 12 is a cross-sectional view showing still another embodiment of the apparatus for producing a resin molded body of the present invention.
The resin molded body manufacturing apparatus 3 according to this embodiment is configured so that the small-diameter columnar members 22 and 22 projecting from the lower surface 18 of the movable mold 13 on the fixed mold 11 side are projected to the upper end 24 d of the core member 24. A difference from the first embodiment described above is that a plurality of small-diameter columnar members 22 ′ and 22 ′ that are disposed at a predetermined interval and project from the movable mold 13 are formed. Accordingly, since the other configuration is the same as that of the first embodiment, the same reference numerals are given to the same structural members, and the description thereof will be omitted.
[0048]
  With respect to a method of obtaining a resin molded body using the apparatus for manufacturing a resin molded body having such a configuration, the small diameter columnar shape formed on the upper end 24d of the core member 24 by causing the core member 14 to protrude toward the movable mold 13 side. Element22 ', 22 ′ is brought into contact with the lower surface of the movable mold 13 and then the molten resin is supplied to the gap 19 formed between the fixed mold 11 and the movable mold 13. Since this is the same, the description thereof is omitted.
[0049]
【The invention's effect】
As described above, according to the method for manufacturing a resin molded body and the manufacturing apparatus therefor according to the present invention, the molten resin supplied to the gap formed between the fixed mold and the movable mold is used to close the mold. Accordingly, the core member is retreated by the pressing pressure during casting, and the molten resin can be pressed, and a plurality of intervenes between the core member and the movable mold can be pressed. By the small-diameter columnar member, a resin molded body in which a mesh-shaped small-diameter porous portion is partially formed is obtained integrally.
[0050]
Moreover, since the molten resin is supplied by projecting the core member to the movable mold side, no gap is formed between the small-diameter columnar member and the fixed mold or the movable mold. Therefore, the molten resin enters the gap. A plurality of mesh-shaped small-diameter holes are not clogged after molding due to the occurrence of planar burrs, and the mesh-shaped small-diameter porous portion is reliably formed. Further, the appearance of the molded product is good, and sufficient mechanical strength can be maintained.
[0051]
In addition, by sandwiching a skin material in advance at a place other than the mesh-shaped small-diameter porous portion planned portion between the fixed mold and the movable mold, a two-layer or multi-layer partially A molded body can be obtained and can be used for various applications such as automobile interior materials such as a door trim provided with a speaker grille.
[0052]
Furthermore, the resin molded body of the present invention can be manufactured by the above-described method and apparatus for manufacturing a resin molded body of the present invention, and the skin layer is integrally fixed to the resin substrate by welding the resin substrate. Therefore, the adhesive application work and the skin member sticking work are unnecessary, the process is simple, and the manufacturing cost is low.
[0053]
Therefore, according to the present invention, a resin molded product in which a mesh-shaped small-diameter porous portion is partially formed, for example, an automotive interior material such as a door trim provided with a speaker grill, a ceiling material having a ventilation opening, and a panel member for air conditioning It can be used for various purposes.
[Brief description of the drawings]
FIG. 1 is a schematic view of an entire production apparatus equipped with a resin molded body production apparatus of the present invention.
FIG. 2 is a cross-sectional view showing a first embodiment of the apparatus for producing a resin molded body of the present invention.
FIG. 3 is a cross-sectional view for explaining another embodiment in which a small-diameter columnar member of the apparatus for producing a resin molded body of the present invention is provided.
FIG. 4 is a schematic diagram for explaining a method for producing a resin molded body using the apparatus for producing a resin molded body according to the present invention.
FIG. 5 is a schematic diagram illustrating a method for producing a resin molded body using the apparatus for producing a resin molded body according to the present invention.
FIG. 6 is a schematic diagram illustrating a method for producing a resin molded body using the apparatus for producing a resin molded body according to the present invention.
FIG. 7 is a schematic view for explaining a method for producing a resin molded body using the apparatus for producing a resin molded body according to the present invention.
FIG. 8 is a schematic view for explaining a method for producing a resin molded body using the apparatus for producing a resin molded body according to the present invention.
FIG. 9 is a partially enlarged sectional view showing an example of a skin layer member used in the present invention.
FIG. 10 is a partially enlarged sectional view of a resin molded body obtained by the present invention.
FIG. 11 is a schematic view of an entire manufacturing apparatus equipped with a resin molded body manufacturing apparatus according to another embodiment of the present invention.
FIG. 12 is a cross-sectional view of still another embodiment of the apparatus for producing a resin molded body of the present invention.
FIG. 13 is a perspective view of a door trim showing an example of a resin molded product obtained by the present invention.
FIG. 14 is a cross-sectional view illustrating a method in the case of manufacturing a resin-made resin body having a small-diameter porous portion using a conventional injection press.
FIG. 15 is a cross-sectional view illustrating a method in the case of manufacturing a resin-made resin body having a small-diameter porous portion using a conventional injection press.
[Explanation of symbols]
1. Manufacturing equipment
2 ... Injection unit
3 .... Resin molded body manufacturing equipment
4 ... Unloading device
11... Fixed mold
13. Movable mold
15 ... Gate part
16 .... Hot runner block
22... Small diameter columnar member
23... Core member guide hole
24... Core member
25 .... Piston chamber

Claims (6)

一対の固定金型と可動金型との間に溶融樹脂を供給して、可動金型を固定金型に対して閉止することによって、溶融樹脂をプレス成形する樹脂成形体の製造方法であって、
前記固定金型の一部分に形成され、加圧シリンダーによって可動金型側に突出動可能なコア部材と前記可動金型との間の、前記可動金型側に一定間隔離間して配設した複数の小径柱状部材を介在させつつ、前記加圧シリンダーで前記コア部材を可動金型側に突出させることによって、前記小径柱状部材に前記コア部材の上面を密着させる工程と、
前記固定金型と可動金型の間に形成される空隙に溶融樹脂を供給する工程と、
前記可動金型を固定金型に対して閉止するとともに、前記可動金型のプレス圧により前記コア部材を後退させて溶融樹脂をプレス成形する工程と、からなり、
前記小径柱状部材に前記コア部材の上面を密着させる工程における前記加圧シリンダーの圧力は、前記溶融樹脂を供給する工程での溶融樹脂圧よりも大であり、
前記プレス成形する工程における前記加圧シリンダーの圧力は、前記プレス成形する工程での前記プレス圧よりも小であり、
これによって部分的にメッシュ形状の小径多孔部が形設された樹脂成形体を得ることを特徴とする樹脂成形体の製造方法。 A method for producing a resin molded body in which a molten resin is supplied between a pair of fixed molds and a movable mold and the movable mold is closed with respect to the fixed mold to press-mold the molten resin. ,
A plurality of core members that are formed on a part of the fixed mold and that can be moved to the movable mold side by a pressure cylinder and the movable mold are spaced apart from each other on the movable mold side. while interposing the small diameter columnar member, by Rukoto protrudes said core member in the pressure cylinder to the movable mold side, a step of adhering the upper surface of the core member to the smaller-diameter columnar member,
A step of supplying the molten resin into the gap formed between the stationary mold and the movable mold,
The movable mold is closed with respect to the fixed mold, and the core member is retracted by the press pressure of the movable mold, and the molten resin is press-molded.
The pressure of the pressure cylinder in the step of bringing the upper surface of the core member into close contact with the small-diameter columnar member is greater than the molten resin pressure in the step of supplying the molten resin,
The pressure of the pressure cylinder in the press molding step is smaller than the press pressure in the press molding step,
In this way, a resin molded body in which a mesh-shaped small-diameter porous portion is partially formed is obtained. 一対の固定金型と可動金型との間に溶融樹脂を供給して、可動金型を固定金型に対して閉止することによって、溶融樹脂をプレス成形する樹脂成形体の製造方法であって、
前記固定金型の一部分に形成され、加圧シリンダーによって可動金型側に突出動可能なコア部材と前記可動金型との間の、前記コア部材側に一定間隔離間して配設した複数の小径柱状部材を介在させつつ、前記加圧シリンダーで前記コア部材を可動金型側に突出させることによって、前記小径柱状部材に前記可動金型の下面を密着させる工程と、
前記固定金型と可動金型の間に形成される空隙に溶融樹脂を供給する工程と、
前記可動金型を固定金型に対して閉止するとともに、前記可動金型のプレス圧により前記コア部材を後退させて溶融樹脂をプレス成形する工程と、からなり、
前記小径柱状部材に前記可動金型の下面を密着させる工程における前記加圧シリンダーの圧力は、前記溶融樹脂を供給する工程での溶融樹脂圧よりも大であり、
前記プレス成形する工程における前記加圧シリンダーの圧力は、前記プレス成形する工程での前記プレス圧よりも小であり、
これによって部分的にメッシュ形状の小径多孔部が形設された樹脂成形体を得ることを
特徴とする樹脂成形体の製造方法。 A method for producing a resin molded body in which a molten resin is supplied between a pair of fixed molds and a movable mold and the movable mold is closed with respect to the fixed mold to press-mold the molten resin. ,
A plurality of core members that are formed on a part of the fixed mold and that can be moved to the movable mold side by a pressure cylinder and the movable mold are spaced apart from each other at a certain interval on the core member side . while interposing the small diameter columnar member, by Rukoto protrudes said core member in the pressure cylinder to the movable mold side, a step of adhering the lower surface of the movable die on the small diameter columnar member,
A step of supplying the molten resin into the gap formed between the stationary mold and the movable mold,
The movable mold is closed with respect to the fixed mold, and the core member is retracted by the press pressure of the movable mold, and the molten resin is press-molded.
The pressure of the pressure cylinder in the step of bringing the lower surface of the movable mold into close contact with the small-diameter columnar member is larger than the molten resin pressure in the step of supplying the molten resin,
The pressure of the pressure cylinder in the press molding step is smaller than the press pressure in the press molding step,
By this, it is possible to obtain a resin molded body in which a mesh-shaped small-diameter porous portion is formed.
A method for producing a resin molded product. 一対の固定金型と可動金型と、
両金型の間に形成される金型空隙に溶融樹脂を供給する溶融樹脂供給手段と、
前記固定金型に嵌着され、加圧シリンダーによって前記可動金型方向に突出動可能なコア部材と、
前記可動金型の下面に装着され、一定間隔離間して配設された複数の小径柱状部材と、
から構成された樹脂成形体の製造装置であって、
前記コア部材は、
溶融樹脂の供給時には、前記加圧シリンダーによって可動金型方向に移動して、前記小径柱状部材に前記コア部材の上面を密着させ、
溶融樹脂のプレス成形時には、前記可動金型を固定金型に対して閉止するとともに前記可動金型のプレス圧によって前記コア部材を後退するように構成し、
前記小径柱状部材に前記コア部材の上面を密着させる際の前記加圧シリンダーの圧力は、前記溶融樹脂を供給する際の溶融樹脂圧よりも大となるように設定され、
前記プレス成形する際の前記加圧シリンダーの圧力は、前記プレス成形する際の前記プレス圧よりも小となるように設定されていることを特徴とする部分的にメッシュ形状の小径多孔部が形設された樹脂成形体の製造装置。A pair of fixed mold and movable mold,
A molten resin supply means for supplying a molten resin to a mold gap formed between both molds ;
A core member that is fitted to the fixed mold and is movable in the direction of the movable mold by a pressure cylinder;
A plurality of small-diameter columnar members mounted on the lower surface of the movable mold and spaced apart from each other;
An apparatus for producing a resin molded body comprising:
The core member is
At the time of supplying the molten resin, it is moved in the direction of the movable mold by the pressure cylinder, and the upper surface of the core member is brought into close contact with the small diameter columnar member,
At the time of press molding of the molten resin, the movable mold is closed with respect to the fixed mold and the core member is moved backward by the pressing pressure of the movable mold,
The pressure of the pressure cylinder when closely contacting the upper surface of the core member to the small diameter columnar member is set to be larger than the molten resin pressure when supplying the molten resin,
The pressure of the pressure cylinder at the time of the press molding is set to be lower than the press pressure at the time of the press molding. An apparatus for manufacturing a resin molded body. 一対の固定金型と可動金型と、
両金型の間に形成される金型空隙に溶融樹脂を供給する溶融樹脂供給手段と、
前記固定金型に嵌着され、加圧シリンダーによって前記可動金型方向に突出動可能なコア部材と、
前記コア部材の上面に装着され、一定間隔離間して配設された複数の小径柱状部材と、
から構成された樹脂成形体の製造装置であって、
前記コア部材は、
溶融樹脂の供給時には、前記加圧シリンダーによって可動金型方向に移動して、前記小径柱状部材に前記可動金型の下面を密着させ、
溶融樹脂のプレス成形時には、前記可動金型を固定金型に対して閉止するとともに前記可動金型のプレス圧によって前記コア部材を後退するように構成し、
前記小径柱状部材に前記可動金型の下面を密着させる際の前記加圧シリンダーの圧力は、前記溶融樹脂を供給する際の溶融樹脂圧よりも大となるように設定され、
前記プレス成形する際の前記加圧シリンダーの圧力は、前記プレス成形する際の前記プレス圧よりも小となるように設定されていることを特徴とする部分的にメッシュ形状の小径多孔部が形設された樹脂成形体の製造装置。A pair of fixed mold and movable mold,
A molten resin supply means for supplying a molten resin to a mold gap formed between both molds ;
A core member that is fitted to the fixed mold and is movable in the direction of the movable mold by a pressure cylinder;
A plurality of small-diameter columnar members mounted on the upper surface of the core member and spaced apart from each other; and
An apparatus for producing a resin molded body comprising:
The core member is
At the time of supplying the molten resin, it is moved in the direction of the movable mold by the pressure cylinder, and the lower surface of the movable mold is brought into close contact with the small diameter columnar member,
At the time of press molding of the molten resin, the movable mold is closed with respect to the fixed mold and the core member is moved backward by the pressing pressure of the movable mold,
The pressure of the pressure cylinder when bringing the lower surface of the movable mold into close contact with the small-diameter columnar member is set to be larger than the molten resin pressure when supplying the molten resin,
The pressure of the pressure cylinder at the time of the press molding is set to be lower than the press pressure at the time of the press molding. An apparatus for manufacturing a resin molded body. 請求項１または２に記載された製造方法を用いて得られた樹脂成形体であって、
前記樹脂成形体は、
樹脂基材の一部分に厚さ方向に欠切した空洞部が形成され、
前記空洞部の樹脂基材表面側に、前記樹脂基材と一体的に形成されたメッシュ形状の小径多孔部が形設されるとともに、前記樹脂基材の前記小径多孔部を除いた表面の少なくとも一部分に、表皮層部材が前記樹脂基材との溶着により一体的に固着されていることを特徴とする樹脂成形体。 A resin molded body obtained by using the production method according to claim 1 or 2,
The resin molding is
A hollow part cut out in the thickness direction is formed in a part of the resin base material,
The resin base material surface side of the hollow portion, with small-diameter porous portion is Katachi設of the resin base material are integrally formed with a mesh shape, at least the small-diameter porous portion excluding the surface of the resin base material A resin molded body characterized in that a skin layer member is integrally fixed to a part by welding with the resin base material. 請求項３または４に記載された製造装置を用いて得られた樹脂成形体であって、
前記樹脂成形体は、
樹脂基材の一部分に厚さ方向に欠切した空洞部が形成され、
前記空洞部の樹脂基材表面側に、前記樹脂基材と一体的に形成されたメッシュ形状の小径多孔部が形設されるとともに、前記樹脂基材の前記小径多孔部を除いた表面の少なくとも一部分に、表皮層部材が前記樹脂基材との溶着により一体的に固着されていることを特徴とする樹脂成形体。 A resin molded body obtained using the production apparatus according to claim 3 or 4,
The resin molding is
A hollow part cut out in the thickness direction is formed in a part of the resin base material,
The resin base material surface side of the hollow portion, with small-diameter porous portion is Katachi設of the resin base material are integrally formed with a mesh shape, at least the small-diameter porous portion excluding the surface of the resin base material A resin molded body characterized in that a skin layer member is integrally fixed to a part by welding with the resin base material.
JP15699097A 1997-06-13 1997-06-13 Resin molded body, method for manufacturing the same, and manufacturing apparatus therefor Expired - Fee Related JP3839135B2 (en)

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