JP3989231B2 - Synthetic resin box-shaped product and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a box-shaped product made of synthetic resin, and more particularly to an improvement of a box-shaped product having a skin material fixed inside.
[0002]
[Prior art]
A box-shaped product having a bottom part and a side wall part provided on the entire circumference of the bottom part and integrally formed of a synthetic resin material is known. For example, a box-shaped container with a bottom formed in a square shape and an outward flange projecting outwardly at the opening end of the side wall is an integral part of a manufacturing process or assembly process for various parts. Is used for storing and transporting. In addition, a skin material such as a woven fabric, a non-woven fabric, or a knitted fabric is applied to the inner surface of the bottom and side walls for the purpose of alleviating the impact sound and improving the design when a part is inserted. It is considered that they are fixed together.
[0003]
[Problems to be solved by the invention]
However, when the skin material is fixed inside the box-shaped product in this way, when using an adhesive, the manufacturing man-hour increases and the cost increases. On the other hand, the skin material simultaneously with the molding of the synthetic resin material When the skin material is integrally fixed by impregnating the synthetic resin material, the skin material is wrinkled at the opening side end surface of the side wall portion, or the synthetic resin material passes through the skin material and the surface. Occasionally, the appearance quality may be impaired. That is, when integrally forming the skin material, the pair of molds are clamped while pulling the skin material to the outer peripheral side so as not to wrinkle, but the woven fabric, nonwoven fabric, or knitted fabric that can be impregnated with the synthetic resin material For example, since the skin material such as the surface material has a small amount of elongation deformation, it is inevitable that wrinkles approach the end surface of the side wall at the opening side, and when the outer periphery of the skin material is strongly fixed, as shown in FIG. After the pair of molding dies 32 and 34 are clamped in a state where a predetermined tension is applied to the material 18, when the synthetic resin material 16 is injection-molded as shown in FIG. 18 does not adhere to the molding surface 40, and the synthetic resin material 16 may pass through the skin material 18 and partially ooze out to the surface.
[0004]
The present invention has been made against the background of the above circumstances, and the object of the present invention is to integrally mold a box-shaped product with a synthetic resin material, and at the same time mold a skin material to be integrally fixed to the inner surface. In this case, the appearance quality of the opening side end face of the side wall is to be improved.
[0005]
[Means for Solving the Problems]
In order to achieve such an object, the first invention is a box-shaped product having a bottom portion and a side wall portion provided on the entire circumference of the bottom portion, and integrally molded with a synthetic resin material, (a) A skin material that can be impregnated with the synthetic resin material is formed simultaneously with the integral molding of the synthetic resin material, and is integrally fixed to the inner surface of the bottom portion and the side wall portion by impregnation of the synthetic resin material. And (b) the end surface of the side wall portion on the opening side is provided with a protrusion provided on the entire periphery of the synthetic resin material that protrudes through the skin material.
[0006]
According to a second aspect of the present invention, in the synthetic resin box-shaped product according to the first aspect of the present invention, the protrusion protrudes continuously from an inner peripheral side portion of an end surface on the opening side of the side wall portion continuously to the inner side surface of the side wall portion. It is provided in.
A third invention is the box-shaped product made of synthetic resin according to the first or second invention, wherein (a) the box-shaped product has a square bottom and the opening side end of the side wall portion. (B) The protrusion is an annular protrusion provided continuously around the entire circumference of the outward flange.
[0007]
A fourth invention is a method for manufacturing a synthetic resin box-shaped product according to any one of the first to third inventions , and (a) has a first molding surface corresponding to the outer shape of the box-shaped product. The first molding die has a second molding surface corresponding to the inner shape to which the skin material of the box-shaped product is fixed, and a recess corresponding to the protrusion is provided on the outer peripheral side of the second molding surface. A mold clamping step of clamping the first mold and the second mold in a state where the skin material is interposed between the second mold and the skin material is restricted from flowing inward. (B) injecting the synthetic resin material between the first molding surface of the first mold and the skin material, and bringing the skin material into close contact with the second molding surface of the second mold; Synthetic resin material is integrally molded, and the skin material is integrated with synthetic resin material by impregnation with the synthetic resin material. At the end face of the side wall portion on the opening side, the projection is integrally formed by the synthetic resin material passing through the skin material whose inflow to the inside is restricted and entering the recess. And a molding step.
[0008]
【The invention's effect】
According to the synthetic resin box-shaped product of the first invention, the skin material is molded simultaneously with the integral molding of the synthetic resin material and is integrally fixed by impregnation of the synthetic resin material. A box-shaped product to which the material is fixed is manufactured at a low cost. In addition, the end surface on the opening side of the side wall portion is provided with protrusions that protrude through the outer surface of the synthetic resin material, so that the synthetic resin material partially oozes out to the surface. As a result, the appearance quality is improved and the degree of freedom in designing the shape of the box-shaped product is improved because there is no need to take into account wrinkles of the skin material or partial exudation of the synthetic resin material on the opening side end face of the side wall . That is, in the present invention, the synthetic resin material does not partially ooze out from the skin material, but actively penetrates and passes through the skin material, so that the projection made only of the synthetic resin material is the opening side end surface of the side wall portion. By providing it, the appearance quality is improved.
[0009]
The third invention is a box-type container for storing and transporting parts and the like. By providing a skin material on the inner side, the design is improved and the impact at the time of putting parts is reduced. In addition, since the annular protrusion is provided continuously around the entire circumference of the outward flange at the upper end of the side wall, the annular protrusion functions as a reinforcing rib, and the strength of the outward flange is improved and deformation and damage are prevented. .
[0010]
4th invention is related with the manufacturing method of the said synthetic-resin box-shaped goods, The effect similar to 1st invention -3rd invention is acquired substantially. In addition, the mold is clamped with a skin material interposed between the pair of first mold and second mold, and a synthetic resin material is injected between the first molding surface of the first mold and the skin material. As a result, the skin material is molded and fixed integrally at the same time as the molding of the synthetic resin material, and at the end surface on the opening side of the side wall portion, the synthetic resin material passes through the skin material and the projection is integrally molded. Therefore, the synthetic resin box-shaped product of the first to third inventions can be manufactured easily and inexpensively. That is, since the recess is provided in the second mold opposite to the side to which the synthetic resin material is supplied, the synthetic resin material is applied at a predetermined injection pressure to the skin material in which inflow to the inside is restricted. When pressed, the synthetic resin material penetrates into the skin material and enters into the recess on the opposite side, and the protrusion corresponding to the recess is integrally formed.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
The present invention is preferably applied to a quadrangular (generally rectangular or square) box-shaped container that accommodates or conveys parts in a part manufacturing process, an assembly process, etc. It can also be applied to other box-shaped products such as furniture. For example, the side wall portion is provided so as to rise substantially vertically with respect to the bottom portion, but may be provided so as to be inclined outwardly toward the opening side.
[0012]
The synthetic resin material used as the base material for the box-shaped product is appropriately determined according to the required strength and the like. For example, in the case of the box-shaped container of the third invention, a thermoplastic material such as polyolefin or polyamide having a predetermined strength. A resin material is preferably used. As a skin material that can be impregnated with a synthetic resin material, a woven fabric, a nonwoven fabric, a knitted fabric, or the like is preferably used.
[0013]
In the third invention, the bottom has a quadrangular shape. However, in the practice of the first invention, other square shapes such as a triangle and a pentagon may be used, and various shapes such as a circle and an ellipse may be employed. . Further, the outward flange of the third invention is not necessarily essential, and the side wall portion may be provided with a constant plate thickness up to the opening side end portion, and a protrusion may be provided on the end surface.
[0014]
For example, a plurality of annular protrusions according to the third aspect of the invention are provided on the upper surface of the outward flange so as to be spaced apart toward the inner and outer peripheral sides, but it is also possible to provide only a single annular protrusion. In carrying out the first invention, instead of providing annular projections, a number of longitudinal projections perpendicular to the circumferential direction are provided at predetermined intervals in the circumferential direction, or a number of longitudinal projections are provided in a posture inclined with respect to the circumferential direction. Various forms can be employed, such as providing a large number of protrusions in the shape of a cylinder or a prism. It is desirable that these protrusions have a trapezoidal cross section or a frustoconical shape so that the width dimension (or diameter dimension) decreases toward the tip side.
[0015]
In the fourth invention, for example, the outer peripheral edge portion of the skin material is gripped by an urging means such as a spring, such as a wrinkle presser in drawing, so that the inflow to the inside is restricted, or a pair of first By clamping the mold and the second mold, the outer peripheral edge of the skin material is clamped by the first mold and the second mold so that the inflow to the inside is prevented. For example, various modes can be adopted.
[0016]
The manufacturing method of the fourth invention is merely an example, and when manufacturing the box-shaped product of the first to third inventions, for example, a molten synthetic resin material is supplied in advance on the first molding surface of the first molding die. After that, press molding is performed with the second mold approached, and at the same time, the synthetic resin material passes through the skin material at the concave portion so that a protrusion is formed, or the synthetic resin material is also formed on the concave side as necessary. For example, various molding techniques can be adopted.
[0017]
【Example】
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a view showing a box-shaped container 10 which is an embodiment of a synthetic resin box-shaped product of the present invention, in which (a) is a perspective view seen obliquely from above, and (b) is B in (a). It is -B sectional drawing. The box-shaped container 10 has a rectangular bottom portion 12 and a substantially flat side wall portion 14 provided on the entire circumference of the bottom portion 12, and is integrally molded with a synthetic resin material 16. A skin material 18 having a predetermined cushion performance is integrally fixed to the inner surface of the bottom portion 12 and the side wall portion 14. As the synthetic resin material 16, a thermoplastic resin such as polyolefin or polyamide having a predetermined required strength is used, and as the skin material 18, a woven fabric, a nonwoven fabric, or a knitted fabric that can be impregnated with the synthetic resin material 16. The skin material 18 is molded simultaneously with the integral molding of the synthetic resin material 16, and the synthetic resin material 16 is integrally fixed by impregnating the surface layer portion on the back surface of the skin material 18. ing.
[0018]
The side wall portion 14 is provided in a posture that is inclined substantially at right angles to the bottom portion 12, strictly, slightly outward, and an outward flange 20 that protrudes outward is formed at the upper end portion that is the opening side end portion. It is provided integrally. On the upper surface of the outward flange 20, an annular protrusion 22 that is continuous over the entire circumference of the outward flange 20 is provided so that the synthetic resin material 16 passes through the skin material 18 and protrudes upward. A plurality of annular protrusions 22 (three in the present embodiment) are provided apart from the inner and outer peripheral sides, and each annular protrusion 22 has a trapezoidal cross section so that the width dimension becomes narrower toward the tip side. Yes.
[0019]
FIG. 2 is a partial cross-sectional view for explaining an injection molding apparatus 30 for manufacturing the box-shaped container 10, and is a diagram showing a portion for molding the side wall portion 14 of FIG. 1 (b). There are provided a first mold 32 and a second mold 34 that can be moved closer to and away from the first mold 32 in the vertical direction. The first molding die 32 has a first molding surface 36 corresponding to the outer shape of the box-shaped container 10, and an injection device 38 that injects the synthetic resin material 16 from the first molding surface 36 at a predetermined injection pressure. It is connected. The second molding die 34 has a second molding surface 40 corresponding to the inner shape to which the skin material 18 of the box-shaped container 10 is fixed, and corresponds to the annular protrusion 22 on the outer peripheral side of the second molding surface 40. Three annular grooves 42 are provided as recesses.
[0020]
In addition, a gripping device 44 that grips the outer peripheral portion of the skin material 18 to restrict inward flow and applies a predetermined tension is provided at the peripheral portions of the first mold 32 and the second mold 34. ing. The gripping device 44 is disposed on the first mold 32 and is disposed on the second mold 34 and the rectangular annular lower pressing mold 48 that is biased upward by a biasing means 46 such as a spring. And a rectangular annular upper pressing die 52 urged downward by an urging means 50 such as a spring, and the second molding surface 40 of the second molding die 34 comes into contact with the skin material 18 and moves downward. When pushed down, the urging force of the urging means 46, 50 restricts the inflow of the skin material 18 to suppress the generation of wrinkles. In the state where the second mold 34 is lowered to the lower end and is clamped, the skin material 18 is sandwiched between the outer peripheral protrusion 54 of the first mold 32 and the outer peripheral protrusion 56 of the second mold 34. Inflow to the inside is substantially prevented.
[0021]
In such an injection molding apparatus 30, first, as shown in FIG. 2, in the state where the second mold 34 is raised and separated from the first mold 32, the skin is placed on the first mold 32. The material 18 is arranged. Next, as shown in FIG. 3, the second molding die 34 is lowered to the descending end and clamped. At this time, the skin material 18 flows inward with the lowering of the second mold 34, but since the peripheral edge is gripped by the gripping device 44, a predetermined tension is applied to the skin material 18, and the bottom portion 12. The skin material 18 is substantially in close contact with the second molding surface 40 of the second molding die 34 at the portion corresponding to. When the second mold 34 reaches the descending end, the skin material 18 is sandwiched between the outer peripheral protrusion 54 of the first mold 32 and the outer peripheral protrusion 56 of the second mold 34, and further to the inside. Inflow is substantially prevented. The transition from the mold open state of FIG. 2 to the mold clamp state of FIG. 3 is a mold clamping process.
[0022]
Subsequently, when the synthetic resin material 16 melted at a predetermined injection pressure is injected from the first molding surface 36 by the injection device 38, the skin material 18 including the portion corresponding to the side wall portion 14 is secondly formed as shown in FIG. The synthetic resin material 16 is integrally molded between the second molding surface 40 and the first molding surface 36 while being brought into close contact with the molding surface 40. Further, the synthetic resin material 16 is impregnated into the surface layer portion of the back surface of the skin material 18, so that the skin material 18 is integrally fixed to the synthetic resin material 16. At this time, since the skin material 18 is substantially prevented from flowing inward, the skin material 18 is mainly brought into close contact with the second molding surface 40 by its own deformation, but the upper end portion of the side wall portion 14. That is, in the portion where the annular groove 42 is provided, the skin material 18 does not greatly enter the annular groove 42 due to the injection pressure of the synthetic resin material 16. FIG. 4 shows this state, but in the annular groove 42 portion, the melted synthetic resin material 16 penetrates and passes through the skin material 18 due to the injection pressure, penetrates into the annular groove 42, and the annular protrusion 22 is integrally formed. Is done. Thus, the process from injecting the melted synthetic resin material 16 until the annular protrusion 22 is integrally molded is the molding process.
[0023]
The width dimension and depth of the annular groove 42, that is, the width dimension w and the height dimension t (see FIG. 1B) of the annular projection 22 are such that the skin material 18 is placed in the annular groove 42 by the deformation of the skin material 18. For example, it is determined to satisfy t ≧ 1.5w so as not to increase and enter. Thereby, the skin material 18 is deformed following the annular groove 42, and there is no possibility that the skin material 18 is partially exposed on the side surface or the upper surface of the annular protrusion 22.
[0024]
Thereafter, after the synthetic resin material 16 is cooled and cured, the second molding die 34 is released upward to take out the integrally formed box-shaped container 10, and the excess extending outward from the outward flange 20. By trimming and removing the skin material 18, the intended box-type container 10 shown in FIG. 1 is obtained.
[0025]
According to the box-shaped container 10 of this embodiment, since the skin material 18 is formed at the same time as the integral molding of the synthetic resin material 16 and is integrally fixed by the impregnation of the synthetic resin material 16, The box-shaped container 10 having the skin material 18 fixed to the side surface is manufactured at low cost. Moreover, the outward flange 20 provided at the upper end portion of the side wall portion 14 is provided with an annular projection 22 made of only the synthetic resin material 16 and the synthetic resin material 16 protrudes through the skin material 18. As shown in FIG. 6, the appearance quality is improved as compared with the case where the synthetic resin material 16 partially oozes on the surface. Further, when designing the shape of the box-shaped container 10, it is not necessary to consider the crease of the skin material 18 in the outward flange 20 portion and the partial exudation of the synthetic resin material 16, so that the degree of freedom in design is improved.
[0026]
On the other hand, since the skin material 18 having a cushioning property is fixed inside the box-shaped container 10 as described above, the design property is improved and the impact at the time of component introduction is reduced. Further, since the plurality of annular protrusions 22 are provided continuously around the entire circumference of the outward flange 20 at the upper end of the side wall portion 14, the annular protrusions 22 function as reinforcing ribs, and the strength of the outward flange 20 is improved. Deformation and damage are prevented.
[0027]
In the present embodiment, the skin material 18 is clamped between the pair of the first molding die 32 and the second molding die 34, and the first molding surface 36 of the first molding die 32 and the skin material 18 are clamped. The synthetic resin material 16 is simply injected between the outer surface 20 and the skin material 18 is molded and fixed together at the same time as the molding of the synthetic resin material 16. Since the annular protrusion 22 is integrally formed by passing the skin material 18 through the skin material 18 and entering the annular groove 42, the box-shaped container 10 can be manufactured easily and inexpensively.
[0028]
As mentioned above, although the Example of this invention was described in detail based on drawing, this is an embodiment to the last, and this invention implements in the aspect which added the various change and improvement based on the knowledge of those skilled in the art. Can do.
[Brief description of the drawings]
1A and 1B are views showing a box-type container according to an embodiment of the present invention, in which FIG. 1A is a perspective view and FIG. 1B is a cross-sectional view along line BB in FIG.
FIG. 2 is a partial cross-sectional view illustrating an injection molding apparatus for manufacturing the box-shaped container of FIG.
3 is a view showing a state in which a pair of molds of the injection molding apparatus of FIG. 2 is clamped.
4 is a view showing a state before the synthetic resin material reaches the inside of the annular groove in the process of injecting and integrally molding the synthetic resin material in the mold-clamped state of FIG. 3;
FIG. 5 is a diagram showing a state of clamping when a conventional box-type container is manufactured by injection molding.
6 shows a state where the synthetic resin material partially passes through the skin material and exudes to the surface at the upper end corner of the side wall when the synthetic resin material is injected and integrally molded in the mold-clamped state of FIG. FIG.
[Explanation of symbols]
10: Box-shaped container (box-shaped product) 12: Bottom portion 14: Side wall portion 16: Synthetic resin material 18: Skin material 20: Outward flange 22: Annular projection (projection) 30: Injection molding device 32: First molding die 34: second mold 36: first molding surface 40: second molding surface 42: annular groove (recess)

Claims (4)

A box-shaped product having a bottom part and a side wall part provided on the entire circumference of the bottom part, and integrally molded with a synthetic resin material,
A skin material that can be impregnated with the synthetic resin material is molded simultaneously with the integral molding of the synthetic resin material, and is integrally fixed to the inner surface of the bottom portion and the side wall portion by impregnation of the synthetic resin material. ,
A synthetic resin box-shaped product, characterized in that the end surface of the side wall portion on the opening side is provided with protrusions protruding from the synthetic resin material through the skin material. The protrusion is provided at least on the inner peripheral side portion of the end surface on the opening side of the side wall portion so as to continuously protrude from the inner side surface of the side wall portion.
The synthetic resin box-shaped product according to claim 1. The box-shaped product is a box-shaped container in which the bottom portion has a rectangular shape and an outward flange projecting outward is integrally provided at an opening side end portion of the side wall portion,
The synthetic resin box-shaped product according to claim 1 or 2, wherein the protrusion is an annular protrusion continuously provided on the entire circumference of the outward flange. It is a manufacturing method of the synthetic resin box shape product according to any one of claims 1 to 3 ,
The first mold having a first molding surface corresponding to the outer shape of the box-shaped product and the second molding surface corresponding to the inner shape to which the skin material of the box-shaped product is fixed are 2 In a state where the skin material is interposed between the second molding die provided with a recess corresponding to the protrusion on the outer peripheral side of the molding surface and the skin material is restricted from flowing inward, A mold clamping step of clamping the first mold and the second mold;
The synthetic resin material is injected between the first molding surface of the first molding die and the skin material, and the synthetic resin material is adhered while the skin material is in close contact with the second molding surface of the second molding die. The skin material, which is integrally molded and fixed integrally to the synthetic resin material by impregnation with the synthetic resin material, and the inflow to the inside is restricted at the end surface on the opening side of the side wall portion A molding step in which the projection is integrally formed by passing the synthetic resin material and entering the recess.
A method for producing a synthetic resin box-shaped product, comprising:

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