JP4066071B2 - Synthetic resin hollow body, method for producing the same, and mold thereof - Google Patents

Synthetic resin hollow body, method for producing the same, and mold thereof Download PDF

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JP4066071B2
JP4066071B2 JP2003163544A JP2003163544A JP4066071B2 JP 4066071 B2 JP4066071 B2 JP 4066071B2 JP 2003163544 A JP2003163544 A JP 2003163544A JP 2003163544 A JP2003163544 A JP 2003163544A JP 4066071 B2 JP4066071 B2 JP 4066071B2
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synthetic resin
hollow body
opening
divided case
holes
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JP2005001115A (en
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正三 西田
孝志 上村
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Japan Steel Works Ltd
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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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined

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  • Details Of Rigid Or Semi-Rigid Containers (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、射出成形機で分割された一対の成形品、つまり、上部分割ケースおよび下部分割ケースと、複数の穴を有する穴付合成樹脂板のそれぞれを成形し、衝合して、衝合後に形成される開口部に溶融樹脂を充填し接合して一体化させて形成する合成樹脂製中空体、その製造方法およびその金型に関するものである。
【０００２】
【従来の技術】
従来、合成樹脂製の中空製品の製造は、合成樹脂製中空体を成形することの容易性からブロー成形方法が多く用いられてきた。ブロー成形方法では、溶融した合成樹脂のパリソンを円筒状にして上から押出して、そのパリソンを金型で挟みパリソン中に空気を吹き込み、合成樹脂製中空製品を製造していた。
しかし、この方法では、大型の合成樹脂製中空製品の場合は、パリソンの全体の重量が大きくなり、また、合成樹脂製中空製品の強度が必要な場合に、強度増加のため厚肉の合成樹脂製中空製品を製造するときにもパリソンの重量が増加して、溶融状のパリソンを成形機の上部から金型に入れるときに下方に垂れるため、上部の肉厚が下部の肉厚よりも薄くなる場合があった。
【０００３】
また、複雑な形状をした合成樹脂製中空製品の場合は、パリソンを金型内で膨張させたときに、パリソンの膨張の割合が製品の部位によって異なる場合があり、製品の肉厚にバラツキが生じる場合があった。
さらに、ブロー成形においては、パリソンを上方から垂らして金型で挟んで成形する為、比較的多くのバリが発生して、材料の無駄が多く、生産性がよくなかった。
特にブロー成形の場合は、強度を増すために合成樹脂製中空体内部にリブおよび張り等の構造体を設けることが困難であった。
そのため合成樹脂製中空体を上下に分割して、それぞれ別に射出成形等により成形して、その後その上部分割ケースと下部分割ケースを突き合せ部にて衝合して中空体を形成していた。
【０００４】
このような、射出成形により金型内に合成樹脂を射出して成形する方法においては、例えば図９に示すように、中空製品を作るにはスライド金型８０を使用して、中空製品を２分割して別々のキャビティー８３、８４で成形し、その後２分割して成形した分割体の分割開口部をスライド型８２をスライドさせて、図１０に示すように、固定型８１のキャビティー８３内の分割体とスライド型８２のキャビティー８４内の分割体とを接合し、固着している。この固着は、接合部分の外周に凹部８５を設けて、その凹部８５に溶融樹脂を射出して、溶融樹脂により分割開口部を溶着している場合がある（特許文献１および２参照。）。
【０００５】
そのとき上部分割ケースと下部分割ケースの突き合せ部に全周にわたり外周に向けて開口した開口部を設け、その開口部の内部に溶融樹脂を充填して、上部分割ケースと下部分割ケースとを融着して、合成樹脂製中空体を形成していた。そして充填した溶融樹脂を合成樹脂製中空体の内部へ洩らさないように突き合せ部において溶融樹脂を止める遮壁をもうけ、その遮壁によって開口部に充填された溶融樹脂が内部に洩れない様になっていた。しかしながら、この障壁を設ける場合には、障壁を形成する分割体の分割開口部や、障壁を受け入れる分割体の分割開口部に設けられた凹部にノッチ部が生じるため、合成樹脂製中空体に外力が加わった場合にノッチ部に応力が集中して強度的に弱くなる恐れがあった。
さらに高い接合強度の得るためには、接合部に高い圧力かけて溶融樹脂を充填する必要があり、この突き合せ部に生じる圧力においても溶融樹脂の漏れを防止するため、突き合せ部の遮壁の肉厚を厚くする必要があった。
【０００６】
しかしながら、遮壁を厚くすることにより、上部分割ケースと下部分割ケースの突き合せ部の形状が大きくなり、合成樹脂製中空体の外面に開口部を形成する部分が張り出したり、合成樹脂製中空体の外形寸法が大きくなるとともに、さらには、遮壁を厚くすることにより、そのノッチが大きくなるため、合成樹脂製中空体へ外側から圧力がかかった場合には、強度的に不利であった。特に外側から合成樹脂製中空体に物体が衝突したりするような外部から応力等が考えられる場合には、その外部からの応力によりそのノッチ部分に応力が集中し、その部分から亀裂が発生する場合があり、強度的に改善が必要であった。
【０００７】
【特許文献１】
特開昭６２−８７３１５号公報（第３−６頁、第６図）
【特許文献２】
特開２００１−１２９８５１号公報（第３−４頁、第１図）
【０００８】
【発明が解決しようとする課題】
以上のような状況に鑑み、本発明はその開口部に溶融樹脂を充填して、ノッチ部を有しない接合形状で、外圧および内圧に対応できる頑丈な合成樹脂製中空体を提供することを目的とする合成樹脂製中空体とその成形方法および成形金型に関するものである。
【０００９】
【課題を解決するための手段】
上記課題を解決するために請求項１の本発明は、分割して成形された合成樹脂製中空体を構成する上部分割ケースと下部分割ケースを衝合させて、衝合部分を溶融樹脂で一体的に接合して形成した合成樹脂製中空体において、上部分割ケースの上部開口端面と下部分割ケースの下部開口端面との間に、複数の穴を有する穴付合成樹脂板の外周端部を挟持し、穴付合成樹脂板の外周側面の全周に凹部を設け、穴付合成樹脂板の外周側面と、上部分割ケースの上部開口端面と、下部分割ケースの下部開口端面とで合成樹脂製中空体の外周部に開口部を形成し、開口部に溶融樹脂を充填して、上部分割ケースと、下部分割ケースと穴付合成樹脂板とを一体的に接合してなる合成樹脂製中空体である。
【００１０】
請求項１の本発明では、上部分割ケースと下部分割ケースとを別々に成形することができるので、それぞれを射出成形で成形した場合には、寸法精度の高い、強度の強い上部分割ケースと下部分割ケースを得ることができるため、上部分割ケースと下部分割ケースとを組み合わせて形成された合成樹脂製中空体は、寸法精度の高い精密な、かつ強度の高い製品を得ることができる。また、上部分割ケースまたは下部分割ケース内に補強リブや内臓部品等を取付けることができる。
また、上部分割ケースの上部開口端面と下部分割ケースの下部開口端面との間に、複数の穴を有する穴付合成樹脂板の外周端部を挟持するため、合成樹脂製中空体の内部に複数の穴を有する穴付合成樹脂板を設けることができ、合成樹脂製中空体の内部に補強板を取付けたこととなり、強度を向上させることができる。また、穴付合成樹脂板は、複数の穴を有するので合成樹脂製中空体内部に保管された液体等を仕切ることなく穴付合成樹脂板を通して自由に移動することができるとともに、合成樹脂製中空体が揺れたり、振動したりしたときにも、保管された内部の液体が波立ったり、泡だったりすることを防止することができる。
さらに、開口部を構成する穴付合成樹脂板の外周側面の全周に凹部が設けられたため、穴付合成樹脂板と溶融樹脂との融着面積が増加し、穴付合成樹脂板との強固な溶着ができる。
【００１１】
また、穴付合成樹脂板の外周側面と、上部分割ケースの上部開口端面と、下部分割ケースの下部開口端面とで合成樹脂製中空体の外周部に開口部を形成したため、穴付合成樹脂板の外周側面で、溶融樹脂の注入圧力を受け止めることができ、強い注入圧力でも穴付合成樹脂板が変形することがないので強く融着をすることができるとともに、上部分割ケースの上部開口端面と、下部分割ケースの下部開口端面には突起等を設ける必要がなく、開口部の形状がシンプルになり、成形が容易である。
【００１２】
さらに、溶融樹脂が融着する上部分割ケースの上部開口端面と下部分割ケースの下部開口端面は、障壁や凹部等の突起や窪みがないため、合成樹脂製中空体に外部から衝撃が加わったり、内部圧力が増大しても、応力が集中することがないため、強度が高い合成樹脂製中空体を得ることができる。
この開口部に溶融樹脂を充填して、上部分割ケースと、下部分割ケースと穴付合成樹脂板とを一体的に接合するため、溶融樹脂で強固に融着された合成樹脂製中空体を得ることができる。
【００１５】
上記課題を解決するために請求項２の本発明は、開口部を構成する穴付合成樹脂板の外周側面の全周に設けられた凹部は、上部分割ケースと下部分割ケースの内面が構成する上記合成樹脂製中空体の内面よりも内側に向けて深く形成され、開口部に充填された溶融樹脂は凹部まで充填されて、上部分割ケースと、下部分割ケースと、穴付合成樹脂板とを一体的に接合してなる請求項１記載の合成樹脂製中空体である。
【００１６】
請求項２の本発明では、穴付合成樹脂板の外周側面の全周に設けられた凹部は、上部分割ケースと下部分割ケースの内面が構成する上記合成樹脂製中空体の内面よりも内側に向けて深く形成され、その凹部まで溶融樹脂を充填したため、穴付合成樹脂板と溶融樹脂の接触面積がより大きくなり、接着強度が増大するとともに、溶融樹脂が上記合成樹脂製中空体の内面よりも深く入り込むため、溶融樹脂が固化した後は上部分割ケースや下部分割ケースに対して穴付合成樹脂板が振動したり、グラついたりすることを防止することができる。
【００１７】
上記課題を解決するために請求項３の本発明は、分割して成形された合成樹脂製中空体を構成する上部分割ケースと下部分割ケースとを中空体成形金型にそれぞれ装着し、上部分割ケースの上部開口端面と下部分割ケースの下部開口端面との間に、複数の穴を有する穴付合成樹脂板を挟持して、穴付合成樹脂板の外周側面の全周に凹部を設け、中空体成形金型内で衝合し合成樹脂製中空体の外周部に開口部を形成し、開口部に溶融樹脂を注入して一体的に接合して形成する合成樹脂製中空体の製造方法において、溶融樹脂を中空体成形金型の注入口から、スプールおよびランナーと、スプールおよびランナーに連続的に繋がり、開口部から少し離れた位置の全周囲に設けられたリング溝と、リング溝と開口部を繋ぐフイルムゲートを経由して、開口部の各部分に時間差なく溶融樹脂を充填させることを特徴とする合成樹脂製中空体の成形方法である。
【００１８】
請求項３の本発明では、合成樹脂製中空体を構成する上部分割ケースと、下部分割ケースとを分割してそれぞれ別々に射出成形するため、合成樹脂製中空体においても射出成形の金型により均一な肉厚で、寸法精度よく分割体を形成することができる。このため各分割ケースの開口部を衝合させるときも寸法精度よく衝合させることができ、密封性に優れた強度の高い合成樹脂製中空体を得ることができる。また、それぞれ別々に射出成形するため、合成樹脂製中空体の内部に補強リブ等を設けることが容易である。
【００１９】
各分割ケースの開口部を中空体成形金型内で衝合し、各分割ケースの開口部が合体してできた開口部に溶融樹脂を注入して一体的に接合して形成する製造方法であるので、中空体成形金型内に分割ケースを保持することにより開口部を形成し、溶融樹脂を注入して接合することができ、接合作業が容易である。さらに、開口部を構成する穴付合成樹脂板の外周側面の全周に凹部が設けられたため、穴付合成樹脂板と溶融樹脂との融着面積が増加し、穴付合成樹脂板との強固な溶着ができる。
この中空体成形金型は、各分割ケースをそれぞれ１つの金型の別のキャビティで成形してその後金型をスライドさせて穴付合成樹脂板を挟持させて各分割体を合体させ、両方の開口部を融着するいわゆるスライド金型でもよいし、別々の金型で成形して、その各分割ケースをさらに別の接合金型にセットして合体させるものでもよい。
【００２０】
接合金型の樹脂の流入経路において、注入口から、スプールおよびランナーと、スプールおよびランナーに連続的に繋がり、開口部から少し離れた位置全周囲に設けられたリング溝と、リング溝と開口部を繋ぐフイルムゲートを経由して、開口部の各部分に時間差なく溶融樹脂を充填させたため、複数のスプールおよびランナーからリング溝に溶融樹脂を注入し、リング溝で溶融樹脂を一旦ためて、バランスよくフイルムゲートから開口部の各部分に時間差なく溶融樹脂を充填したため、大型の合成樹脂製中空体であっても開口部の全周にわたり均一に同時に、溶融樹脂を送ることができる。このため、溶融樹脂を略同じ温度で開口部に注入することができ、開口部を均一に確実に融着することができる。
【００２１】
上記課題を解決するために請求項４の本発明は、分割して成形された合成樹脂製中空体を構成する上部分割ケースと、下部分割ケースをそれぞれ装着し、上部分割ケースと下部分割ケースを衝合させて衝合後にできる開口部に溶融樹脂を注入して一体的に接合して形成する合成樹脂製中空体の中空体成形金型において、
中空体成形金型は、上部分割ケース又は下部分割ケースの一方を取付ける中空体成形固定型と、上部分割ケース又は下部分割ケースの他方を取付ける中空体成形可動型から構成され、上部分割ケースの上部開口端面と下部分割ケースの下部開口端面との間に、複数の穴を有する穴付合成樹脂板を挟持して衝合し合成樹脂製中空体の外周部に開口部を形成し、穴付合成樹脂板の外周側面の全周に凹部を設け、開口部に溶融樹脂を注入して一体的に接合して形成する合成樹脂製中空体の中空体成形金型である。
【００２２】
請求項４の本発明では、中空体成形金型は、上部分割ケース又は下部分割ケースの一方を取付ける中空体成形固定型と、上部分割ケース又は下部分割ケースの他方を取付ける中空体成形可動型から構成され、上部分割ケースの上部開口端面と下部分割ケースの下部開口端面との間に、複数の穴を有する穴付合成樹脂板を挟持して衝合したため、中空体成形金型を閉じるのみで、溶融樹脂を注入する開口部を形成でき、中空体成形金型の注入口から開口部に注入することができる。
さらに、開口部を構成する穴付合成樹脂板の外周側面の全周に凹部が設けられたため、穴付合成樹脂板と溶融樹脂との融着面積が増加し、穴付合成樹脂板との強固な溶着ができる。
【００２３】
上記課題を解決するために請求項５の本発明は、中空体成形固定型は、溶融樹脂が注入される注入口と、スプールおよびランナーと、スプールおよびランナーに連続的に繋がり開口部から少し離れた位置全周囲に設けられたリング溝と、リング溝と開口部を繋ぐフイルムゲートとを有する請求項５記載の中空体成形金型である。
【００２４】
請求項５の本発明では、スプールおよびランナーに連続的に繋がり開口部から少し離れた位置の全周囲に設けられたリング溝を設けたため、スプールおよびランナーを経由して注入された溶融樹脂を開口部の近傍に一時的に溜めることができ、フイルムゲートから略時間差なく開口部に溶融樹脂を注入することができる。
リング溝と開口部を繋ぐフイルムゲートを設けたため、開口部の全周にわたり均一に溶融樹脂を注入することができ、合成樹脂製中空体を均一に融着することができるとともに、融着後に固化したフイルムゲートの部分は肉厚が薄いので容易に除去することができる。
以上
【００２５】
【発明の実施の形態】
本発明の実施の形態を、図１〜図８に基づき説明する。
図１は、合成樹脂製中空体１を斜め上方から見た斜視図である。図２は図１のＡ−Ａ線に沿った断面図である。
【００２６】
合成樹脂製中空体１は分割して成形された２個の分割体と内部に取付けられる穴付合成樹脂板２７から形成され、第１の分割体である上部分割ケース１０と第２の分割体である下部分割ケース２０からなる。上部分割ケース１０、下部分割ケース２０と穴付合成樹脂板２７はそれぞれ後述のように射出成形で金型を使用し成形される。
合成樹脂製中空体１の分割は２個ばかりでなく３個以上に分割することも可能である。上部分割ケース１０は、上部分割ケース本体１１と、上部分割ケース本体１１の先端でその開口の全周に亘り設けられた上部分割ケース開口部１２とからなる。
【００２７】
図３で示すように上部分割ケース開口部１２は、上部分割ケース本体１１から外側に断面が略Ｔ字状に突出して外周部の全周にわたり環状に形成される上部フランジ部１４と、下部分割ケース開口部２２と対抗する面を構成する上部開口端面１３と、上部開口端面１３の合成樹脂製中空体１内面側の端部に設けられた段部１３ａとからなる。
下部分割ケース開口部２２は、下部分割ケース本体２１から外側に断面が略Ｔ字状に突出して外周部の全周にわたり環状に形成される下部フランジ部２４と、上部分割ケース開口部１２と対抗する面を構成する下部開口端面２３と、下部開口端面２３の合成樹脂製中空体１の内面側の端部に設けられた段部２３ａとからなる。
【００２８】
上部分割ケース開口部１２と下部分割ケース開口部２２とは、穴付合成樹脂板２７の外周周縁部を挟持する。
図２に示すように、穴付合成樹脂板２７は、上部分割ケース１０と下部分割ケース２０の開口部分を衝合して合成樹脂製中空体１を形成するときにその衝合面に合成樹脂製中空体１を上下に区分するように取付けられる。合成樹脂製中空体１は、多数の貫通穴２７ａを有しているので、合成樹脂製中空体１の内部に貯蔵された液体は自由に上下に移動できる。さらに、合成樹脂製中空体１が振動したり、揺れたりしたときに、内部に貯蔵された液体が波立ったり、泡だったりすることを防止できる。
また、穴付合成樹脂板２７は、合成樹脂製中空体１の内部の中央付近に取り付けられるので、補強板の働きをすることができ、外部からの衝撃等に対して強度を高くすることができる。
【００２９】
穴付合成樹脂板２７は、上部分割ケース開口部１２と下部分割ケース開口部２２において、それぞれの段部１３ａ、２３ａに嵌め込まれて保持され、上部分割ケース開口部１２の上部開口端面１３と、下部分割ケース開口部２２の下部開口端面２３と、穴付合成樹脂板２７の外周側面２７ｂとで合成樹脂製中空体１の外周 の全周に亘り開口部２５が形成される。この穴付合成樹脂板２７の外周側面２７ｂには、内部方向に向かって凹部２７ｃが設けられている。凹部２７ｃの深さは、上部分割ケース１０と下部分割ケース２０との内面で形成する合成樹脂製中空体１の内面よりも内部まで形成することができる。凹部２７ｃを深く形成すると後述のように、溶融樹脂が凹部２７ｃの奥まで注入されて、溶融樹脂と穴付合成樹脂板２７が強固に融着される。
【００３０】
次に、この合成樹脂製中空体１の製造方法について説明する。
まず、合成樹脂製中空体１を構成する上部分割ケース１０と、下部分割ケース２０と、穴付合成樹脂板２７とを成形する工程を説明する。合成樹脂製中空体１を構成する上部分割ケース１０と、下部分割ケース２０と、穴付合成樹脂板２７とは、図４〜図６に示すようにそれぞれ別の金型を使用して射出成形により成形される。射出成形により成形されるため、ブロー成形等と比べて、寸法精度が高く、強度も高い。
【００３１】
但し、このとき図９と図１０に示すようなスライド金型を使用して、１個の金型でキャビティを２個設けてそれぞれのキャビティで上部分割ケース１０と下部分割ケース２０を成形することができる。
図４は、上部分割ケース１０を成形する上部分割ケース成形金型４０である。上部分割ケース成形金型４０は、固定型４１と可動型４２によりキャビティ４３を形成し、このキャビティ４３に合成樹脂を射出して上部分割ケース１０を成形する。
【００３２】
下部分割ケース２０の成形は、上部分割ケース１０の成形と同様に、図５に示す下部分割ケース成形金型５０を使用する。下部分割ケース成形金型５０は固定型５１と可動型５２によりキャビティ５３を形成し、このキャビティ５３に合成樹脂を射出して下部分割ケース２０を成形する。
穴付合成樹脂板２７の成形は、上部分割ケース１０の成形と同様に、図６に示す穴付合成樹脂板成形金型６０を使用する。穴付合成樹脂板成形金型６０は固定型６１と可動型６２によりキャビティ６３を形成し、このキャビティ６３に合成樹脂を射出して穴付合成樹脂板２７を成形する。
【００３３】
次に、上部分割ケース１０と、下部分割ケース２０と、穴付合成樹脂板２７とを一体に溶着する工程と中空体成形金型３０を説明する。
まず、図７に示すように上部分割ケース１０と、下部分割ケース２０と、穴付合成樹脂板２７とをそれぞれ上部分割ケース成形金型４０と、下部分割ケース成形金型５０と、穴付合成樹脂板成形金型６０とから取出し、中空体成形金型３０に取付ける。中空体成形金型３０は中空体成形固定型３１と中空体成形可動型３９からなり、中空体成形固定型３１のキャビティに下部分割ケース２０を、中空体成形可動型３９のキャビティに上部分割ケース１０を取付け、穴付合成樹脂板２７は、上部分割ケース１０あるいは下部分割ケース２０にいずれかに取付ける。このとき、中空体成形固定型３１のキャビティに上部分割ケース１０を取付け、中空体成形可動型３９のキャビティに下部分割ケース２０を取付けてもよい。
【００３４】
なお、合成樹脂製中空体１内に内臓する構成部品を取付ける場合には、中空体成形金型３０に取付ける前に、上部分割ケース１０あるいは下部分割ケース２０に取付ける。これによって、中空樹脂製品内に容易に構成部品を取付けることができる。
中空体成形金型３０を閉じた後に、射出成形機（図示せず）から注入口３２へ、熱可塑性合成樹脂である溶融樹脂を射出する。このとき射出する溶融樹脂は、合成樹脂製中空体１を構成する合成樹脂と溶着することができる合成樹脂を用いるが、合成樹脂製中空体１を構成する合成樹脂と同じかあるいは同質の熱可塑性合成樹脂が好ましい。例えば、ポリエチレン、ポリプロピレン、ポリアセタール、ポリアミド等を使用することができる。
【００３５】
注入口３２から注入された溶融樹脂は、まず第１スプール３３を通り、ランナー３４との連続点まで流入する。ここで図７に示すように、第１スプール３３から流入した溶融樹脂は放射状に分岐した複数のランナー３４に分かれて金型面に平行に流れる。中空体成形固定型３１は、ランナー割面３１ｂにおいて２個のブロックに分かれており、その割面３１ｂの中空体成形固定型３１あるいは中空体成形移動型３９のいずれかに溝を設けてランナー３４としている。
【００３６】
ランナー３４の途中には溶融樹脂の流量を調整する流量調整弁３７をそれぞれ設けてもよい。この流量調整弁３７を調節することによってランナー３４の長さが異なっても溶融樹脂の流量と流速を調整することができる。
それぞれのランナー３４を流れた溶融樹脂は、次にそのランナー３４の先端と連続する第２スプール３５に入り、中空体成形固定型３１を垂直に流れる。第２スプール３５は、ランナー３４の先端から中空体成形固定型３１の金型面とは垂直に、キャビティ３１ｃの周囲を取り巻くように設けられている。そして、第２スプール３５を流れた溶融樹脂は、リング溝３６に流入する。
【００３７】
リング溝３６は、図７に示すように、上部分割ケース１０と下部分割ケース２０の接合部分における、上部開口端面１３と、下部開口端面２３と、穴付合成樹脂板２７の外周側面２７ｂとが形成する合成樹脂製中空体１外周に設けられた開口部２５に近接して、若干離れたところにその開口部２５に沿うように、全周にわたり中空体成形可動型３９に設けられている。なお、リング溝３６は中空体成形固定型３１に設けてもよい。
それぞれの第２スプール３５からリング溝３６に流入した溶融樹脂は略同時にリング溝３６に流入し始めて、それぞれの第２スプール３５とリング溝３６との連結部からリング溝３６を満たすように流入する。このとき、リング溝３６は、スプールと比べて断面積が大きいので、バッファの役割を果たし、リング溝３６の各部分が略同時に溶融樹脂により充填される。
【００３８】
図８に示すように、中空体成形金型３０が閉じられたときに、上部開口端面１３と、下部開口端面２３と、穴付合成樹脂板２７の外周側面２７ｂが形成する合成樹脂製中空体１の外周に設けられた開口部２５は、断面が薄い板状のフイルムゲート３８によりリング溝３６と連続されている。フイルムゲート３８は、リング溝３６に沿って全周に設けられているので、リング溝３６に流入した溶融樹脂は、リング溝３６から時間差なく均一に開口部に素早く注入することができる。このため、溶融樹脂が部分的に冷やされることがなく、上部分割ケース１０と下部分割ケース２０を均一に溶着することができる。
【００３９】
なお、このゲート３８は断面が円形または四角形状のゲートでもよい。断面が円形または四角形状の場合は金型の加工が容易であり、フィルムゲートの場合は、より一層均一に溶融樹脂をリング溝３６に注入することができる。
このとき、図８に示すように、上部分割ケース１０の上部分割ケース開口部１２の上部フランジ部１４を中空体成形固定型３１が保持して、下部分割ケース２０の下部分割ケース開口部２２の下部フランジ部２４を中空体成形可動型３９が保持しているため、上部開口端面１３と下部開口端面２３との間に溶融樹脂が流入しても、上部分割ケース開口部１２と下部分割ケース開口部２２が開くことはなく、合成樹脂製中空体１内に溶融樹脂が流入することがない。
【００４０】
また、開口部２５の奥の面は、穴付合成樹脂板２７の外周側面２７ｂで形成されるので、溶融樹脂の圧力により変形することはないため、溶融樹脂が合成樹脂製中空体１内部に流入することがない。
穴付合成樹脂板２７の外周側面２７ｂには、全周に亘り凹部２７ｃが設けられており、溶融樹脂を凹部２７ｃまで注入することにより、上部分割ケース１０と、下部分割ケース２０と、穴付合成樹脂板２７とを一体的に溶着することができ、特に穴付合成樹脂板２７との融着面積を大きくすることができるため、強固な融着ができる。
【００４１】
上部分割ケース開口部１２と、下部分割ケース開口部２２と、穴付合成樹脂板２７の外周側面２７ｂとで形成する開口部２５に溶融樹脂が流入してその溶融樹脂が固化した後に、中空体成形金型３０の中空体成形固定型３１と中空体成形可動型３９を開き、合成樹脂製中空体１を取り出す。
そして、合成樹脂製中空体１の開口部２５の周囲に付いているリング溝３６とフイルムゲート３８中の部分で形成されたリング状の合成樹脂を取り除く。このときフイルムゲート３８は、フィルム状であるため、このゲート部分で容易に折ることができ、取り除きは容易にすることができる。
【００４２】
合成樹脂製中空体１を取り出した後は、中空体成形固定型３１のランナー割面３１ｂを開き、第１スプール３３、ランナー３４と第２スプール３５の部分の合成樹脂を取り出す。これによって次の溶融樹脂の注入工程を実施することができる。
なお第１スプール３３、ランナー３４と第２スプール３５の部分を冷却せずにいわゆるホットランナータイプにした場合は、上記の合成樹脂の取り出しは不要である。
【００４３】
【発明の効果】
本発明は、大型中空樹脂製品を２個以上の分割体で形成した後、その両方の分割体の開口部の開口端面を溶融樹脂により接合するため、接合面が平坦であり外力が加わっても応力集中が起きることがなく、強固な、耐圧性の高い合成樹脂製中空体を得ることができる。
分割体をそれぞれ射出成形により成形したため、寸法精度の高い、強度の高い合成樹脂製中空体を得ることができる。
合成樹脂製中空体の内部に多数の貫通穴を有する穴付合成樹脂板を設けたため、内部の液体等が外部の振動及び揺れにより生じる波立ち、泡立ち等を緩和することができる。また、衝突等に外力がかかっても、穴付合成樹脂板により構造剛性が向上して合成樹脂製中空体の外力による変形を防止することができる。
【図面の簡単な説明】
【図１】本発明の実施の態様である合成樹脂製中空体の斜視図である。
【図２】本発明の実施の態様である合成樹脂製中空体の図１のＡ−Ａ線に沿った断面図である。
【図３】本発明の実施の態様である合成樹脂製中空体の開口部の拡大一部断面図である。
【図４】本発明の実施の態様である合成樹脂製中空体の上部分割ケースを成形する金型の断面図である。
【図５】本発明の実施の態様である合成樹脂製中空体の下部分割ケースを成形する金型の断面図である。
【図６】本発明の実施の態様である合成樹脂製中空体の穴付合成樹脂板を成形する金型の断面図である。
【図７】本発明の実施の態様である上部分割ケースと、下部分割ケースと、穴付合成樹脂板とを接合する中空体成形金型の断面図である。
【図８】本発明の実施の態様である中空体成形金型の開口部へ溶融樹脂を注入する部分の拡大一部断面図である。
【図９】従来の中空樹脂製品を成形するスライド金型のスライド前の断面図である。
【図１０】従来の中空樹脂製品を成形するスライド金型のスライド後の断面図である。
【符号の説明】
１ 合成樹脂製中空体
１０ 上部分割ケース
１２ 上部分割ケース開口部
１３ 上部開口端部
１４ 上部フランジ部
２０ 下部分割ケース
２２ 下部分割ケース開口部
２３ 下部開口端面
２４ 下部フランジ部
２５ 開口部
２７ 穴付合成樹脂板
２７ｂ 外周側面
２７ｃ 凹部
３０ 中空体成形金型
３１ 中空体成形固定型
３４ ランナー
３５ 第２スプール
３６ リング溝
３８ フイルムゲート[0001]
BACKGROUND OF THE INVENTION
The present invention forms a pair of molded products divided by an injection molding machine, that is, an upper divided case and a lower divided case, and a synthetic resin plate with a hole having a plurality of holes, and abuts each other. The present invention relates to a synthetic resin hollow body formed by filling a molten resin into an opening formed later and joining and integrating them, a manufacturing method thereof, and a mold thereof.
[0002]
[Prior art]
Conventionally, the blow molding method has been often used for the production of a hollow product made of synthetic resin because of the ease of molding a hollow body made of synthetic resin. In the blow molding method, a melted synthetic resin parison is formed into a cylindrical shape and extruded from above, the parison is sandwiched between molds, and air is blown into the parison to produce a synthetic resin hollow product.
However, in this method, in the case of a large synthetic resin hollow product, the total weight of the parison increases, and when the strength of the synthetic resin hollow product is required, a thick synthetic resin is used to increase the strength. When manufacturing hollow products, the weight of the parison increases and droops downward when the molten parison is put into the mold from the top of the molding machine, so the top wall thickness is thinner than the bottom wall thickness. There was a case.
[0003]
In addition, in the case of a synthetic resin hollow product with a complicated shape, when the parison is expanded in the mold, the rate of expansion of the parison may vary depending on the part of the product, and the thickness of the product varies. There was a case.
Furthermore, in blow molding, since the parison is hung from above and sandwiched between molds, a relatively large number of burrs are generated, resulting in waste of material and poor productivity.
In particular, in the case of blow molding, it has been difficult to provide structures such as ribs and tension inside the synthetic resin hollow body in order to increase the strength.
For this reason, the synthetic resin hollow body is divided into upper and lower parts, molded separately by injection molding or the like, and then the upper divided case and the lower divided case are brought into contact with each other at the abutting portion to form a hollow body.
[0004]
In such a method of injecting synthetic resin into a mold by injection molding, for example, as shown in FIG. 9, a hollow mold is made by using a slide mold 80 to make a hollow product. The mold is divided into separate cavities 83 and 84, and then divided into two, and then the slide mold 82 is slid through the divided openings of the divided body, and as shown in FIG. The inner divided body and the divided body in the cavity 84 of the slide mold 82 are joined and fixed. In this fixing, there is a case where a concave portion 85 is provided on the outer periphery of the joining portion, a molten resin is injected into the concave portion 85, and the divided openings are welded by the molten resin (see Patent Documents 1 and 2).
[0005]
At that time, an opening that opens toward the outer circumference is provided at the abutting part of the upper divided case and the lower divided case, the inside of the opening is filled with molten resin, and the upper divided case and the lower divided case are The synthetic resin hollow body was formed by fusing. In addition, a shielding wall is provided to stop the molten resin at the butt portion so that the filled molten resin does not leak into the inside of the synthetic resin hollow body, and the molten resin filled in the opening by the shielding wall does not leak into the interior. It was like. However, when this barrier is provided, a notch portion is generated in the divided opening of the divided body that forms the barrier and the recessed portion provided in the divided opening of the divided body that receives the barrier. However, when stress is added, there is a possibility that stress concentrates on the notch portion and the strength is weakened.
In order to obtain higher bonding strength, it is necessary to fill the joint with molten resin at a high pressure. In order to prevent the molten resin from leaking even at the pressure generated at the butt, the barrier of the butt is used. It was necessary to increase the wall thickness.
[0006]
However, by increasing the thickness of the shielding wall, the shape of the abutting portion between the upper and lower divided cases increases, and the portion forming the opening on the outer surface of the synthetic resin hollow body projects or the synthetic resin hollow body In addition, the notch is increased by increasing the thickness of the shielding wall, and this is disadvantageous in terms of strength when pressure is applied to the synthetic resin hollow body from the outside. In particular, when external stress such as an object colliding with a synthetic resin hollow body from the outside is considered, stress concentrates on the notch due to the external stress, and a crack is generated from that portion. In some cases, improvement in strength was necessary.
[0007]
[Patent Document 1]
JP 62-87315 A (page 3-6, FIG. 6)
[Patent Document 2]
JP 2001-129851 (page 3-4, FIG. 1)
[0008]
[Problems to be solved by the invention]
In view of the circumstances as described above, an object of the present invention is to provide a strong synthetic resin hollow body that can be filled with molten resin in its opening, and has a notched portion and can cope with external pressure and internal pressure. And a synthetic resin hollow body, a molding method thereof, and a molding die.
[0009]
[Means for Solving the Problems]
In order to solve the above-mentioned problem, the present invention of claim 1 is configured such that the upper divided case and the lower divided case constituting the synthetic resin hollow body formed by division are brought into contact with each other, and the abutting portion is integrated with molten resin. In the synthetic resin hollow body formed by jointing, the outer peripheral end portion of the synthetic resin plate with holes having a plurality of holes is sandwiched between the upper opening end surface of the upper divided case and the lower opening end surface of the lower divided case AndA recess is provided on the entire outer peripheral side surface of the synthetic resin plate with holes,An opening is formed in the outer periphery of the synthetic resin hollow body by the outer peripheral side surface of the synthetic resin plate with holes, the upper opening end surface of the upper division case, and the lower opening end surface of the lower division case, and the opening is filled with molten resin And it is the synthetic resin hollow body formed by integrally joining the upper divided case, the lower divided case, and the synthetic resin plate with holes.
[0010]
In the present invention of claim 1, since the upper divided case and the lower divided case can be separately molded, when each is molded by injection molding, the upper divided case and the lower portion having high dimensional accuracy and high strength are obtained. Since the split case can be obtained, the synthetic resin hollow body formed by combining the upper split case and the lower split case can provide a precise and high strength product with high dimensional accuracy. Moreover, a reinforcing rib, a built-in component, etc. can be attached in an upper division | segmentation case or a lower division | segmentation case.
In addition, since the outer peripheral end portion of the synthetic resin plate with holes having a plurality of holes is sandwiched between the upper opening end surface of the upper divided case and the lower opening end surface of the lower divided case, a plurality of holes are formed inside the synthetic resin hollow body. The synthetic resin plate with a hole which has this hole can be provided, the reinforcement board was attached to the inside of the synthetic resin hollow body, and the strength can be improved. In addition, since the synthetic resin plate with holes has a plurality of holes, it can move freely through the synthetic resin plate with holes without partitioning the liquid stored inside the hollow body made of synthetic resin, and the hollow made of synthetic resin. Even when the body shakes or vibrates, the stored internal liquid can be prevented from undulating or foaming.
Further, since the concave portion is provided on the entire outer peripheral side surface of the synthetic resin plate with holes constituting the opening, the fusion area between the synthetic resin plate with holes and the molten resin is increased, and the synthetic resin plate with holes is strong. Can be welded.
[0011]
Moreover, since the opening was formed in the outer peripheral part of the synthetic resin hollow body by the outer peripheral side surface of the synthetic resin plate with holes, the upper opening end surface of the upper division case, and the lower opening end surface of the lower division case, the synthetic resin plate with holes In the outer peripheral side surface, the injection pressure of the molten resin can be received, and since the synthetic resin plate with holes does not deform even with a strong injection pressure, it can be strongly bonded, and the upper opening end surface of the upper divided case In addition, it is not necessary to provide a protrusion or the like on the lower opening end face of the lower divided case, and the shape of the opening becomes simple and the molding is easy.
[0012]
Furthermore, since the upper opening end surface of the upper divided case to which the molten resin is fused and the lower opening end surface of the lower divided case are free of protrusions and depressions such as barriers and recesses, an external impact is applied to the synthetic resin hollow body, Even if the internal pressure increases, the stress does not concentrate, so that a high strength synthetic resin hollow body can be obtained.
Filling the opening with molten resin and integrally bonding the upper divided case, the lower divided case, and the synthetic resin plate with holes to obtain a synthetic resin hollow body firmly fused with the molten resin be able to.
[0015]
Claims to solve the above problems2In the present invention, the concave portion provided on the entire circumference of the outer peripheral side surface of the synthetic resin plate with a hole constituting the opening is more than the inner surface of the synthetic resin hollow body formed by the inner surfaces of the upper divided case and the lower divided case. The molten resin that is deeply formed inward and filled in the opening is filled up to the recess, and the upper divided case, the lower divided case, and the synthetic resin plate with holes are integrally joined.1It is a synthetic resin hollow body described.
[0016]
Claim2In the present invention, the concave portions provided on the entire circumference of the outer peripheral side surface of the synthetic resin plate with holes are deeper toward the inside than the inner surface of the synthetic resin hollow body formed by the inner surfaces of the upper and lower divided cases. Since the molten resin is filled up to the concave portion, the contact area between the synthetic resin plate with a hole and the molten resin is increased, the adhesive strength is increased, and the molten resin enters deeper than the inner surface of the hollow body made of the synthetic resin. Therefore, after the molten resin is solidified, it can be prevented that the synthetic resin plate with holes vibrates or becomes glazed with respect to the upper divided case and the lower divided case.
[0017]
Claims to solve the above problems3According to the present invention, the upper divided case and the lower divided case constituting the synthetic resin hollow body molded separately are mounted on the hollow body molding die, respectively, and the upper opening end surface of the upper divided case and the lower divided case are Holding a synthetic resin plate with a hole having a plurality of holes between the lower opening end face,A recess is provided on the entire outer peripheral side surface of the synthetic resin plate with holes,Method of manufacturing a synthetic resin hollow body formed by joining in a hollow body molding die, forming an opening in the outer peripheral portion of the synthetic resin hollow body, and injecting molten resin into the opening and integrally joining them In the above, the molten resin is continuously connected to the spool and the runner from the injection port of the hollow body molding die, the ring groove provided in the entire circumference at a position slightly away from the opening, and the ring groove, A synthetic resin hollow body molding method characterized in that molten resin is filled in each part of the opening without a time lag through a film gate connecting the openings.
[0018]
Claim3In the present invention, since the upper divided case and the lower divided case constituting the synthetic resin hollow body are divided and separately injection-molded, even in the synthetic resin hollow body, a uniform meat is formed by an injection mold. A divided body can be formed with high thickness and dimensional accuracy. For this reason, even when the openings of the respective divided cases are brought into contact with each other, it is possible to make contact with high dimensional accuracy and to obtain a high-strength synthetic resin hollow body excellent in sealing performance. Moreover, since each is separately injection-molded, it is easy to provide a reinforcing rib or the like inside the synthetic resin hollow body.
[0019]
A manufacturing method in which the openings of each divided case are abutted in a hollow body mold, and the molten resin is injected into the opening formed by combining the openings of each divided case and integrally joined. Therefore, by holding the divided case in the hollow body molding die, an opening can be formed, and molten resin can be injected and joined, and joining work is easy.Further, since the concave portion is provided on the entire outer peripheral side surface of the synthetic resin plate with holes constituting the opening, the fusion area between the synthetic resin plate with holes and the molten resin is increased, and the synthetic resin plate with holes is strong. Can be welded.
In this hollow body molding mold, each divided case is molded in a separate cavity of one mold, and then the mold is slid to sandwich the synthetic resin plate with holes to unite each divided body. A so-called slide mold for fusing the opening may be used, or a separate mold may be used, and the divided cases may be set in another joining mold and combined.
[0020]
In the resin inflow path of the bonding mold, the spool and the runner, the ring groove continuously provided to the spool and the runner from the inlet, the ring groove provided around the entire position slightly apart from the opening, the ring groove and the opening The melted resin is filled in each part of the opening without time difference via the film gate that connects the two, so that the molten resin is injected into the ring groove from multiple spools and runners, and the molten resin is temporarily stored in the ring groove and balanced. Since the melted resin is often filled from the film gate into each part of the opening without time difference, the molten resin can be fed uniformly and uniformly over the entire periphery of the opening even in a large synthetic resin hollow body. For this reason, molten resin can be inject | poured into an opening part at the substantially same temperature, and an opening part can be fuse | melted uniformly and reliably.
[0021]
Claims to solve the above problems4The present invention has an opening formed by attaching an upper divided case and a lower divided case, each of which forms a synthetic resin hollow body formed by dividing, and abutting the upper divided case and the lower divided case. In a hollow molding die of a synthetic resin hollow body that is formed by injecting a molten resin into and integrally bonding to
The hollow body mold is composed of a hollow body fixed mold for attaching one of the upper divided case or the lower divided case, and a hollow body forming movable mold for attaching the other of the upper divided case or the lower divided case, and the upper part of the upper divided case. Between the opening end surface and the lower opening end surface of the lower divided case, a synthetic resin plate with a hole having a plurality of holes is sandwiched and collided to form an opening in the outer peripheral portion of the synthetic resin hollow body,A recess is provided on the entire outer peripheral side surface of the synthetic resin plate with holes,This is a hollow molding die of a synthetic resin hollow body formed by injecting molten resin into an opening and integrally bonding the molten resin.
[0022]
Claim4In the present invention, the hollow body molding die is composed of a hollow body molding fixed mold for attaching one of the upper divided case or the lower divided case, and a hollow body molding movable mold for attaching the other of the upper divided case or the lower divided case, A synthetic resin plate with a plurality of holes is sandwiched between the upper opening end surface of the upper divided case and the lower opening end surface of the lower divided case, so that the molten resin can be obtained simply by closing the hollow body molding die. Can be formed, and can be injected into the opening from the injection port of the hollow body molding die.
Further, since the concave portion is provided on the entire outer peripheral side surface of the synthetic resin plate with holes constituting the opening, the fusion area between the synthetic resin plate with holes and the molten resin is increased, and the synthetic resin plate with holes is strong. Can be welded.
[0023]
Claims to solve the above problems5According to the present invention, the hollow body molding fixed mold has an injection port into which a molten resin is injected, a spool and a runner, and a ring groove that is continuously connected to the spool and the runner and provided around the entire position at a distance from the opening. The hollow body molding die according to claim 5, further comprising a film gate connecting the ring groove and the opening.
[0024]
Claim5In the present invention, since the ring groove is provided continuously around the spool and the runner and provided at a position slightly away from the opening, the molten resin injected via the spool and the runner is disposed in the vicinity of the opening. The molten resin can be poured into the opening from the film gate without a substantial time difference.
Since the film gate connecting the ring groove and the opening is provided, the molten resin can be injected uniformly over the entire circumference of the opening, and the hollow body made of synthetic resin can be uniformly fused and solidified after the fusion. Since the film gate portion is thin, it can be easily removed.
more than
[0025]
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention will be described with reference to FIGS.
FIG. 1 is a perspective view of a synthetic resin hollow body 1 as viewed obliquely from above. FIG. 2 is a cross-sectional view taken along the line AA of FIG.
[0026]
The synthetic resin hollow body 1 is formed of two divided bodies formed by division and a synthetic resin plate 27 with holes attached to the inside, and an upper divided case 10 as a first divided body and a second divided body. The lower divided case 20 is. The upper divided case 10, the lower divided case 20, and the synthetic resin plate 27 with holes are each molded using a mold by injection molding as described later.
The synthetic resin hollow body 1 can be divided into not only two but also three or more. The upper divided case 10 includes an upper divided case main body 11 and an upper divided case opening 12 provided at the tip of the upper divided case main body 11 over the entire circumference of the opening.
[0027]
As shown in FIG. 3, the upper divided case opening 12 includes an upper flange portion 14 that is formed in an annular shape over the entire circumference of the outer peripheral portion by projecting a substantially T-shaped cross section outward from the upper divided case body 11. It consists of an upper opening end face 13 that constitutes a surface facing the case opening 22 and a step 13 a provided at the end of the upper opening end face 13 on the inner surface side of the synthetic resin hollow body 1.
The lower divided case opening 22 is opposed to the upper divided case opening 12 and the lower flange portion 24 that is formed in an annular shape over the entire circumference of the outer peripheral portion by projecting a substantially T-shaped cross section outward from the lower divided case main body 21. The lower opening end surface 23 which comprises the surface to perform, and the step part 23a provided in the edge part by the side of the inner surface of the synthetic resin hollow body 1 of the lower opening end surface 23 are comprised.
[0028]
The upper divided case opening 12 and the lower divided case opening 22 sandwich the outer peripheral edge of the synthetic resin plate 27 with holes.
As shown in FIG. 2, the synthetic resin plate 27 with holes is formed on the abutting surface when the synthetic resin hollow body 1 is formed by abutting the openings of the upper divided case 10 and the lower divided case 20. It attaches so that the hollow body 1 may be divided up and down. Since the synthetic resin hollow body 1 has many through holes 27a, the liquid stored in the synthetic resin hollow body 1 can freely move up and down. Furthermore, when the synthetic resin hollow body 1 vibrates or shakes, it is possible to prevent the liquid stored in the inside from being rippled or foamed.
Moreover, since the synthetic resin board 27 with a hole is attached near the center inside the hollow body 1 made of synthetic resin, it can function as a reinforcing plate and can increase the strength against external impacts and the like. it can.
[0029]
The holed synthetic resin plate 27 is fitted and held in the respective step portions 13a and 23a in the upper divided case opening 12 and the lower divided case opening 22, and the upper opening end surface 13 of the upper divided case opening 12 and The lower opening end surface 23 of the lower divided case opening 22 and the outer peripheral side surface 27b of the synthetic resin plate 27 with holes form an opening 25 over the entire outer periphery of the synthetic resin hollow body 1. On the outer peripheral side surface 27b of the synthetic resin plate 27 with holes, a concave portion 27c is provided in the inner direction. The depth of the recess 27 c can be formed from the inner surface of the synthetic resin hollow body 1 formed by the inner surfaces of the upper divided case 10 and the lower divided case 20 to the inside. When the concave portion 27c is formed deeply, as will be described later, the molten resin is poured into the deep portion of the concave portion 27c, and the molten resin and the synthetic resin plate 27 with holes are firmly fused.
[0030]
Next, the manufacturing method of this synthetic resin hollow body 1 will be described.
First, a process of molding the upper divided case 10, the lower divided case 20, and the synthetic resin plate 27 with holes that constitute the synthetic resin hollow body 1 will be described. The upper divided case 10, the lower divided case 20, and the synthetic resin plate with holes 27 constituting the synthetic resin hollow body 1 are injection-molded using different molds as shown in FIGS. 4 to 6. Is formed by. Since it is molded by injection molding, it has higher dimensional accuracy and higher strength than blow molding or the like.
[0031]
However, at this time, using a slide mold as shown in FIGS. 9 and 10, two cavities are provided in one mold, and the upper divided case 10 and the lower divided case 20 are formed in each cavity. Can do.
FIG. 4 shows an upper split case molding die 40 for molding the upper split case 10. In the upper divided case molding die 40, a cavity 43 is formed by a fixed mold 41 and a movable mold 42, and a synthetic resin is injected into the cavity 43 to mold the upper divided case 10.
[0032]
The lower divided case 20 is molded using a lower divided case molding die 50 shown in FIG. 5 in the same manner as the upper divided case 10 is molded. In the lower divided case molding die 50, a cavity 53 is formed by a fixed mold 51 and a movable mold 52, and a synthetic resin is injected into the cavity 53 to mold the lower divided case 20.
The synthetic resin plate 27 with holes is molded using a synthetic resin plate molding die 60 with holes shown in FIG. 6 in the same manner as the upper divided case 10. In the synthetic resin plate molding die 60 with a hole, a cavity 63 is formed by a fixed die 61 and a movable die 62, and a synthetic resin is injected into the cavity 63 to mold the synthetic resin plate 27 with a hole.
[0033]
Next, the process of integrally welding the upper divided case 10, the lower divided case 20, and the synthetic resin plate 27 with holes and the hollow body molding die 30 will be described.
First, as shown in FIG. 7, the upper divided case 10, the lower divided case 20, and the synthetic resin plate 27 with holes are respectively divided into an upper divided case molding die 40, a lower divided case molding die 50, and a synthetic with holes. It is taken out from the resin plate molding die 60 and attached to the hollow body molding die 30. The hollow body molding die 30 includes a hollow body molding fixed mold 31 and a hollow body molding movable mold 39, and the lower divided case 20 is provided in the cavity of the hollow body molding fixed mold 31 and the upper divided case is formed in the cavity of the hollow body molding movable mold 39. 10 and the synthetic resin plate 27 with holes is attached to either the upper divided case 10 or the lower divided case 20. At this time, the upper divided case 10 may be attached to the cavity of the hollow body forming fixed die 31, and the lower divided case 20 may be attached to the cavity of the hollow body forming movable die 39.
[0034]
In addition, when attaching the component parts incorporated in the synthetic resin hollow body 1, it is attached to the upper divided case 10 or the lower divided case 20 before being attached to the hollow body molding die 30. Accordingly, the component parts can be easily mounted in the hollow resin product.
After closing the hollow body molding die 30, a molten resin, which is a thermoplastic synthetic resin, is injected from an injection molding machine (not shown) into the injection port 32. The molten resin injected at this time uses a synthetic resin that can be welded to the synthetic resin constituting the synthetic resin hollow body 1, but is the same or the same thermoplasticity as the synthetic resin constituting the synthetic resin hollow body 1. Synthetic resins are preferred. For example, polyethylene, polypropylene, polyacetal, polyamide and the like can be used.
[0035]
The molten resin injected from the injection port 32 first flows through the first spool 33 to the continuation point with the runner 34. Here, as shown in FIG. 7, the molten resin flowing in from the first spool 33 is divided into a plurality of runners 34 that diverge radially, and flows parallel to the mold surface. The hollow body forming fixed die 31 is divided into two blocks on the runner split surface 31b, and a groove is provided in either the hollow body forming fixed die 31 or the hollow body forming movable die 39 on the split surface 31b. It is said.
[0036]
A flow rate adjustment valve 37 for adjusting the flow rate of the molten resin may be provided in the middle of the runner 34. By adjusting the flow rate adjusting valve 37, the flow rate and flow rate of the molten resin can be adjusted even if the length of the runner 34 is different.
The molten resin that has flowed through each runner 34 then enters a second spool 35 that is continuous with the tip of the runner 34, and flows vertically through the hollow body fixed mold 31. The second spool 35 is provided so as to surround the cavity 31 c from the tip of the runner 34 perpendicular to the mold surface of the hollow body forming fixed die 31. Then, the molten resin that has flowed through the second spool 35 flows into the ring groove 36.
[0037]
As shown in FIG. 7, the ring groove 36 includes an upper opening end surface 13, a lower opening end surface 23, and an outer peripheral side surface 27 b of the synthetic resin plate 27 with a hole at a joint portion between the upper divided case 10 and the lower divided case 20. Near the opening 25 provided on the outer periphery of the synthetic resin hollow body 1 to be formed, the hollow body forming movable mold 39 is provided over the entire circumference so as to be along the opening 25 at a slight distance. The ring groove 36 may be provided in the hollow body fixed mold 31.
The molten resin that has flowed into the ring groove 36 from each second spool 35 begins to flow into the ring groove 36 at substantially the same time, and flows into the ring groove 36 from the connecting portion between each second spool 35 and the ring groove 36. . At this time, since the ring groove 36 has a larger cross-sectional area than the spool, it plays the role of a buffer, and each part of the ring groove 36 is filled with the molten resin substantially simultaneously.
[0038]
As shown in FIG. 8, when the hollow body molding die 30 is closed, the synthetic resin hollow body formed by the upper opening end surface 13, the lower opening end surface 23, and the outer peripheral side surface 27 b of the synthetic resin plate 27 with holes. The opening 25 provided on the outer periphery of the ring 1 is continuous with the ring groove 36 by a plate-like film gate 38 having a thin cross section. Since the film gate 38 is provided along the entire circumference of the ring groove 36, the molten resin that has flowed into the ring groove 36 can be quickly and uniformly injected from the ring groove 36 into the opening without any time difference. For this reason, the molten resin is not partially cooled, and the upper divided case 10 and the lower divided case 20 can be welded uniformly.
[0039]
The gate 38 may be a gate having a circular or square cross section. When the cross section is circular or quadrangular, the mold can be easily processed. In the case of a film gate, the molten resin can be injected into the ring groove 36 more uniformly.
At this time, as shown in FIG. 8, the hollow body forming fixed die 31 holds the upper flange portion 14 of the upper divided case opening 12 of the upper divided case 10, and the lower divided case opening 22 of the lower divided case 20. Since the hollow body forming movable die 39 holds the lower flange portion 24, even if molten resin flows between the upper opening end surface 13 and the lower opening end surface 23, the upper divided case opening 12 and the lower divided case opening The portion 22 does not open, and the molten resin does not flow into the synthetic resin hollow body 1.
[0040]
Further, since the inner surface of the opening 25 is formed by the outer peripheral side surface 27b of the synthetic resin plate 27 with holes, the molten resin is not deformed by the pressure of the molten resin. There is no inflow.
The outer peripheral side surface 27b of the synthetic resin plate 27 with holes is provided with a concave portion 27c over the entire circumference. By injecting molten resin into the concave portion 27c, the upper divided case 10, the lower divided case 20, and the holes are provided. The synthetic resin plate 27 can be integrally welded, and in particular, since the fusion area with the synthetic resin plate 27 with holes can be increased, strong fusion can be achieved.
[0041]
After the molten resin flows into the opening 25 formed by the upper divided case opening 12, the lower divided case opening 22, and the outer peripheral side surface 27b of the synthetic resin plate 27 with a hole, The hollow body molding fixed mold 31 and the hollow body molding movable mold 39 of the molding die 30 are opened, and the synthetic resin hollow body 1 is taken out.
Then, the ring-shaped synthetic resin formed by the ring groove 36 and the film gate 38 around the opening 25 of the synthetic resin hollow body 1 is removed. At this time, since the film gate 38 is in the form of a film, it can be easily folded at the gate portion and can be easily removed.
[0042]
After the synthetic resin hollow body 1 is taken out, the runner split surface 31b of the hollow body forming fixed die 31 is opened, and the synthetic resin in the first spool 33, the runner 34 and the second spool 35 is taken out. Thus, the next molten resin injection process can be performed.
When the so-called hot runner type is used without cooling the first spool 33, the runner 34, and the second spool 35, it is not necessary to take out the synthetic resin.
[0043]
【The invention's effect】
In the present invention, after forming a large hollow resin product with two or more divided bodies, the opening end faces of the openings of both divided bodies are joined by molten resin, so that even if the joining surface is flat and external force is applied There is no stress concentration, and a strong synthetic resin hollow body with high pressure resistance can be obtained.
Since the divided bodies are molded by injection molding, a synthetic resin hollow body with high dimensional accuracy and high strength can be obtained.
Since the synthetic resin plate with holes having a large number of through holes is provided inside the hollow body made of synthetic resin, it is possible to alleviate undulations, bubbles, etc. generated by external vibrations and vibrations. Moreover, even if an external force is applied to the collision or the like, the structural rigidity is improved by the synthetic resin plate with holes, and deformation of the synthetic resin hollow body due to the external force can be prevented.
[Brief description of the drawings]
FIG. 1 is a perspective view of a synthetic resin hollow body according to an embodiment of the present invention.
2 is a cross-sectional view taken along line AA of FIG. 1 of a synthetic resin hollow body according to an embodiment of the present invention.
FIG. 3 is an enlarged partial cross-sectional view of an opening of a synthetic resin hollow body according to an embodiment of the present invention.
FIG. 4 is a cross-sectional view of a mold for molding an upper divided case of a synthetic resin hollow body according to an embodiment of the present invention.
FIG. 5 is a cross-sectional view of a mold for molding a lower divided case of a synthetic resin hollow body according to an embodiment of the present invention.
FIG. 6 is a sectional view of a mold for molding a synthetic resin plate with holes in a synthetic resin hollow body according to an embodiment of the present invention.
FIG. 7 is a cross-sectional view of a hollow body mold that joins an upper divided case, a lower divided case, and a synthetic resin plate with holes according to an embodiment of the present invention.
FIG. 8 is an enlarged partial cross-sectional view of a portion for injecting molten resin into an opening of a hollow body molding die that is an embodiment of the present invention.
FIG. 9 is a cross-sectional view of a conventional slide mold for molding a hollow resin product before sliding.
FIG. 10 is a cross-sectional view after sliding of a slide mold for forming a conventional hollow resin product.
[Explanation of symbols]
1 Hollow body made of synthetic resin
10 Upper split case
12 Upper split case opening
13 Upper opening edge
14 Upper flange
20 Lower split case
22 Lower split case opening
23 Lower opening end face
24 Lower flange
25 opening
27 synthetic resin plate with holes
27b Outer peripheral side
27c recess
30 Hollow body mold
31 Hollow body fixed mold
34 Runner
35 Second spool
36 Ring groove
38 film gate

Claims (5)

分割して成形された合成樹脂製中空体を構成する上部分割ケースと下部分割ケースを衝合させて、衝合部分を溶融樹脂で一体的に接合して形成した合成樹脂製中空体において、
上記上部分割ケースの上部開口端面と下部分割ケースの下部開口端面との間に、複数の穴を有する穴付合成樹脂板の外周端部を挟持し、上記穴付合成樹脂板の外周側面の全周に凹部を設け、該穴付合成樹脂板の外周側面と、上記上部分割ケースの上部開口端面と、下部分割ケースの下部開口端面とで上記合成樹脂製中空体の外周部に開口部を形成し、該開口部に溶融樹脂を充填して、上部分割ケースと、下部分割ケースと穴付合成樹脂板とを一体的に接合してなる合成樹脂製中空体。In the synthetic resin hollow body formed by joining the upper divided case and the lower divided case constituting the synthetic resin hollow body formed by dividing and joining the molten resin integrally with the molten resin,
Between the upper opening end surface of the upper divided case and the lower opening end surface of the lower divided case, the outer peripheral end portion of the synthetic resin plate with holes having a plurality of holes is sandwiched, and the entire outer peripheral side surface of the synthetic resin plate with holes is sandwiched. A recess is provided in the periphery, and an opening is formed in the outer periphery of the synthetic resin hollow body by the outer peripheral side surface of the synthetic resin plate with holes, the upper opening end surface of the upper split case, and the lower opening end surface of the lower split case A synthetic resin hollow body obtained by filling the opening with molten resin and integrally joining the upper divided case, the lower divided case, and the synthetic resin plate with holes. 上記開口部を構成する穴付合成樹脂板の外周側面の全周に設けられた上記凹部は、上記上部分割ケースと下部分割ケースの内面が構成する上記合成樹脂製中空体の内面よりも内側に向けて深く形成され、上記開口部に充填された溶融樹脂は上記凹部まで充填されて、上部分割ケースと、下部分割ケースと、穴付合成樹脂板とを一体的に接合してなる請求項１記載の合成樹脂製中空体。The concave portion provided on the entire circumference of the outer peripheral side surface of the synthetic resin plate with holes constituting the opening is located on the inner side of the inner surface of the synthetic resin hollow body formed by the inner surfaces of the upper divided case and the lower divided case. formed deeper toward the molten resin filled in the opening is filled up the recess, and the upper case member, and a lower case member, claim a hole with a synthetic resin plate formed by integrally joined 1 The hollow body made of synthetic resin as described. 分割して成形された合成樹脂製中空体を構成する上部分割ケースと下部分割ケースとを中空体成形金型にそれぞれ装着し、上部分割ケースの上部開口端面と下部分割ケースの下部開口端面との間に、上記複数の穴を有する穴付合成樹脂板を挟持して、該穴付合成樹脂板の外周側面の全周に凹部を設け、上記中空体成形金型内で衝合し上記合成樹脂製中空体の外周部に開口部を形成し、該開口部に溶融樹脂を注入して一体的に接合して形成する合成樹脂製中空体の製造方法において、
上記溶融樹脂を上記中空体成形金型の注入口から、スプールおよびランナーと、該スプールおよびランナーに連続的に繋がり上記開口部から少し離れた位置の全周囲に設けられたリング溝と、該リング溝と上記開口部を繋ぐフイルムゲートを経由して、上記開口部の各部分に時間差なく溶融樹脂を充填させることを特徴とする合成樹脂製中空体の成形方法。The upper divided case and the lower divided case constituting the synthetic resin hollow body molded by dividing are respectively attached to the hollow body molding die, and the upper opening end surface of the upper divided case and the lower opening end surface of the lower divided case are A synthetic resin plate with holes having a plurality of holes is sandwiched between them, and a recess is provided on the entire outer peripheral side surface of the synthetic resin plate with holes, and the synthetic resin is abutted in the hollow body molding die. In the manufacturing method of a synthetic resin hollow body formed by forming an opening in the outer peripheral portion of the hollow body and injecting a molten resin into the opening and integrally joining them,
The molten resin from the injection port of the hollow body molding die, a spool and a runner, a ring groove continuously provided to the spool and the runner and provided at a position slightly apart from the opening; and the ring A method for molding a hollow body made of synthetic resin, comprising filling a molten resin without time difference to each part of the opening through a film gate connecting the groove and the opening. 分割して成形された合成樹脂製中空体を構成する上部分割ケースと、下部分割ケースをそれぞれ装着し、上部分割ケースと下部分割ケースを衝合させて衝合後にできる開口部に溶融樹脂を注入して一体的に接合して形成する合成樹脂製中空体の中空体成形金型において、
該中空体成形金型は、上記上部分割ケース又は下部分割ケースの一方を取付ける中空体成形固定型と、上記上部分割ケース又は下部分割ケースの他方を取付ける中空体成形可動型から構成され、
上記上部分割ケースの上部開口端面と下部分割ケースの下部開口端面との間に、上記複数の穴を有する穴付合成樹脂板を挟持して衝合し上記合成樹脂製中空体の外周部に開口部を形成し、上記穴付合成樹脂板の外周側面の全周に凹部を設け、上記開口部に溶融樹脂を注入して一体的に接合して形成する合成樹脂製中空体の中空体成形金型。Attach the upper and lower divided cases that make up the synthetic resin hollow body that has been divided into pieces, and inject the molten resin into the opening created after the upper and lower divided cases. In a hollow molding die of a synthetic resin hollow body formed by integrally joining
The hollow body molding die is composed of a hollow body molding fixed mold for attaching one of the upper divided case or the lower divided case, and a hollow body molding movable mold for attaching the other of the upper divided case or the lower divided case,
A synthetic resin plate with a hole having a plurality of holes is sandwiched between the upper opening end surface of the upper divided case and the lower opening end surface of the lower divided case, and opened to the outer peripheral portion of the synthetic resin hollow body. A hollow body molding metal of a synthetic resin hollow body formed by forming a recess, providing a recess on the entire circumference of the outer peripheral side surface of the synthetic resin plate with holes, and injecting molten resin into the opening and integrally bonding Type. 上記中空体成形固定型は、溶融樹脂が注入される注入口と、スプールおよびランナーと、該スプールおよびランナーに連続的に繋がり上記開口部から少し離れた位置全周囲に設けられたリング溝と、該リング溝と上記開口部を繋ぐフイルムゲートとを有する請求項４記載の中空体成形金型。The hollow body molding fixed mold includes an injection port into which a molten resin is injected, a spool and a runner, a ring groove that is continuously connected to the spool and the runner and is provided around the position slightly away from the opening, The hollow body molding die according to claim 4 , further comprising a film gate connecting the ring groove and the opening.
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