JP4723110B2 - Method for producing middle mold for in-mold foam molding and middle mold - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
This invention is used when foaming a large number of pre-expanded beads filled in a mold into an in-mold foam molded body by steam heating, and is used to form a design pattern on the surface of the in-mold foam molded body. The present invention relates to a method for manufacturing an intermediate mold for in-mold foam molding in which is formed on a molding surface, and the intermediate mold.
[0002]
[Prior art]
As a conventional technique of this type, for example, as disclosed in JP-A-12-108134, a model in which a sheet material having a concavo-convex pattern is bonded to a wooden mold is manufactured, and then the concavo-convex pattern is transferred from the model. There is known a method of manufacturing an intermediate mold for in-mold foam molding in which an uneven pattern is further transferred from the sand mold to a molding surface by casting after the sand mold is manufactured.
[0003]
[Problems to be solved by the invention]
However, the above-described method has a problem that the design pattern of the in-mold foam molded product produced using the obtained middle mold for in-mold foam molding is unclear.
[0004]
The present invention has been made in view of the above problems, and an object of the present invention is to provide a method for producing an intermediate mold for in-mold foam molding that can sharpen the design pattern of the in-mold foam molded article, and the intermediate mold. To do.
[0005]
In order to achieve the above object, the production method of claim 1 is the production of a mold for in-mold foam molding in which a concavo-convex pattern for forming a design pattern on the surface of the in-mold foam molded body is formed on the molding surface during casting. In the method, an inverted concavo-convex pattern obtained by inverting the concavo-convex pattern is formed on a surface of the medium-sized production model that is formed in substantially the same shape as the molding surface, and is produced by cast hardening on the medium-sized production model 1 The surface of the secondary mold made of an inorganic material produced by cast-curing on the primary mold is formed on the surface of the secondary mold by forming the primary concavo-convex pattern by transferring the reverse concavo-convex pattern during cast-curing. after forming the second uneven pattern by transferring said primary uneven pattern during casting cured to form the uneven pattern by transferring said second uneven pattern on the mold surface during casting, flat A plurality of shaped components, the ends of the components as they are, Are those articulating and screwed against after having cut out at a predetermined angle, the bolt tabular or L-shaped cross-section of backing material on the back side of the butt portion.
[0006]
The manufacturing method according to claim 2 is a method in which the raw material of the primary mold is applied to the surface of the medium-sized manufacturing model in advance before the casting of the primary mold is cast.
[0007]
According to a third aspect of the present invention, the secondary mold raw material is applied to the surface of the primary mold in advance before the second mold is cast and cured.
[0008]
According to a fourth aspect of the present invention, the secondary mold casting is performed while applying vibration.
[0009]
In the manufacturing method of claim 5, the medium-sized manufacturing model is made of synthetic resin.
[0010]
In the manufacturing method of claim 6, the primary mold is made of silicone rubber.
[0011]
In the manufacturing method of claim 7, the secondary mold is made of gypsum or cement.
[0012]
The middle mold for in-mold foam molding according to claim 8 is the middle mold for in-mold foam molding manufactured by the method according to any one of claims 1 to 7, wherein a vapor hole is provided in the convex portion of the uneven pattern. .
[0014]
The middle mold for in-mold foam molding according to claim 9 is provided with a steam hole at the joint between the constituent members.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
As shown in FIGS. 1 to 14, the manufacturing method of the constituent member 2 constituting the in-mold foam molding middle mold 1 according to the first embodiment forms the design pattern 4 on the surface 3 a of the in-mold foam molded body 3. In the manufacturing method of the constituent member 2 in which the concavo-convex pattern 5 is formed on the molding surface 1 a during casting, the reverse concavo-convex pattern 7 is formed on the surface 6 a of the medium-sized production model 6, and the A primary concavo-convex pattern 9 is formed on the surface 8a of the primary mold 8 produced by mold curing by transferring the reverse concavo-convex pattern 7 during cast curing, and the primary mold 8 is produced by cast curing on the primary mold 8. After the secondary concavo-convex pattern 11 is formed on the surface 10a of the secondary mold 10 by transferring the primary concavo-convex pattern 9 during casting curing, the secondary concavo-convex pattern 11 is formed on the molding surface 1a of the component 2 during casting. As a result, the concavo-convex pattern 5 is formed.
[0016]
As shown in FIG. 2, the in-mold foam molding middle mold 1 is formed by connecting a plurality of plate-shaped component members 2 so as to have a convex shape, and has a concavo-convex pattern 5 formed on a molding surface 1a. Yes. As shown in FIG. 3, the in-mold foam molding middle mold 1 has a molding surface 1a on a middle plate 15 attached to one of the two molds 13 and 14 constituting the molding mold 12. Is fixed so as to face the mold 12a. In this embodiment, the in-mold foam molding middle mold 1 has a convex shape, and the other in-mold foam molding middle mold 17 fixed to the middle plate 16 of the other mold 14 has a concave shape. However, the present invention is not limited, and the in-mold foam molding middle mold 1 may be a concave shape, and the other in-mold foam molding middle mold 17 may be a convex shape.
[0017]
In order to connect the constituent members 2, as shown in FIGS. 2 and 3, the constituent members 2 are directly butted together in an L shape, or the end portions are cut out at a predetermined angle such as 45 degrees, for example, into an L shape. For example, the concave and convex pattern 5 on the molding surface 1a may be continuous. The connecting portion between the constituent members 2 may be fixed without gaps, for example, by screwing the backing members 18A and 18B having a flat plate shape or an L-shaped cross section with bolts on the back side or the like.
[0018]
As shown in FIG. 4, the in-mold foam-molded body 3 is manufactured by foam-molding in a molding mold 12a as shown in FIG. 3. At this time, the molding surface 1a of the in-mold foam-molding middle mold 1 is formed. The uneven pattern 5 is transferred to form the design pattern 4 on the surface 3a. Thereby, the turtle shell pattern based on foaming of the pre-expanded beads becomes inconspicuous, and the appearance of the in-mold foam molded body 3 is improved.
[0019]
The component member 2 is made of an appropriate metal such as aluminum, and is formed in a flat plate shape by casting. In order to form the concavo-convex pattern 5 on the molding surface 1a of the constituent member 2, first, as shown in FIGS. 5 to 7, an inverted concavo-convex pattern obtained by inverting the concavo-convex pattern 5 on the surface 6a of the medium-sized production model 6 is used. 7 is formed. An NC (Numeral Controll) machine tool (numerical control machine tool, for example, “Machining Center PC55V” manufactured by Shin Nippon Koki Co., Ltd.) or the like can be suitably used to form the inverted concavo-convex pattern 7.
[0020]
As shown in FIGS. 5, 6, and 13, the surface 6 a of the medium-sized manufacturing model 6 is formed in substantially the same shape as the molding surface 1 a of the component member 2. As in this embodiment, when the component member 2 has a flat plate shape, the medium-sized production model 6 may also have a flat plate shape. In short, the shape of the surface 6a of the medium-sized production model 6 may be matched with the shape of the molding surface 1a of the component 2 formed during casting.
[0021]
Here, when the medium-sized manufacturing action model 6 is made of a synthetic resin such as polyurethane (for example, “Ciba Tool (Len / Shape 450)” manufactured by Ciba Specialty Chemicals Co., Ltd.), it can be manufactured at low cost because it is inexpensive. Since it is relatively soft, there is an advantage that it is easy to form the inverted concavo-convex pattern 7.
[0022]
Next, as shown in FIG. 8 and FIG. 9, the reverse concavo-convex pattern 7 is transferred to the surface 8 a of the primary mold 8 manufactured by cast hardening on the medium-sized production model 6 during cast hardening. Next, an uneven pattern 9 is formed.
[0023]
In order to manufacture the primary mold 8 by cast hardening, for example, a medium-sized production model 6 arranged with the surface 6a on which the inverted concavo-convex pattern 7 is formed facing upward, and the periphery of the medium-sized production model 6 The casting mold 20 is configured from an appropriate frame body 19 installed on the casting mold 20, and the raw material of the primary mold 8 is poured into the casting mold 20 and cured. As a result, the reverse concavo-convex pattern 7 of the middle-sized production model 6 is transferred to the surface 8 a of the primary mold 8 to form the primary concavo-convex pattern 9.
[0024]
Here, if the raw material of the primary mold 8 is previously applied to the surface 6a of the medium-sized manufacturing model 6 with a brush or the like before cast hardening of the primary mold 8, the raw material of the primary mold 8 is shown in FIG. The details of the concave and convex portions 21 of the reverse concavo-convex pattern 7 are filled in and the bubbles are less likely to remain between the reverse concavo-convex pattern 7 and the primary concavo-convex pattern 9, so the primary concavo-convex pattern 9 is formed more clearly. There is an advantage that you can.
[0025]
The material of the primary mold 8 is not particularly limited, but those having good bubble separation in the raw material state and a fast curing rate are preferable. Examples of such a material include silicone rubber (for example, “ROAD SIL RTV533” sold by Rhodia Japan Co., Ltd.). However, when the primary mold 8 is made of silicone rubber, there is an advantage that the cost can be reduced because it is inexpensive. is there.
[0026]
In addition, the pattern and size of the inverted concavo-convex pattern 7 are not particularly limited, and may be, for example, a lattice shape, a mesh shape, a stripe shape, a column shape (projection shape), or a curved surface. . Examples of the size when forming the groove as the pattern of the inverted concavo-convex pattern 7 include a groove width of about 0.5 to 1 mm, a depth of about 0.5 to 1 mm, and a pitch of about 1 to 2 mm. It may be rough, or finer below this, for example, a matte shape.
[0027]
After the primary mold 8 is manufactured, as shown in FIGS. 10 and 11, cast hardening is performed on the surface 10 a of the secondary mold 10 made of an inorganic material manufactured by cast hardening on the primary mold 8. The secondary concavo-convex pattern 11 is formed by transferring the primary concavo-convex pattern 9 therein.
[0028]
In order to manufacture the secondary mold 10 by casting hardening, for example, the frame body 22, the casting sand 23 filled in the frame body 22, and the surface 8 a at a predetermined position of the casting sand 23 are provided. The casting mold 24 may be configured from the primary mold 8 embedded in the upward direction, and the raw material of the secondary mold 10 may be poured into the casting mold 24 and cured. As a result, the primary concavo-convex pattern 9 of the primary mold 8 is transferred to the surface 10 a of the secondary mold 10 to form the secondary concavo-convex pattern 11.
[0029]
Here, similarly to the above, if the raw material of the secondary mold 10 is previously applied to the surface 8a of the primary mold 8 with a brush or the like before cast hardening of the secondary mold 10, the raw material of the secondary mold 10 is used. 9 is filled in the details such as the concave portions 25 of the primary concavo-convex pattern 9 as shown in FIG. 9, and it becomes difficult for bubbles to remain between the primary concavo-convex pattern 9 and the secondary concavo-convex pattern 11. There is an advantage that can be formed more clearly. Further, if the casting mold 24 is placed on the diaphragm 26, for example, and the casting hardening of the secondary mold 10 is performed while applying vibration, the secondary uneven pattern 11 can be more reliably and clearly formed. There are advantages.
[0030]
The secondary mold 10 is made of an appropriate inorganic material that can be used for casting the component member 2 or the like, and is preferably a material that has good bubble separation in the raw material state and a high curing rate. Examples of such a material include gypsum (for example, “Suncast 1100” manufactured by Sankei Gypsum Co., Ltd.) and cement (for example, Portland cement, mixed cement, special cement, etc.). The secondary mold 10 is made of gypsum or cement. In this case, since it is inexpensive, there is an advantage that the cost can be reduced and the handleability is excellent.
[0031]
After the secondary mold 10 is cured, the secondary mold 10 and the primary mold 8 are taken out from the casting mold 24 as shown in FIG. If the secondary mold 10 is ignited with a fire 27 above, a dispersant such as alcohol can be burned, so that it can be dried more quickly and easily.
[0032]
After the secondary mold 10 is manufactured, as shown in FIGS. 13 and 14, the concave / convex pattern 5 is transferred by transferring the secondary concave / convex pattern 11 to the molding surface 1 a of the constituent member 2 during casting of the constituent member 2. Form.
[0033]
For producing the component 2 by casting, various conventionally known casting methods can be used. For example, the lower frame 28, the foundry sand 29 filled in the lower frame 28, and a predetermined position of the foundry sand 29 A lower mold 30 having a secondary mold 10 embedded with the surface 10a facing upward, an upper frame 31 disposed on the lower frame 28, and foundry sand 32 filled in the upper frame 31. A method of forming a sand mold 34 from the provided upper mold 33 and pouring molten metal such as aluminum into the sand mold 34 may be mentioned. Note that drying by combustion of the secondary mold 10 illustrated in FIG. 12 may be performed in the lower mold 30. In this case, there is an advantage that the foundry sand 29 is solidified more firmly.
[0034]
In this way, if the concave / convex pattern 5 is formed by transferring the secondary concave / convex pattern 11 of the secondary mold 10 to the molding surface 1a of the component member 2 during casting, the concave / convex pattern 5 becomes clear. There is an advantage that the design pattern 4 of the in-mold foam-molded product 3 manufactured using the in-mold foam-molding middle mold 1 can be made clear. In this case, the primary concavo-convex pattern 9 of the primary mold 8 transferred from the inverted concavo-convex pattern 7 of the medium-sized production model 6 and the secondary concavo-convex pattern 11 of the secondary mold 10 transferred from the primary concavo-convex pattern 9 are also included. Since each is clear, the design pattern 4 can be faithfully formed on the basis of the inverted concavo-convex pattern 7.
[0035]
The steam hole 35 for supplying water vapor to the previously described molding die 12a may be provided at a predetermined position on the molding surface 1a of the component 2 or the in-mold foam molding middle die 1 after assembly by machining or the like. However, as shown in FIG. 15 to FIG. 17, if this vapor hole 35 is provided in the convex portion 36 of the concavo-convex pattern 5, a vapor hole mark 37 that expands and protrudes into the vapor hole 35 during foam molding is formed in the mold. Since it forms in the recessed part 38 of the design pattern 4 of the foaming molding 3, there exists an advantage that the vapor hole trace 37 is not conspicuous.
[0036]
Further, as shown in FIGS. 18 to 20, when the joint 39 between the constituent members 2 is located at the corner portion or the like of the in-mold foam molding middle mold 1, the same applies even when the steam hole 35 is provided in the joint 39. Since the vapor hole marks 37 are formed at the corners 40 and the like of the in-mold foam molded body 3, there is an advantage that the vapor hole marks 37 are hardly noticeable.
[0037]
Further, when the in-mold foam-molding middle mold 1 is configured by connecting a plurality of constituent members 2 as in this embodiment, a simple-shaped constituent member 2 such as a flat plate shape can be used. There is an advantage that the mold 1 for molding can be easily manufactured. In this case, the large-sized component 2 may be manufactured and then cut into a plurality of pieces to be assembled into the in-mold foam molding middle mold 1.
[0038]
As shown in FIG. 21 to FIG. 25, the method for manufacturing the in-mold foam molding middle mold 51 according to the second embodiment is performed without connecting the plurality of constituent members 2 of the first embodiment, 51 is cast directly.
[0039]
As shown in FIGS. 22 and 25, the shape of the surface 6a of the medium-sized production working model 6 may be matched with the shape of the molding surface 51a of the in-mold foam molding middle die 51 finally obtained. As shown in FIG. 24, other operations are the same as those in the first embodiment. At the time of casting, as shown in FIG. 24, a core 52 having a predetermined shape may be accommodated in the lower mold 30 or the like as necessary.
[0040]
According to this embodiment, the in-mold foam molding middle mold 51 itself can be manufactured directly by casting, and there is no need to assemble the component member 2.
[0041]
As described above, according to the first aspect of the present invention, since the concavo-convex pattern is formed on the molding surface by transferring the secondary concavo-convex pattern of the secondary mold during casting, the concavo-convex pattern becomes clear, and therefore the mold The design pattern of the in-mold foam molded product produced using the inner mold for inner foam molding can also be made clear. In this case, the primary-type primary concavo-convex pattern transferred from the inverted concavo-convex pattern of the medium-sized manufacturing model and the secondary-type secondary concavo-convex pattern transferred from the primary concavo-convex pattern are also clear. A design pattern can be formed faithfully based on the uneven pattern. Further, since a plurality of simple plate-shaped constituent members are connected, an in-mold foam molding middle mold can be easily manufactured.
[0042]
According to the second aspect of the present invention, since the primary type raw material is applied to the surface of the medium-sized manufacturing model in advance before the primary mold is cast-cured, the primary type raw material has an inverted concavo-convex pattern. Filling in the details such as the recesses makes it difficult for bubbles to remain between the inverted concavo-convex pattern and the primary concavo-convex pattern, and the primary concavo-convex pattern can be formed more clearly.
[0043]
According to the invention of claim 3, since the secondary mold raw material is applied to the surface of the primary mold in advance before the cast casting of the secondary mold, the secondary unevenness is the same as the effect of claim 2. The pattern can be formed more clearly.
[0044]
According to the fourth aspect of the present invention, since the secondary mold hardening is performed while applying vibration, the secondary concavo-convex pattern can be more reliably and clearly formed.
[0045]
According to the invention of claim 5, since the medium-sized production model is made of an inexpensive synthetic resin, it can be made at a lower cost and can be easily formed with an inverted concavo-convex pattern because it is relatively soft.
[0046]
According to the invention of claim 6, since the primary mold is made of inexpensive silicone rubber, there is an advantage that the cost can be further reduced.
[0047]
According to the invention of claim 7, since the secondary mold is made of cheap gypsum or cement, the cost can be further reduced and the handleability is excellent.
[0048]
According to the eighth aspect of the present invention, since the vapor holes are provided in the convex portions of the concavo-convex pattern, the vapor hole marks that expand and project into the vapor holes during foam molding are formed in the concave portions of the design pattern of the in-mold foam molded article. It is formed and vapor hole traces are not noticeable.
[0050]
According to the ninth aspect of the present invention, since the steam holes are provided at the joints between the constituent members, the steam hole marks are formed in the mold when the joints between the constituent members are located at the corner of the middle mold for in-mold foam molding. It is formed at the corners of the foamed molded article, and the vapor hole traces are hardly noticeable.
[Brief description of the drawings]
FIG. 1 is a flowchart showing a method for manufacturing a component according to a first embodiment.
FIG. 2 is a schematic cross-sectional view of an in-mold foam molding middle mold in which a plurality of manufactured components are connected.
FIG. 3 is a schematic sectional view of a mold.
FIG. 4 is a cross-sectional view of an in-mold foam molded article.
FIG. 5 is a cross-sectional view of a medium-sized manufacturing action model before forming a reverse concavo-convex pattern.
FIG. 6 is a cross-sectional view of a medium-sized manufacturing model in which a reverse concavo-convex pattern is formed on the surface.
FIG. 7 is an enlarged cross-sectional view of a main part showing the vicinity of an inverted concavo-convex pattern of a medium-sized manufacturing model.
FIG. 8 is a schematic cross-sectional view showing a state of cast hardening of a primary mold.
FIG. 9 is an enlarged cross-sectional view of the main part showing the vicinity of the primary uneven pattern of the primary mold.
FIG. 10 is a schematic cross-sectional view showing a state of secondary type cast hardening.
FIG. 11 is an enlarged cross-sectional view of a main part showing the vicinity of a secondary uneven pattern of a secondary mold.
FIG. 12 is a schematic cross-sectional view showing a state where a secondary mold is lit.
FIG. 13 is a schematic cross-sectional view showing a state of casting of component members.
FIG. 14 is an enlarged cross-sectional view of the main part showing the vicinity of the concavo-convex pattern of the constituent members.
FIG. 15 is an enlarged cross-sectional view of an essential part showing an example in which a steam hole is provided in a convex portion of a concavo-convex pattern on a molding surface of an intermediate mold for in-mold foam molding.
FIG. 16 is an enlarged cross-sectional view of a main part showing a state of foam molding.
FIG. 17 is an enlarged cross-sectional view of a main part showing a state in which a vapor hole mark is formed in a concave portion of a design pattern on the surface of an in-mold foam molded body.
FIG. 18 is an enlarged cross-sectional view of a main part showing an example in which a steam hole is provided at a joint between constituent members.
FIG. 19 is an enlarged cross-sectional view of a main part showing a state of foam molding.
FIG. 20 is an enlarged cross-sectional view of a main part showing a state in which vapor hole marks are formed at corners on the surface of the in-mold foam molded article.
FIG. 21 is a flowchart showing a method of manufacturing the middle mold for in-mold foam molding according to the second embodiment.
FIG. 22 is a schematic cross-sectional view showing a state of primary type cast hardening.
FIG. 23 is a schematic cross-sectional view showing a state of secondary type cast hardening.
FIG. 24 is a schematic cross-sectional view showing a state of casting of the middle mold for in-mold foam molding.
FIG. 25 is a cross-sectional view of the produced middle mold for in-mold foam molding.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1,51 Middle mold 1a for in-mold foam molding, 51a Molding surface 2 Constituent member 3 In-mold foam molding 3a Surface 4 Design pattern 5 Irregular pattern 6 Medium size production model 6a Surface 7 Inverted irregular pattern 8 Primary mold 8a Surface 9 1 Next uneven pattern 10 Secondary mold 11 Secondary uneven pattern 35 Steam hole 36 Convex part 39 Seam

Claims (9)

In the method for producing a mold for in-mold foam molding in which a concavo-convex pattern for forming a design pattern is formed on the molding surface during casting on the surface of the in-mold foam molded article, the shape is substantially the same as the molding surface of the medium mold manufacturing model. A reverse concavo-convex pattern obtained by inverting the concavo-convex pattern is formed on the surface formed on the surface, and the reverse concavo-convex pattern is formed on the surface of the primary mold produced by cast-curing on the medium-sized production model. A primary concavo-convex pattern is formed by transferring, and the primary concavo-convex pattern is transferred to the surface of the secondary mold made of an inorganic material manufactured by cast curing on the primary mold during cast curing. After forming the secondary concavo-convex pattern by the above , a plurality of plate-shaped constituent members formed with the concavo-convex pattern by transferring the secondary concavo-convex pattern to the molding surface during casting , or the ends thereof as they are, or Make a notch at a predetermined angle and match Butt portion rear surface side plate-like or cross-section mold foam fabrication method of the molding medium-sized, characterized in that the L-shaped backing material is connected by screwed by bolts to the. The method for producing an intermediate mold for in-mold foam molding according to claim 1, wherein the primary mold raw material is applied in advance to the surface of the medium-sized manufacturing model before the primary mold is cast and cured. The method for producing an intermediate mold for in-mold foam molding according to claim 1 or 2, wherein the secondary mold raw material is applied in advance to the surface of the primary mold before the secondary mold is cast and cured. The method for producing an intermediate mold for in-mold foam molding according to any one of claims 1 to 3, wherein the casting of the secondary mold is performed while applying vibration. The method for producing an intermediate mold for in-mold foam molding according to any one of claims 1 to 4, wherein the medium model manufacturing model is made of a synthetic resin. The method for producing an intermediate mold for in-mold foam molding according to any one of claims 1 to 5, wherein the primary mold is made of silicone rubber. The method for producing an intermediate mold for in-mold foam molding according to any one of claims 1 to 6, wherein the secondary mold is made of gypsum or cement. 8. A mold for in-mold foam molding produced by the method according to claim 1, wherein a steam hole is provided in a convex portion of the concavo-convex pattern. The intermediate mold for in-mold foam molding according to claim 8, wherein a steam hole is provided at a joint between the constituent members.

Images