JP5100275B2 - Manufacturing method of perforated plate made of synthetic resin - Google Patents

Description

  The present invention relates to a method for producing a synthetic resin porous plate, and more particularly to a method for producing a thick synthetic resin porous plate such as a filter panel of a dust remover installed in a water channel.

  In order to remove contaminants in the water channel, dust removers with various structures are installed, and as one of them, a plurality of filter panels oriented transversely to the water flow are connected endlessly and circulated. A dust remover having a structure is known (for example, see Patent Document 1). The filter panel of this dust remover can use a metal perforated plate (punching metal) or a metal mesh, but by using a thick mesh panel, fine impurities in the water channel can be removed efficiently and reliably. This has the advantage that the hair and fibers are less likely to get entangled.

The filter panel varies depending on the conditions of the water channel in which the dust remover is installed, but is generally a crescent moon having a diameter of about 600 mm, and has a large number of water holes, for example, 1,000 or more water holes. A hole is provided. In order to secure the maximum cross-sectional area of the water passage portion in the filter panel, for example, in the case of a water passage hole having a diameter of 10 mm, the water passage hole is adjacent to each vertex of an equilateral triangle having a side length of 11 mm. In this case, the thickness of the partition between adjacent water holes is 1 mm at the minimum. The plate thickness of the filter panel is about 15 mm in consideration of improving the removal efficiency of impurities, water pressure resistance, and durability.
Special Table 2003-505241

  As a method for manufacturing a thick perforated plate such as the filter panel described above, for example, a method of drilling a 10 mm diameter through hole in a predetermined position on a metal plate or synthetic resin plate having a thickness of 15 mm by a drill or the like is conceivable. However, since heat generation during drilling must be taken into account, there is a problem that it takes a very long time to drill 1,000 or more through holes. Although it is possible to manufacture by metal casting or synthetic resin injection molding, it is possible if the diameter is about several tens mm and the plate thickness is about 5 mm, but the diameter is about 600 mm as described above. Then, in normal casting or injection molding, it can be said that it is extremely difficult and impossible to sufficiently allow molten metal or molten resin to flow into the partition between the through holes.

  Furthermore, when a thick filter panel is made of a metal such as stainless steel, it is difficult to handle due to its heavy weight, and the strength of each part of the dust remover must be increased, leading to an increase in overall price. Therefore, there is a demand for a lightweight and inexpensive synthetic resin filter panel.

  Accordingly, the present invention provides a method for producing a synthetic resin porous plate capable of efficiently producing a synthetic resin thick porous plate in which a large number of through holes are arranged adjacent to a synthetic resin thick plate material. It is aimed.

In order to achieve the above object, the synthetic resin porous plate manufacturing method of the present invention has a large number of through holes arranged adjacent to each other, the plate thickness is larger than the diameter of the through holes, and between the adjacent through holes. A method of manufacturing a synthetic resin porous plate in which the thickness of the partition portion is set smaller than the diameter of the through hole, comprising a fixed mold, a movable mold, and a stripper plate that form a cavity for forming the porous plate, the movable type, said stripper plate number of cores for retractable hole molded into the cavity through is provided, said the stationary mold, in a state along the position for forming the partition portion, using an injection molding mold recessed groove opening width is formed wider than a thickness of the partition portion as well as have a deeper dimension than the thickness of the product perforated plate is provided to communicate with the gate, the at mold clamping The core is larger than the thickness of the product perforated plate A state which projects into the cavity, a first step of filling by flowing a thermoplastic resin in a molten state from the gate into the cavity containing the groove, further the concave thermoplastic resin in a molten state from the gate A second step of allowing molten resin to flow into the groove and filling the gap between the cores from the inside of the concave groove , filling the molten resin by cooling and hardening the molten resin, and removing the core from the stripper plate Through the third step of drawing in, an injection molded product having a bottomed hole formed by the core in the through hole portion of the product perforated plate was formed by the plate thickness of the through hole forming portion being thicker than the product perforated plate thickness. Thereafter, by cutting the fixed mold side of the injection molded product, the plate thickness is set to the thickness set in the product perforated plate, and at the same time, the bottom of the bottomed hole is opened to form a through hole. .

Also, it is characterized in that before Symbol synthetic resin porous plate is a filter panel used for dust remover for removing contaminants through the water channel.

  According to the method for producing a synthetic resin porous plate of the present invention, a thick synthetic resin porous plate such as a filter panel used in a dust remover can be efficiently produced.

  FIG. 1 is a perspective view showing an example of a synthetic resin porous plate manufactured by the manufacturing method of the present invention. This porous plate 11 made of synthetic resin has a large number of through holes 13 arranged adjacent to the inner part of the substrate 12, and the thickness A of the substrate 12 is larger than the diameter B of the through holes 13, and the adjacent through holes The thickness C of the partition 14 between the 13 is set smaller than the diameter B. For example, with respect to the diameter B, the plate thickness A is set to about 1.2 to 2 times, and the thickness C is set to about 0.1 to 0.3 times.

  Hereinafter, a procedure for manufacturing the synthetic resin porous plate 11 will be described with reference to FIGS. 2 to 11. First, the synthetic resin porous plate 11 is produced by injection-molding a thermoplastic synthetic resin according to the procedure shown in the cross-sectional views of FIGS. 2 to 8 to produce an injection-molded body 21 shown in FIGS. 9 to 11. As the injection molding machine to be used, a general injection molding machine can be used. A fixed mold 31 connected to the injection unit, a movable mold 32 provided so as to be detachable from the fixed mold 31, and a fixed mold. A stripper plate 33 disposed between the movable mold 32 and the movable mold 32, and the movable mold 32 can protrude through the through-hole 34 provided in the stripper plate 33 in the direction of the fixed mold 31. A cylindrical core 35 is provided.

  The through hole 34 and the core 35 have the same diameter as the diameter of the through hole 13 formed in the synthetic resin porous plate 11 as a product, and are provided at positions corresponding to the positions of the respective through holes 13. Yes. The fixed mold 31 is provided with a recess 36 having a dimension deeper than the plate thickness A of the substrate 12 of the synthetic resin porous plate 11, and a gate 37 is provided at the center of the recess 36. The recess 36 may be the same size as the entire substrate 12, but only the through hole forming portion for forming the through hole 13 is sufficient. In particular, the opening width is set to the thickness C of the partition portion 14. It is preferable to provide the groove formed wider so as to follow the position where the partition portion 14 is formed. In addition, an appropriate draft angle is provided at the tip of the core 35.

  As shown in FIG. 2, when the mold is clamped, the core 35 protrudes into the cavity 38 larger than the plate thickness A of the substrate 12, and the recess 36 is positioned facing the group of cores 35. . In this state, when a molten thermoplastic resin (molten resin P) is injected from the injection unit (not shown) into the runner 39, the molten resin P includes a cavity including the recess 36 through the gate 37 from the runner 39 as shown in FIG. 38 flows in. Since the flow of the first molten resin P is narrow in the width of the gap 40 between the cores 35 and has a larger flow resistance than the portion that molds the outside of the substrate 12, as shown in an enlarged view in FIG. Almost does not flow into the gap 40, and the entire cavity 38 including the recess 36 facing the core group is filled with the molten resin P (first step).

  When the molten resin P is further injected from the injection unit in this state, as shown in FIG. 5, the molten resin P in the recess 36 flows into the gaps 40 between the cores 35 by this injection pressure, and all the gaps 40 The inside is filled with the molten resin P. In this way, after the molten resin P is filled in the recesses 36 facing the core group, the molten resin P is caused to flow into the gaps 40 in the axial direction of the core 35, so that each gap 40 is averaged. The molten resin P can be made to flow evenly (second step).

  After the injection of the molten resin P is completed, the molten resin P is cooled and cured, and then the mold is opened and the injection molded body 21 is taken out (third step). That is, as shown in FIG. 6, after the fixed mold 31 is separated from the fixed side mounting plate 41 and the runner stripper plate 42, and further, as shown in FIG. 7, after the stripper plate 33 and the movable mold 32 are separated from the fixed mold 31. As shown in FIG. 8, by separating the stripper plate 33 and the movable mold 32, the tip of the core 35 provided integrally with the movable mold 32 is drawn into the through hole 34 of the stripper plate 33. Thereby, the injection molded body 21 can be taken out from the mold.

  The injection-molded body 21 shown in FIGS. 9 to 11 is obtained by performing injection molding using the concave portion 36 provided in the fixed mold 31 as the concave groove as described above. FIG. 9 is a plan view, and FIG. XX sectional drawing and FIG. 11 are perspective views. The injection molded body 21 is formed so that the thickness of the outer substrate portion 22 is slightly thicker, for example, about 1 to 2 mm than the thickness A of the substrate 12 in the synthetic resin porous plate 11 of the product. A bottomed hole 23 formed by the core 35 is formed corresponding to the through hole 13 in the synthetic resin porous plate 11.

  Further, the partition 14 in the synthetic resin porous plate 11 is formed between the adjacent bottomed holes 23, and an opening is formed on the surface on the fixed mold 31 side of each partition 14 that is upper in FIG. 10. A convex portion 24 formed by the concave portion 36 formed of a concave groove having a width wider than the thickness C of the partition portion 14 is formed along one end of the partition portion 14. Is formed with a concave portion 25 that faces the outer surface of the bottom of the bottomed hole 23.

  Finally, this injection-molded body 21 cuts the surface on the convex portion 24 side from the cutting line 26 shown in FIG. 10, thereby reducing the thickness of the outer substrate portion 22 in the synthetic resin porous plate 11 as a product. The thickness A is set to the substrate 12, and at the same time, the bottoms of the bottomed holes 23 are cut and opened to form the through holes 13 in the synthetic resin porous plate 11. For this cutting, a general machining machine such as an end mill or a slicer can be used, and the synthetic resin porous plate 11 shown in FIG. 1 can be obtained by performing chamfering as necessary.

  Thus, in order to form the partition part 14 between the adjacent through-holes 13, a large number of cores 35 corresponding to the through-holes 13 protrude from the stripper plate 33 and face the group of cores 35 so as to be molten resin. By providing a recess 36 for guiding the resin, and by providing the gate 37 in the recess 36, the molten resin is caused to flow directly from the gate 37 into the recess 36 to be filled. Resin can flow in the gaps 40 between the cores 35 in the axial direction of the core 35, so that the molten resin can surely flow into the gaps 40. At this time, by forming the concave portion 36 in a concave groove shape, the flow of the molten resin can be made smooth and the amount of resin corresponding to the concave portion 25 can be reduced.

  When the area of the substrate 12 is larger than the formation range of the through holes 13, the thickness of the substrate portion 22 in the injection molded body 21 is formed to be the same as the thickness A of the substrate 12, and this portion is cut. It may be omitted.

  By manufacturing a synthetic resin porous plate by such a method, as in the above-described filter panel of a dust remover, a thick substrate having a plate thickness of about 15 mm has a through hole having a diameter of about 10 mm with a clearance of 1000 or more. It is possible to easily manufacture a thick porous plate made of synthetic resin having a shape as if they are arranged side by side.

It is a perspective view which shows an example of the synthetic resin porous board manufactured with the manufacturing method of this invention. It is sectional drawing which shows the state which clamped the metal mold | die of the injection molding machine. It is sectional drawing which shows the inflow state of the molten resin in a 1st process. It is an expanded sectional view of the important section in the 1st process. It is an expanded sectional view of the important section in the 2nd process. It is sectional drawing which shows the state which released | separated the fixed type | mold from the stationary-side mounting plate and the runner stripper plate. It is sectional drawing which shows the state which separated the stripper plate and the movable mold | type from the fixed mold | type. It is sectional drawing which shows the state which released | separated the stripper plate and the movable mold | type and pulled the core in the through-hole. It is a top view of an injection molded object. It is XX sectional drawing of FIG. It is a perspective view of an injection molded object.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 11 ... Synthetic resin porous plate, 12 ... Board | substrate, 13 ... Through-hole, 14 ... Partition part, 21 ... Injection molded object, 22 ... Substrate part, 23 ... Bottomed hole, 24 ... Convex part, 25 ... Concave part, 26 ... cutting line, 31 ... fixed type, 32 ... movable type, 33 ... stripper plate, 34 ... through hole, 35 ... core, 36 ... recess, 37 ... gate, 38 ... cavity, 39 ... runner, 40 ... gap, 41 ... Fixed side mounting plate, 42 ... Runner stripper plate

Claims (2)

A large number of through holes are arranged adjacent to each other, the plate thickness is larger than the diameter of the through holes, and the thickness of the partition between adjacent through holes is set to be smaller than the diameter of the through holes. a method of manufacturing a perforated plate, fixed to form a cavity for a porous plate molding, a movable mold and the stripper plate, the movable type, retractable through the stripper plate in the cavity through provided a number of core holes forming the the fixed die, the state along the position for forming the partition portion, the opening width as well as have a deeper dimension than the thickness of the product perforated plate of the partitioning portion Using an injection mold in which a concave groove formed wider than the thickness is provided in communication with the gate, the core is protruded into the cavity larger than the plate thickness dimension of the product porous plate at the time of mold clamping, Molten heat from the gate A first step of filling with the plastic resin to flow into the cavity containing the groove, from the gate after further allowed to flow into the recessed groove of the molten thermoplastic resin in the groove between the cores The thickness of the through-hole forming portion is determined by the second step of filling the gap with the molten resin and the third step of opening the mold after cooling and hardening the molten resin and drawing the core into the stripper plate. After molding an injection molded product having a bottomed hole formed by the core in the through hole portion of the product porous plate, which is thicker than the product porous plate thickness, by cutting the fixed mold side of the injection molded product, A manufacturing method of a synthetic resin porous plate, characterized in that the plate thickness is set to a thickness set for a product porous plate, and at the same time, the bottom of the bottomed hole is opened to form a through hole. Method for producing a synthetic resin porous plate of claim 1 Symbol placement, wherein the synthetic resin porous plate is a filter panel used for dust remover for removing contaminants through the water channel.

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