JP5793671B2 - Mold structure and casting method using the mold structure - Google Patents

Description

  The present invention relates to a mold structure and a casting method using the mold structure.

  Conventionally, as a resin molded product, for example, there is a bathtub or the like whose surface is a design surface, and the bathtub is exposed to the exterior, and the back surface is provided on the back side of the surface layer and performs reinforcement or heat insulation of the surface layer. A layer. As a manufacturing method of this type of resin molded product, there is a cast molding method of forming a resin molded product in which a surface layer and a back surface layer are laminated by injecting and curing a resin material into a cavity formed by a mold apparatus. .

  And as this mold apparatus, for example, in the apparatus shown in Patent Document 1, etc., a casting mold (first mold) for forming an acrylic resin deformed body (surface layer), and a dicyclopentadiene polymer A casting mold (second mold) for forming the (back layer). The mold apparatus forms an acrylic resin deformed shape, removes the molded body from the first mold and sets it in the second mold, and pours the polymerizable composition into a gap (cavity) in the second mold. By curing, a laminated molded body in which the front surface layer and the back surface layer are integrated is formed.

JP 2002-34635 A

  However, in the mold apparatus as disclosed in Patent Document 2, when the acrylic resin deformed shaped body is set in the second mold, the surface of the molded body becomes the second surface mold due to blurring on the machine of the set device. May rub against. And when the said rubbing arises, a rubbing wrinkle etc. will generate | occur | produce on the surface of the molded object which is a design surface, and may reduce the commercial value of a laminated molded object (resin molded product).

  Accordingly, in view of this situation, to provide a mold structure that suppresses generation of scratches on the surface of the molded body when the molded body is set (when the mold is changed), and a casting method using the mold structure. Was an issue.

In order to solve the above problems, the mold structure of the present invention is a surface mold in which the molded body is set in advance when the resin layer is cast-molded on the back side of the molded body. A holding surface for holding the surface side of the molded body, and a surface rubbing suppression member that suppresses rubbing between the surface and the holding surface during the setting is provided on the holding surface; It is a nonwoven fabric integrated and embedded in the surface mold .

  As this mold structure, it is preferable that the surface scuff suppressing member is provided on the entire holding surface.

  As the mold structure, it is preferable that the surface scuff suppressing member is provided so as to be scattered and protrude from the holding surface.

  The casting molding method of the present invention is characterized in that casting molding of the resin layer is performed using any of the mold structures described above.

  By adopting such a configuration, it is possible to easily suppress the occurrence of rubbing on the surface of the molded body when the molded body is set (when the mold is replaced).

It is composition explanatory drawing of the 2nd metal mold | die and a molded object in the metal mold apparatus of 1st Embodiment. It is a perspective view of the surface type | mold (2nd surface type | mold) in a 2nd metal mold | die same as the above. It is composition explanatory drawing of the 1st metal mold | die in a metal mold apparatus same as the above. It is a perspective view of the resin molded product formed with the mold apparatus same as the above. It is composition explanatory drawing of the 2nd surface type of a 2nd embodiment. It is a perspective view of the 2nd surface type same as the above.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

(First embodiment)
The resin molded product 1 formed in the first embodiment is, for example, a bathtub 5 having a front surface layer 2 and a back surface layer 4 as shown in FIG. The bathtub 5 is mainly composed of a bottom portion 6 having a stepped portion 7 for sitting on one end and a side wall 8 rising upward from the outer peripheral end of the bottom portion 6 and continuing in the circumferential direction, and is surrounded by the bottom portion 6 and the side wall 8. This space is a hot water storage space where hot water is stored. The bathtub 5 has a design surface in which the surface of the bottom portion 6 and the side wall 8 facing the hot water storage space is exposed to the appearance, and is formed on the surface of the surface layer 2, and the back surface layer 4 lowers the temperature of the hot water stored in the hot water storage space. It is a heat-insulating layer for suppressing or a reinforcing layer that reinforces the surface layer 2.

  Moreover, the resin molded product 1 (bathtub 5) is formed by a mold apparatus for cast molding, and the apparatus includes a first mold 10 for forming the surface layer 2 shown in FIG. And a second mold 20 for forming the back surface layer 4 shown in FIG. Details will be described later.

  In the method of manufacturing the resin molded product 1 using the mold apparatus, the first resin material is injected and cured into the cavity 13 formed by the first mold 10 to form the molded body 3 to be the surface layer 2. Thereafter, the molded body 3 released from the first mold 10 is conveyed to the second mold 20 and set on the second mold 20. Then, in a state where the molded body 3 is set, the mold apparatus injects and cures the second resin material into the cavity 23 formed by the second mold 20, and the back surface layer 4 (resin is formed on the back surface side of the molded body 3. Layer) and a resin molded product 1 in which two resins are laminated is manufactured.

  Specifically, as shown in FIG. 3, the first mold 10 includes a surface mold (first surface mold 11) having a transfer surface 11 a on the surface 3 a side of the molded body 3 (surface layer 2), and the molded body 3. A back surface type (first back surface type 12) having a transfer surface 12a on the back surface 3b side. The first mold 10 is closed (between the transfer surface 11a of the first surface mold 11 and the transfer surface 12a of the first back surface mold 12) by closing the first surface mold 11 and the first back surface mold 12. A cavity 13 for forming the surface layer 2 is formed on the substrate. Then, the first mold 10 is formed by injecting the first resin material into the cavity 13 and curing it to form the molded body 3 that becomes the surface layer 2 of the resin molded product 1. Open the mold.

  The mold apparatus further includes a setting unit (not shown) that removes the molded product from the first mold 10 and then transports it to the second mold 20 and sets (attaches) it to the second mold 20. The setting section includes a transport function and an attachment function, such as those attached after the molded body 3 is suspended and supported from the back surface 3b side and transported to the second mold 20. The setting unit is not limited to the exemplary configuration having two functions, but includes a conveyance unit for conveying the molded body 3 and an attachment part for attaching the second mold 20 of the conveyed molded body 3. It may be. In addition, the setting unit is not limited to the one that conveys the molded body 3, but the one that moves the mold device side such as the one that moves the second mold 20 to enable the molded body 3 to be set in the second mold 20. It may be.

  As shown in FIGS. 1 and 2, the second mold 20 includes a surface mold (second surface mold 21) having a holding surface 21 a that holds the surface 3 a side of the molded body 3, and a back surface 3 b of the molded body 3. The back surface type | mold (2nd back surface type | mold 22) which has the transfer surface 22a of the back surface side of the back surface layer 4 formed in the side is provided. The second metal mold 20 is set by holding the surface 3 a side of the molded body 3 with the holding surface 21 a of the second surface mold 21. And the 2nd metal mold | die 20 closes the 2nd surface type | mold 21 and the 2nd back surface type | mold 22 in the state in which the molded object 3 was set, and the back surface 3b (refer the dotted line in FIG. 1) of the molded object 3. ) And the transfer surface 22 a of the second back surface mold 22, a cavity 23 for forming the back surface layer 4 is formed. Further, the second mold 20 is formed by injecting the second resin material into the cavity 23 and curing it, thereby forming the back surface layer 4 of the resin molded product 1 on the back surface 3b side of the molded body 3. And the back surface layer 4 are laminated and the resin molded product 1 is manufactured.

  Further, the second mold 20 is formed of a member having a higher hardness (harder) than the molded body 3 so that it can be repeatedly used for improving the mass productivity of the resin molded product 1. Concomitant consumption (abrasion, chipping, etc.) of the holding surface 21a and the transfer surface 22a is suppressed. The members constituting the holding surface 21a and the transfer surface 22a are preferably, for example, a metal material such as iron, aluminum, or an alloy containing these as a main component, but are not limited to those illustrated.

  By the way, when the molded body 3 formed in advance by the first mold 10 is set in the second mold 20, mechanical blurring occurs in the setting portion due to an error in the conveyance amount, and the surface 3 a of the molded body 3 is The second surface mold 21 may rub against the holding surface 21a. When the rubbing occurs, the molded body 3 is softer than the holding surface 21a of the second surface mold 21 as described above, and thus the surface 3a, which is the design surface of the resin molded product 1, is rubbed, There is a risk of reducing the commercial value of the resin molded product 1.

  On the other hand, in this mold apparatus, as shown in FIGS. 1 and 2, the mold structure of the second surface mold 21 is provided with a surface rubbing suppression member 40 that suppresses the generation of the scraping on the holding surface 21a. It becomes the composition. The surface rubbing suppression member 40 is, for example, a non-woven fabric such as felt, and the non-woven fabric is bonded to the holding surface 21a and covers substantially the entire holding surface 21a. The mold size of the holding surface 21a is adjusted by, for example, making the second surface mold 21 smaller by the thickness of the surface scuff suppressing member 40 such as a nonwoven fabric or an adhesive.

  Therefore, the second surface mold 21 has a mold structure in which the holding surface 21a is covered with a soft nonwoven fabric as compared with the holding surface 21a, and the molded body 3 is held on the holding surface 21a by being in contact with the surface rubbing suppression member 40. Is done. And since the holding surface 21a holds the molded body 3 via the surface rubbing suppression member 40, the surface rubbing suppression member 40 makes it difficult for the surface 3a of the molded body 3 to generate scuffing, and the product value due to the scratching is reduced. It becomes easy to suppress a fall etc.

(Second Embodiment)
Further, the mold structure of the second surface mold 21 may be a structure in which the surface rubbing suppression member 40 is scattered on the holding surface 21a as shown in FIGS. In addition, description of the structure substantially the same as 1st Embodiment, such as the 1st metal mold | die 10 and the 2nd back surface type | mold 22, is abbreviate | omitted.

  The surface rubbing wrinkle suppressing member 40 has a substantially columnar shape, and a plurality of the surface rubbing suppression members 40 are arranged at predetermined intervals, and are provided at positions where the surface rubbing suppressing member 40 easily contacts the surface 3a when the holding surface 21a is set. As the position, for example, the end surface 30 that holds the portion of the molded body 3 that becomes the bottom portion 6 and the flange portion, the side surface 31 that holds the portion that becomes the side wall 8, and the recess 32 that holds the portion that becomes the stepped portion 7. An end surface 33, a side surface 34, and the like are formed. Further, it is preferable that at least a part of the surface rubbing suppression member 40 on the side surface 31 is located at substantially the same height as the end surface 33 of the recess 32 or slightly above (position close to the end surface 30 side).

  Further, the surface rubbing suppression member 40 is a circular protrusion protruding from the holding surface 21a by about 2 mm in the direction in which the axis is substantially orthogonal to the holding surface 21a, and the holding surface 21a suppresses the surface scuffing. The molded body 3 is held via the member 40. The surface rubbing suppression member 40 is mainly composed of, for example, a fluororesin such as Teflon (registered trademark), and generates scratches on the surface 3a of the molded body 3 due to physical properties such as a low friction coefficient unique to the fluororesin. Make it difficult. In addition, the protrusion amount from the holding surface 21a of the surface rubbing suppression member 40 is not limited to the illustrated numerical value. The protrusion is not limited to a circular shape, and may be a rectangular shape or a belt shape.

  As described above, by providing the circular protrusion mainly made of fluororesin and protruding from the holding surface 21a, it becomes easy for the molded body 3 to come into direct contact with the holding surface 21a during setting, and the surface of the molded body 3 during setting. It becomes easy to suppress a decrease in commercial value due to the rubbing of 3a.

  In addition, the surface scratch wrinkle suppressing member 40 has a fluororesin provided on substantially the entire holding surface 21a, a non-woven fabric provided on the holding surface 21a, and a fluororesin provided on the holding surface 21a. The remaining exposed portion of the surface 21a may be covered with a nonwoven fabric. The non-woven fabric is not limited to the one provided by bonding, but may be one provided integrally with the holding surface 21a by embedding at the time of manufacturing the mold, or the like provided detachably so that it can be replaced when worn. May be. The fluororesin is provided by, for example, adhering or detachably arranging, in addition to what is provided by surface treatment such as so-called fluorine processing. Of course, the method of providing the nonwoven fabric or the fluororesin is not limited to the illustrated configuration.

  In the illustrated embodiment, the second surface mold 21 is a lower mold on which the holding surface 21a is located on the upper side and the molded body 3 is placed, but the second surface mold 21 is not limited to the lower mold. An upper mold having the holding surface 21a on the lower side may be used. Further, the second mold 20 is not limited to the so-called vertical closed type in which the second front surface mold 21 and the second back surface mold 22 are arranged side by side in the vertical direction, and the mold is moved in the vertical direction to close the mold. A so-called laterally closed type in which the molds are arranged side by side and the molds are moved in the lateral direction to close the molds may be used.

  In addition, the resin molded product 1 is not limited to a two-layer molded product in which the front surface layer 2 and the back surface layer 4 are laminated, and may be a three or more layered product having an intermediate layer. And if the molded object 3 makes the surface hold | maintained by the holding surface 21a into the design surface of the resin molded product 1, it will not be limited to what was formed by cast-molding the surface layer 2, but fiber reinforced plastics etc. The sheet material may be formed by press molding. That is, the manufacturing method of this resin molded product 1 is the molding with the surface mold provided with the surface rubbing suppression member 40 when the resin layer is formed on the back surface 3b side of the molded body 3 molded in advance by casting. Any method for holding the surface 3a of the body 3 may be used.

  Further, the resin molded product 1 is not limited to the illustrated bathtub 5, but may be a wash bowl of a washstand, a filth receiving bowl portion of a toilet device, or the like. It may be an outer shell member such as a case or a housing having the back layer 4. The resin molded product 1 is not limited to the container shape, and may be a plate or the like having a design surface as one plate surface such as a counter of a kitchen or a washstand or a floor pan. Of course, the resin layer (back surface layer 4) formed on the back surface 3b side of the molded body 3 is not limited to the exemplified heat insulating layer and reinforcing layer, but is a fire resistant layer that is less flammable than the surface layer 2, a chemical resistant layer that is less susceptible to chemicals, and the like. It may be.

  In addition, the resin molded product 1 is not limited to the design surface of the surface layer 2 alone, but has a design surface on both the front and back surfaces of a so-called western-style bathtub or shelf that is placed alone in the bathroom. May be. In this case, the surface to be the design surface of the previously formed molded body 3 is held by the holding surface 21a of the second surface mold 21, and the remaining resin layer is formed on the back surface 3b side of the molded body 3. . Further, in the case where the resin molded product 1 has three or more layers, and the intermediate layer (resin layer) is formed after forming the front surface layer and the back surface layer, the surface of the mold that forms the cavity for forming the intermediate layer The surface rubbing suppression member 40 may be provided on each of the mold and the back mold.

1 resin molded product 2 surface layer 3 molded body 3a surface 3b back surface 4 resin layer (back surface layer)
20 Second mold 21 Surface mold (second surface mold)
21a Holding surface 40 Surface scuff suppressing member

Claims (4)

When casting the resin layer on the back side of the molded body, in the surface mold to set the molded body that has been molded in advance,
The surface mold has a holding surface for holding the surface side of the molded body,
Provided on the holding surface a surface scuff suppressing member that suppresses rubbing between the surface and the holding surface during the setting ,
A mold structure characterized in that the surface scuff suppressing member is a non-woven fabric embedded integrally with the surface mold .   The mold structure according to claim 1, wherein the surface scuff suppressing member is provided on the entire holding surface.   2. The mold structure according to claim 1, wherein the surface scuff suppressing member is provided on the holding surface so as to be scattered and protruded. 3. A cast molding method, wherein the resin layer is cast using the mold structure according to any one of claims 1 to 3.

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