JP5894899B2 - Foam molding - Google Patents

Description

  The present invention relates to a foamed molded article that is molded using a molding apparatus including a mold that can be opened and closed.

  Conventionally, this type of foamed molded body includes a mold that can be opened and closed, a cylindrical filling means for filling foaming resin particles in a molding space formed by closing the mold, and the molding space. A rod-shaped release means for releasing the foamed molded article from the mold, and one end of the filling means and one end of the release means form the molding space. A product formed by foam molding using a molding device provided facing the molding surface is known (for example, Patent Document 1).

  Here, the mold is configured so that the fixed mold and the movable mold can be opened and closed (contactable and separable), and at least one wall portion of the fixed mold or the movable mold is inserted into the through hole and filled with the filling means. Mold release means. One end portion of the filling means and one end portion of the release means slightly protrude from the inner wall surface (surface on the molding space side) of the wall portion. Therefore, at the time of the above molding, among the expandable synthetic resin particles, those in the vicinity of one end portion of the filling means and one end portion of the mold release means are molded according to the respective outer shapes. That is, on the surface of the foamed molded article after molding, a concave trace is provided as a trace between one end of the filling means and one end of the release means.

  Such a foam-molded product has a sheet of polypropylene resin or the like superimposed on at least one surface of the surface that is flat or curved, for example, in a trunk lid or a food container of a passenger car (automobile). It is used.

JP 2000-167860 A

  However, in the conventional foamed molded article, when the sheet is overlaid on the one surface of the foamed molded body, the portion overlapping the concave trace portion of the sheet by the force for superimposing the sheet on the one surface However, there is room for improvement in terms of quality, such as dents in other parts, that is, dents are formed in the appearance of the foamed molded article on which the sheets are stacked.

  Then, this invention is made | formed in view of the said problem, and provides the foaming molding which can suppress that a dent arises in the external appearance of the foaming molding which piled up the sheet | seat, and can improve quality. Let it be an issue.

The foamed molded product according to the present invention includes a mold that can be opened and closed, a cylindrical filling means for filling foaming resin particles in a molding space formed by closing the mold, and foam molding in the molding space. And a mold-shaped molding surface in which one end portion of the filling means and one end portion of the mold release means form the molding space. A foam molded body formed by foam molding using a molding apparatus provided facing the sheet, and having a planar or curved surface on which sheets can be superimposed, and a filling means in molding by the molding apparatus A trace portion formed on the one surface by at least one of the one end portion and one end portion of the release means, and a convex portion protruding from the one surface around the trace portion, From the end in the height direction of the convex portion toward the one surface side The distance from the one surface to the height direction end of the convex portion is substantially equal to the distance from the one surface to the bottom surface of the trace portion in the height direction, or from the one surface It is larger than the distance to the bottom face of the said trace part .

According to the foam molded body having such a configuration, since the convex portion is formed around the trace portion so as to protrude from the one surface, when the sheet is superimposed on the one surface of the foam molded body, the sheet is The convex part is compressed and deformed to the one surface side by the force for superimposing the sheet, and the part of the sheet that overlaps the convex part and the trace part is leveled with respect to the other parts without unevenness, and the sheet is smooth along the entire surface. Can be superimposed on each other. Therefore, in such a foam-molded product, it is possible to improve the quality by suppressing the formation of a dent in the appearance of the foam-molded product obtained by superimposing sheets. Further, according to the foam molded body having such a configuration, the distance from the one surface to the height direction end of the convex portion is substantially the same as the distance from the one surface to the bottom surface of the trace portion in the height direction. Equal to or larger than the distance from the one surface to the bottom surface of the trace portion, when the sheet is overlapped on the one surface of the foam molded article, the convex portion is placed on the one surface side by the force for overlapping the sheet on the one surface. The portion of the sheet that overlaps the convex portion and the trace portion is leveled without unevenness, and the sheets can be smoothly overlapped along one surface. Therefore, in such a foam-molded product, it is possible to improve the quality by suppressing the formation of a dent in the appearance of the foam-molded product obtained by superimposing sheets.

  Moreover, in the foaming molding which concerns on this invention, the said convex part can also be comprised so that it may be provided over the perimeter of the circumference | surroundings of the said trace part.

  According to the foamed molded body having such a configuration, since the convex portion is provided over the entire circumference around the trace portion, when the sheet is superimposed on the one surface of the foamed molded body, the sheet The convex portion is uniformly compressed and deformed on the one surface side by the force for superimposing, and the portion of the sheet that overlaps the convex portion and the trace portion can be leveled evenly with respect to the other portions without unevenness, Sheets can be smoothly stacked along one side. Therefore, in such a foam-molded product, it is possible to improve the quality by suppressing the formation of a dent in the appearance of the foam-molded product obtained by superimposing sheets.

  According to the foamed molded product of the present invention, at least one of a planar or curved surface on which sheets can be superposed and one end of the filling means and one end of the release means during molding by the molding apparatus. Are provided with a trace portion formed on the one surface, and a convex portion protruding from the one surface around the trace portion, and a protrusion protruding from the one surface around the trace portion. Since the portion is formed, when the sheet is overlaid on the one surface of the foam molded article, the convex portion is compressed and deformed to the one surface side by the force for superimposing the sheet on the one surface, and the convex portion and the trace of the sheet The portion overlapping the portion is leveled with respect to the other portions without unevenness, and the sheets can be smoothly overlapped along one surface. Therefore, according to the foamed molded product of the present invention, there is an effect that it is possible to improve the quality by suppressing the occurrence of dents in the appearance of the foamed molded product in which the sheets are overlapped.

The perspective view of the foaming molding concerning this embodiment is shown. The top view of the foaming molding is shown. The bottom view of the foaming molding is shown. (A) shows the top view of the area | region T of FIG. 2, (b) shows the AA sectional view taken on the line of (a). (A) shows the schematic sectional drawing of the state which the metal mold | die concerning this embodiment opened, (b) shows the schematic sectional drawing of the state which the metal mold | die closed. The schematic sectional drawing of the state which has taken out the foaming molding from the metal mold | die is shown. The schematic sectional drawing of the filling port provided in the metal mold | die is shown. The schematic sectional drawing of the mold release pin provided in the metal mold | die is shown. The top view of the state which piled up the sheet | seat on the foaming molding is shown. (A) shows the top view of the area | region T of FIG. 9, (b) shows the BB sectional drawing of (a).

  Hereinafter, an embodiment of a foamed molded product according to the present invention will be described with reference to FIGS. 1 to 4. In the following invention, the plan view means a case where the foamed resin molded body is viewed from a direction in which a projection view as shown in FIG. 2 is obtained. Then, on the basis of the plan view of FIG. 2, the longitudinal direction of the foamed molded product is defined as the left-right direction, the short direction of the foamed molded product is defined as the front-rear direction, and the front / back direction of the paper surface is defined as the vertical direction or the thickness direction. .

  As shown in FIG. 1, the foamed molded body 1 according to the present embodiment is used as a core material of a trunk lid in a passenger car (automobile), and is configured such that a sheet of polypropylene resin or the like is overlaid on at least one surface. The The foamed molded body 1 has a plate-like (flat plate) main body 2 as shown in FIG. 1-3. The main body 2 has a substantially rectangular shape in plan view that is long in the left-right direction, and is configured such that the length in the vertical direction (thickness direction) is shorter than the length in the left-right direction and the front-rear direction. The main body 2 has, for example, a length in the left-right direction of about 1200 mm, a length in the front-rear direction of about 300 to 800 mm, and a length in the vertical direction (thickness direction) of about 18 to 20 mm.

  As shown in FIG. 2, the main body 2 has a planar surface (or upper surface) 2U, one or a plurality of protrusions 3 formed on the surface 2U, and the rear end side of the surface 2U along the left-right direction. And a notch 5 formed by notching a central portion in the left-right direction at the front end of one surface 2U. Further, as shown in FIG. 3, the main body 2 includes a planar other surface (or lower surface) 2 </ b> L, a central groove portion 6 formed on the other surface 2 </ b> L along the left-right direction at the center portion in the front-rear direction, and the like. The rear groove part 7 formed along the left-right direction on the rear end side of the surface 2L, and the finger hook part 8 recessed at the center in the left-right direction at the front end of the other surface 2L are provided. In addition, the planar shape on the one surface 2U and the other surface 2L of the main body 2 includes a smooth surface or a surface on which unevenness is formed on the smooth surface. Further, the one surface 2U and the other surface 2L of the main body 2 are not limited to a flat shape, but may be a curved surface. The curved surface shape includes a curved surface that is convex upward or downward, or a surface that has irregularities formed on the curved surface.

  The protrusion 3 has a substantially circular shape or a polygonal shape in plan view, and is protruded from the surface 2U. In the present embodiment, the protrusion 3 has a substantially circular shape in plan view, and a plurality of protrusions 3 are provided. As shown in FIG. 4, the protrusion 3 is configured by integrally forming a columnar portion 31 and a convex portion 32 protruding around the columnar portion 31. The columnar portion 31 has a columnar shape and is projected from the one surface 2U. A convex portion 32 is provided so as to protrude from the entire surface 2U over the entire circumference of the columnar portion 31. The convex portion 32 is formed integrally with the columnar portion 31, and the height direction end portion 32 </ b> A of the convex portion 32 protrudes higher than the upper surface of the columnar portion 31 in the height direction. That is, in the protrusion 3, the upper surface (or upper end surface) of the columnar portion 31 is lower than the height direction end portion 32 </ b> A of the convex portion 32 in the height direction, and a recess is formed. This recess is a recess 33 that forms a recess from the end 32 </ b> A in the height direction of the protrusion 32 toward the upper surface (one surface) 2 </ b> U of the main body 2. That is, the bottom surface 33 </ b> A of the concave portion 33 is the upper surface (or upper end surface) of the columnar portion 31 and is located above the one surface 2 </ b> U of the main body portion 2, and protrudes over the entire circumference around the concave portion 33. A part 32 is provided. Here, the distance H1 from the one surface 2U of the main body 2 to the height direction end 32A of the convex portion 32 is configured to be greater than the distance H2 from the one surface 2U to the bottom surface 33A of the concave portion 33 in the height direction. (See FIG. 4B). The distance H1 from the one surface 2U of the main body 2 to the height direction end 32A of the convex portion 32 is substantially equal to the distance H2 from the one surface 2U to the bottom surface 33A of the concave portion 33 in the height direction. It is also possible. In this case, the upper surface (height direction end portion) of the columnar portion 31 is configured to be substantially equal (substantially equal) to the height direction end portion 32A of the convex portion 32 in the height direction.

  In addition, in the projection body 3 of this embodiment, although the case where it comprised by the columnar part 31 and the convex part 32 was demonstrated, not only this but the projection body 3 is a concave upper surface recessed part provided in one surface 2U. And a convex portion 32 that protrudes from one surface 2U around the concave portion on the upper surface. In this case, in the protrusion 3, the bottom surface of the upper surface concave portion is lower than the one surface 2 </ b> U of the main body portion 2 in the height direction, so that the upper surface (one surface) of the main body portion 2 from the height direction end portion side of the convex portion 32. ) A concave portion 33 having a concave shape is formed on the 2U side. That is, the bottom surface 33A of the concave portion 33 is the bottom surface of the upper surface concave portion and is located below the one surface 2U of the main body portion 2, and the convex portion 32 extends from the one surface 2U over the entire circumference around the concave portion 33. Projected. Here, the distance H1 from the one surface 2U of the main body 2 to the height direction end 32A of the convex portion 32 is configured to be greater than the distance H2 from the one surface 2U to the bottom surface 33A of the concave portion 33 in the height direction. Yes.

  As shown in FIG. 2, the rear groove portion 4 is a concave groove portion formed along the left-right direction on the one surface 2U of the main body portion 2. The rear groove portion 4 is a hinge portion that can be bent with the groove portion as a fulcrum so that the one surface 2U or the other surface 2L on the front end side of the groove portion and the one surface 2U or the other surface 2L on the rear end side of the groove portion face each other. (Folded part). On the other surface 2L of the main body 2, a rear groove 7 corresponding to the rear groove 4 is recessed in the left-right direction (see FIG. 3).

  As shown in FIGS. 2 and 3, the notch portion 5 is a portion that is cut out in a substantially rectangular shape along the vertical direction from the one surface 2 </ b> U to the other surface 2 </ b> L at the central portion in the left-right direction of the front end of the main body portion 2. . On the other surface 2 </ b> L of the main body 2, as shown in FIG. 3, a concave finger-hanging portion (recessed portion) 8 capable of hooking a finger is provided around the notch portion 5.

  As shown in FIG. 3, the central groove 6 is a concave groove formed on the other surface 2 </ b> L of the main body 2 along the left-right direction. The central groove 6 is, for example, for light weight or for bending (for example, the other surface 2L on the front end side with respect to the groove portion and the other surface 2L on the rear end side with respect to the groove portion face each other. It is possible to bend) or design properties.

  Here, a molding method of the foam molded body 1 having the above-described configuration will be described with reference to conceptual diagrams of molding apparatuses shown in FIGS. As shown in FIG. 5, the foam molded body 1 includes a mold 10 that can be opened and closed, and a cylindrical filling means 11 for filling a molding space F formed by closing the mold 10 with foamable resin particles. And a rod-shaped mold release means 12 for releasing the foam molded body 1 foam-molded in the molding space F from the mold 10, and one end of the filling means 11 and one end of the mold release means 12. The part is formed by foam molding using a molding device provided facing the molding surface of the mold 10 forming the molding space F. Specifically, the foam molded body 1 is molded by heating the foamable resin particles filled in the molding space F from one end of the filling means 11 with steam by closing the mold 10 (see FIG. 5), The mold 10 is pushed out of the mold 10 by one end of the mold release means 12 that is opened and relatively moved along the opening and closing direction of the mold 10 (see FIG. 6).

  The molding apparatus includes a mold 10 configured such that the fixed mold 13 and the movable mold 14 can be opened and closed (contacted and separated). The fixed mold 13 and the movable mold 14 are each a molding unit for molding the molding space F. 13A and 14A, and a steam chamber 15c disposed on the back side of the forming portions 13A and 14A. Steam for supplying steam to the steam chamber 15c is respectively supplied to the back plate 15a of the fixed mold 13 (member supporting the molding part 13A) and the back plate 15b of the movable mold 14 (member supporting the molding part 14A). A supply pipe 15d is connected (see FIG. 5A).

  The fixed mold 13 has a first molded portion 13A formed in a convex shape or a concave shape along the opening and closing direction. As shown in FIG. 5A, the first molded portion 13A of the present embodiment has a concave shape. 13 A of 1st shaping | molding parts are provided with the substantially rectangular plate-shaped bottom wall part, and four side wall parts which stand along the opening-and-closing direction of a metal mold | die from four sides of a bottom wall part. One end portion of one or a plurality of filling means 11 and one end portion of one or a plurality of release means (for example, a release pin as an extruding means) 12 are provided on the bottom wall portion of the first molding portion 13A. It has been. Further, one or a plurality of vents (steam supply means) V each having one or a plurality of steam holes opened at one end thereof are provided on the bottom wall portion and the side wall portion of the first molding portion 13A.

  The filling means 11 is constituted by a cylindrical body (cylindrical body). As shown in FIG. 7, the one end part 11a and the other end part 11b of the cylindrical body are open. The diameter of the opening of the one end portion 11a is smaller than the diameter of the opening of the other end portion 11b. That is, the radial thickness on the one end 11a side is thicker than the radial thickness on the other end 11b side. The opening of the one end 11a can be opened and closed by an opening / closing means 16 comprising a columnar tip 16a having a diameter substantially equal to the diameter of the opening and a rod-like connecting portion 16b connected to the tip 16a. .

  As shown in FIG. 7, the filling means 11 is formed in the bottom wall portion of the first molding portion 13A so that the one end portion 11a side is positioned on the molding space F side formed by closing the mold. Inserted into the through-hole 17 to be provided. The through-hole 17 is formed by communicating a large-diameter large hole 17a on the molding space F side (inner side) with a small-diameter small hole 17b on the opposite side (outer side) from the molding space F. Here, the filling means 11 is such that the tip surface of the one end portion 11a is located in the middle of the large hole 17a in the axial direction, and does not protrude from the inner surface of the bottom wall portion of the first molding portion 13A. (See FIG. 7). Therefore, a portion of the one end portion 11a of the filling means 11 that protrudes with respect to the large hole 17a (specifically, an outer peripheral surface and an end surface that are outer surfaces of the one end portion 11a) faces the molding space F. . The molding space F is a molding surface (including the outer surface of one end portion 11a of the filling means 11) between the first molding portion 13A and the second molding portion 14A when the mold 10 is closed. This is a space determined by the surface that determines the outer shape of the foam molded body 1.

  In addition, in the filling means 11, in addition to the tip surface of the one end portion 11a being positioned in the middle of the axial direction of the large hole 17a, the tip surface of the one end portion 11a is positioned at the communication position between the large hole 17a and the small hole 17b. It is also possible to configure such that the tip surface of the one end portion 11a protrudes from the bottom wall portion of the first molding portion 13A to the molding space F side.

  The mold release means 12 is comprised by the rod-shaped body (columnar body). As shown in FIG. 8, the mold release means 12 is formed in the bottom wall portion of the first molding portion 13A so that the one end portion 12a side is positioned on the molding space F side formed by closing the mold. It is provided by being inserted into the through-hole 18 provided. The through hole 18 is formed by communicating a large hole 18a having a large diameter on the molding space F side (inner side) and a small hole 18b having a small diameter on the opposite side (outer side) from the molding space F. Here, the mold release means 12 is located in the bottom wall portion without the tip surface of the one end portion 12a being located in the middle of the large hole 18a in the axial direction and protruding from the inner surface of the bottom wall portion of the first molding portion 13A. (See FIG. 8). Therefore, a portion of the one end portion 12a of the release means 12 that protrudes with respect to the large hole 18a (specifically, an outer peripheral surface and an end surface that are outer surfaces of the one end portion 12a) faces the molding space F. Yes. The molding space F is a molding surface that is an inner wall surface of the first molding portion 13A and the second molding portion 14A (including the outer surface of the one end portion 12a of the mold release means 12) when the mold 10 is closed. Is a space determined by

  The mold release means 12 has a tip end surface of the one end portion 12a positioned at a midway position in the axial direction of the large hole 18a, and a tip end surface of the one end portion 12a at a communication position between the large hole 18a and the small hole 18b. It is also possible to be positioned, or the tip surface of the one end portion 12a can be configured to protrude from the bottom wall portion of the first molding portion 13A to the molding space F side.

  The vent (steam supply means) V is a cylindrical body (cylindrical body). One end portion of the cylindrical body is closed by a disc portion, and the other end portion is open. In the disc portion of the vent V, a plurality of slits (long holes) which are steam holes are formed in parallel. The slits are formed as long holes, and a plurality of slits are formed side by side at substantially equal intervals in parallel with the short direction so that the longitudinal direction is along the radial direction of the disk portion. Moreover, the slit is formed so that the length in the longitudinal direction becomes shorter as the slit is located on the outer side in the lateral direction. In addition, the separation width of each of the plurality of slits can be set, and each separation width is configured to be narrow, and a large number of slits are provided in the disk portion, or each separation width is configured to be wide. A small number of slits can be provided in the disk portion. Moreover, the shape of the vapor hole of the vent V is not limited to a plurality of slits (long holes), and may be configured by a plurality of circles (round holes). The vent V is inserted into a through hole formed in the bottom wall portion and the side wall portion of the first molding portion 13A so that one end side is located on the molding space F side formed by closing the mold 10. Is provided. Here, the vent V is configured such that the front end surface of one end portion faces the inner surface of the bottom wall portion or the side wall portion of the first molding portion 13A. Therefore, one end of the vent V (specifically, the front end surface that is the outer surface of the one end) faces the molding space F. The molding space F is a molding that is the inner surface of the wall portion of the first molding portion 13A and the second molding portion 14A (including the tip surface that is the outer surface of one end of the vent V) when the mold 10 is closed. It is a space determined by the surface.

  The vent V has a large diameter on the side of the molding space F (inside) in addition to the tip surface of one end portion facing the bottom wall portion or the inner surface of the side wall portion of the first molding portion 13A. A structure in which the large hole communicates with a small hole having a small diameter on the side opposite to the molding space F (outside), and the tip surface of one end of the vent V is located at a midway position in the axial direction of the large hole, or A configuration in which the tip surface of the one end is located at a communication position between the large hole and the small hole, or the tip surface of the one end is located to project from the bottom wall portion or the side wall portion of the first molding portion 13A to the molding space F side. A configuration is also possible.

  The movable die 14 has a second molding portion 14A formed in a convex or concave shape along the opening / closing direction, and is configured to move (movable) relative to the fixed die 13 along the opening / closing direction (see FIG. 5 (a)). 14 A of 2nd shaping | molding parts of this embodiment make convex shape. 14A of 2nd shaping | molding parts are provided with the substantially rectangular plate-shaped top wall part, and four side wall parts hanging down along the opening-and-closing direction of a metal mold | die from four sides of a ceiling wall part. One or a plurality of vents (steam supply means) V each having one or a plurality of steam holes opened at one end thereof are provided on the top wall portion of the second molding portion 14A. The vent V has the same configuration as the vent V of the first molded portion 13A.

  In the present embodiment, only the movable mold 14 of the mold 10 is configured as a movable mold. However, both the fixed mold 13 and the movable mold 14 can be configured as a movable mold, or It is also possible to configure the fixed mold 13 as a movable mold and the movable mold 14 as a fixed mold. Further, the opening / closing direction of the mold 10 may be either the horizontal direction or the vertical direction.

  In order to obtain the foamed molded body 1 with such a molding apparatus, the foamable synthetic resin particles are filled from the one end portion 11a of the filling means 11 into the molding space F formed by closing the opened mold 10 (FIG. 5). (See (a) and (b)). Next, steam is supplied to the steam chamber 15c provided so as to cover the rear sides of the fixed mold 13 and the movable mold 14 of the mold 10 to warm the mold 10, and the steam is supplied through the steam hole of the vent V. By supplying the resin into the molding space F, the foamable synthetic resin particles are heated and foam-molded. Thereafter, the mold 10 is cooled by supplying cooling water into the steam chamber 15c, and the mold 10 is opened. Then, the molded foam molded body 1 is released from the mold 10 by being pushed out by the one end portion 12a of the release means 12 moved along the opening and closing direction (that is, taken out of the mold (FIG. 6). reference)).

  Here, when the foamable synthetic resin particles are heated and subjected to foam molding, among the foamable synthetic resin particles, those in the vicinity of the one end portion 11a of the filling means 11 and the one end portion 12a of the release means 12 pass through. Since the one end portion 11a of the filling means 11 and the one end portion 12a of the mold release means 12 project to the middle positions of the large holes 17a, 18a of the holes 17, 18 in the axial direction, the one end portion 11a of the fill means 11 and the mold release means 12 are projected. A concave shape conforming to the outer shape of the one end portion 12a (that is, a cylindrical shape) and a convex shape corresponding to the large holes 17a and 18a around the concave shape. The concave shape is a trace portion formed on one surface 2U by the one end portion 11a of the filling means 11 and the one end portion 12a of the mold release means 12 during molding by the molding apparatus, and is the concave portion 33 of the foam molded body 1. . Further, the shape of the convex portion is a convex portion protruding from one surface 2U around the trace portion by the large holes 17a and 18a of the through holes 17 and 18 during molding by the molding device, and the foam molded body 1 It is a convex part 32. That is, the trace portion is a concave portion 33 that is recessed from the height direction end portion side of the convex portion 32 toward the one surface side. Further, the protruding length (height) of the one end portion 11a of the filling means 11 and the one end portion 12a of the mold release means 12 with respect to the large holes 17a and 18a of the through holes 17 and 18 is the depth of the concave portion 33 in the concave direction. Therefore, the length (height) is such that the distance H1 from the surface 2U to the height direction end 32A of the convex portion 32 is from the surface 2U to the bottom surface 33A of the concave portion (trace portion) 33 in the height direction. It is set to be substantially equal to the distance H2 or larger than the distance H2 from the one surface 2U to the bottom surface 33A of the concave portion (trace portion) 33 (see FIG. 4B).

  In this embodiment, the one end 11a of the filling means 11 and the one end 12a of the mold release means 12 protrude in the axial direction of the through holes 17 and 18 with respect to the large holes 17a and 18a of the through holes 17 and 18. The protruding length of the one end portions 11a and 12a in the large holes 17a and 18a is about 0 to 2 mm, preferably about 2 mm. Further, the height direction end portion 32A of the convex portion 32 is about 1 to 3 mm from one surface 2U in the height direction. Further, the bottom surface 33A of the trace portion (concave portion) 33 is in the height direction (or indentation direction), from one surface 2U to -3 (3 mm lower than one surface 2U) to about 3 mm, preferably from one surface 2U to about -1 to 3 mm. Of height.

  The foamed molded body 1 molded as described above can be used, for example, for a trunk lid in a passenger car (automobile) shown in FIGS. This trunk lid is formed by blow molding (for example, Twin Blow Molding) so that the entire surface including one surface 2U and the other surface 2L of the foam molded body 1 is made of polypropylene (PP) resin and carpet as shown in FIG. It is formed by overlapping sheets S such as materials. Specifically, a sheet S composed of a polypropylene (PP) resin sheet lower layer S1 and a carpet sheet upper layer S2 is superimposed on one surface 2U, and a polypropylene (PP) resin sheet layer S1 is superimposed on the other surface 2L. Sheets S made of are overlaid. A sheet S made of a polypropylene (PP) resin sheet layer S1 is also superimposed on the side surface connecting the one surface 2U and the other surface 2L. Note that the sheet S is a cover material (covering material), a reinforcing material, and a buffer material, and may be formed of, for example, a synthetic resin other than polypropylene (PP) resin, metal, or wood. .

  Here, when the sheet S composed of the lower layer S1 of polypropylene (PP) resin and the upper layer S2 of the carpet material is overlaid on the one surface 2U of the foam molded body 1, the sheet S is superimposed on the one surface 2U. The convex portion 32 is compressed and deformed to the one surface side by the force, and the portion of the sheet S that overlaps the convex portion 32 and the concave portion (the trace portion) 33 is leveled with respect to the other portions without unevenness, and the sheet S becomes the one surface 2U. It is smoothly overlapped along (see FIG. 10B).

  In the present embodiment, only the polypropylene (PP) resin sheet layer S1 is superimposed on the other surface 2L of the foam molded body 1, and the polypropylene (PP) resin sheet lower layer is disposed on one surface 2U of the foam molded body 1. Since the sheet S composed of S1 and the carpet sheet upper layer S2 is overlapped, the convex portion 32 and the concave portion (trace portion) 33 are formed on the surface 2U, which is a surface having a strong sheet thickness or a force for overlapping the sheets. By being formed, the sheets S are more smoothly superimposed along the one surface 2U. In addition, it is also possible to provide the convex part 32 and the recessed part (trace part) 33 in the other surface 2L on which the sheet | seat S by the sheet layer S1 of polypropylene (PP) resin is piled up.

  As described above, the foam molded body 1 according to this embodiment includes a mold 10 that can be opened and closed, and a cylindrical filling means 11 for filling a molding space F formed by closing the mold 10 with foamable resin particles. And a rod-shaped mold release means 12 for releasing the foam molded body 1 foam-molded in the molding space from the mold 10, one end portion 11 a of the filling means 11 and one end of the mold release means 12. A foam molded body 1 formed by foam molding using a molding apparatus in which a portion 12a faces the molding surface of the mold 10 forming the molding space F, and the sheets S can be overlaid. A trace surface 33 formed on the one surface 2U by one end 2a of the filling means 11 and one end 12a of the mold release means 12 at the time of molding by the molding apparatus, and the trace portion 33 formed on the one surface 2U. From the surface 2U around the part 33 Characterized in that it comprises a convex portion 32 to be set.

  According to the foam molded body 1 having such a configuration, since the convex portion 32 protruding from the one surface 2U is formed around the trace portion 33, the sheet S is overlapped on the one surface 2U of the foam molded body 1. When aligning, the convex portion 32 is compressed and deformed to the one surface side by the force for superimposing the sheet S on the one surface 2U, and the portion of the sheet S that overlaps the convex portion 32 and the trace portion 33 with respect to the other portion. Thus, the sheet S can be leveled without unevenness, and the sheet S can be smoothly overlapped along the entire surface 2U. Therefore, in this foaming molding 1, it can suppress that a dent arises in the external appearance of the foaming molding 1 which piled up the sheet | seat S, and can improve quality.

  Moreover, in the foaming molding 1 which concerns on this embodiment, the said trace part 33 is the recessed part 33 dented toward the said one surface side from the height direction edge part side of the said convex part 32, and the said convex from the said one surface 2U. The distance H1 from the one surface 2U to the bottom surface 33A of the trace portion 33 in the height direction is substantially equal to the distance H2 from the one surface 2U to the bottom surface 33A of the trace portion 33 or from the one surface 2U to the trace portion. It is also possible to configure it to be larger than the distance H2 to the bottom surface 33A of 33.

  According to the foam molded body 1 having such a configuration, the distance H1 from the one surface 2U to the height direction end portion 32A of the convex portion 32 is from the one surface 2U to the bottom surface 33A of the trace portion 33 in the height direction. The distance S2 is substantially equal to or larger than the distance H2 from the one surface 2U to the bottom surface 33A of the trace portion 33. Therefore, when the sheet S is overlapped with the one surface 2U of the foam molded body 1, the sheet S The convex portion 32 can be reliably compressed and deformed to the one surface side by the force for superimposing the two on one surface 2U, and the portion of the sheet S that overlaps the convex portion 32 and the trace portion 33 with respect to the other portion The sheets S are leveled without unevenness, and the sheets S can be smoothly overlapped along one surface. Therefore, in this foam molded object 1, it can suppress that a dent arises in the external appearance of the foam molded object 1 which piled up the sheet | seat S, and can improve quality.

  Moreover, in the foaming molding 1 which concerns on this embodiment, the said convex part 32 can also be comprised so that it may be provided over the perimeter of the circumference | surroundings of the said trace part 33. FIG.

  According to the foam molded body 1 having such a configuration, since the convex portion 32 is provided over the entire circumference around the trace portion 33, the sheet S is overlapped on the one surface 2U of the foam molded body 1. At this time, the convex portion 32 is uniformly compressed and deformed to the one surface side by the force for superimposing the sheet S on the one surface 2U, and the portion of the sheet S overlapping the convex portion 32 and the trace portion 33 is changed to another portion. On the other hand, the sheet S can be evenly distributed without unevenness, and the sheets S can be smoothly overlapped along the surface 2U. Therefore, in this foaming molding 1, it can suppress that a dent arises in the external appearance of the foaming molding 1 which piled up the sheet | seat S, and can improve quality.

  In addition, this invention is not limited to the said embodiment, A various change is possible in the range which does not deviate from the summary of this invention.

  In the said embodiment, although the foaming molding 1 demonstrated the case where it was used as a core material of the trunk lid in a passenger car (automobile), the foaming molding 1 is a core material in floor boards, such as a veranda, and a core material in a food container. It is also possible to use a sheet made of polypropylene resin or the like so as to be superposed on at least one surface (a surface having a planar shape or a curved surface shape).

  Moreover, in the said embodiment, the trace part 33 of the foaming molding 1 is formed in the said surface 2U by the one end part 11a of the filling means 11 and the one end part 12a of the mold release means 12 in the case of shaping | molding by the said shaping | molding apparatus. Although the case has been described, the trace portion 33 is at least one of the one end portion 11a of the filling means 11 and the one end portion 12a of the mold release means 12 during molding by the molding apparatus, and is one end portion of the filling means 11. It may be formed on the one surface 2U only by 11a or only by one end portion 12a of the release means 12.

  Moreover, although the said embodiment demonstrated the case where the convex part 32 of the foaming molding 1 was provided over the perimeter of the recessed part 33, the convex part 32 is a predetermined space | interval (for example, around the recessed part 33). It is also possible to provide a plurality at a regular interval. Further, the convex portion 32 can be provided only in a part around the concave portion 33. For example, the convex portion 32 can be provided over a length of half of the entire circumference around the concave portion 33, 1/3 of the entire circumference, or 1/4 of the entire circumference.

  DESCRIPTION OF SYMBOLS 1 ... Foam molded object, 2 ... Main part, 2U ... One surface of main part, 2L ... Other side of main part, 3 ... Projection body, 4 ... Back groove part, 5 ... Notch part, 10 ... Mold, 11 ... Filling Means, 11a: One end of filling means, 12: Mold releasing means, 12a: One end of mold releasing means, 13: Fixed mold, 13A: First molding section, 14: Moving mold, 14A: Second molding section, 17 , 18 ... through holes, 17a, 18a ... large holes, 31 ... columnar parts, 32 ... convex parts, 33 ... concave parts (trace parts), F ... molding spaces, H1, H2 ... distance, S ... sheets, V ... vents

Claims (2)

A mold that can be opened and closed, a cylindrical filling means for filling foaming resin particles in a molding space formed by closing the mold, and a foam molded body foam-molded in the molding space. And a rod-shaped release means for releasing from the mold, and one end of the filling means and one end of the release means are provided facing the molding surface of the mold forming the molding space It is a foam molded article formed by foam molding using an apparatus,
A flat or curved surface on which sheets can be superimposed;
A trace formed on the one surface by at least one of one end of the filling unit and one end of the mold release unit during molding by the molding apparatus;
And a convex portion protruding from the one surface around the trace portion ,
The trace portion is a concave portion recessed from the height direction end portion side of the convex portion toward the one surface side,
The distance from the one surface to the end of the convex portion in the height direction is substantially equal to the distance from the one surface to the bottom surface of the trace portion in the height direction, or from the one surface to the bottom surface of the trace portion. A foam-molded article characterized by being larger than the distance . The convex portion is foamed molding of claim 1 Symbol mounting, characterized in that provided over the entire circumference around the trace portion.

Images