JP6651251B2 - Method for producing foamed resin molded article, and foamed resin molded article - Google Patents

Description

  The present invention relates to a method for manufacturing a foamed resin molded article incorporating a foamed resin material, a rod-shaped member made of a material different from the foamed resin material, and a foamed resin molded article.

Conventionally, there has been a case where a foamed resin molded body is formed by incorporating a foamed resin material and a member made of a material different from the foamed resin material.
For example, when forming a sheet core with a foamed resin molded body, a rod-shaped member made of a material different from the foamed resin material, such as metal, is embedded in a molded body made of foamed resin in order to maintain the shape of the core. May be.
However, since the molded body made of foamed resin and the above-mentioned metal rod-shaped member have different heat shrinkage rates, the molded body shrinks more than the metal rod-shaped member when contracted after in-mold molding. When the molded body of the foamed resin shrinks more than the rod-shaped member in this way, the contraction force of the molded body acts on the rod-shaped member, giving stress to the rod-shaped member.

  This stress deforms the annular shape of the rod-shaped member, and eventually the shape of the foamed resin molded article. As a foamed resin molded article in which a rod-shaped member is incorporated in a foamed main body, for example, a foamed resin molded article described in Patent Document 1 has been known for a long time.

JP-A-2011-36275

This conventional foamed resin molded article relates to a sheet core material of an automobile, in which a part of an annular rod-shaped member is embedded in a molded body made of foamed resin, and most of the other parts are exposed on one side of the molded body. I have. In other words, this exposed portion is not structured to be pressed from both sides.
Therefore, as shown in FIG. 8 of Patent Document 1, when most of the metal rod-shaped members are exposed on one side of the molded body, when some impact is applied, the rod-shaped members are easily placed on the exposed side. And the rod-shaped member and the molded body may be separated from each other. If the rod-shaped member of the foamed resin molded body constituting the seat core material is partially separated from the molded body, the seat fixed to the vehicle will rattle.

On the other hand, if it is attempted to embed the entire rod-shaped member in the molded body of the foamed resin so as not to separate the rod-shaped member and the molded body, the rod-shaped member may be deformed by the shrinkage force of the molded body as described above. Therefore, it is conceivable to form a gap around the embedded rod-shaped member to suppress the action of the contraction force of the molded body.
However, when trying to obtain a foamed resin molded body having a gap around the rod-shaped member in the mold while embedding the entire rod-shaped member in the molding body, the molded body and the rod-shaped member are easily separated from each other, It was difficult to maintain the integration of the molded body and the rod-shaped member.
Further, when the rod-shaped member is embedded in the molded body after in-mold molding and curing of the foamed resin material, it is possible to prevent the rod-shaped member from being deformed due to the contraction force of the molded body. In such a case, a rod-shaped member has to be inserted into the device, which complicates the process. Furthermore, it is difficult to maintain the integration of the molded body and the rod-shaped member even when the rod-shaped member is later inserted into the molded body.

An object of the present invention is to maintain the integration of a molded body and a rod-shaped member while providing a gap around the rod-shaped member incorporated in the molded body to suppress the contraction force of the molded body acting on the rod-shaped member. It is an object of the present invention to provide a production method capable of easily forming a foamed resin molded article that can be easily formed.
Another object is to provide a foamed resin molded article in which a rod-shaped member of a different material is incorporated in a molded body, and which can prevent warping or distortion due to shrinkage of the molded body. is there.

The first invention is a method for manufacturing a foamed resin molded article in which a foamed resin material and a rod-shaped member made of a material different from the foamed resin material are integrally assembled, and the molds can be opened in opposite directions. Using a pair of molds, one mold has a pair of first protrusions protruding toward the other mold, and the other mold has a second protrusion protruding toward the one mold. A groove is formed at each of the tips of the first and second protrusions, and the groove width of the groove corresponds to the width of the rod-shaped member held by the groove. In the process of holding the rod-shaped member in the concave groove of one of the first convex portion and the second convex portion and clamping the pair of molds, the second convex portion is provided between the pair of first convex portions. Part, and the space defined by all the grooves described above is made continuous. Positioning the shaped member, filling the foamed resin material into the mold clamped mold, after molding the foamed resin material in the mold, form a pair of molds to form a molded body, in the mold opening process, In the molded body, a first concave portion and a second concave portion are formed in the traces of the first convex portion and the second convex portion, and at least a side surface of the first concave portion and a side surface of the second concave portion and the rod-shaped member are formed. A feature is to form a gap between them.
In the first invention, a gap is formed at least between the side surface of the first concave portion and the side surface of the second concave portion and the rod-shaped member. That is, in the first invention, a gap may be formed only between the side surface of the first concave portion and the side surface of the second concave portion and the rod-shaped member, and the side surface of the first concave portion, the side surface of the second concave portion, A gap may be formed between the bottom surface of the first recess or the bottom surface of the second recess and the rod-shaped member 1.

  A second invention is a foamed resin molded article in which a foamed resin material and a rod-shaped member made of a material different from the foamed resin material are integrally assembled, and a pair of first concave portions opened on one surface side. And a second recess located on the other surface side of the molded body, located on the opposite side via the rod-shaped member, and located between the pair of first recesses, and a space defined by the first recess and a second recess. Is continuous in the axial direction of the rod-shaped member, and the space formed by the continuous first concave portion and the space formed by the second concave portion are penetrated by the rod-shaped member. (2) A gap is provided between the side surface of the concave portion and the rod-shaped member.

According to the manufacturing method of the first invention, the rod-shaped member of a different material penetrating the molded body of the foamed resin can be formed by simply filling the foamed resin material into the inside of the mold clamped and holding the rod-shaped member and molding in the mold. A foamed resin molded body having a gap can be formed around the member.
The foamed resin molded article formed by this manufacturing method can suppress the shrinkage force of the molding body acting on the rod-shaped member by the gap, and the surface of the rod-shaped member is alternately exposed in the opposite direction, Since it is surrounded by the bottom surfaces of the first concave portion and the second concave portion, integration of the rod-shaped member and the molded body can be maintained.

According to the second aspect of the present invention, since the opening of the concave portion forming the gap is formed on the surface in the opposite direction of the molded body with the rod-shaped member interposed therebetween, the surface of the rod-shaped member is alternately exposed in the opposite direction. In other words, the first concave portion and the second concave portion alternately pinch the rod-shaped member, thereby preventing the molded body of the foamed resin from being separated from the rod-shaped member.
In addition, a gap is formed between the side surfaces of the first and second recesses and the rod-shaped member, and the gap can suppress the contraction force of the molded body acting on the rod-shaped member.

  Furthermore, when a gap is provided only between the side surface of the first concave portion and the side surface of the second concave portion and the rod-shaped member, the rod-shaped member is sandwiched by the bottom surfaces of the first concave portion and the second concave portion, and is formed more. It is difficult to separate from the main body. On the other hand, in the case where a gap is provided between the bottom surface of the first concave portion or the second concave portion and the rod-shaped member, all directions acting on the rod-shaped member while preventing separation of the molded body and the rod-shaped member are prevented. Of the molded body is suppressed.

It is a perspective view of a 1st embodiment of this invention. FIG. 2 is a sectional view taken along line II-II of FIG. 1. FIG. 3 is a sectional view taken along line III-III of FIG. 1. It is a perspective view of one type | mold of 1st Embodiment. It is a perspective view of the other type | mold of 1st Embodiment. FIG. 10 is an end view when a rod-shaped member is incorporated in one mold of the second embodiment.

A first embodiment of the present invention will be described with reference to FIGS.
1 to 3 show a part of a foamed resin molded article of the present invention in which a rod-shaped member 1 is incorporated into a molded body 2 of foamed resin. FIGS. 4 and 5 show the production of the foamed resin molded article of the first embodiment. Shows the type for
The molded body 2 is formed by molding a foamed resin material in a mold. The rod-shaped member 1 is, for example, a metal member having a smaller shrinkage ratio than the molded body 2.

1 to 3 show a state immediately after the molding of the molding body 2 in the mold, and the molding body 2 contracts from this state.
Further, FIG. 1 shows a portion in which the shrinking force of the molding body 2 acts on the rod-shaped member 1 in the foamed resin molded article into which the rod-shaped member 1 is incorporated. It is assumed that it is connected to and fixed to another member at a location not shown.

As shown in FIG. 1, the molding body 2 has a pair of first concave portions 3 and 4 opened at one surface 2a sandwiching the rod-shaped member 1 with an interval therebetween, and the other surface 2b has The second recess 5 located between the first recesses 3 and 4 is opened.
In the first embodiment, as shown in FIG. 2, the pair of first concave portions 3 and 4 and the second concave portion 5 have a width, that is, an interval between opposing side surfaces 3 a and 3 b, a side surface 4 a, The intervals of 4b and the intervals of the side surfaces 5a and 5b are all equal, and these intervals are larger than the width of the rod-shaped member 1.

The pair of first recesses 3 and 4 have the same depth, and the bottom surfaces 3c and 4c have the same distance from the one surface 2a (see FIGS. 2 and 3).
On the other hand, the second recess 5 has a depth such that the bottom surface 5c is located closer to one surface 2a than the bottom surfaces 3c and 4c of the first recesses 3 and 4. The vertical distance between the bottom surface 5c and the bottom surface 3c in FIG. 1 is substantially equal to the vertical dimension of the rod-shaped member.
The first concave portion 3, the second concave portion 5, and the first concave portion 4 form a continuous space, and the rod-shaped member 1 penetrates the space.

Since the space through which the rod-shaped member 1 penetrates is larger than the width of the rod-shaped member 1, gaps S1 and S1 are held on both left and right sides of the rod-shaped member 1 in FIG.
In addition, since the vertical distance between the bottom surfaces 3c, 4c of the first concave portions 3, 4 and the bottom surface 5c of the second concave portion 5 corresponds to the vertical dimension of the rod-shaped member 1, the upper and lower sides of the bottom rod-shaped member 1 As shown in FIGS. 2 and 3, the bottom surface 3 c of the first concave portion 3, the bottom surface 5 c of the second concave portion 5, and the bottom surface 4 c of the first concave portion 4 alternately contact with each other from the opposite direction along the axis of the rod-shaped member 1. These bottom surfaces sandwich the rod-shaped member 1.
As described above, since the rod-shaped member 1 incorporated in the molding body 2 is sandwiched from the vertical direction in FIGS. 1 and 2, the rod-shaped member 1 does not separate from the molding body 2.

  Further, since the gaps S1 and S1 are formed between the rod-shaped member 1 and the side surface in the first concave portions 3 and 4 and the second concave portion 5, the molded body 2 contracts in the direction of the arrow x in FIG. In this case, the molding body 2 and the rod-shaped member 1 relatively move within the range of the gap S1, and the contraction force acting on the rod-shaped member 1 is suppressed by absorbing the displacement caused by the contraction. For this reason, it is possible to prevent the rod-shaped member 1 from being deformed due to the contraction of the molding main body 2 and distorting the foamed resin molded body.

Next, a manufacturing method for forming the foamed resin molded article by in-mold molding will be described.
FIGS. 4 and 5 show a part of a pair of molds used in the manufacturing method of the first embodiment. The mold is clamped so that one mold 6 shown in FIG. 4 is covered with the other mold 7 in FIG. .
The one mold 6 includes a rectangular bottom plate 8 and a pair of first protrusions 9 and 10 formed on the bottom plate 8 at both ends in the longitudinal direction. Then, the width W1 and the length L1 of each of the first protrusions 9 and 10 are made to correspond to the interval and the length of the side surfaces of the first recesses 3 and 4 formed in the molded body 2 in FIG.
Further, at the tips of the first convex portions 9 and 10, concave grooves 9a and 10a each having a U-shaped cross section are formed, and the groove widths and depths of these concave grooves 9a and 10a are made to correspond to the rod-shaped member 1. I have.

On the other hand, the other mold 7 shown in FIG. 5 is a member having a hollow shape in which the inner side matches the outer shape of the molding main body 2 and a lower bottom surface is opened. At the time of mold clamping, the released bottom surface is closed by the bottom plate 8 of the one mold 6.
FIG. 5 shows a state in which, out of the four side surfaces constituting the other mold 7, the side surface facing the side surface 7b parallel to the axis of the rod-shaped member 1 is cut out.

  A second convex portion 11 is formed inside the upper bottom surface 7a of the other mold 7 so as to project downward, that is, toward the one mold 6 at the time of mold clamping. A concave groove 11a is formed at the tip of 11. The second convex portion 11 has a position and a length L2 that coincide between the first convex portions 9a and 10a of the one mold 6 at the time of mold clamping, and forms a width W2 and a length L2 on the molded body 2. The width and the length of the second concave portion 5 are matched with each other.

  Further, cutouts 7e and 7f are formed in a pair of side surfaces 7c and 7d orthogonal to the side surface 7b, respectively. The opening widths of the notches 7e and 7f correspond to the width of the rod-shaped member 1, and the vertical positions of the upper ends 7g and 7h of the openings are adjusted to the bottom surface 11b of the groove 11a formed in the second convex portion 11, and The positions correspond to the positions of the tip surfaces 9b and 10b of the first protrusions 9 and 10 in the one mold 6 described above.

The procedure for forming the foamed resin molded article of FIG. 1 using the pair of dies 6 and 7 as described above is as follows.
First, one mold 6 is installed, and the bar-shaped member 1 is held in the concave grooves 9a, 10a of the first convex portions 9, 10 as shown by a two-dot chain line in FIG.
Next, the other mold 7 is covered and clamped. At this time, the opening on the bottom surface of the other mold 7 is closed by the bottom plate 8 of the one mold 6.
The bar-shaped member 1 protrudes from the notches 7 e and 7 f of the other mold 7, and the openings of the notches 7 e and 7 f other than the protruding portion of the bar-shaped member 1 are formed by the first mold 6. The projections 9 and 10 are closed by end faces.

The rod-shaped member 1 held by the concave grooves 9a, 10a of the first convex portions 9, 10 is also held by the concave groove 11a of the second convex portion 11 between the first convex portions 9, 10.
In this state, the molding space (cavity) between the pair of dies 6 and 7 is filled with a foamed resin material from an injection hole (not shown), heated and molded in the dies, and then the dies 6 and 7 are moved vertically. And open the mold.
In the process of opening the mold, spaces are formed in the traces of the first convex portions 9 and 10 and the second convex portions 11, and each of the formed spaces corresponds to the first concave portions 3 and 4 and FIG. The second recess 5 is formed. At this time, the first concave portions 3 and 4 and the second concave portion 5 are formed so that all the spaces are continuous.

Specifically, the bottom surfaces 3c, 4c of the first concave portions 3, 4 are formed by the tip surfaces 9b, 10b of the first convex portions 9, 10 of the one mold 6 and the rod-shaped member 1 held in the concave grooves 9, 10. Are formed, and the bottom surface 5c of the second concave portion 5 is formed by the tip end surface 11c of the second convex portion 11 of the other mold 7 and the rod-shaped member 1 held in the concave groove 11a. The gaps S1 and S1 are formed on both sides of the rod-shaped member 1, and the dimensions of the gaps S1 and S1 are the same as those of the concave grooves 9a, 10a, and 11a of the first and second projections 9, 10, and 11, respectively. This corresponds to the thickness d1, d2 of the side wall.
The thickness d1, d2 of the side wall is appropriately changed depending on the size of the foamed resin molded article, the diameter of the rod-shaped member, and the like, but is preferably 1 to 30 mm, more preferably 2 to 20 mm, and still more preferably 3 to 15 mm.

In the first embodiment, the width W1 of the first protrusions 9 and 10 and the width W2 of the second protrusion 11 are equal, and the thickness d1 and d2 of the side wall are equal. Need not necessarily be equal.
If the width W1 of the first protrusions 9 and 10 and the width W2 of the second protrusion 11 are different, the widths of the first recesses 3 and 4 formed in the molded body 2 and the width of the second recess 5 become larger. Differently, the sizes of the gaps S1 formed in the respective concave portions are not the same, but the sizes of the gaps S1 are not necessarily all uniform as long as the size can absorb the shrinkage of the molded body. Further, the groove depths of the concave grooves 9a and 10a of the first convex portions 9 and 10 are not necessarily all constant. Further, the size of the gap S1 formed in the pair of first concave portions 3 and 4 may be different, and the sizes of the gaps S1 and S1 on both sides of the bar-shaped member 1 may be different.

The size of the gap S1 may be set according to the expected amount of shrinkage and the direction of shrinkage of the molded body 2.
Further, in the traces of the first convex portions 9, 10 and the second convex portion 11, the spaces to be the first concave portions 3, 4 and the second concave portion 5 in FIG. 1 are all formed so as to be continuous. When the foamed resin material is filled and molded in the mold, the opposing surfaces of the first convex portions 9 and 10 and the second convex portion 11 are preferably in contact with each other. There may be an interval between the opposing surfaces of the first and second protrusions 11 as long as the foamed resin material does not enter.

Further, it is preferable that the lengths L1, L1, L2 of the first convex portions 9, 10 and the second convex portion 11 formed on the pair of dies 6, 7 are all equal. If the lengths L1, L1, and L2 of the first protrusions 9, 10, and the second protrusions 11 are all equal, the length of the portion that alternately presses the bar-shaped member 1 becomes equal, so that good balance can be expected. .
As described above, in the first embodiment, the gap S1 for absorbing the shrinkage of the molded body 2 is formed in the first, second concave portions 3, 4, and 5 opened on the outer surface of the molded body 2. Therefore, the gap S1 can be molded in the mold at the same time as the molding body 2.

  The foamed resin material for forming the molded body 2 can be appropriately selected, but is preferably a thermoplastic resin, for example, a polyolefin-based resin such as polyethylene and polypropylene, a polystyrene-based resin, and a polylactic acid-based resin. A polyester resin, a polycarbonate resin, or the like can be used. These resins may be used alone, or a mixture of two or more resins may be used.

Among these resins, it is more preferable to use a polyolefin-based resin or a composite resin of a polyolefin-based resin and a polystyrene-based resin from the viewpoint of strength and impact resistance. Further, as the polyolefin resin, a polypropylene resin or a polyethylene resin is preferable. When a polyolefin-based resin is used, it is easy to form the molded body 2 having a specific compression elasticity. Examples of the polypropylene-based resin include polypropylene, a copolymer of propylene and another comonomer, or a mixture thereof. Examples of the copolymer of propylene and another comonomer include a propylene-ethylene copolymer and a propylene-ethylene-butene copolymer.
The shape of the foamed resin material may be a column, a sphere, a prism, an oval sphere, a cylinder, or the like. In addition, it is preferable that the foamed resin material is made of foamed particles from the viewpoint of filling properties into the mold. When the foamed resin material is made of foamed particles, the foamed resin material has a foamed particle shape substantially corresponding to the resin shape before foaming.

  The foamed resin material can be manufactured by a conventionally known method. For example, if necessary, a surfactant is added to a required amount of a dispersion medium (usually water) in a pressurized closed container such as an autoclave to disperse the resin material, and a foaming agent is pressed in and stirred under heating. The resin material impregnated with the foaming agent is impregnated into the resin material, and after a predetermined time, the resin material impregnated with the foaming agent is discharged together with the dispersing medium from a container under a high-temperature and high-pressure condition into a low-pressure region (usually under atmospheric pressure) to form It is manufactured by a method of obtaining a foamed resin material.

After filling the foamed resin material previously foamed in a mold having a second convex portion between the rod-shaped member 1 and the pair of first convex portions, which can be opened, heated steam is introduced. In this way, if the in-mold molding is performed, the foamed particles are secondary foamed, and the surface of the foamed resin material is melted and integrated, so that a foamed resin molded article can be obtained.
Also, at this time, the rod-shaped member 1 and the foamed resin material are fused and integrated by disposing the rod-shaped member 1 at a predetermined position in the mold and performing in-mold molding, and the foamed material in which the rod-shaped member 1 is embedded is formed. The resin molding is obtained as an integral molding.

  Further, in the first embodiment, the rod-shaped member 1 having a rectangular cross section is incorporated, but the rod-shaped member 1 may have another shape such as a circular shape or a polygonal shape. However, if the cross-sectional shape of the rod-shaped member 1 and the concave groove holding the rod-shaped member 1 are different and a gap is formed on the side surface of the rod-shaped member 1, the foamed resin material enters the side surface of the rod-shaped member 1 from the opening of the groove. As a result, there is a possibility that the entered resin may hinder the relative movement of the rod-shaped member 1. Therefore, it is necessary to design so that the size of the gap into which the foamed resin material enters does not become too large. In addition, from the viewpoint of achieving both the lightness of the foamed resin molded article and the rigidity of the rod-shaped member 1, the diameter of the rod-shaped member 1 is preferably 1 to 30 mm, and more preferably 2 to 25 mm.

The second embodiment shown in FIG. 6 is an embodiment in which the openings of the concave grooves 9a and 10a of one mold 6 shown in FIG. Other configurations are the same as those of the first embodiment.
The same components as those in the first embodiment are denoted by the same reference numerals as those in the first embodiment, and the following description also refers to FIGS.
FIG. 6 is an end view of a state in which the bar-shaped member 1 is held by the one mold 6 of the second embodiment as viewed from the first convex portion 9 side.

The procedure for manufacturing the foamed resin molded article of the second embodiment will be described.
The rod-shaped member 1 is held in the concave grooves 9a and 10a of the first convex portions 9 and 10 of one mold 6.
The lid member 12 is placed on the upper portions of the concave grooves 9a and 10a.
Furthermore, the other mold 7 is clamped so as to cover the one mold 6.

Next, the inside of the molds 6 and 7 is filled with a foamed resin material, and heated to perform in-mold molding. Thereafter, the pair of dies 6 and 7 are opened to remove the lid member 12.
In the process of opening the mold, spaces formed in the traces of the first convex portions 9 and 10 and the second convex portion 11 correspond to the first concave portions 3 and 4 and the second concave portion 5 in FIG.
However, in the second embodiment, the upper surface 12a of the lid member 12 shown in FIG. 6 forms the bottom surfaces 3c, 4c of the first concave portions 3, 4 formed in the molded body 2.

Therefore, between the rod-shaped member 1 incorporated in the molding body 2 and the bottom surfaces 3c, 4c of the first concave portions 3, 4, a gap (not shown) corresponding to the thickness h of the lid member 12 shown in FIG. S2 is formed.
Further, since the upper part of the rod-shaped member 1 is originally released in the second concave part 5, the second concave part 5 does not hinder the movement of the rod-shaped member 1 in the y direction (see FIG. 6).
Therefore, the rod-shaped member 1 can move relative to the forming body 2 in the y direction in FIG. 6, that is, in the vertical direction, within the range of the gap S2. The size of the gap S2 can be adjusted by the thickness h of the lid member 12.

Moreover, the thickness d1, d2 of the side wall of the concave grooves 9a, 10a, 11a of the first convex portions 9, 10 and the second convex portion 11 is formed on both left and right sides of the rod-shaped member 1 similarly to the first embodiment. A minute gap S1 is formed.
Accordingly, in the foamed resin molded article formed by the manufacturing method of the second embodiment, the rod-shaped member 1 can be relatively moved with respect to the molded body 2 in both the x direction and the y direction in FIG. Therefore, the shrinkage of the molding body 2 in all directions after the in-mold molding is absorbed in the range of the gaps S1 and S2, and the deformation of the rod-shaped member 1 and the distortion of the foamed resin molded article can be prevented.
Also in the second embodiment, since the rod-shaped member is surrounded by the side surfaces and the bottom surfaces of the first concave portions 3 and 4 and the second concave portion 5 located in opposite directions, the rod-shaped member 1 separates from the molded body 2 or Large rattling can be prevented.

  Note that a material for forming the lid member 12 can be appropriately selected as long as it can withstand heating during in-mold molding. For example, a metal material made of iron, aluminum, copper, or the like, a resin material made of engineering plastic, glass fiber reinforced resin, or the like can be given. Among these, metal materials are preferred from the viewpoint of strength and the like. The thickness of the lid member is appropriately set according to the diameter of the rod-shaped member 1 and the like, and for example, a thickness of about 2 to 20 mm can be used.

Further, the outer shape of the molded body 2 of the first and second embodiments can be freely set by the inner shapes of the pair of dies 6 and 7.
Further, any number of gaps for suppressing the contraction force on the rod-shaped member 1 can be formed along the rod-shaped member 1. For example, when the rod-shaped member 1 has a loop shape, it is formed along the loop. You can also.
In any case, if the rod-shaped members 1 are alternately sandwiched by the bottom surfaces of a plurality of continuous concave portions, the molding is performed without a post-process, while maintaining a gap for suppressing a contraction force acting on the rod-shaped members. The integrity of the main body 2 and the rod-shaped member 1 can also be maintained.

Furthermore, in the first and second embodiments, the one mold 6 is covered with the other mold 7 from above. However, if the mold clamping and opening directions of the pair of molds are opposite, It is not limited to the upper and lower sides, and the positional relationship is not limited.
However, when the lid member 12 for closing the concave groove is used as in the second embodiment, if the mold on which the lid member 12 is provided is positioned below, the lid member 12 can be connected to the first convex portion and the second convex portion. Since it is sufficient to simply place it on the convex part, it is preferable because the configuration of the mold can be simplified. In addition, from the viewpoint of preventing the lid member 12 from being displaced or dropped, the contact surfaces of the lid member 12 and the first convex portion and the contact surfaces of the lid member 12 and the second convex portion are provided with shapes that can be fitted such as irregularities. Is preferred.

  In the first and second embodiments, a total of three convex portions are formed by the pair of the first convex portion and the second convex portion. However, in the present invention, the first convex portion and the second convex portion are provided. May be used. When using a mold having two or more first and second convex portions, the first and second convex portions are arranged so as to be alternately continuous, and the space formed by all the concave grooves is reduced. Set to be continuous.

  The present invention can be applied to various products that utilize the advantages of foamed resin while maintaining the shape and strength of a metal frame and the like, such as sun visors, seat backs, door trims, and other automotive applications, body boards, chairs, and the like. is there.

REFERENCE SIGNS LIST 1 bar-shaped member 2 molded body 3 first concave portion 4 first concave portion 5 second concave portion 6 one mold 7 the other mold 9 first convex portion 9a concave groove 10 first convex portion 10a concave groove 11 second convex portion 11a concave groove 12 Cover member S1, S2 Clearance

Claims (2)

A foamed resin material, the foamed resin material is a method of manufacturing a foamed resin molded body integrally incorporating a rod-shaped member of a different material,
Using a pair of molds that can be opened in opposite directions,
One of the molds has a pair of first protrusions protruding toward the other mold,
The other mold has a second protrusion protruding toward the one mold,
A concave groove is formed at the tip of each of the first convex portion and the second convex portion.
The groove width of the groove corresponds to the width of the rod-shaped member to be held in the groove,
Causing the rod-shaped member to be held in one of the concave grooves of the first convex portion or the second convex portion,
In the process of clamping the pair of molds, a second convex portion is inserted between the pair of first convex portions to make the space formed by all the concave grooves continuous, and the rod-shaped space is formed by the continuous concave grooves. Position the member,
Fill the closed mold with foamed resin material,
After the in-mold molding of the foamed resin material, the pair of molds is opened to form a molded body,
In the mold opening process, in the molded body, the first concave portion and the second concave portion are formed in the traces of the first convex portion and the second convex portion,
A method for producing a foamed resin molded article, wherein a gap is formed between at least the side surface of the first concave portion and the side surface of the second concave portion and the rod-shaped member. A foamed resin material, the foamed resin material is a foamed resin molded body integrally incorporating a rod-shaped member of a different material,
A pair of first recesses opening on one surface side and a second recess opening on the other surface side of the molded body and located between the pair of first recesses, which are located on the opposite side via a rod-shaped member. The space defined by the first recess and the space defined by the second recess are continuous in the axial direction of the rod-shaped member, and the space defined by the continuous first recess and the space defined by the second recess are penetrated by the rod-shaped member. A foamed resin molded article, wherein at least a gap is provided between the side surface of the first concave portion and the side surface of the second concave portion and the rod-shaped member.

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