JP6721344B2 - Mold for molding and method for producing resin molded product using the same - Google Patents

Description

The present invention relates to a molding die and a method for producing a resin molded article using the same, and more particularly to a molding die used in a pressure molding method and a method for producing a resin molded article using the same.

As a method of molding a resin molded product into a predetermined shape, there are various molding methods such as a press molding method and a pressure molding method. Among them, the pressure molding method has an advantage that a complicated 3D shape can be produced as compared with the press molding method. Such a pressure forming method is described in Patent Document 1, for example.

Generally, in film insert molding, first, a resin plate material is shaped into a three-dimensional shape using a molding die, and the shaped resin plate material is set in an injection molding die, and the resin is molded. Appearance design parts are manufactured by hitting resin on the back of a plate.

The pressure molding method described in Patent Document 1 will be described with reference to the sectional view shown in FIG. With reference to this drawing, a pressure molding die 100 used in a pressure molding method includes a table 101 for supporting the whole, an inner layer 102 and a surface layer 104 arranged on the inner bottom surface of the table 101, and an upper surface of the table 101. It mainly has a pressure box 103 that closes from. The internal space surrounded by the table 101 and the pressure box 103 is sealed. Further, a ventilation circuit 106 is formed that penetrates the inner layer 102 and the table 101 and connects the inner space and the outside. The pressure box 103 has a pressure port 107 through which the gas supplied to the internal space passes.

In order to mold the resin sheet 105 by the pressure molding method using the pressure molding die 100 having the above-described configuration, first, the resin sheet 105 is placed so as to be sandwiched between the table 101 and the pressure box 103. Next, the pressure box 103 and the table 101 are fitted to close the internal space, and gas is injected from the pressure port 107 to raise the atmospheric pressure of the internal space. By doing so, the resin sheet 105 is molded into a predetermined shape following the outer shape of the surface layer 104.

Along with the above molding, the air present between the resin sheet 105 and the surface layer 104 is discharged to the outside via the ventilation circuit 106. Therefore, air does not stay between the surface layer 104 and the resin sheet 105, and the resin sheet 105 can be accurately molded along the surface shape of the surface layer 104.

JP, 2010-17908, A

However, when a molded product is manufactured using the above-mentioned pressure molding method, it may be difficult to mold the molded product into a predetermined shape while keeping the aesthetic appearance of the design surface depending on the shape of the molded product.

Such a problem will be described with reference to FIG. FIG. 10(A) is a cross-sectional view showing a convex mold 110 used for pressure molding, and FIG. 10(B) is a cross-sectional view showing a concave mold 120 used for pressure molding.

With reference to FIG. 10(A), the upper surface of the convex mold 110 is provided with a shaping surface 111 conforming to the shape of the product to be molded. When pressure molding is performed using the convex mold 110, a resin sheet is placed on the upper surface of the convex mold 110, and pressure is applied from above as described above. By doing so, a molded product 113 conforming to the shape of the shaping surface 111 is molded. When molding is performed using the convex mold 110, the design surface 112, which is the outer surface of the molded product 113, does not contact the shaping surface 111 of the convex mold 110. Therefore, since the design surface 112 of the molded product 113 does not contact the shaping surface 111 of the convex die 110, it is possible to avoid scratching the design surface 112 of the molded product 113.

When the groove 114 is formed in the molded product, the groove 115 having a corresponding shape is also formed in the convex mold 110. Further, at the time of molding, in order to let the air existing between the molded product 113 and the shaping surface 111 escape to the outside, the convex die 110 is formed with an air hole 116 connected from the shaping surface 111 to the outside. Has been done.

When the molded product 113 is molded by the pressure molding method using the convex die 110 described above, when the width of the groove 114 in the horizontal direction is narrow and the length in the vertical direction is long, the groove 115 corresponding to the shape is projected. In some cases, it may be difficult to form and shape the metal mold 110. In such a case, it is conceivable to perform shaping by a pressure molding method using a concave die.

With reference to FIG. 10B, when the molded product 123 is molded by the pressure molding method using the concave mold 120, the upright surface portion 125 having a shape corresponding to the groove portion 124 of the molded product 123 is formed. As a result, the groove portion 124 having a narrow width in the horizontal direction and a long length in the vertical direction can be formed by the pressure forming method.

However, when the concave die 120 is used, the shaping surface 121 comes into contact with the design surface 122 of the molded product 123. Therefore, when air holes 126 are generated in the concave mold 120 in order to allow the air existing between the molded product 123 and the shaping surface 121 to escape to the outside during molding, when the air holes 126 are formed in the design surface 122 of the molded product 123. There is a possibility that traces may remain and the appearance of the design surface of the molded product 123 may deteriorate.

The present invention has been made in view of such problems, and an object of the present invention is to provide a molding die capable of molding a molded article having a groove shape by a pressure molding method and a resin molded article using the same. It is to provide a manufacturing method.

The present invention is a molding die used in a compressed air molding method for molding the resin plate material into a predetermined product shape by applying pressure to the resin plate material, and a concave surface for shaping the resin plate material into the product shape. A shaped part formed with the shaped part, and an upright part obtained by projecting a part of the shaped part into a wall shape so as to have a shape corresponding to the groove part forming the product shape. Extending the surface portion to the outer peripheral edge portion of the shaping portion , further formed outside the shaping portion, continuous with the upright portion, when the pressure is applied to the resin plate material, A gas lead-out portion through which a gas existing between the resin plate material and the shaping portion passes .

Further, the molding die of the present invention is characterized in that the gas lead-out portion is a continuous upright portion continuous with the upright portion.

Furthermore, the molding die of the present invention is characterized in that groove-shaped lead-out grooves are formed on both sides of the continuous upright portion.

Further, the molding die of the present invention is characterized in that the gas lead-out portion is a lead-out groove continuous with the upright portion.

The present invention is a molding die used in a compressed air molding method for molding the resin plate material into a predetermined product shape by applying pressure to the resin plate material, and a concave surface for shaping the resin plate material into the product shape. A shaped part formed with the shaped part, and an upright part obtained by projecting a part of the shaped part into a wall shape so as to have a shape corresponding to the groove part forming the product shape. It is characterized in that the surface portion extends to the outer peripheral edge portion of the shaped portion, and a gas passage portion through which gas passes in the thickness direction is provided on the upright portion .

Further, the molding die of the present invention is characterized in that the gas passage portion is a slit obtained by partially cutting out the upright portion.

Further, the molding die of the present invention is characterized in that the gas passage portion is a lateral hole penetrating the upright portion.

Further, the molding die of the present invention is characterized in that the gas passage portion is a porous body forming a part of the upright portion.

The present invention is a molding die used in a compressed air molding method for molding the resin plate material into a predetermined product shape by applying pressure to the resin plate material, and a concave surface for shaping the resin plate material into the product shape. A shaped part formed with the shaped part, and an upright part obtained by projecting a part of the shaped part into a wall shape so as to have a shape corresponding to the groove part forming the product shape. A surface portion extending to an outer peripheral edge portion of the shaping portion, further comprising a shaping die in which the shaping portion is formed; and an internal die in which the shaping die is housed, It is characterized in that a path through which air flowing along the upright portion is discharged is formed between the shaping mold and the inner mold .

According to the present invention, a molding die is arranged on one side of a resin plate material, and pressure is applied from the other side of the resin plate material so that the resin plate material has a predetermined product shape in accordance with the shape of the molding die. It is a method of manufacturing a resin molded product using a compressed air molding method for molding into a shaped part having a concave surface for forming the resin plate material into a product shape, and a shape corresponding to a groove part constituting the product shape As described above, a molding die is provided, which comprises: an elevating part in which a part of the shaping part is projected in a wall shape, and the elevating part extends to an outer peripheral edge part of the shaping part. And the step of placing the resin plate material on the upper surface of the molding die, and applying pressure to the resin plate material to shape the resin plate material along the shape of the shaping part. And a step of discharging the gas existing between the resin plate material and the shaping portion to the outside via the upright portion.

The present invention is a molding die used in a compressed air molding method for molding the resin plate material into a predetermined product shape by applying pressure to the resin plate material, and a concave surface for shaping the resin plate material into the product shape. A shaped part formed with the shaped part, and an upright part obtained by projecting a part of the shaped part into a wall shape so as to have a shape corresponding to the groove part forming the product shape. Extending the surface portion to the outer peripheral edge portion of the shaping portion , further formed outside the shaping portion, continuous with the upright portion, when the pressure is applied to the resin plate material, A gas lead-out portion through which a gas existing between the resin plate material and the shaping portion passes .

Therefore, when forming a product having a complicated shape by the pressure molding method, the gas existing between the resin plate material as the material and the shaping portion of the mold is released to the outside to facilitate the shaping of the resin plate material. I can do it. Specifically, in the case of a resin molded product in which multiple designs are made into one part, a deep groove may be formed between each design part, and such a molded product is subjected to air pressure molding using a female mold. When forming by the method, it is necessary to form an upright portion corresponding to the groove on the shaping portion of the mold. When such an upright surface portion is formed, it is not easy to let the gas existing between the resin plate material and the upright surface escape to the outside. I am present. Therefore, it is possible to escape the gas existing in the vicinity of the elevation portion to the outside along the elevation portion and form the resin plate material into a complicated product shape.

Furthermore, as described above, the film insert molding is a shaping step of shaping a resin plate material using a shaping die, and the shaped resin plate material is set in an injection die and resin is applied to the back surface thereof. Has a hitting injection process. Since the present invention is a concave mold similar to the injection mold used in the injection process, even if the resin plate material has a complicated 3D shape, it is easy to set the resin plate material in the injection mold in the injection process. And the molding quality is stable.

Further, the molding die of the present invention is characterized in that the gas lead-out portion is a continuous upright portion continuous with the upright portion. Therefore, the air that has flowed along the rising surface inside the shaping portion is guided further outward along the continuous rising portion, so that the effect of letting air out during shaping is further increased.

Furthermore, the molding die of the present invention is characterized in that groove-shaped lead-out grooves are formed on both sides of the continuous upright portion. Therefore, in addition to the continuous upright portion, the lead-out grooves formed on both sides of the continuous upright portion also act as paths for circulating air, so that the effect of letting air out during shaping is remarkable.

Further, the molding die of the present invention is characterized in that the gas lead-out portion is a lead-out groove continuous with the upright portion. Therefore, the air that has flowed along the vertical portion inside the shaping portion is guided further outward along the guide groove, so that the effect of letting the air escape to the outside during shaping is further increased.

The present invention is a molding die used in a compressed air molding method for molding the resin plate material into a predetermined product shape by applying pressure to the resin plate material, and a concave surface for shaping the resin plate material into the product shape. A shaped part formed with the shaped part, and an upright part obtained by projecting a part of the shaped part into a wall shape so as to have a shape corresponding to the groove part forming the product shape. It is characterized in that the surface portion extends to the outer peripheral edge portion of the shaped portion, and a gas passage portion through which gas passes in the thickness direction is provided on the upright portion . Therefore, air comes to escape in the thickness direction of the elevation portion, so that even in the case where the elevation portion has a complicated shape, the air near the elevation portion can escape to the outside.

Further, the molding die of the present invention is characterized in that the gas passage portion is a slit obtained by partially cutting out the upright portion. Therefore, the air escapes in the thickness direction of the upright portion via the slits, so that the air near the upright portion can be released to the outside.

Further, the molding die of the present invention is characterized in that the gas passage portion is a lateral hole penetrating the upright portion. Therefore, the air escapes in the thickness direction of the upright portion via the lateral holes, so that the air near the upright portion can be released to the outside.

Further, the molding die of the present invention is characterized in that the gas passage portion is a porous body forming a part of the upright portion. Therefore, since the air escapes in the thickness direction of the elevation portion via the porous body, the air near the elevation portion can be released to the outside.

The present invention is a molding die used in a compressed air molding method for molding the resin plate material into a predetermined product shape by applying pressure to the resin plate material, and a concave surface for shaping the resin plate material into the product shape. A shaped part formed with the shaped part, and an upright part obtained by projecting a part of the shaped part into a wall shape so as to have a shape corresponding to the groove part forming the product shape. Extending the surface portion to the outer peripheral edge portion of the shaping portion , further formed outside the shaping portion, continuous with the upright portion, when the pressure is applied to the resin plate material, A gas lead-out portion through which a gas existing between the resin plate material and the shaping portion passes . Therefore, it is possible to more efficiently exhaust the air that has the raised surface portion formed in the shaping mold and flows to the outside via the path formed as the gap between the molds.

According to the present invention, a molding die is arranged on one side of a resin plate material, and pressure is applied from the other side of the resin plate material so that the resin plate material has a predetermined product shape in accordance with the shape of the molding die. It is a method of manufacturing a resin molded product using a compressed air molding method for molding into a shaped part having a concave surface for forming the resin plate material into a product shape, and a shape corresponding to a groove part forming the product shape. As described above, a molding die is provided, which comprises: an elevating part in which a part of the shaping part is projected in a wall shape, and the elevating part extends to an outer peripheral edge part of the shaping part. And the step of placing the resin plate material on the upper surface of the molding die, and applying pressure to the resin plate material to shape the resin plate material along the shape of the shaping part. And a step of discharging the gas existing between the resin plate material and the shaping portion to the outside via the upright portion. Therefore, similar to the above, when forming a product having a complicated shape by the pressure forming method, the gas existing between the resin plate material as a material and the shaping part of the mold is released to the outside, and Can be easily shaped.

It is a figure which shows the resin mold manufactured by the metal mold|die for molding concerning embodiment of this invention, and the manufacturing method of the resin molded product using the same, (A) is a top view, (B) is a cross section. It is a perspective view. It is a figure which shows the shaping die concerning embodiment of this invention, (A) is a perspective view, (B) is a top view. It is a figure which shows the shaping die concerning embodiment of this invention, (A) is a top view which shows a gas lead-out part, (B) is a perspective view which shows another gas lead-out part. It is a figure which shows the metal mold|die for molding concerning embodiment of this invention, (A)-(C) is a perspective view which shows the specific example of the gas passage part formed in an upright part. It is a figure which shows the metal mold|die for molding concerning embodiment of this invention, (A) is a perspective view, (B) is a sectional perspective view, (C) is another sectional perspective view. It is sectional drawing which shows the metal mold|die for molding concerning embodiment of this invention. It is a figure which shows the manufacturing method of the resin molded product concerning embodiment of this invention, and (A) to (C) is sectional drawing which shows the process of shaping sequentially. It is a figure which shows the manufacturing method of the resin molded product concerning embodiment of this invention, (A) is a cross-sectional perspective view which shows the path|route where air is discharged|emitted via an air lead-out part, (B) is other. FIG. 6 is a cross-sectional perspective view showing a path through which air is discharged via the air outlet of FIG. It is sectional drawing which shows the air-pressure molding method of the resin plate material which concerns on background art. It is sectional drawing which shows the pressure molding method of the resin plate material which concerns on background art, (A) shows the case where a convex mold is used, (B) shows the case where a concave mold is used.

Hereinafter, a molding die according to the present embodiment and a method for manufacturing a resin molded product using the same will be described with reference to the drawings.

With reference to FIG. 1, the shape and the like of a resin mold 10 manufactured by the molding die of the present embodiment and a method of manufacturing a resin molded product using the same will be described. 1A is a plan view of the resin molded product 10 as viewed from its design surface, and FIG. 1B is a sectional perspective view taken along line BB of FIG. 1A.

With reference to FIG. 1(A), a resin molded product 10 is made of a plate-shaped resin molded by a pressure molding method described later, and is, for example, an interior part or an exterior part of a vehicle such as an automobile or a part of a home electric appliance. It is what constitutes.

Here, the pneumatic molding method of the present embodiment includes a pneumatic molding method in which molding is performed with an air pressure of less than 10 atm and an ultra-high pressure molding method in which molding is performed with an air pressure of 50 atm to 235 atm.

The resin molded product 10 is molded, for example, by performing multicolor printing on a flat resin sheet and then shaping it by a pressure molding method described later, in order to increase the sense of quality of the design surface, which is the outer surface, It is composed of multiple molded parts with different patterns. Specifically, the resin molded product 10 is composed of a first molded portion 11, a second molded portion 12, and a third molded portion 13. The 2nd shaping|molding part 12 is arrange|positioned between the 1st shaping|molding part 11 and the 3rd shaping|molding part 13, and is elongate along the X direction.

The first molding portion 11, the second molding portion 12, and the third molding portion 13 have different colors and patterns on their design surfaces. On the paper surface, the respective molding portions are shown by different hatching, but in reality, for example, the design surface of the first molding portion 11 is a wood grain, and the design surface of the second molding portion 12 is a metallic tone. The design surface of the third molding portion 13 has a checkered pattern.

Grooves are formed between the above-mentioned molded portions so that the boundary between the designs does not appear in the appearance. Specifically, the groove portion 15 is formed between the first molding portion 11 and the second molding portion 12. As a result, the boundary between the woodgrain design surface of the first molding portion 11 and the metallic design surface of the second molding portion 12 is arranged in the groove portion 15 and does not appear in the appearance of the product. Similarly, by forming the groove portion 16 between the second molding portion 12 and the third molding portion 13, the metallic design surface of the second molding portion 12 and the checkerboard design of the third molding portion 13 are formed. The boundary with the surface is hidden by the groove 16. Further, similarly, by forming the groove portion 17 between the first molding portion 11 and the third molding portion 13, the woodgrain design surface of the first molding portion 11 and the checkerboard pattern of the third molding portion 13 are formed. The boundary with the design surface of is hidden by the groove portion 17. By doing so, the resin molded product 10 can be treated as an aggregate of a plurality of parts having different designs, the number of design combinations of the resin molded product 10 can be increased, and the number of parts can be reduced to reduce the cost. Can be reduced.

With reference to FIG. 1(B), the groove portions 15, 16 and 17 formed between the above-mentioned respective molding portions are formed so as to be recessed downward (−Z side). The groove portions 15, 16 and 17 have a narrow width in the Y direction and a depth in the Z direction so that the design switching portion formed in each molding portion does not appear in the appearance. Formed deeply.

When the resin molded product 10 having the groove portions 15, 16 and 17 having such a shape is molded by a pressure molding method using a mold, the film elongation is insufficient in order to form a deep and thin Y-shaped groove. Molding is not easy because the film is less likely to enter the groove. The shape of a mold for producing a resin molded product having such a shape will be described with reference to FIGS.

The configuration of the molding die used for molding the above-mentioned resin molded product 10 will be described with reference to FIG. FIG. 2(A) is a perspective view showing the shaping die 20 and the inner die 40 used in the compressed air forming method, and FIG. 2(B) is a top view showing the shaping die 20 and the inner die 40. Is. In these figures, the shaping mold 20 is shown by a solid line and the inner mold 40 is shown by a dotted line.

With reference to FIG. 2(A), a shaping part 21 for shaping a plate-shaped resin plate material into a predetermined shape is formed on the upper surface of the shaping die 20. Most of the shaping part 21 has a smooth concave curved surface corresponding to the surface shape of the resin molded product 10. In the present embodiment, “shape” refers to an act of transferring the shape of the shape forming portion 21 of the shape forming die 20 to the resin plate material by applying pressure to the resin plate material. The shaping mold 20 is called a concave mold, a concave mold or a female mold, and has a concave shaped portion 21 corresponding to the convex shape of the resin molded product 10 to be molded. At the time of molding, the design surface of the resin sheet on which the pattern or the like is attached contacts the shaping portion 21 of the shaping die 20. Further, a flat portion 27 is formed around the shaped portion 21 with a constant width. Here, a portion corresponding to the outer peripheral edge portion of the resin molded product 10 shown in FIG. 1 is shown by a chain line.

The shaping die 20 having the above shape is housed in the inner die 40. That is, the inner die 40 is formed with a cavity conforming to the outer shape of the shaping die 20, and the shaping die 20 is housed in the cavity. The upper surface of the shaping mold 20 and the upper surface of the inner mold 40 are continuous. In addition, the upper surface portion 28 of the inner die 40 has an inclined shape that gradually decreases toward the periphery. Further, a peripheral flat portion 29 having a constant width is formed around the upper surface portion 28. As will be described later, when molding a resin molded product by pressure molding, the shaping mold 20 and the inner mold 40 are housed in the outer mold.

With reference to FIG. 2(B), the shaped portion 21 is provided with upright portions 23, 22, 24 corresponding to the groove portions 15, 16, 17 described with reference to FIG. 1(A). ing. The upright portions 22 and the like are portions where the shaped portion 21 is projected upward in the shape of a wall. The upright portion 22 extends from the side of the shaping section 21 on the +X side to the middle portion of the shaping section 21. The upright surface portion 23 is on the +Y side of the upright surface portion 22 and extends from the +X side side of the shaping portion 21 to an intermediate portion of the shaping portion 21. The upright surface portion 24 is continuous with the upright surface portion 22 and the upright surface portion 23 at an intermediate portion of the shaping portion 21, and extends to the +Y side side of the shaping portion 21. The upright portion 22 and the upright portion 24 are formed as a continuous upright surface.

When the upright surface portion 22 and the like are formed as described above, when the resin plate material is shaped by the pressure forming method, the air existing between the upright surface portion 22 and the peripheral portion thereof and the resin plate material is discharged to the outside. It's not easy. Further, if an air hole for letting this air escape to the outside is formed in the shaping part 21, the shaping part 21 of the shaping die 20 abuts on the design surface of the resin plate material, so that the air hole is formed in the design surface of the resin plate material. There is a possibility that the mark of will remain.

In this embodiment, in order to let the air in the portion escape to the outside, the upright surface portion 22 and the like are extended to the outer peripheral end portion of the shaped portion 21. Specifically, the +X-side end portions of the upright portions 22 and 23 reach the +X-side end portion of the shaping portion 21. Therefore, at the time of shaping, the air existing between the resin plate material and the shaping portion 21 advances to the +X side along the upright portions 22 and 23 and is discharged to the outside of the shaping portion 21. .. The +Y side end of the upright portion 24 reaches the +Y side end of the shaping section 21. Therefore, at the time of shaping, the air existing between the resin plate material and the shaping section 21 flows to the outer peripheral edge portion of the shaping section 21 along the upright portions 22, 23, 24, and the shaping is performed. It is discharged to the outside of the portion 21.

Further, in this embodiment, the gas lead-out portions 25 and 26 are formed. The gas lead-out portion 25 is a portion that is formed continuously with the +X-side end portions of the upright portions 22 and 23 and that leads out the air flowing along the upright portions 22 and 23 toward the +X side to the outside. The gas outlet portion 26 is a portion that is formed continuously at the +Y-side end portion of the upright portion 24 and that leads out the air flowing along the upright portion 24 toward the +Y side to the outside. The shapes of the gas outlets 25 and 26 will be described later.

The shapes of the gas lead-out portions 25 and 26 described above will be described in detail with reference to FIG. 3A is a plan view showing the gas lead-out portion 26, and FIG. 3B is a perspective view showing the gas lead-out portion 25.

With reference to FIG. 3(A), as the gas lead-out portion 26, a continuous upright portion is formed by upwardly protruding the upper surface of the flat portion 27 in a groove shape so as to be continuous with the +Y side end portion of the upright portion 24. The surface portion 30 is formed. By forming the continuous upright portion 30, air can be released to the outside along the continuous upright portion 30 when the resin plate material is shaped by the pressure molding method. Specifically, the air existing between the upright portion 24 and the resin plate material (not shown) at the time of shaping travels in the +Y direction along the upright portion 24, and then along the continuous upright portion 30 +. Proceed in the direction. By doing so, the air existing between the upright portion 24 and the resin plate material is reliably discharged from the shaping portion 21 to the outside. Therefore, the shape of the upright portion 24 is accurately transferred to the resin plate material, and the shape of the groove portion 17 shown in FIG. 1 becomes a predetermined groove shape.

Further, the lead-out groove 31 may be formed by recessing the flat portion 27 in a groove shape along the continuous upright portion 30. Here, the lead-out groove 31 is formed on the +X side and the −X side of the continuous upright portion 30. By forming the lead-out groove 31 having such a shape in the flat portion 27 of the shaping die 20, air is discharged to the outside via the lead-out groove 31 during shaping, and thus the above-described shaping is further performed. It can be done accurately.

Further, the gas lead-out portion 26 described above may be formed on the upper surface portion 28 of the inner die 40. That is, the continuous upright portion 37 continuous with the +Y side end of the continuous upright portion 30 formed on the flat portion 27 of the shaping die 20 may be formed on the upper surface portion 28 of the inner die 40. .. The +Y side end of the continuous upright portion 37 extends to the outer peripheral edge portion of the upper surface portion 28 of the inner die 40. By doing so, the air existing between the upright portion 24 and the resin plate material (not shown) at the time of shaping flows along the continuous upright portion 30 and then further along the continuous upright portion 37. It is discharged to the outside. Further, also on the upper surface portion of the inner die 40, the lead-out groove 38 may be formed by recessing both sides of the continuous upright portion 37 in a groove shape. By doing so, the air escaping from the shaping portion to the outside at the time of shaping passes through the outlet groove 38, so that the above-described effect can be made remarkable.

As described above with reference to FIG. 3B, the gas lead-out portion 25 is formed at the +X side end of the upright portion 22, but here, as the gas lead-out portion 25, the upper surface of the flat portion 27 is used. Is formed in a groove shape to form a lead-out groove 33. As shown in the figure, the cross-sectional shape of the upright portion 22 is a skirt-widening shape in which the width thereof widens toward the +Z side. The lead-out groove 33 is formed on the upper surface of the flat portion 27 so as to be continuous with the end portion on the +X side and the end portion on the +Y side at the +X side end portion of the upright portion 22. By forming the lead-out groove 33 in this way, the air existing between the resin plate material and the upright portion 22 at the time of shaping flows to the +X side along the upright portion 22, and then the lead-out groove 33. You can move to the outside via.

Similarly, the lead-out groove 33 is formed on the upper surface of the flat portion 27 so as to be continuous with the −Y-side end portion and the +Y-side end portion of the upright portion 23 as well. ing. Thereby, the air existing between the resin plate material and the upright surface portion 23 at the time of shaping flows to the +X side along the upright surface portion 23, and then moves to the outside via the lead-out groove 33. Can be done.

Furthermore, a lead-out groove 46 that is continuous with each of the above-mentioned lead-out grooves 33 may be formed in the upper surface portion 28 of the inner die 40. By doing so, at the time of shaping, the air that has flowed along the upright portions 22 and 23 is led out to the outside via the lead-out groove 33 and the lead-out groove 46. The effect of releasing it to the outside can be made remarkable.

With reference to FIG. 4, a gas passage portion may be formed in each of the above-described upright portions to allow gas to pass in the thickness direction thereof. 4A shows the slit 50 as a gas passage portion, FIG. 4B shows a lateral hole 51 as a gas passage portion, and FIG. 4C shows a porous portion 52 as a gas passage portion. There is.

With reference to FIG. 4(A), here, a slit 50 is formed by partially cutting out the upright portion 22. In this figure, the flow of air during shaping is indicated by arrows.

The slit 50 may be formed from the upper end of the upright portion 22 to the lower end thereof, or may be formed from the upper end of the upright portion 22 to an intermediate portion thereof. The slit 50 functions as a path for allowing the air existing between the upright portions 22 and 23 to escape to the outside when performing the shaping described above. Specifically, when performing shaping by the compressed air molding method, the air between the upright portions 22 and 23 passes through the slits 50 of the upright portions 22 and then escapes to the −Y side. , Moves in the -X direction along the side surface of the upright portion 22 on the -Y side, and then advances in the +Y direction along the side surface of the upright portion 24 on the -X side. After that, as shown in FIG. 3(A), the air moves to the +Y-side end of the upright portion 24 and is then discharged to the outside via the gas lead-out portion 26.

The slit 50 having the above configuration may also be formed in the upright portion 23. By doing so, the air existing between the resin plate material and the shaped portion 21 at the time of shaping escapes to the +Y side via the slit 50 of the upright portion 23. After that, the air travels toward the −X side along the side surface on the +Y side of the upright portion 23. After that, the air travels toward the +Y side along the side surface on the +X side of the upright portion 24, and is discharged to the outside via the gas outlet portion 26 shown in FIG. 3 as described above.

Here, referring to FIG. 2B, the upright portion 22 and the upright portion 23 surround a region 45 that is a region of the shaping portion 21. That is, the area 45 is a closed area. Therefore, it is not easy to let the air existing inside the region 45 escape to the outside during shaping. In the present embodiment, as described above, by forming the slit 50 in the upright portion 22 or the upright portion 23, the air existing in the area 45 surrounded by the upright portion 22 and the upright portion 23 can be satisfactorily discharged to the outside. Has been missed. Therefore, at the time of shaping, the shapes of the upright portions 22 and 23 can be accurately transferred to the resin plate material.

In addition, in the continuous portion 44 in which the upright portion 22, the upright portion 23, and the upright portion 24 are continuous, the shape of the shaped portion 21 becomes complicated, so that the shaped portion 21 is formed in the vicinity of the continuous portion 44. It is not easy to let the air existing between the resin plate material and the resin plate material escape to the outside. In this embodiment, since the slits 50 are formed in the upright portions 22 and 23 in the vicinity of the continuous portion 44, air is guided to the outside via the slits 50 as described above, and during shaping. In addition, air is prevented from remaining near the continuous portion 44.

Here, although one slit 50 is formed in each of the upright portions 22 and 23, a plurality of slits 50 may be formed in each. By doing so, the effect of letting air out through the slit 50 during shaping is remarkable.

By thus forming the slits 50 on the upright portions 22 and 23, the shape of the slits 50 is transferred to the resin molded product 10 shown in FIG. However, the portions of the upright portions 22 and 23 to which the slits 50 are transferred are the groove portions 15 and 16 of the resin molded product 10 that are difficult to appear in appearance. Therefore, the portion to which the slit 50 is transferred does not have a great adverse effect on the appearance of the resin molded product 10.

Referring to FIG. 4(B), a lateral hole 51 is formed here as a gas passage portion. Specifically, a horizontal hole 51 that penetrates the upright portion 22 in the thickness direction is formed, and a similar horizontal hole 51 is also formed in the upright portion 23. The path through which air flows during shaping is similar to that of the slit 50 described with reference to FIG.

Referring to FIG. 4C, here, a porous portion 52 is formed as a gas passage portion. The above-mentioned upright portion 22 is made of a metal such as aluminum like the other parts of the shaping die 20, but here, the upright portion 22 is partially or entirely made up of the porous portion 52. doing. As the porous portion 52, for example, a porous metal in which fine pores are formed in a metal such as aluminum is adopted. Similarly, with respect to the upright portion 23, a part or the whole thereof is the porous portion 52. The porous portion 52 is permeable to air. The path through which air flows during shaping is similar to that of the slit 50 described with reference to FIG.

Next, with reference to FIG. 5, a mold used in the compressed air molding method of the present embodiment is generally shown. FIG. 5(A) is a perspective view showing a lower portion of the mold used, FIG. 5(B) is a cross-sectional view showing a case where the mold is cut along the XZ plane, and FIG. [Fig. 4] is a cross-sectional perspective view showing a case where the mold is cut in the YZ cross section.

As described above with reference to FIG. 5(A), the shaping die 20 used for shaping the resin plate material is housed in the inner die 40, and the inner die 40 is the outer lower die. It is stored in 42. The outer lower mold 42 is mounted on the support mold 43.

Referring to FIG. 5B, the outer upper mold 41 is placed on the upper surface of the outer lower mold 42. A cavity 34 is formed in the central portion of the lower surface of the outer upper mold 41, and when the outer upper mold 41 is placed on the upper surface of the outer lower mold 42, the peripheral portion of the cavity 34 becomes the periphery of the inner mold 40. It will be almost the same as the section. In other words, the cavity 34 is arranged above the shaping mold 20 and the inner mold 40.

An exhaust path 36 through which air is discharged during shaping is formed inside the inner mold 40, and the configuration of the exhaust path 36 will be described later.

As shown in FIG. 5C, the outer upper mold 41 is formed with a vent hole 35 that connects the upper end of the cavity 34 and the outside. In the present embodiment, by supplying gas from the outside to the cavity 34 via the ventilation hole 35, pressure is applied to the resin plate material (not shown here), and the resin plate material is formed in the shape of the shaping part 21 of the shaping die 20. I am following.

The air path formed in the mold will be described with reference to FIG. Here, in order to clearly show the air path during shaping, the gap between the molds is shown larger than it actually is.

As described above, when the gas is injected into the cavity 34 from the ventilation hole 35 during shaping by the pressure forming method, the internal pressure of the cavity 34 increases, and the resin plate material 14 is attached to the shaping portion 21 of the shaping die 20. It can be pressed. As a result, shaping is performed in which the shape of the shaping portion 21 of the shaping die 20 is transferred to the resin plate material 14.

In this embodiment, a path for discharging air existing between the resin plate material 14 and the shaping die 20 is formed in the die during shaping. Specifically, the inner mold 40 has an exhaust path 36 formed in a groove shape on the bottom surface while penetrating in the vertical direction. Further, the outer lower mold 42 is provided with an exhaust path 39 formed in a groove shape on the lower surface thereof.

With the shaping, the air existing between the resin plate material 14 and the shaping die 20 is discharged to the outside through the gap between the respective dies. Specifically, the air existing between the resin plate material 14 and the shaping die 20 flows into the exhaust path 36 via the clearance 47 between the shaping die 20 and the inner die 40, and then, It is discharged to the outside via the exhaust path 39. Further, a part of the air existing between the resin plate material 14 and the shaping die 20 flows downward via the clearance 48 between the inner die 40 and the outer lower die 42, and then the exhaust path. It is released to the outside via 39.

Next, based on FIGS. 7 and 8, a method for producing a resin molded product by a pressure molding method will be described with reference to the above-mentioned drawings as appropriate. FIG. 7 is a sectional view sequentially showing the shaping method of the present embodiment. FIG. 8 is a diagram showing a state in which air existing between a resin plate material (not shown) and the shaping die 20 is discharged to the outside.

With reference to FIG. 7A, first, the resin plate material 14 is placed on the upper surfaces of the shaping die 20 and the inner die 40. The resin plate material 14 is the material of the resin molded product 10 shown in FIG. 1, and a plurality of different design portions as shown in FIG. 1(A) are formed on the main surface thereof. Here, the resin plate material 14 is arranged so that its design surface faces downward. Thereby, the design surface of the resin plate material 14 comes to face the shaping portion 21 of the shaping die 20 which is a concave die.

The resin plate material 14 is formed to be slightly larger than the inner die 40, and its peripheral edge portion is arranged on the upper surface of the outer lower die 42. By doing so, the outer peripheral die of the resin plate material 14 can be pressed by the outer lower die 42 and the outer upper die 41 in a later step. Here, the resin plate material 14 may be placed on the upper surface of the shaping die 20 in a heated state in order to facilitate shaping.

With reference to FIG. 7B, next, the outer upper mold 41 is lowered, and the outer upper mold 41 and the outer lower mold 42 press and fix the peripheral portion of the resin plate material 14. At this time, the cavity 34 of the outer upper mold 41 is arranged on the upper surfaces of the shaping mold 20 and the inner mold 40 on which the resin plate material 14 is arranged. In this state, air is press-fitted into the cavity 34 via the ventilation hole 35 to bring the inside of the cavity 34 into a high pressure state.

When the pressure inside the cavity 34 is increased as described above with reference to FIG. 7C, the resin plate material 14 is pressed against the shaping portion 21 of the shaping die 20 by the pressure, and the shaping portion 21 The shape is transferred to the resin plate material 14 to realize shaping. Along with this step, the air existing between the shaping die 20 and the resin plate material 14 is discharged to the outside via the gas outlets 25 and 26 shown in FIG. Further, the air existing between the shaping die 20 and the resin plate material 14 is also discharged to the outside by the air flowing through the slits 50 and the like shown in each drawing of FIG. 4. Therefore, the shape of the shaped portion 21 is accurately transferred to the resin plate material 14. After that, the outer upper mold 41 is raised, the resin plate material 14 is released from the shaping mold 20, and the product portion is cut out from the resin plate material 14 to obtain a resin molded product as shown in FIG. Is obtained.

Next, with reference to FIG. 8, a path through which the air existing between the resin plate material 14 and the shaping section 21 is discharged to the outside in the shaping step described above will be described in detail. FIG. 8A is a sectional perspective view showing a situation where air flows near the gas outlet portion 25, and FIG. 8B is a sectional perspective view showing a situation where air flows near the gas outlet portion 26. Is. In the drawings, a hatched arrow indicates a path through which air flows in the first half of shaping, and a white arrow indicates a path through which air flows in the latter half of shaping.

The flow of air near the gas outlet 25 will be described with reference to FIG. When the shaping is performed by the pressure molding method, the cavity 34 is pressurized, so that the air existing between the resin plate material 14 (not shown) and the shaping die 20 is discharged to the outside. Further, in the initial stage of shaping, the resin plate material 14 (not shown) has a small contact area with the shaping die 20, so that the air existing between the two flows relatively freely. Specifically, a part of the air enters the clearance 47 between the shaping die 20 and the inner die 40, and is discharged to the outside of the die via the exhaust path 36. Further, the other part of the air enters the clearance 48 between the inner mold 40 and the outer lower mold 42, and then is discharged to the outside of the mold.

On the other hand, as the above-described shaping progresses, the resin plate material 14 (not shown) covers the upper surfaces of the shaping die 20 and the inner die 40, so that the above-mentioned air path is limited. As a result, this air flows in the +X direction along the upright portions 22 and 23 formed in the shaping section 21, passes through the gas outlet section 25, and then passes through the clearance 47 and the exhaust path 36. Is released to the outside. In addition, a part of this air is discharged to the outside after entering the clearance 48 via the above-mentioned gas outlet 25.

With reference to FIG. 8(B), a situation in which air flows near the gas outlet 26 during shaping will be described. In this drawing, only the flow of air in the latter half stage of shaping is indicated by a white arrow.

In the initial stage of shaping, air can freely flow as described above. Therefore, even in the vicinity of the gas outlet portion 26, the air existing between the resin plate material (not shown) and the shaping die 20 enters the clearances 47 and 48 and is then discharged to the outside of the die.

On the other hand, when the above-described shaping progresses, the path of the air is restricted as described above. As a result, the air flows in the +Y direction along the upright portion 24 formed in the shaping portion 21, passes through the gas lead-out portion 26, and then through the clearance 47 and the exhaust path 36 to the outside. Is released to. In addition, a part of this air is released to the outside after entering the clearance 48 via the above-mentioned gas outlet 26.

As described above, in the latter half of shaping, the flow of the air existing between the two is restricted, but in the present embodiment, the air existing between the two forms the elevations 22, 23, 24. It goes through the clearances 47 and 48 and is discharged to the outside of the mold. In addition, since the air flows through the gas outlet portions 25 and 26 that are continuous with the end portions of the upright portions, the effect of letting the air escape to the outside becomes remarkable. Accordingly, the shape of the shaping part 21 can be accurately transferred to the resin plate material by escaping the air between the resin plate material and the shaping part 21 to perform shaping.

Although the embodiment of the present invention has been described above, the present invention is not limited to this, and modifications can be made without departing from the gist of the present invention.

10 Resin Molded Product 11 First Molded Part 12 Second Molded Part 13 Third Molded Part 14 Resin Plate Material 15 Groove 16 Groove 17 Groove 20 Shaped Mold 21 Shaped Part 22 Elevated Surface 23 Elevated Surface 24 Elevated Surface 25 Gas outlet portion 26 Gas outlet portion 27 Flat portion 28 Top surface portion 29 Peripheral flat portion 30 Continuous standing surface portion 31 Leading groove 33 Leading groove 34 Cavity 35 Vent hole 36 Exhaust passage 37 Continuous standing portion 38 Leading groove 39 Exhaust passage 40 Inner gold Mold 41 Outer Upper Mold 42 Outer Lower Mold 43 Support Mold 44 Continuous Part 45 Region 46 Outlet Groove 47 Clearance 48 Clearance 50 Slit 51 Side Hole 52 Porous Part 100 Pressure Mold 101 Table 102 Inner Layer 103 Pressure Box 104 Surface layer 105 Resin sheet 106 Vent circuit 107 Pressure port 110 Convex mold 111 Shaped surface 112 Design surface 113 Molded product 114 Groove portion 115 Groove portion 116 Air hole 120 Concave mold 121 Shaped surface 122 Designed surface 123 Molded product 124 Groove portion 125 Elevation part 126 Air hole

Claims (10)

By applying pressure to the resin plate material, a molding die used in a pressure molding method for molding the resin plate material into a predetermined product shape,
A shaping portion in which a concave surface for shaping the resin plate material into a product shape is formed,
To have a shape corresponding to the groove portion that constitutes the product shape, an elevating surface portion obtained by projecting a part of the shaped portion into a wall shape,
Extending the elevation portion to the outer peripheral edge portion of the shaped portion,
Further, formed on the outside of the shaping portion, continuous with the upright portion, when the pressure is applied to the resin plate material, the gas present between the resin plate material and the shaping portion. A molding die , comprising: a gas lead-out portion that passes through . The molding die according to claim 1 , wherein the gas lead-out portion is a continuous upright portion that is continuous with the upright portion. The molding die according to claim 2 , wherein groove-shaped lead-out grooves are formed on both sides of the continuous upright portion. The molding die according to claim 1 , wherein the gas lead-out portion is a lead-out groove that is continuous with the upright portion. By applying pressure to the resin plate material, a molding die used in a pressure molding method for molding the resin plate material into a predetermined product shape,
A shaping portion in which a concave surface for shaping the resin plate material into a product shape is formed,
To have a shape corresponding to the groove portion that constitutes the product shape, an elevating surface portion obtained by projecting a part of the shaped portion into a wall shape,
Extending the elevation portion to the outer peripheral edge portion of the shaped portion,
A molding die , wherein a gas passage portion for allowing gas to pass in the thickness direction is provided on the elevation portion . The molding die according to claim 5 , wherein the gas passage portion is a slit in which the upright portion is partially cut out. The molding die according to claim 5 , wherein the gas passage portion is a lateral hole penetrating the upright portion. The molding die according to claim 5 , wherein the gas passage portion is a porous body forming a part of the upright portion. By applying pressure to the resin plate material, a molding die used in a pressure molding method for molding the resin plate material into a predetermined product shape,
A shaping portion in which a concave surface for shaping the resin plate material into a product shape is formed,
To have a shape corresponding to the groove portion that constitutes the product shape, an elevating surface portion obtained by projecting a part of the shaped portion into a wall shape,
Extending the elevation portion to the outer peripheral edge portion of the shaped portion,
A shaping die in which the shaping portion is formed,
And an internal mold for accommodating the shaping mold,
A molding die , wherein a path through which air flowing along the upright portion is discharged is formed between the shaping die and the inner die. A molding die is arranged on one side of the resin plate material, and pressure is applied from the other side of the resin plate material, so that the resin plate material is molded into a predetermined product shape by following the shape of the molding die. A method of manufacturing a resin molded product using a molding method,
A shaped part formed with a concave surface for making the resin plate material into a product shape, and a standing part obtained by projecting a part of the shaped part in a wall shape so as to have a shape corresponding to the groove part forming the product shape. A surface part, and a step of preparing a molding die in which the upright surface part is extended to the outer peripheral edge part of the shaping part,
A step of placing the resin plate material on the upper surface of the molding die;
By applying the pressure to the resin plate material, the resin plate material is shaped along the shape of the shaped portion, and the gas existing between the resin plate material and the shaped portion is changed to the upright portion. And a step of discharging the resin to the outside through the method.

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