JP6974692B2 - Molded body and its manufacturing method - Google Patents

Description

The present invention relates to a molded body such as a deck board mounted on a vehicle and a method for manufacturing the same.

Patent Document 1 describes vehicle interior parts in which the height position of the parting line is appropriately changed for each predetermined portion according to the characteristics required for each predetermined portion along the circumferential direction of the interior component. It has been disclosed.

Japanese Unexamined Patent Publication No. 2014-104690

By the way, in a molded body having a parting line, the parting line is the most convex portion of the molded body due to the structure of the mold used for molding the molded body. Therefore, when the molded body is mounted at a predetermined mounting position of the vehicle, the parting line may damage the object to be mounted (eg, the trim for the luggage compartment).

Further, if the molded body is dropped during transportation of the molded body or the like, the molded body may be cracked due to the impact applied to the parting line. This is because the strength of the parting line is relatively weak as compared with the parts other than the parting line.

It is known to attach a non-woven fabric in order to solve such a problem, but the man-hours and the man-hours increase.

The present invention has been made in view of such circumstances, and even a molded body having a parting line can reduce damage to the object to be mounted and the molded body without taking special measures. It provides a molded body and a manufacturing method.

According to the present invention, the molded body is a molded body, and the molded body is provided with an upper surface and a lower surface facing each other apart from each other, and a connecting side surface connecting the upper surface and the lower surface, and a parting line is provided on the connecting side surface. Provided is a molded body provided with a protrusion provided on the connecting side surface so as to project outside the molded body from the parting line.

The molded body according to the present invention is provided with a parting line on the connecting side surface and a protruding portion protruding to the outside of the molded body from the parting line on the connecting side surface. As a result, the parting line does not become the most convex portion, and the object to be mounted and the molded body can be appropriately protected.

Hereinafter, various embodiments of the present invention will be illustrated. The embodiments shown below can be combined with each other.
Preferably, the parting line is provided within 45% of the height of the connecting side surface from the midpoint in the height direction of the connecting side surface.
Preferably, the protrusion is formed by a reverse taper provided on the connecting side surface.
Preferably, the value of (projection distance of the protrusion) / (height of the connecting side surface) is 0.01 to 1.
Preferably, the protrusion distance is 0.5 to 5 mm.
Preferably, the angle of inclination of the connecting side surface is 1 ° to 30 ° at the portion where the protrusion is provided with respect to the plane perpendicular to the upper surface and parallel to the parting line on the connecting side surface.
Preferably, the protrusions are provided at two opposite positions on the connecting side surface.
Preferably, a shaping step of sucking the hanging resin sheet by a mold having a cavity to shape the resin sheet into a shape along the inner surface of the cavity, and releasing the mold from the resin sheet. The cavity comprises a mold release step to be molded, and the cavity has an inner surface shape corresponding to the protrusion.
Preferably, in the mold release step, the molded product is forcibly removed from the mold.
Preferably, the mold is an assembly mold composed of a main body and a slide piece, and the slide piece is slid in the mold release step.
Preferably, the shaping step is followed by a welding step of welding the foam to the resin sheet.

FIG. 1A is a perspective view of the molded body 3 according to the first embodiment of the present invention. FIG. 1B is a side view seen from the rear connecting side surface 3sb of the molded body 3. It is a partially enlarged view of the region X in FIG. 1B. It is a figure showing the appearance that the molded body 3 is arranged in the vicinity of the trim 50 which is an object to be attached. It is a perspective view seen from the right side of the molding machine 1 which concerns on 1st Embodiment of this invention. It is a perspective view seen from the left side of the molding machine 1 which concerns on 1st Embodiment of this invention. It is a figure which showed the lower side from the resin sheets 23, 24 hung from the slit of the T die 18 in the end view which passes through the midpoint of the molding machine 1 in the front-rear direction of FIG. FIG. 6 is an end view corresponding to FIG. 6, showing a state in which the resin sheets 23 and 24 are shaped by the molds 21 and 22 of FIG. It is a perspective view which shows the state which the mold 22 is forcibly pulled out after shaping. Of the end views of the molding machine 1 according to the second embodiment of the present invention, the lower side is shown from the resin sheets 23 and 24 hanging from the slits of the T die 18, and is the end view corresponding to FIG. be. FIG. 10A is a perspective view showing how the main body 22A and the slide piece 22B constituting the mold 22 behave as one mold. FIG. 10B is a perspective view showing a state in which the main body 22A and the slide piece 22B are separated from each other. 9 is an end view corresponding to FIG. 9, showing a state in which the resin sheets 23 and 24 are shaped by the molds 21 and 22 of FIG. 9. It is a perspective view which shows the state of sliding the slide piece 22B after shaping.

Hereinafter, embodiments of the present invention will be described. The various features shown in the embodiments shown below can be combined with each other. In addition, the invention is independently established for each feature.

<First Embodiment>
<Molded body 3>
Hereinafter, the molded body 3 according to the first embodiment of the present invention will be described with reference to FIGS. 1 to 3. In the present embodiment, the molded body 3 is a deck board attached to a trim for a luggage compartment of a vehicle. Here, as shown in FIG. 7, the molded body 3 is formed of the foam 31 and the resin sheets 23 and 24 attached around the foam 31. Further, the nonwoven fabric NF is integrally molded on the surface of the molded body 3. The non-woven fabric NF is not essential.

As shown in FIGS. 1A and 1B, the molded body 3 includes an upper surface 3t and a lower surface 3b that are separated from each other and face each other, and a connecting side surface 3s that connects the upper surface 3t and the lower surface 3b. Here, in the present embodiment, the connecting side surface 3s is composed of a front connecting side surface 3sf, a rear connecting side surface 3sb, a right connecting side surface 3sr, and a left connecting side surface 3sl. The size of these surfaces is not particularly limited, but the area S of the upper surface 3t and the lower surface 3b is preferably ^{, for example, 2,000 to 30,000 mm 2.} Further, the height H (see FIG. 2) of the connecting side surface 3s is preferably 5 to 50 mm, for example. The height H is preferably 10 to 30 mm. The value of (area S) / (height H) is preferably 100 to 3,000, more preferably 300 to 1,500, and even more preferably 500 to 1,000.

Further, a parting line PL is provided on the connecting side surface 3s. In the present embodiment, the parting line PL is formed along the four connecting side surfaces 3sf, 3sr, 3sb, and 3sl. Here, as shown in FIGS. 1A and 1B, focusing on the rear connecting side surface 3sb and the right connecting side surface 3sr, the parting line PL is connected from the rear connecting side surface 3sb to the right connecting side surface 3sr at the point P1. Further, as shown in FIG. 2, the parting line PL is provided substantially at the center of the connecting side surface in the height H direction. Here, the position of the parting line PL is not limited to this, and may be provided at a position within 45% of the height H from the midpoint M in the height H direction of the connecting side surface 3s. Preferably, the parting line PL is within 45% of the height H from the midpoint in the height H direction of the connecting side surface, more preferably 30%, still more preferably 20%, still more preferably 10%, still more preferably 5. %. In the case of 0%, the parting line PL passes through the midpoint M as shown in FIG.

The right connecting side surface 3sr and the left connecting side surface 3sl (two facing portions of the connecting side surface) are provided with protruding portions 3P protruding to the outside of the molded body 3 from the parting line PL. Here, it is preferable that the protrusions 3P are provided on at least the right connecting side surface 3sr and the left connecting side surface 3sl corresponding to two sides in the left-right direction of the vehicle on which the molded body 3 is mounted. Further, it is more preferable to provide the protruding portion 3P on the front connecting side surface 3sf corresponding to the front of the vehicle. The connecting side surface 3s on which the protruding portion 3P is provided is not limited to this, and the protruding portion 3P may be provided on either the right connecting side surface 3sr or the left connecting side surface 3sl. Further, the protrusion 3P may be provided on the front connecting side surface 3sf or the rear connecting side surface 3sb.

Further, a taper TP is provided below the right connecting side surface 3sr and the left connecting side surface 3sl, and a reverse taper RT is provided above the right connecting side surface 3sr. Here, as shown in FIG. 6, the reverse taper RT is a surface formed by the reverse taper surface (inner surface shape Y) narrowing toward the opening end in the cavity 22a of the mold 22. In the embodiment, it is referred to as a reverse taper RT for convenience. The protrusion 3P is formed by the reverse taper RT.

Here, in the present embodiment, since the shapes and sizes of the protrusions 3P provided on the right connecting side surface 3sr and the left connecting side surface 3sl are substantially the same, FIG. 2 which is a partially enlarged view of the region X in FIG. 1B is shown. The protruding portion 3P provided on the right connecting side surface 3sr will be described with reference to.

As shown in FIG. 2, a taper TP is formed on the right connecting side surface 3sr from the point P2 on the lower surface 3b to the point P1. Here, the radius of curvature of the lower curved surface 3R2 at the point P2 is preferably 0.5 to 3 mm. Further, a reverse taper RT is formed on the right connecting side surface 3sr from the point P4 on the upper surface 3t to the point P1. Here, the radius of curvature of the upper curved surface 3R1 at the point P4 is preferably 1 to 4 mm. The reverse taper RT in the present embodiment is a shape that protrudes to the outside of the molded body 3 and is inclined toward the inside of the molded body 3 with respect to the height H direction of the molded body 3 in the side view of the connecting side surface 3s. Is. The protrusion 3P is formed by such a reverse taper RT. Here, in FIG. 2, the most protruding point in the protruding portion 3P is indicated by a point P3.

The protrusion 3P may be formed so that the protrusion distance d2 from the point P1 where the parting line PL is connected from the rear connecting side surface 3sb to the right connecting side surface 3sr is 0.5 to 5 mm in the side view. preferable. This is because when the mold 22 to be described later is forcibly pulled out, if the protrusion distance d2 is too large, the molded body 3 may be damaged. More preferably, the protrusion distance d2 is 1 to 4 mm, more preferably 2 to 3 mm. Specifically, for example, it is 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5 mm, and is between any two of the numerical values exemplified here. It may be within the range.

Further, it is preferable that the protruding portion 3P is formed so that the protruding distance d1 from the point P2 which is the starting point of the taper TP is 2 to 10 mm in the side view. More preferably, the protrusion distance d1 is 3 to 8 mm, more preferably 4 to 6 mm. Specifically, it is, for example, 2,3,4,5,6,7,8,9,10 mm, and may be within the range between any two of the numerical values exemplified here. Here, in the present embodiment, the size of the protrusion distance d1 from the point P2 which is the start point of the taper TP is specified, but the point P4 which is the start point of the reverse taper RT is formed more than the point P2. When it is located outside the body 3, the protrusion distance from the point P4 may be set as the above range.

Further, the value of (projection distance d2 of the protrusion 3P) / (height H of the connecting side surface) is preferably 0.01 to 1. More preferably, such value is 0.1 to 0.5, still more preferably 0.15 to 0.2. Specifically, for example, 0.01, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, It is 0.55, 0.6, 0.65, 0.7, 0.75, 0.8, 0.85, 0.9, 0.95, 1, and any two of the numerical values exemplified here. It may be within the range between.

Further, it is preferable that the inclination angle θ1 of the right connecting side surface 3sr is 1 ° to 30 ° at the portion where the protrusion 3P is provided with respect to the plane PA perpendicular to the upper surface 3t and parallel to the parting line PL on the right connecting side surface 3sr. .. More preferably, the inclination angle θ1 is 5 ° to 25 °, and even more preferably 10 ° to 20 °.

Here, in the present embodiment, the inclination angle θ2 of the taper TP with respect to the plane PB horizontal to the plane PA is substantially the same as the inclination angle θ1. However, the inclination angle θ2 is not limited to this, and the inclination angles θ1 and θ2 may be different angles.

As shown in FIG. 3, due to such a structure, the protruding portion 3P protrudes to the outside of the molded body 3 from the parting line PL, and therefore, when the molded body 3 is arranged in the vicinity of the trim 50 to be mounted. The non-woven fabric NF covering the protrusion 3P and the trim 50 come into contact with each other, and the contact between the parting line PL and the trim 50 can be reduced. Here, since the parting line PL is sharp and the degree of damage to the trim 50 is larger than that of other parts, the non-woven fabric NF covering the protruding portion 3P is brought into contact with the trim 50 instead of the parting line PL. The parting line PL can reduce the possibility of damaging the trim 50. Further, since the parting line PL has a lower strength than other parts, it tends to be easily cracked when an external force is applied. However, since the molded body 3 is applied, the molded body 3 and other objects are separated from each other. By applying the external force applied at the time of collision to the non-woven fabric NF covering the protruding portion 3P, it is possible to reduce the damage to the molded body 3 as compared with the case where the external force is applied to the parting line PL. Even when the non-woven fabric NF is not provided, the contact between the parting line PL and the trim 50 can be reduced by the contact between the protruding portion 3P and the trim 50.

<Molding machine 1>
Next, the molding machine 1 for molding the molded body 3 according to the first embodiment of the present invention will be described with reference to FIGS. 4 to 6. As shown in FIGS. 4 to 6, the molding machine 1 includes resin sheet forming devices 2a and 2b and dies 21 and 22. Each of the resin sheet forming devices 2a and 2b includes a hopper 12, an extruder 13, an accumulator 17, and a T-die 18. The extruder 13 and the accumulator 17 are connected via a connecting pipe 25. The accumulator 17 and the T-die 18 are connected via a connecting pipe 27.
Hereinafter, each configuration will be described in detail.
<Hopper 12, extruder 13>
The hopper 12 is used to charge the raw material resin into the cylinder 13a of the extruder 13. The form of the raw material resin is not particularly limited, but is usually in the form of pellets. The raw material resin is, for example, a thermoplastic resin such as a polyolefin, and examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, an ethylene-propylene copolymer and a mixture thereof. The raw material resin is charged into the cylinder 13a from the charging port 12a of the hopper 12 and then heated in the cylinder 13a to be melted into the molten resin 11. Further, it is conveyed toward the tip of the cylinder 13a by the rotation of the screw arranged in the cylinder 13a. The screw is arranged in the cylinder 13a, and the molten resin 11 is kneaded and conveyed by its rotation. A gear device is provided at the base end of the screw, and the screw is rotationally driven by the gear device. The number of screws arranged in the cylinder 13a may be one or two or more.

<Accumulator 17, T-die 18>
The molten resin 11 is extruded from the resin extrusion port of the cylinder 13a and injected into the accumulator 17 through the connecting pipe 25. The accumulator 17 includes a cylinder 17a and a piston 17b slidable inside the cylinder 17a, and the molten resin 11 can be stored in the cylinder 17a. Then, by moving the piston 17b after a predetermined amount of the molten resin 11 is stored in the cylinder 17a, the molten resin 11 is pushed out from the slit provided in the T-die 18 through the connecting pipe 27 and hung down to be in a molten state. The resin sheets 23 and 24 are formed.

<Molds 21 and 22>
The resin sheets 23 and 24 are guided between the molds 21 and 22. As shown in FIGS. 4 to 6, the molds 21 and 22 have cavities 21a and 22a, and pinch-off portions 21f and 22f are provided so as to surround the cavities 21a and 22a. Suction holes (not shown) are provided in the cavities 21a and 22a, and the resin sheets 23 and 24 can be sucked through the suction holes to form a shape along the inner surface of the cavities 21a and 22a. It has become. The suction hole is a very small hole, one end of which is communicated to the inner surface of the cavities 21a and 22a through the inside of the mold 21 and 22, and the other end is connected to the decompression device.

Further, as shown in FIG. 6, the cavity 22a of the mold 22 has an inner surface shape Y corresponding to the protrusion 3P. In the present embodiment, the inner surface shape Y is provided at two locations by a part of the pinch-off portion 22f and the inner surface of the cavity 22a. The inner surface shape Y is a shape corresponding to the reverse taper RT forming the protruding portion 3P of the molded body 3. Further, due to the inner surface shape Y, the right connecting side surface 3sr and the left connecting side surface 3sl are provided with protruding portions 3P protruding to the outside of the molded body 3 from the parting line PL.

<Manufacturing method>
Next, a method for manufacturing the molded body 3 according to the embodiment of the present invention will be described with reference to FIGS. 6 to 8. The manufacturing method of the present embodiment includes a placement step, a shaping step, a welding step, a mold clamping step, a mold release step, and a finishing step. Hereinafter, it will be described in detail.

(1) Arrangement Step In this step, as shown in FIG. 6, the resin sheets 23, 24 and the non-woven fabric NF formed by extruding the molten resin 11 in a molten state from the slit of the T die 18 and hanging the molten resin NF are formed in the mold 21. Arrange between 22. Here, the wall thicknesses of the resin sheets 23 and 24 are not particularly limited, but are, for example, 0.5 to 5 mm, preferably 1 to 3 mm. Specifically, this wall thickness is, for example, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5 mm, and any of the numerical values exemplified here. It may be within the range between the two.

(2) Shape shaping step In this step, the resin sheets 23 and 24 are sucked by the molds 21 and 22, and the resin sheets 23 and 24 are shaped into the shapes of the cavities 21a and 22a.

(3) Welding step In this step, the foam 31 is welded to the resin sheet 24. The foam 31 may be welded to the resin sheet 23. The foam 31 is molded using, for example, a thermoplastic resin. The resin material is not limited, and includes, for example, any one of polyolefins such as polypropylene and polyethylene, and acrylic derivatives such as polyamide, polystyrene and polyvinyl chloride, or a mixture of two or more kinds. The foaming ratio of the foam 31 is preferably 1.5 to 6 times. The foam 31 can be omitted, and in that case, the welding step can also be omitted.

(4) Mold clamping step In this step, the molds 21 and 22 are mold-clamped as shown in FIG. In the present embodiment, the resin sheets 23 and 24 are crushed in the mold clamping direction of the molds 21 and 22, and the parting line PL is formed. Therefore, the resin sheets 23 and 24 are firmly adhered to each other in the parting line PL, and the strength of the molded body 3 in the parting line PL is improved. In this step, the resin sheets 23 and 24 are welded to obtain a molded product 3 in which the periphery of the foam 31 is covered with the resin sheet. At this time, since the nonwoven fabric NF receives pressure while being sandwiched between the resin sheet 24 and the mold 22, the nonwoven fabric NF adheres to the upper surface 3t of the molded body 3. Further, the outside of the pinch-off portions 21f and 22f becomes burrs. If air is blown into the space surrounded by the resin sheets 23 and 24, there may be a problem that the foaming ratio of the foam 31 is lowered, so it is preferable not to blow air.

(5) Mold release step In this step, the molds 21 and 22 are released from the resin sheets 23 and 24. Specifically, as shown in FIG. 8, by moving the mold 21 in the direction of arrow A and moving the mold 22 in the direction of arrow B, the molds 21 and 22 are forcibly removed from the molded body 3. , Take out the molded body 3. Here, the directions of the arrows A and B are substantially perpendicular to the hanging direction of the resin sheets 23 and 24 with respect to the molded body 3. At this time, the inner surface shape Y of the mold 22 and the protruding portion 3P of the molded body 3 interfere with each other, but since the protruding portion 3P is formed under the above-mentioned conditions and is covered with the non-woven fabric NF, the mold 22 is used. Even if the molded body 3 is forcibly pulled out, it is possible to reduce the deformation of the shape of the protruding portion 3P.
(6) Finishing Step After the forcible removal step, the molded product 3 shown in FIG. 1 is obtained by removing burrs. The molded body 3 has a structure in which the periphery of the foam 31 is covered with a resin sheet.

<Second Embodiment>
Next, the manufacturing method according to the second embodiment of the present invention will be described with reference to FIGS. 9 to 12. Hereinafter, the same components as those of the first embodiment are designated by the same reference numerals, and the description thereof will be omitted.

As shown in FIGS. 9 and 10, in the second embodiment, the molded body 3 is molded by using the mold 22 composed of the main body 22A and the slide piece 22B. Here, the mold 22 in the present embodiment is an assembled mold composed of the main body 22A and the slide piece 22B. A cavity 22Aa and a pinch-off portion 22Af are formed in the main body 22A. Further, a cavity 22Ba and a pinch-off portion 22Bf are formed in the slide piece 22B.

As shown in FIG. 10A, in a state where the main body 22A and the slide piece 22B are integrated, the cavity 22Aa and the cavity 22Ba form one cavity, and the pinch-off portion 22Af and the pinch-off portion 22Bf form one pinch-off portion. .. As a result, it has the same function as the mold 22 in the first embodiment. That is, in the second embodiment, the resin sheets 23 and 24 are sucked by the molds 21 and 22, and the resin sheets 23 and 24 are shaped into the shapes of the cavities 21a and the cavities 22Aa and 22Ba.

Here, as shown in FIG. 9, the cavity 22Aa of the main body 22A has an inner surface shape Y corresponding to the protrusion 3P. In the present embodiment, the inner surface shape Y is provided by a part of the pinch-off portion 22Af and the inner surface of the cavity 22Aa. Further, the cavity 22Ba of the slide piece 22B has an inner surface shape Z corresponding to the protruding portion 3P. In the present embodiment, the inner surface shape Z is provided by a part of the pinch-off portion 22Bf and the inner surface of the cavity 22Ba. The inner surface shapes Y and Z are shapes corresponding to the reverse taper RT forming the protruding portion 3P of the molded body 3. Further, due to the inner surface shapes Y and Z, protrusions 3P protruding to the outside of the molded body 3 from the parting line PL are provided on the right connecting side surface 3sr and the left connecting side surface 3sl.

In the second embodiment, as shown in FIG. 11, the molds 21 and 22 are molded in the above-mentioned mold clamping step. Here, as in the first embodiment, the resin sheets 23 and 24 are crushed in the mold clamping direction of the molds 21 and 22, and the parting line PL is formed. Therefore, the resin sheets 23 and 24 are firmly adhered to each other in the parting line PL, and the strength of the molded body 3 in the parting line PL is improved. In this step, the resin sheets 23 and 24 are welded to obtain a molded product 3 in which the periphery of the foam 31 is covered with the resin sheet. At this time, since the nonwoven fabric NF receives pressure while being sandwiched between the resin sheet 24 and the mold 22, the nonwoven fabric NF adheres to the upper surface 3t of the molded body 3. Further, the outside of the pinch-off portion 21f and the pinch-off portions 22Af and 22Bf becomes burrs.

Here, as shown in FIG. 11, since the main body 22A and the slide piece 22B are arranged along the upper surface 3t of the molded body 3, the main body 22A and the slide piece 22B are integrated into one mold 22. By behaving, the molds 21 and 22 can be firmly molded.

Next, in the above-mentioned mold release step, as shown in FIG. 12, the mold 21 is moved in the direction of arrow A, and the mold 22 is moved in the direction of arrow B. Such movement is the same as in the first embodiment (see FIG. 8).

In the second embodiment, the slide piece 22B is further slid in the direction of the arrow C. Here, the arrow C direction is a direction substantially horizontal to the molded body 3 in the hanging direction of the resin sheet 24. By moving the slide piece 22B in the direction of the arrow C in this way, it is possible to reduce the interference between the inner surface shape Z of the slide piece 22B and the protruding portion 3P of the molded body 3.

In the present embodiment, the mold 22 is composed of the main body 22A and the slide piece 22B, but the present invention is not limited to this. For example, the portion corresponding to the inner surface shape Y of the main body 22A may be substituted with a slide piece, and the mold 22 may be configured by the main body 22A and the two slide pieces. In this case, it is possible to reduce the interference between the two slide pieces and the two protruding portions 3P of the molded body 3.

As described above, in the molded body 3 molded by the manufacturing methods according to various embodiments, the parting line PL is provided on the connecting side surface 3s, and the connecting side surface (right connecting side surface 3sr and left connecting side surface 3sl) is provided. , A protruding portion 3P that protrudes to the outside of the molded body 3 from the parting line PL is provided. As a result, the parting line PL does not become the most convex portion, and the object to be mounted and the molded body 3 can be appropriately protected. Such an action / effect is established even when the non-woven fabric NF is not used.

Further, since the resin sheets 23 and 24 are crushed in the mold clamping direction of the molds 21 and 22 to form the parting line PL, the resin sheets 23 and 24 are firmly adhered to and parted in the parting line PL. The strength of the molded body 3 in the line PL is improved.

Although various embodiments have been described above, the molded body 3 according to the present invention is not limited thereto. For example, the molded body 3 can be provided as a hollow molded body formed of the resin sheets 23 and 24 without using the foam 31.

Further, the shape and size of the molded body 3 can be appropriately changed according to the shape and size of the object to be mounted.

1: Molding machines 2a, 2b: Resin sheet molding device 12a: Hopper 11: Melting resin 12: Input port 13: Extruder 13a: Cylinder 17: Accumulator 17a: Cylinder 17b: Piston 18: T-die 21 and 22: Mold 21f, 22f: Pinch-off portion 21a, 22a: Cavity 23, 24: Resin sheet 22A: Main body 22B: Slide 22Af, 22Bf: Pinch-off portion 22Aa, 22Ba: Cavity 25, 27: Connecting tube 31: Foam 3: Molded body 3s: Connecting side surface 3sf: Front connecting side surface 3sb: Rear connecting side surface 3sr: Right connecting side surface 3sl: Left connecting side surface 3t: Top surface 3b: Bottom surface 50: Trim PL: Parting line TP: Tapered RT: Reverse taper 3P: Protruding portion 3R1: Top Curved surface 3R2: Lower curved surface NF: Non-woven fabric

Claims (8)

A molded product having an upper surface and a lower surface that are separated from each other and face each other, and a connecting side surface that connects the upper surface and the lower surface.
Equipped with a foam and a resin sheet,
The foam is covered with the resin sheet, and the foam is covered with the resin sheet.
The surface of the resin sheet constitutes the upper surface, the lower surface, and the connecting side surface.
A parting line is provided on the connecting side surface.
A protrusion is provided on the connecting side surface so as to project outside the molded body from the parting line.
The protrusion is formed by a reverse taper provided on the connecting side surface.
Wherein a top in the vertical and the inclined angle of 5 ° to 25 ° of the connecting sides at the site where the projecting portion with respect to the parting line and parallel to the plane of the connection side is provided,
A gap is formed in the molded body, and the molded body has a gap.
The gap is formed between the inner surface of the protrusion on the connecting side surface and the end of the foam.
Molded body. The molded product according to claim 1, wherein the parting line is provided within 45% of the height of the connecting side surface from the midpoint in the height direction of the connecting side surface. The molded product according to claim 1 or 2, wherein the value of (protruding distance of the protruding portion) / (height of the connecting side surface) is 0.01 to 1. The molded product according to claim 3, wherein the protrusion distance is 0.5 to 5 mm. The molded product according to any one of claims 1 to 4, wherein the protruding portions are provided at two facing positions on the connecting side surfaces. The method for manufacturing a molded product according to any one of claims 1 to 5.
The manufacturing method includes a shaping step of sucking the hanging resin sheet by a mold having a cavity to shape the resin sheet into a shape along the inner surface of the cavity.
A mold release step for releasing the mold from the resin sheet,
Equipped with
The cavity has an inner surface shape corresponding to the protrusion.
Production method. The manufacturing method according to claim 6, wherein in the mold release step, the molded product is forcibly removed from the mold. The manufacturing method according to claim 6 or 7 , further comprising a welding step of welding the foam to the resin sheet after the shaping step.

Images