JPH03180331A - Manufacture of air spoiler - Google Patents

Abstract

PURPOSE:To obtain a high quality air spoiler-shaped body having uniform wall thickness and flat outer surface by a method wherein swollen part, which is developed at the mating surfaces of a top part and a bottom part, is removed for finishing. CONSTITUTION:A top part 1 and a bottom part 2, both of which are produced through injection molding, are combined into an air spoiler-shaped body B. In this case, in order to prevent the offset molding from occurring, the positions of the parts are fixed by fixing ribs (r), which are provided in advance. On the mating surfaces of the top part 1 and of the bottom part 2, notched parts are formed respectively so as to set an inverted dome-shaped recess (c), when both the parts are united. Next, a certain amount of synthetic resin material is injected and poured in the inverted dome-shaped recess (c) in order to weld the parts in an air spoiler-shaped body B. After the completion of welding, burr (d) developed by pouring synthetic resin material is swollen. The swollen part of the burr (d) developed is removed for finishing and finally painting is applied to the body.

Description

[Detailed Description of the Invention] [Industrial Application Field] This invention relates to a method for manufacturing an air boiler that provides stability during high-speed operation of automobiles. [Prior Art] ■ As a method for manufacturing an air boiler, , Figure 1, Figure 2,
As shown in Fig. 3, the air boiler (^) is made with a blow bottom shape so that the inside is hollow; ■ As shown in the cross section of Figs. The common method was to provide a) and manufacture it by reaction molding of foamable soft and hard urethane resins.

[Problem to be solved by the invention] The conventional construction method had the following drawbacks.

In the blow molding method (2), large "burrs" are generated on the split surface of the mold. In addition, during the molding process, after the parison process, a vacuum is drawn from the mold surface at the same time as the mold is clamped, and high-pressure air or gas is injected into the parison. Pinholes and the like occur in the surface layer of the mold, and in order to apply a high-quality coating on a flush (flat) surface when the product is manufactured, a large amount of work is required, including polishing and sanding.

Also, because it is not possible to obtain a uniform wall thickness depending on the shape of the product, by designing the product based on a wall thickness other than necessary,
This results in waste of material, and furthermore, it is difficult to obtain a complex internal shape that would form reinforcing ribs, seating surfaces for attaching other parts, etc.

According to the urethane reaction molding method (2), there is a reinforcing metal fitting (a) inside.
), the disadvantage is that it is heavier.

After reaction molding, voids that exist inside the product during the painting process cause white spots on the surface, and post-foaming occurs when the paint dries, resulting in white spots on the painted surface, resulting in poor yields and the inability to obtain high-quality products. There were drawbacks.

This invention solves these problems.

[Means for solving the problem] This invention provides a first molded product [upper part] (+), a second acid (1)
The upper part (1) and the lower part (2) are combined using the same synthetic resin material as the upper part (+) and lower part (2) molded using the injection molding method. The material is injected into the recesses of the eyes to solidify and weld them together to form an air boiler.

[Function] According to the present invention, an air boiler can be obtained in which the upper part (1) and the lower part (2), which are molded by injection molding and have extremely flat outer surfaces, are welded together. By simply removing the raised blemishes and finishing, it is possible to obtain a high-quality air boiler with no seams and a good yield when painting.

[Example] This invention will be explained in detail below.

As shown in FIG. 6, this invention consists of an upper part (1) and a lower part (
It consists of two parts (2) and is molded from thermoplastic synthetic resin material using the injection molding method.

In order to obtain a hollow air boiler with a uniform wall thickness that has a sense of unity, there must be no discrepancy between the upper part (1) and the lower part (2), so they must have the same shrinkage rate and be the same. It is preferable to use materials of similar quality.

In general, the qualities required for air boilers include resistance to impact and no deformation or distortion due to heat.
It uses PPE, alloy material of PPE and PA-6, PA-
6. Materials such as PBT, heat-resistant ABS, and PC are suitable.

Upper part (1) and lower part (2) molded by injection molding method
As shown in Fig. 7, they are combined to form the air boiler shape body (B). The upper part (1) and the lower part (2
), each seam is set in the form of a hollowed out part, so that when the two are combined, it becomes an inverted roof-shaped concave part (e) (Fig. 8).

Next, the integrated air boiler shape body (It
) are set and fixed in jigs (3) and (4), and then
Place the rotating table (5) so that the concave part (c) of the seam is always on top.
) (Figure 9).

On the other hand, the same material is injected into the inverted roof-shaped recess (c) for the upper part (1) and the lower part (2).

The injection mechanism consists of a hot nozzle (6) and a hot nozzle (
6) to a fixed position, and an injection device (7) that applies heat to soften the thermoplastic synthetic resin material of the same quality as the air boiler shaped body (B) and sends out a fixed amount with an injection cylinder.
) and a high-pressure, heat-resistant hose (6) that connects the injection device (7) and the hot nozzle (6). It has become.

The rotational relationship between these injection mechanisms and the air boiler shaped body (B) is set by electrical control, and a certain amount of synthetic resin material is injected into the inverted roof-shaped recess (c) to form the air boiler shaped body. Weld (B).

Figure 10 shows a cross section after welding is completed, and if the raised bulges (d) of the injected synthetic resin material are removed, finished, and painted, it will be similar to conventional blow molding or reaction molding products. It is possible to obtain a low-cost air boiler with the same appearance, uniform wall thickness, and good yield.

Fig. 11 shows an example in which the fixing rib (r) is replaced with a claw-shaped rib (') in order to increase the combined strength in the example shown in Fig. 7.
In the figure, the upper part (1) is provided with a claw-like rib (°), and the lower part (2) is provided with a groove (1) into which the claw (s) of the claw-like rib (r') fits, and the parts are combined. However, this fitting structure may be provided in the upper part (1) and lower part (2) in reverse.

[Effects of the Invention] According to the present invention, by simply removing the raised portion that occurs at the seam of the upper part (1) and the lower part (2) and finishing it, a uniform wall thickness and a flat outer surface can be achieved. A high quality air boiler shape can be obtained. In the painting process, there is no need to sand the entire outer surface, and there are no voids or swelling due to post-foaming, resulting in a high-quality, low-cost air boiler.

[Brief explanation of drawings]

Figure 1 is an overall perspective view of the air boiler, Figure 2 is a sectional view taken along the line E in Figure 1, Figure 3 is a sectional view taken along the Rollo line in Figure 1, and Figure 4 is another example of the Air Boiler. Fig. 1 is a sectional view taken along the line E-I, Fig. 5 is a sectional view taken along the line E-I' of Fig. 1, which is the same as that shown in Fig. 4, and Fig. 6 is a perspective view of the upper and lower parts of the air boiler of this invention. , Fig. 7 is a vertical sectional view of the air boiler shaped body of the present invention, showing the state immediately before molding, Fig. 8 is an enlarged sectional view of the main part of Fig. 7, and Fig. 9 is a longitudinal sectional view of the air boiler of the present invention. FIG. 10 is a cross-sectional view showing the joined state in FIG. 8; FIG. 11 is a cross-sectional view of a main part showing an embodiment of the claw-shaped rib. (^ ・・・・・・Air Boiler

Claims (1)

[Scope of Claims] 1. Two parts, an upper part and a lower part, are molded from thermoplastic synthetic resin material by an injection molding method, and the upper part and the lower part are combined, and the upper part and the lower part are made with a thinner material at the seam. A cutout is formed so that when the two parts are combined, it becomes an inverted roof-shaped concave part, and the integrated air boiler shape body is set and fixed in a jig, and the air boiler is fixed. A fixed amount of synthetic resin is injected and welded following the shape of the concave part of the boiler shape body, and then the raised part of the seam is removed and finished, and the air boiler is integrally molded by welding. A manufacturing method for an air boiler characterized by obtaining. 2. The method of manufacturing an air boiler according to claim 1, wherein the positions of the upper part and the lower part are fixed by fixing ribs. 3. A hot nozzle, a robot that guides this hot nozzle to a fixed position, an injection device that applies heat to a thermoplastic synthetic resin material that is the same as the air boiler shape to soften it, and sends out a fixed amount with an injection cylinder, and this injection An injection mechanism characterized by consisting of a high-pressure, heat-resistant hose that connects the device and the hot nozzle.