JPH091597A - Method for molding of front panel - Google Patents

Abstract

PURPOSE: To attempt reduction of a cost by saving labors for coating or the like by a method wherein a weld is prevented from occurring on a front panel of an indoor device of an air conditioning machine. CONSTITUTION: In molding of a front panel 4 of an indoor device of an air conditioning machine, a position 7 of a gate provided to a mold is limited to a plurality of positions left and right to a formed horizontal muntin 5a of the front panel 4. Besides, thin wall thickness parts 9, 9 delaying a flow from a lateral direction of a heated molten synthetic resin are provided left and right to a lower part center liable to generate a weld 8. Thereby, collision of resins against each other in the center is decreased. Since occurrence of the weld 8 is almost gone in molding by such a method, labors of coating or the like for concealing the weld 8 are saved, and a cost is reduced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for molding a front panel provided in front of an indoor unit of an air conditioner.

[0002]

2. Description of the Related Art A housing for an indoor unit of an air conditioner has a main body 2 as shown in FIG. 1, a front cover 3 detachably attached to the main body 2, and a front cover 3 which can be freely opened and closed. The front panel 4 and A suction port 5 for taking in indoor air is provided inside the housing 1 between the upper left and right sides of the front panel 4, and the suction port 5 is composed of a plurality of horizontal rails and a plurality of vertical rails orthogonal to the horizontal rails. Has been done. FIG. 4 shows the back side of the conventional front panel 4, and a plurality of cross marks 7 on the horizontal rail 5a indicate the position of the gate which is the filling port of the heat-melting synthetic resin at the time of molding.

[0003]

By the way, in the molding of the front panel 4, when the heat-melting synthetic resin is filled from a plurality of positions of the X marks 7 as shown in FIG. 5, the time required for molding is shortened. While there are advantages, the synthetic resin paths inside the mold are increased as shown by the arrows, and the number of collision points between the synthetic resins increases. Furthermore, since the temperature of the synthetic resin flowing inside the mold decreases toward the tip, the fusion state when the synthetic resins collide with each other is poor,
As a result, welds 8 occur at a plurality of points on the surface that should be flat. Moreover, since the weld 8 appears vertically on the surface of the front panel 4, the appearance is spoiled and the commercial value is reduced. It is possible to make the weld 8 difficult to see by subjecting the surface to secondary processing such as painting or hot stamping, but it is troublesome and costly. Therefore, it is an object of the present invention to provide a front panel molding method capable of further reducing the occurrence of welds.

[0004]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and includes a cross rail forming cavity, an upper front face forming cavity located above the cross rail, and a cross rail forming cavity. One mold with a lower front surface forming cavity recessed in the mating surface and a vertical crosspiece forming cavity are recessed in the mating surface, and at the predetermined positions on the left and right of the central portion of the lower front surface forming cavity. And a mold for forming the thin-walled portion forming another thin-walled portion forming convex surface on the mating surface, wherein the horizontal rail forming cavity and the vertical rail forming cavity are orthogonal to each other, and the lower front surface forming cavity The two molds are closed so that the thin-walled portion forming convex surface fits in the predetermined position of the mold, and the heat-melting synthetic resin is heated from a plurality of gates which are properly arranged in the other molds in the respective cavities in advance. Charge And was to be taken out front panel molded.

[0005]

In the case of the front panel formed by the mold as described above, the thin-walled portions are formed on the left and right sides of the lower center of the front panel, so that the flow of the heat-melting synthetic resin from the left and right gates toward the lower center. Since the timing is shifted and the collision between the synthetic resins is avoided, the occurrence of an unpleasant weld is reduced.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. FIG. 1 is a perspective view showing the appearance of an indoor unit. A housing 1 includes a main body 2, a front cover 3 that is detachably attached to the main body 2, and a front surface that is openably and closably attached to the front of the front cover 3. A suction port 5 is formed between the upper surface of the front cover 3 and the upper part of the front panel 4 for allowing room air to pass through, and an air outlet 6 is formed in the lower front part of the front cover 3. FIG. 2 shows the back side of the front panel 4, and the suction port 5 is composed of a plurality of horizontal rails 5a and a plurality of vertical rails 5b orthogonal to the horizontal rails 5a. The front panel 4 is made of a heat-melting synthetic resin.
The mark 7 represents the position of the gate which is the filling port for the heat-melting synthetic resin. Further, the front panel 4 has two thin-walled portions 9 provided on the assumption that the welds 8 which impair the appearance are not generated. Hereinafter, a method of molding the front panel 4 will be described.

A mold is required to mold the front panel 4, but in this embodiment, as shown in FIG. 3, the horizontal rail forming cavity 10 and the upper front surface forming cavity located above the horizontal rail 5a are formed. 11, a movable die 14 in which a lower front face forming cavity 12 located at the lower portion of the horizontal rail 5b is recessed in the mating surface 13, and a vertical rail forming cavity 15 is recessed in the mating surface 13, and a lower front face is formed. Forming a thin wall portion 9 at predetermined positions on the left and right of the central portion of the cavity 12 for forming a thin metal portion forming convex surface 16 on the mating surface 13; Cavities 15 are orthogonal to each other, and a lower front face forming cavity 12 is formed.
The two molds 14 and 17 are closed so that the thin-walled portion forming convex surface 16 fits in the predetermined position, and the molten metal is heated and melted from a plurality of gates 18 which are provided in the respective fixed cavities of the fixed mold 17 in advance. The synthetic resin is filled, the mold is opened after the filled hot-melt synthetic resin is solidified, and the molded front panel 4 is taken out. Although not shown, the movable mold 14 is also provided with a cavity for forming a side wall of the front panel 4.

As shown in FIG. 2, the heat-melting synthetic resin is divided into a plurality of vertical bars 5b and is located in the left and right regions most distant from the center. It is filled from the cavity of the middle cross rail in the second region from the bottom to the center of the lower part with two thin parts 9. The shape of the thin portion 9 is such that the bottom side is shorter than the top side, the vertical side near the center of the front panel 4 is substantially orthogonal to the top side and the bottom side, and the outside side far from the center is inclined. It has a shape. By providing such a thin portion 9 symmetrically in the center of the lower portion, the timing of the flow of the synthetic resin from the left-right direction to the center of the lower portion can be delayed compared to the flow from the upper portion of the center, so that a large collision between the synthetic resins occurs. It will be avoided, and the occurrence of the weld 8 will be small enough not to be noticed. In the present embodiment, the thin portion forming convex surface 16 is formed.
4A is formed almost vertically to form a sharp step around the thin portion 9 as shown in FIG. 4A.
The thin-walled portion is not limited to this shape, but the thin-walled portion forming convex surface 16 is changed in shape so that an inclined surface 19 is formed around the thin-walled portion 9 as shown in FIG. 4B. The flow of the synthetic resin into the cavity where 3 is molded becomes smooth, and the finish around the thin portion becomes more beautiful.

[0009]

EFFECTS OF THE INVENTION In the case of a front panel molded by the method described above, there is almost no collision between synthetic resins during molding, and welds that may damage the appearance do not occur. It is inexpensive because it does not require secondary processing.

[Brief description of the drawings]

FIG. 1 is an external perspective view of an indoor unit of an air conditioner according to the present invention and a conventional example.

FIG. 2 is a rear view of a front panel showing an embodiment of the present invention.

FIG. 3 is a cross-sectional view of a front panel molding die manufactured according to the present invention.

FIG. 4 is an enlarged cross-sectional view of an essential part of a front panel molded according to the present invention.

FIG. 5 is a rear view of a front panel showing a conventional example.

[Explanation of symbols]

 4 Front Panel 5 Suction Port 5a Horizontal Bar 5b Vertical Bar 7 Gate Position 8 Weld 9 Thin Wall Part 10 Horizontal Bar Forming Cavity 11 Upper Front Forming Cavity 12 Lower Front Forming Cavity 13 Mating Surface 14 Movable Mold 15 Vertical Bar Forming Cavity 16 Thin surface forming convex surface 17 Fixed mold 18 Gate

Claims (7)

[Claims] 1. A mold in which a cross rail forming cavity, an upper front face forming cavity located at an upper portion of the cross rail, and a lower front forming cavity located at a lower portion of the cross rail are recessed in a mating surface. Another mold in which a vertical bar forming cavity is provided as a recess on the mating surface, and a thin portion forming convex surface for forming a thin portion at predetermined positions on the left and right of the central portion of the lower front face forming cavity is provided on the mating surface. And forming the horizontal rail forming cavity and the vertical rail forming cavity orthogonal to each other, and closing the two molds so that the thin portion forming convex surface fits in a predetermined position of the lower front surface forming cavity, A method of molding a front panel, characterized in that the cavity is filled with a hot-melt synthetic resin from a plurality of gates provided in advance in an appropriate arrangement in the other mold and molded. 2. The method of molding a front panel according to claim 1, wherein the convex portion for forming the thin portion, which is provided on the lower left and right sides of the center of the other mold, has a rectangular shape symmetrical to the left and right. 3. The thin-walled portion-forming convex surfaces projecting from the lower left and right sides of the center of the other mold are symmetrical, the inner sides are made substantially parallel, and the outer sides gradually move from the lower side to the upper side. The front panel molding method according to claim 1, wherein the front panel is formed into a trapezoidal shape. 4. The method for molding a front panel according to claim 1, wherein an inclined surface is provided around the convex surface for forming the thin portion. 5. The cavity of the upper horizontal rail and the cavity of the lower horizontal rail and the second area from the left and right in the left and right areas that are the most distant from the center and are divided by a plurality of vertical bars from the molten synthetic resin from the gate. The front panel molding method according to claim 1, wherein the molding is carried out by filling from a cavity of a middle cross rail inside the mold. 6. The method for molding a front panel according to claim 1, wherein a cavity for a side wall of the front panel is provided in the one die. 7. The front panel molding method according to claim 1, wherein the one mold is a movable mold and the other mold is a fixed mold.