WO2012029823A1 - Foaming mold and foam molded article formed using same - Google Patents

Abstract

The present invention addresses the problem of providing a foaming mold that is easily released and a foam molded article that is formed using the foaming mold. Also, the present invention provides a foaming mold capable of both improving formability and increasing cycle and a foam molded article that is formed using the foaming mold. The foaming mold for heating expandable resin particles filled in molding space that is formed by a molding tool to form the foam molded article is formed in such a manner that continuous groove sections from one end to the other end are aligned in one direction at regular intervals in a target area on the molding surface of the molding tool for forming the molding space.

Description

Mold for foam molding and foam molded body molded using the same

The present invention relates to a foam molding die for molding a foam molded article by heating foamable resin particles filled in a molding space, and a foam molded article molded using the mold.

The foamed molded body is generally manufactured by the manufacturing method described below. First, the resin particles are pre-foamed to obtain expandable resin particles. Next, the obtained expandable resin particles are filled into a foam mold (hereinafter also referred to as a mold). And the expandable resin particle with which the metal mold | die was filled is heated with vapor | steam, and is foamed again, and a foaming molding is formed. The formed molded foam is cooled using cooling water or the like in the mold. And the foaming molding is obtained by releasing the cooled foaming molding from a metal mold | die (for example, refer patent document 1, paragraph 0003).

By the way, in foam molded articles used for automobile interior materials and the like, in recent years, the appearance value has been increased by forming patterns such as irregularities on the surface of the foam molded article. And the foaming mold for shape | molding the foaming molding is proposed (for example, refer patent document 2, FIG. 3, FIG. 4). Specifically, a mold for foam molding has been proposed in which the molding surface has irregularities corresponding to the irregularities formed on the surface of the foam molded body.

By forming irregularities on the molding surface of the mold for foam molding, irregularities can be formed on the surface of the foam molded body, and the contact area between the foam molded body and cooling water (or cooling air) can be increased. Thus, the cooling efficiency can be increased (for example, see Patent Document 2 and FIG. 3).

Japanese Laid-Open Patent Publication No. 11-343360 Japanese Unexamined Patent Publication No. 2005-88442

The foam molding die of Patent Document 2 has a large number of independent recesses formed vertically and horizontally at predetermined intervals on the molding surface. For this reason, at the time of foam molding, the convex portions of the foam molded product are bitten into the insides of the large number of independent concave portions. As a result, in the mold release step of releasing the foamed molded product from the mold, friction is generated between the concave portion and the convex portion, the convex portion becomes a large resistance, and the foam molded product is difficult to release from the mold. Inconvenience occurred.

Further, although the cooling efficiency can be improved by forming irregularities on the molding surface of the foam molding die, there are the following disadvantages.

For example, through holes for supplying steam or cooling water (or cooling air) into the mold (inside the cavity) are formed in the projections formed on the molding surface of the foam molding mold. The through hole has an opening at the upper end of the convex portion. Then, steam or the like is supplied from the upper end opening of the convex portion into the mold through the through hole. The steam supplied into the mold is cooled to become water, and the water accumulates in the recess. The water accumulated in the concave portion is difficult to move to the upper end opening of the convex portion located above the bottom of the concave portion.

Therefore, the accumulated water is not easily discharged to the outside of the mold, and the water remains in the mold. Thus, if water remains in the mold, the foamable resin particles cannot be sufficiently filled in the mold at the next molding, which causes a problem that moldability is deteriorated.

Such a problem can be solved by adopting a cooling process using cooling air instead of cooling water. However, the cooling air has a lower cooling efficiency than the cooling water, and requires much time for cooling. For this reason, the problem that the cycle up at the time of manufacturing a foaming molding cannot be aimed at arises.

Therefore, the first object of the present invention is to provide a mold for foam molding that is easy to release and a foam molded article molded using the mold.

The second object of the present invention is to provide a foam molding die that can be improved in moldability and cycle-up, and a foam molded article molded using the mold.

In order to solve the first problem, the foam molding die of the first aspect of the present invention heats the foamable resin particles filled in the molding space formed by the molding die and molds the foam molding. A mold for foam molding for forming a groove that is continuous from one end to the other end in a target area of the molding surface of the mold that forms the molding space so as to be aligned at a constant interval in one direction. Has been.

According to the above configuration, for example, unlike the configuration in which the foamed molded product bites into a large number of independent recesses, the protrusion formed in the groove portion continuously formed from one end to the other end of the target area is the groove portion. There is no great resistance due to contact. In addition, when the foamed molded product is released, air passes through a groove that extends from one end of the target area to the other end, so that the air is between the region corresponding to the target area in the foamed molded product and the mold. It becomes easy to be transmitted uniformly. Thereby, since a gap is easily generated between the mold and the foam molded body, the foam molded body can be released smoothly. In addition, since the groove portions are aligned at a constant interval in one direction, the foamed molded body does not easily come off from the mold partly. The target area is a location where the foamed molded product molded with the mold is difficult to release from the mold, that is, a location where the user wants to easily release.

Here, it is preferable that the foam molding die of the first aspect of the present invention includes a second groove portion that is aligned at a constant interval in another direction different from the one direction so as to cross the groove portion.

According to this, when releasing the foamed molded product after foaming, the air for releasing can be more uniformly dispersed. For this reason, mold release of a foaming molding can be performed more smoothly.

In the foam molding die according to the first aspect of the present invention, a steam chamber into which at least a heating medium and a cooling medium are introduced is provided, and the molding die has a through hole that communicates the steam chamber and the molding space. It is preferable that the groove is formed corresponding to the formation pitch of the through holes.

According to this, air for releasing through the through hole can be uniformly supplied to the molding surface.

In the foam molding die of the first aspect of the present invention, it is preferable that the groove is formed so as to pass through the through hole.

According to this, it becomes easy to uniformly distribute the air supplied through the through hole to the molding surface using the groove.

In the foam molding die of the first aspect of the present invention, it is preferable that the groove portion has a tapered shape in which the cross section tapers as it goes in the depth direction.

For example, when the protrusion formed in the groove has a shape with a corner at the tip, the corner may be caught by a mold (inner surface of the groove) and may not be easily released. However, as described above, if the groove section has a tapering shape that tapers as it goes in the depth direction, a part of the foam molded body (projection) is a mold (inner surface of the groove section). It will not get caught in. For this reason, the resistance at the time of mold release can be kept small by that much. Thereby, mold release of a foaming molding can be performed more smoothly.

In order to solve the second problem, the foam molding die of the second aspect of the present invention is provided with a steam chamber into which at least a heating medium and a cooling medium are introduced, and fills a molding space formed by the molding die. A foam molding die for forming a foamed molded article by heating and cooling the expanded resin particles formed by a heating medium and a cooling medium introduced into the steam chamber, wherein the steam chamber and the molding space are separated from each other. A communicating hole is formed in the mold, and a groove portion continuous from one end to the other end of the target area is formed in one direction on the target area of the molding surface of the mold. .

According to this, the cooling water supplied into the mold through the through hole from the steam chamber is uniform in the target area of the molding surface through the groove portion continuously formed from one end to the other end of the target area of the molding surface. Easy to spread. For this reason, the cooling efficiency is increased, and the cycle can be improved by shortening the cooling time. The target area is a part that improves the cooling efficiency of the foamed molded product, improves the cycle by shortening the cooling time, and considers increasing the discharge of water generated by the cooling process. This target area may be the entire surface or a part of the mold.

Here, it is preferable that the foam molding die of the second aspect of the present invention includes a second groove portion aligned in another direction different from the one direction so as to intersect with the groove portion.

According to this, the cooling water tends to spread more uniformly over the target area of the molding surface. For this reason, it is possible to further increase the cycle.

In the foam molding die of the second aspect of the present invention, it is preferable that the through hole is formed in the groove or the second groove.

In the foam molding die of the second aspect of the present invention, it is preferable that the through hole is formed between the groove portions.

According to this, water after cooling (including cooling water as well as water that has cooled and turned into water) is easily discharged from the through hole to the steam chamber outside the mold. This makes it difficult for water to accumulate in the mold. For this reason, at the time of the next molding, the filling property of the expandable resin particles in the mold is increased, and the moldability is improved. Moreover, since water does not easily accumulate in the mold, a water cooling process can be actively employed. Thereby, the cycle up by shortening of cooling time can further be aimed at.

As described above, according to the first aspect of the present invention, both improvement in formability and cycle up can be achieved by the groove portion extending from one end to the other end of the target area of the molding surface.

Further, according to the second aspect of the present invention, the continuous groove portion extending from one end to the other end is formed in the target area of the molding surface of the molding die so as to be aligned at a constant interval in one direction. Is easily transmitted to the molding surface through the groove. Thereby, mold release of a foaming molding can be performed smoothly.

FIG. 2 is a foam molding die for molding a foam molded article, wherein (a) is a longitudinal sectional view, and (b) is a plan view (bottom view) of the left mold. It is a perspective view of the state just before closing the lid | cover of the tool box (foaming molding of 1st embodiment) with which the vehicle was mounted | worn. It is an enlarged view of the upper surface of the flange part of the tool box, (a) is a perspective view, (b) is a plan view, and (c) is a longitudinal sectional view. It is a longitudinal cross-sectional view of the vehicle lower part provided with the tibia pad (foaming molding of 2nd embodiment). (A), (b), (c) is a longitudinal cross-sectional view of the foaming mold (specifically, the left mold) of another embodiment. (A), (b), (c) is a longitudinal cross-sectional view of the foaming molded object each shape | molded with the metal mold | die for foam molding (specifically, the left side mold) of FIG. It is a foaming mold (specifically, a left mold) according to another embodiment in which the position of the through hole is changed, and (a) is a plan view (bottom view) of the left mold (b) ) Is a longitudinal sectional view of the left mold. It is an enlarged view of the foaming molding of other embodiments which aligned the ridge only in one direction, (a) is a perspective view, (b) is a top view, (c) is a longitudinal section FIG.

Hereinafter, an embodiment of a mold for foam molding of the present invention (hereinafter also simply referred to as “mold”) will be described with reference to the drawings.

As shown in FIGS. 1A and 1B, the mold 11 includes a pair of mold main bodies 12 and 13 facing each other. The mold 12A constituting the mold body 12 and the mold 13A constituting the mold body 13 are arranged so as to face each other. Then, the left and right molding dies 12 </ b> A and 13 </ b> A are combined on the front surface side (opposite surface side), whereby a molding space filled with the expandable resin particles S is formed in the mold 11. The mold 11 shown in FIG. 1A is a horizontal mold that opens and closes a pair of mold bodies 12 and 13 in the left-right direction (horizontal direction), but a vertical mold that opens and closes in the vertical direction. It may be a mold. In FIG. 1A, the right mold 13A is plate-shaped, but the molding space may be formed by the same box-shaped mold as the left mold 12A.

In the left mold body 12, a steam chamber 12a is formed by covering the back side of the mold 12A with a back plate 12B. That is, the steam chamber 12a is formed by the mold 12A and the back plate 12B. Similarly, in the right mold body 13, a steam chamber 13a is formed by the mold 13A and the back plate 13B.

The upper plate portion 12b of the back plate 12B of the left mold body 12 has predetermined one end sides (lower end sides) of a steam supply pipe 21, a cooling water supply pipe 22, and a compressed air supply pipe 23 communicating with the steam chamber 12a. It is fixed in a state where it penetrates with a gap. On the way of the steam supply pipe 21, the cooling water supply pipe 22, and the compressed air supply pipe 23, open / close valves 21V, 22V, and 23V are provided. The cooling water supply pipe 22 has an extending portion 22A that extends from the upper plate portion 12b to the vicinity of a lower plate portion 12c described later. The extension 22A has an opening 22a for supplying cooling water with a predetermined interval in the extension direction. Although not shown, a steam supply pipe 21, a cooling water supply pipe 22, and a compressed air supply pipe 23 provided with open / close valves 21V, 22V, and 23V are also fixed to the right mold body 13.

Further, one end side (upper end side) of the drain pipe 24 and the vacuum supply pipe 25 connected to the vacuum device penetrates the lower plate portion 12c of the back plate 12B of the left mold body 12 with a predetermined interval. It is fixed in the state. On the way of the drain pipe 24 and the vacuum supply pipe 25, open / close valves 24V and 25V are provided. Although not shown, a drain pipe 24 and a vacuum supply pipe 25 provided with opening / closing valves 21V, 22V, and 23V are also fixed to the right mold body 13.

FIG. 1 (b) is an enlarged view of a molding surface (bottom surface of the wall surface forming the molding space) when the box-shaped molding die 12A is viewed from the steam chamber 12a side. A plurality of first groove portions M1 extending continuously in one direction (specifically, the vertical direction) are provided at predetermined locations (hereinafter also referred to as target areas) on the molding surface 12K (that is, the bottom surface) of the molding die 12A. Is formed. Further, in the target area, a large number of second groove portions M2 extending continuously in other directions (specifically, the front-rear direction) so as to be orthogonal to the first groove portions M1 have the same depth (high height) as the first groove portions M1. A). In addition, the front-back direction means the direction orthogonal to the left-right direction and the up-down direction.

A large number of first groove portions M1 are aligned with a predetermined interval P1 in the front-rear direction (see FIG. 1B). Further, the multiple second groove portions M2 are aligned with a constant interval P2 in the vertical direction (P1 = P2 in the present embodiment) (see FIG. 1B). The vertical direction is the same as the vertical direction on the paper. In addition, the front-rear direction is a direction from the front surface to the back surface perpendicular to the paper surface in FIG. The intervals between the multiple first groove portions M1 and second groove portions M2 are preferably determined so as to improve the cooling efficiency. Needless to say, the intervals between all the grooves need not be constant. In the present embodiment, the first groove portion M1 and the second groove portion M2 are orthogonal to each other. However, in order to improve the cooling efficiency and the like, the first groove portion M1 and the second groove portion M2 are along different directions. What is necessary is just to be formed so that it may extend. For example, depending on the shape or the like of the molded product (foamed molded body), the first groove portion M1 and the second groove portion M2 may be formed so as to cross obliquely rather than orthogonally.

Here, the target area is set to a range where a desired effect is desired. That is, for example, the target area is set at a location where an effect desired by the user is desired, such as improved releasability, improved cooling efficiency, and improved moldability. Therefore, as shown in FIG. 1 (a), it is necessary to define the target area only on the surface (that is, the molding surface 12K) facing one mold (molding mold 12A) and the other mold (molding mold 13A). There is no. That is, it goes without saying that the target area may be set on the upper wall surface, the lower wall surface, or the like on the molding surface of the mold 12A. Moreover, a target area may be set in the whole area of each wall surface which comprises the shaping | molding surface of the shaping | molding die 12A, or a part, and a target area may be set in several places. Furthermore, for example, when the target area is set over the entire molding surface of the molding die 12A, the end portions of the first groove portions M1 or the end portions of the second groove portions M2 on each wall surface may be continuous. And it does not have to be continuous. The foamable resin particles S are filled in the molding space formed by the molds 12A and 13A configured as described above. And the foaming molding is shape | molded by heating the filled expandable resin particle S. A large number of first protrusions 8T1 and second protrusions 8T2 (see FIGS. 3A, 3B, and 3C), which will be described later, are formed on the surface of the molded foam molded body. The

Further, the steam and cooling water (or cooling air) introduced into the steam chamber 12a through the steam supply pipe 21, the cooling water supply pipe 22, the compressed air supply pipe 23, and the drain pipe 24 are supplied to the molding space (cavity). A first through hole 12K1 for supply is formed on the bottom surface of the first groove portion M1 of the mold 12A. Moreover, the same 2nd through-hole 12K2 is formed in the bottom face of the 2nd groove part M2 of the shaping | molding die 12A. The first through holes 12K1 are formed in the first groove portions M1, and are formed at a predetermined interval P1 in the front-rear direction, like the first groove portions M1. On the other hand, the second through holes 12K2 are formed in the respective second groove portions M2, and are formed with a constant interval P2 in the vertical direction, like the second groove portions M2. The first and second through holes 12K1 and 12K2 may have a circular shape, an elliptical shape, a rectangular shape, or the like, or a vertically long slit shape. Moreover, in this embodiment, although the 1st and 2nd through-hole 12K1, 12K2 has shown the case where only one is formed with respect to each in the 1st and 2nd groove part M1, M2, 2 or more are shown. It may be formed. Further, in addition to being formed in each first groove portion M1, one or more first through holes 12K1 may be formed in every other first groove portion M1. Alternatively, one or more may be formed in every second first groove M1. Or one or more may be formed in the specific 1st groove part M1 selected at random. Similarly, the second through holes 12K2 may be formed with one or more second through holes 12K2 in every other second groove portion M2. Alternatively, one or more second through holes 12K2 may be formed in every second second groove portion M2. Or one or more 2nd through-holes 12K2 may be formed in the specific 2nd groove part M2 selected at random. Of course, through holes similar to the first and second through holes 12K1 and 12K2 may be formed at the intersecting positions of the first groove portion M1 and the second groove portion M2. Further, here, the diameter of the first through hole 12K1 or the second through hole 12K2 is larger than the width of the first groove part M1 or the second groove part M2, and further the pitch P1 or P2 of the first groove part M1 or the second groove part M2. May be big. In this case, a part of the first through hole 12K1 or the second through hole 12K2 may be formed inside at least one of the first groove part M1 or the second groove part M2. The positions of the first and second through holes 12K1 and 12K2 with respect to the first and second groove portions M1 and M2 may be regular with a constant interval P2 as described above, or may be random. Good. Of course, at least the through-holes may be regularly or randomly formed in the mold 13A of the right mold body 13.

Here, the depth of the first groove part M1 and the second groove part M2 is preferably 1 mm or less, and more preferably 0.3 mm or less. Further, the interval P1 between the first groove portions M1 and M1 and the interval P2 between the second groove portions M2 and M2 are preferably 2 mm to 50 mm, and more preferably 30 mm or less (excluding 0). By setting the intervals P1 and P2 as described above, the releasability of the foamed molded product from the mold 11 (specifically, the left mold 12A) can be further improved. The depths of the plurality of first and second groove portions M1 and M2 may all be the same, or may be all or a part of which is different. The widths of the plurality of first and second groove portions M1 and M2 may all be the same, or may be different from all or only a part.

Moreover, the method for producing the mold 11 (specifically, the left mold 12A) is not particularly limited, and other production methods such as cutting can be used. As described above, since the depths of the first groove portion M1 and the second groove portion M2 are shallow, it is preferable to use an etching process as a method for manufacturing the mold 11 (specifically, the left mold 12A). . By using such a processing method, not only the degree of freedom of design is increased, but also the molding surface of a complex-shaped mold can be formed with high accuracy.

Next, the process of molding the foam molded body using the mold 11 configured as described above will be described with a focus on the left mold body 12. The mold 11 shown in FIG. 1 is a conceptual diagram for explaining the first groove portion M1, the second groove portion M2, the first through hole 12K1, and the second through hole 12K2. And the form does not match.

First, a molding space is formed by matching the opposing sides of the molding dies 12A and 13A. The formed molding space is filled with the expandable resin particles S using a filling device (not shown). And heat processing are performed in the following procedures. First, steam is supplied from the steam supply pipe 21 to the steam chamber 12 a of the mold body 12 by opening the open / close valve 21 </ b> V of the mold body 12. At this time, the drain pipe (not shown) of the mold body 13 is opened. The steam supplied to the steam chamber 12a of the mold body 12 heats the outer (back) surface of the mold 12A of the mold body 12, and the first and second through holes 12K1, 12K2 of the mold 12A. And is supplied to the molding space. The steam supplied to the molding space is guided to the steam chamber 13a of the molding die 13A through a through hole (not shown) of the molding die 13A of the mold body 13. The steam introduced into the steam chamber 13 a is discharged to the outside of the mold body 13 through a drain pipe (not shown) of the mold body 13. Next, the open / close valve 21V of the mold body 12 is closed, and the drain pipe 24 is opened. Further, the drain pipe (not shown) of the mold body 13 is closed, and the opening / closing valve (not shown) of the mold body 13 is opened. Then, steam is supplied from the steam supply pipe (not shown) of the mold body 13 to the steam chamber 13a. The steam supplied to the steam chamber 13a heats the back surface of the molding die 13A and is supplied to the molding space through a through hole (not shown) of the molding die 13A. The steam supplied to the molding space is guided to the steam chamber 12a of the molding die 12A through the first and second through holes 12K1 and 12K2 of the molding die 12A. The steam introduced into the steam chamber 12 a is discharged to the outside of the mold body 12 through the drain pipe 24 of the mold body 12. Finally, the drain pipe 24 of the mold body 12 is closed, that is, the drain pipes 24 of the mold bodies 12 and 13 (the drain pipe of the mold body 13 is not shown) are closed. Then, the open / close valves 21V of both mold bodies 12, 13 (the open / close valve of the mold body 13 is not shown) are opened, and steam is supplied from the steam supply pipe 21 to the steam chambers 12a, 13a. The supplied steam heats the outer surfaces of the molds 12A and 13A and passes through the first and second through holes 12K1 and 12K2 of the mold 12A and the through holes (not shown) of the mold 13A. To be supplied. Thereby, the expandable resin particles S filled in the molding space are heated again.

When the heating is completed, the open / close valves 22V of the mold bodies 12, 13 (the open / close valve of the mold body 13 is not shown) are opened. And cooling water is sprayed on the shaping | molding die 12A, 13A from opening 22a of the extension part 22A, and shaping | molding die 12A, 13A is cooled. At this time, a part of the cooling water passes through the first and second through holes 12K1 and 12K2 of the mold main body 12 and the through holes of the mold main body 13 and between the molds 12A and 13A (that is, inside the molding space). Get in. Thereby, cooling of a foaming molding is accelerated | stimulated. The foamed molded body starts to shrink when cooled. Thereby, a gap is formed between the foamed molded body and the molds 12A and 13A. The cooling water flows into the first and second groove portions M1 and M2 through this gap and easily propagates through the target area. Therefore, the cooling efficiency of the foamed molded product is improved.

When the cooling with the cooling water is completed, the opening / closing valve 23V of both the mold bodies 12, 13 (the opening / closing valve of the mold body 13 is not shown) is opened. Then, compressed air is supplied from the compressed air supply pipe 23 to the steam chambers 12a and 13a. The compressed air supplied to the steam chambers 12a and 13a is supplied between the molds 12A and 13A (that is, in the molding space) through the first and second through holes 12K1 and 12K2 and the through hole of the mold 13A. Is done. The compressed air supplied to the molding space uses the first and second through holes 12K1, 12K2, and the molding die 13A to cool the cooling water accumulated in the molding die 12A through the gap between the foam molding and the molding dies 12A, 13A. Guide to the through hole. Thus, the cooling water is discharged to the steam chambers 12a and 13a of the molds 12A and 13A through the first and second through holes 12K1 and 12K2 and the through holes of the mold 13A. The cooling water discharged to the steam chambers 12a and 13a is discharged outside the mold main bodies 12 and 13 through the left and right drain pipes 24, respectively. The compressed air also serves to release the foamed molded product from the molds 12A and 13A.

Subsequently, a vacuum cooling process is performed. In the vacuum cooling process, the opening / closing valve 24V (the opening / closing valve of the mold body 13 is not shown) of the drain pipe 24 of both the mold bodies 12, 13 is closed, and then the opening / closing valve 25V (opening / closing of the mold body 13) is performed. The valve (not shown) is opened. Then, the inside of the steam chambers 12 a and 13 a is depressurized by the vacuum supply pipe 25. Thereby, the moisture remaining in the vapor chambers 12a and 13a and the moisture attached to or contained in the molded foam molded body evaporate, and the vacuum cooling process is completed. Under the present circumstances, cooling of a foaming molding is accelerated | stimulated using the evaporation latent heat accompanying evaporation of a water | moisture content. Thereafter, the molds 12A and 13A are separated from each other, the mold 11 is opened, and the open / close valve 23V of the mold main bodies 12 and 13 (the open / close valve of the mold main body 13 is not shown) is opened. The compressed air (air) for releasing the foamed molded product from the molds 12A and 13A is compressed air supply pipe 23 of the mold bodies 12 and 13 (the compressed air supply pipe of the mold body 13 is not shown). To the steam chambers 12a and 13a. As a result, the first and second through holes 12K1, 12K2 and the through hole of the mold 13A (the through hole of the mold 13A is not shown) are interposed between the molds 12A, 13A and the foamed molded body. Compressed air (air) is supplied, and the foamed molded product is released from the molds 12A and 13A. And a foaming molded object is taken out from between mold 12A, 13A, and a work is completed. Of course, a mold may be provided with a release pin and used together with compressed air (air) to release the foamed molded product and take it out. Alternatively, the foamed molded product may be released by using only a release pin.

As described above, according to the mold 11 of the present embodiment, the first and second through holes 12K1 and 12K2 cool the steam for heating the foamable resin particles or the foamed molded body immediately after the foam molding. It is used as an inlet / outlet hole for supplying cooling water (or cooling air) to the inside of the mold. For this reason, the steam and cooling water supplied through the first through hole 12K1 and the second through hole 12K2 are likely to spread to the target area of the molding surface through the continuously formed first and second groove portions M1 and M2. . Moreover, since steam and cooling water are uniformly supplied from any direction of the molding surface, the moldability and cooling efficiency can be improved.

Further, water or cooling water generated by cooling the steam in the molding space in the cooling process is accumulated inside the mold 11 (specifically, the molding space). The accumulated water or cooling water is quickly and reliably discharged from the molding space through the first through hole 12K1 and the second through hole 12K2 formed corresponding to the first groove portion M1 and the second groove portion M2. From this, it is possible to prevent water from accumulating in the mold 11 (specifically, the mold body 12). As a result, the filling of the expandable resin particles is not hindered by the water accumulated in the mold 11 (specifically, the mold body 12) during the next foam molding process. From this, the filling operation can be performed reliably, and the moldability can be improved. And since the problem that water accumulates in the metal mold | die 11 (specifically metal mold main body 12) does not arise, the water cooling process by water-cooled water can be employ | adopted actively. As a result, the cooling efficiency of the foamed molded product can be improved, and the cycle can be increased by shortening the time.

Further, since the first and second through holes 12K1 and 12K2 are formed in the first and second groove portions M1 and M2, compressed air (air) is directly supplied to the first and second groove portions M1 and M2. be able to. Thereby, compressed air (air) becomes easy to be uniformly transmitted to the object area of a molding surface through groove part M1, M2. For this reason, mold release of a foaming molding can be performed smoothly. In addition, since the compressed air (air) passes through the two first and second groove portions M1 and M2 in different directions, the compressed air (air) is molded at the time of releasing the foamed molded product after the foam molding. It can be uniformly distributed over the target area of the surface. Thereby, mold release of a foaming molding can be performed more smoothly.

FIG. 2 and FIG. 3 show a foam molded body obtained by foam molding with such a mold 11. The expansion ratio can be appropriately changed according to the purpose of use. In FIG. 2, the tool box 1 mounted in a vehicle is shown as an example of a foaming molding. The tool box 1 includes a rectangular box body 5 having three storage portions 2, 3, and 4 and an annular flange portion 6 formed at the upper end of the box body 5. The tool box 1 is supported by placing the flange portion 6 on the upper surface 9A of the metal frame member 9 which is substantially U-shaped on the vehicle body side. Further, the tool box 1 includes a plate-like lid 7 for covering the upper surface of the box body 5. A plate-like and annular contact member 7 </ b> A that contacts the upper surface of the box body 5 is formed on the outer peripheral edge of the lid 7.

Further, the foam molded body can be made of any foamable resin material. For example, the foamed molded body is preferably molded from a thermoplastic resin among foamable resin materials. Examples of the thermoplastic resin include polystyrene resins, polyolefin resins (eg, polypropylene resins, polyethylene resins), polyester resins (eg, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate), polycarbonate resins, and polylactic acid resins. Resin etc. are mentioned. Among these, it is preferable to use a composite resin containing polystyrene and polyethylene as the foamable resin material.

The upper surface 8A of the outer peripheral edge (rectangular shape) of the horizontal upper surface of the tool box 1 is a portion corresponding to the target area of the molding surface of the mold 11. As shown in FIGS. 2 and 3A, 3B, and 3C, the upper surface 8A has a large number of first protrusions that protrude upward from the upper surface 8A and extend straight in the left-right direction. 8T1 is formed. Further, the upper surface 8A has a large number of first protrusions that protrude upward from the upper surface 8A so as to be at the same height as the first protrusion 8T1 and extend in a straight line in the front-rear direction so as to be orthogonal to the first protrusion 8T1. Two protrusions 8T2 are formed. A large number of first protrusions 8T1 are aligned with a predetermined interval P1 in the front-rear direction. In addition, the multiple second protrusions 8T2 are aligned at a constant interval P2 in the left-right direction. Moreover, the cross-sectional shape of the 1st protrusion 8T1 and the 2nd protrusion 8T2 is a taper shape toward the front end side. Specifically, the cross-sectional shapes of the first and second ridges 8T1 and 8T2 have a substantially triangular shape having an acute outline (configured by an acute outline).

Therefore, the abutting member 7A of the lid 7 is pressed against the upper surface 8A of the tool box 1 by the weight of the lid 7 when the lid 7 is closed. Accordingly, the contact member 7A can be stably supported by the first and second protrusions 8T1 and 8T2. Further, since the cross-sectional shapes of the first and second ridges 8T1 and 8T2 are substantially triangular, the contact area between the first and second ridges 8T1 and 8T2 and the contact member 7A is reduced. . For this reason, the first protrusion 8T1 and the second protrusion 8T2 can be appropriately brought into contact with the contact member 7A. As a result, an anchor effect occurs and the upper lid 7 is less likely to move with respect to the tool box 1. Further, it is possible to prevent the contact member 7A and the tool box 1 from rubbing and generating abnormal noise.

Generally, the mechanism (sounding mechanism) that generates abnormal noise (sounding) is explained by the stick-slip phenomenon. This stick-slip phenomenon occurs when two objects are pressed against each other under a load, and when they move relative to each other while maintaining contact, adhesion and slip occur alternately on the surfaces of these objects. This is a phenomenon in which the smooth relative movement of two objects is hindered. When such a phenomenon occurs, vibration (frictional vibration) occurs in the object, and a phenomenon in which sound is generated appears. That is, it is considered that sound is generated by repeatedly performing small movements such that one object slides on and adheres to the other (partner) object and slips on the other object. For such a phenomenon, the first protrusion 8T1 and the second protrusion 8T2 are very effective.

In particular, as described above, a large number of first ridges 8T1 and a large number of second ridges 8T2 are formed so as to be orthogonal to each other, so that an annular (rectangular) frame portion surrounded on all sides is front and rear. It is formed in a state that continues in the left-right direction. Thereby, the shape retention strength of the 1st protrusion 8T1 and the 2nd protrusion 8T2 can be raised. For this reason, it is effective in preventing abnormal noise and preventing displacement.

Also, the first protrusion 8T1 and the second protrusion 8T2 may be formed on the lower surface 6A of the flange portion 6. In this case, for example, it is possible to prevent the tool box 1 from moving relative to the metal frame member 9 due to vibration during traveling of the vehicle. Thereby, it can prevent that the lower surface 6A of the flange part 6 and the upper surface 9A of the frame member 9 rub against each other, and noise is generated. Moreover, the 1st protrusion 8T1 and the 2nd protrusion 8T2 may be formed also in the lower surface 5A of the box main body 5 which contacts the vehicle body structural member 10 shown with the dashed-two dotted line of FIG. In this case, it is possible to prevent the tool box 1 from moving relative to the vehicle body constituent member 10 due to vibrations during traveling of the vehicle. Thereby, it can prevent that the lower surface 5A of the box main body 5 and the vehicle body structural member 10 rub against each other, and abnormal noise is generated.

In addition, the 1st protrusion 8T1 and the 2nd protrusion 8T2 are short protrusions whose height becomes 1 mm or less. For this reason, in FIG. 2, the 1st protrusion 8T1 and the 2nd protrusion 8T2 are shown with the line. 3 (a), (b), and (c), the first and second ridges 8T1 and 8T2 are enlarged to clarify the shapes of the first and second ridges 8T1 and 8T2. It is shown greatly by.

By the way, on the surface of the tool box 1 which is a foamed molded product formed by heating the foamable resin particles filled in the mold (molding space), the particle diameter of the foamable resin particles, the variation in the foaming density, etc. Due to this, a turtle shell pattern may occur. Even when the turtle shell pattern is generated in this way, as described above, the first ridge 8T1 and the second ridge 8T2 are formed on the upper surface of the tool box 1 (foamed molded body), so that the turtle shell pattern is hardly noticeable. can do. Thereby, it can be set as the tool box 1 excellent in the designability, and can raise a commercial value. Further, even when the surface of the tool box 1 (foamed molded body) is scratched, the scratch is canceled out by the first and second protrusions 8T1 and 8T2, so that the scratch can be made inconspicuous. For the purpose of these effects, the first ridge 8T1 and the second ridge 8T2 are formed in other locations where the first ridge 8T1 and the second ridge 8T2 are not formed in the tool box 1 described above. May be.

The foamed molded product can be used as a tibia pad 14 provided at the front seat foot of the vehicle shown in FIG. 4 (or can be used as a floor spacer provided at the rear seat foot of the vehicle). The tibia pad 14 is disposed between the floor panel 15 and a floor carpet 16 as an interior material disposed thereon. The purpose of the tibia pad 14 arranged in this way is to increase the cushioning of the occupant's feet 17 and increase the ride comfort.

The tibia pad 14 is composed of a foamed molded body in which foamable resin particles are heated and foam-molded into a plate shape. The tibia pad 14 includes a plurality of first protrusions 14T1 protruding upward from the upper surface 14A and extending in a straight line in the left-right direction. Further, the tibia pad 14 protrudes upward from the upper surface 14A so as to have the same height as the first protrusion 14T1, and extends in a straight line in the front-rear direction so as to be orthogonal to the first protrusion 14T1. It has. A large number of first protrusions 14T1 are aligned with a predetermined interval P3 in the front-rear direction. The interval P3 may be the same as or different from the constant interval P1 in FIG. In addition, the multiple second protrusions 14T2 are aligned at regular intervals in the left-right direction. The interval between the second ridges 14T2 may be the same as the constant interval P3 of the first ridges 14T1, or may be a different interval. Moreover, the cross-sectional shape of the 1st protrusion 14T1 and the 2nd protrusion 14T2 is a taper shape toward the front end side, specifically, a substantially triangular shape.

The tibia pad 14 formed in this way is disposed between the floor panel 15 and the floor carpet 16, so that, for example, when the occupant gets into the vehicle, the floor carpet 16 receives the load of the foot 17, The load can be stably supported by the first protrusion 14T1 and the second protrusion 14T2. Thereby, since the 1st protrusion 14T1 and the 2nd protrusion 14T2 contact the floor carpet 16 appropriately, it can prevent effectively that abnormal noise generate | occur | produces. In addition, since the floor carpet 16 is less likely to move with respect to the tibia pad 14, it is possible to prevent the floor carpet 16 from being displaced with respect to the tibia pad 14. In FIG. 4, the first protrusion 14T1 and the second protrusion 14T2 are formed only on the surface of the tibia pad 14 (the surface that contacts the floor carpet 16), but the back surface (the surface that contacts the floor panel 15) of the tibia pad 14 Alternatively, the first protrusion 14T1 and the second protrusion 14T2 may be formed.

The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the gist of the present invention.

In the said embodiment, although the metal mold | die for shape | molding the foaming molded object used as an interior material (tibia pad 14) in a vehicle was shown, things other than the interior material in a vehicle, for example, the ornaments put in a room, A cushion material or the like placed in a sofa, bed, or under the floor may be molded with the mold of the present invention.

In the embodiment, the cross-sectional shape of the mold body 12 (specifically, the mold 12A) is V-shaped so that the cross-sectional shapes of the first and second protrusions of the foamed molded body are substantially triangular. The first and second groove portions M1 and M2 were formed. In this way, by forming each groove portion in a tapered shape that tapers in the depth direction of each groove portion, the protrusions of the molded foam molded body are caught on the inner surface of the groove portion at the time of mold release and become large. It is preferable because it does not become a resistance. Moreover, as shown to Fig.5 (a), each groove part may be 1st and 2nd groove part M3, M4, etc. of semicircle shape. Alternatively, each groove may be a first and second groove M5, M6 having an upper half shape as shown in FIG. Or each groove part may be the 1st and 2nd groove parts M7 and M8 of the shape of the upper half of an ellipse, etc., as shown in Drawing 5 (c). In addition, each groove may have a rectangular cross-sectional shape having the same width in the depth direction (having corners at the four corners of the tip).

FIGS. 6 (a), (b), and (c) show foamed molded articles molded by the molding die 12A shown in FIGS. 5 (a), (b), and (c). That is, FIG. 6 (a) shows a foamed molded article formed by the mold 12A shown in FIG. 5 (a). In such a foam-molded body, protrusions 18T1 and 18T2 having a semicircular cross-sectional shape protruding upward from the surface are formed. One protrusion 18T1 extends in a straight line in the left-right direction. The other protrusion 18T2 extends in a straight line in the front-rear direction. Moreover, the foaming molding shape | molded with the shaping | molding die 12A of FIG.5 (b) is shown in FIG.6 (b). In such a foam molded body, protrusions 19T1 and 19T2 are formed in which the cross-sectional shape protruding upward from the surface is the shape of the upper half of the oval shape. One protrusion 19T1 extends in a straight line in the left-right direction. The other protrusion 19T2 extends in a straight line in the front-rear direction. Moreover, the foaming molding shape | molded with the shaping | molding die 12A of FIG.5 (c) is shown in FIG.6 (c). In such a foamed molded article, protrusions 20T1 and 20T2 are formed in which the cross-sectional shape protruding upward from the surface is the shape of the upper half of an elliptical shape. One protrusion 20T1 extends in a straight line in the left-right direction. The other protrusion 20T2 extends in a straight line in the front-rear direction. The tip of the ridge may be any shape as long as it is tapered, but it is preferably a round shape with no corners at the tip.

Moreover, in the said embodiment, although both the 1st groove part M1 and the 2nd groove part M2 were arranged with the fixed space | interval, it implemented by setting one or both of the 1st groove part M1 or the 2nd groove part M2 to the non-fixed unfixed space | interval. May be.

Moreover, in the said embodiment, although the space | interval between 1st protrusion 8T1 and the space | interval between 2nd protrusion 8T2 were both made into the fixed space | interval, you may implement by setting one or both to the non-constant space | interval. .

Moreover, in the said embodiment, although the 1st protrusion 8T1 and the 2nd protrusion 8T2 of the foaming molding were comprised in the straight line shape, you may comprise in a continuous zigzag shape, and comprise in a continuous curve shape. Also good. In addition to making the first protrusion 8T1 and the second protrusion 8T2 orthogonal, the first protrusion and the second protrusion may be formed so as to intersect at a predetermined angle other than 90 degrees.

Moreover, in the said embodiment, although the 1st through-hole 12K1 was formed in the 1st groove part M1, and the 2nd through-hole 12K2 was formed in the 2nd groove part M2, it shows to Fig.7 (a), (b). Thus, the through-hole 12K3 may be formed in a portion other than the first groove portion M1 and the second groove portion M2. Specifically, an intermediate portion (not necessarily an intermediate portion) between the first groove portions M1 and M1 arranged in parallel (not an intermediate portion) and an intermediate portion (not an intermediate portion) between the second groove portions M2 and M2 arranged in parallel. May be formed). More specifically, the through-hole 12K3 may be formed in the center portion (not necessarily the center portion) of the flat surface portion 12H formed by being surrounded by the first groove portion M1 and the second groove portion M2. In FIG. 7A, the through holes 12K3 are formed in all of the flat surface portions 12H surrounded by the four sides, but the through holes 12K3 may be formed only in the specific flat surface portions 12H. Thus, by forming the through-hole 12K3 in the thickest flat surface portion 12H, the first and second grooves M1 and M2 having the reduced thickness as shown in FIG. Compared to the configuration in which the second through holes 12K1 and 12K2 are formed, the thickness of the mold 12A can be reduced, and the mold (specifically, the mold body) can be downsized. Can do. Moreover, the metal mold | die provided with not only the 1st through-hole 12K1 and the 2nd through-hole 12K2 which were shown in FIG. 1 but also the through-hole 12K3 which was shown to FIG. 7 (a), (b) may be sufficient.

In the embodiment, the plurality of straight first groove portions M1 having different directions and the second groove portion M2 are formed so as to be orthogonal to each other (may be crossed), but only the first groove portion M1 or Only the second groove portion M2 may be formed. For example, FIGS. 8A, 8 </ b> B, and 8 </ b> C show foamed molded articles formed by a mold in which only the first groove portion M <b> 1 or only the second groove portion M <b> 2 is formed. The foamed molded body is formed with a plurality of protrusions 8T3 that protrude upward from the upper surface 8A and extend linearly in the front-rear direction. The multiple protrusions 8T3 are aligned with a constant interval P2 in the left-right direction. Further, the cross section of the protrusion 8T3 is tapered toward the tip side, specifically a substantially triangular shape constituted by an acute outline, but is not limited to this, and can be freely changed. can do.

DESCRIPTION OF SYMBOLS 1 ... Tool box, 2, 3, 4 ... Storage part, 5 ... Box main body, 5A ... Lower surface of box main body, 6 ... Flange part, 6A ... Lower surface of flange part, 7 ... Cover, 7A ... Contact member of a lid, 8A ... Upper surface of tool box, 8T1 ... 1st protrusion, 8T2 ... 2nd protrusion, 9 ... Frame member, 9A ... Upper surface of frame member, 10 ... Car body component, 11 ... Foam molding die, 12, 13 ... Mold body, 12A, 13A ... Mold, 12B, 13B ... Back plate, 12b ... Upper plate part, 12c ... Lower plate part, 12H ... Plane part, 12K ... Molding surface, 12K1, 12K2, 12K3 ... Through hole, 12a, 13a ... steam chamber, 14 ... tibia pad, 14A ... upper surface of tibia pad, 14T1 ... first ridge, 14T2 ... second ridge, 15 ... floor panel, 16 ... floor carpet, 17 ... foot, 18T1, 18T2, 19 1,19T2,20T1,20T2 ... ridges, M1 ... first groove, M2 ... second groove, M3 ~ M8 ... groove, S ... expandable resin particles

Claims (10)

1. A mold for foam molding for heating a foamable resin particle filled in a molding space formed by a mold and molding a foam molded article,
   A foam molding die, wherein a groove portion continuous from one end to the other end is formed in a target area of a molding surface forming the molding space so as to be aligned at a constant interval in one direction.
2. 2. The foam molding die according to claim 1, further comprising a second groove portion that is aligned at a predetermined interval in another direction different from the one direction so as to intersect the groove portion.
3. A steam chamber into which at least a heating medium and a cooling medium are introduced is provided, and a through hole is formed in the mold for communicating the steam chamber and the molding space, and the groove portion corresponds to a formation pitch of the through holes. The mold for foam molding according to claim 1 or 2, which is formed as described above.
4. The foam mold according to claim 3, wherein the groove is formed so as to pass through the through hole.
5. The foam molding die according to any one of claims 1 to 4, wherein the groove portion has a tapered shape in which a cross-section thereof tapers in a depth direction.
6. A steam chamber into which at least a heating medium and a cooling medium are introduced is provided, and the foamable resin particles filled in the molding space formed by the molding die are heated and cooled by the heating medium and the cooling medium introduced into the steam chamber. A mold for foam molding for molding a foam molded article,
   A through-hole communicating with the steam chamber and the molding space is formed in the molding die, and a groove portion continuous from one end of the target area to the other end is aligned in one direction in the target area of the molding surface of the molding die. A mold for foam molding formed as described above.
7. The foam molding die according to claim 6, further comprising a second groove portion aligned in another direction different from the one direction so as to intersect with the groove portion.
8. The foaming mold according to claim 6 or 7, wherein the through hole is formed in the groove or the second groove.
9. The foaming mold according to claim 6 or 7, wherein the through hole is formed between the groove portions.
10. A foam molded article molded using the foam molding die according to any one of claims 1 to 9.

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