Mold

Abstract

To provide mold that can suppress the occurrence of short shots.SOLUTION: Mold 40 comprises a first mold having a first molding surface and a second mold 60 having a second molding surface 61 opposite the first molding surface. Mold 40 forms an intermediate member having a plate-shaped base portion and a plurality of projections protruding from the base portion between the first forming surface and the second forming surface 61. The second forming surface 61 has a plurality of forming recesses 63 for forming the plurality of projections and a connecting groove 64 extending to connect the adjacent two forming recesses 63. When the width direction is defined as the direction perpendicular to both the thickness direction of the base portion and the arrangement direction of the two adjacent forming recesses 63, the length of the connecting groove 64 in the width direction is shorter than the length of the forming recesses 63 in the width direction.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a mold.

Background Art

[0002] Patent Document 1 discloses a laminated composite part including a base material, a skin material covering the base material, and an intermediate member provided between the base material and the skin material. In this laminated composite part, the intermediate member has a plate-shaped base portion and a plurality of protrusions protruding from the base portion toward the base material.

[0003] In the above laminated composite part, when the skin material is pushed toward the base material, at least a part of the plurality of protrusions provided on the intermediate member comes into contact with the base material and is bent and deformed. Therefore, it is possible to present a feeling similar to that of a composite part in which a foaming material such as urethane foam is embedded to the user.

[0004] Patent Document 1 discloses a mold for molding an intermediate member. This mold includes a fixed mold having a first molding surface and a movable mold having a second molding surface facing the first molding surface. In this mold, the intermediate member is molded between the first molding surface of the fixed mold and the second molding surface of the movable mold.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] The intermediate member of the above laminated composite part has a complex shape having a plurality of protrusions. Therefore, when molding this intermediate member using the above mold, short shots are likely to occur.

Means for Solving the Problems

[0007] The mold for solving the above problems includes a first mold having a first molding surface and a second mold having a second molding surface facing the first molding surface, and is a mold for molding a resin molded product having a plate-shaped base portion and a plurality of protrusions protruding from the base portion between the first molding surface and the second molding surface. At least one of the first molding surface and the second molding surface includes a plurality of forming recesses for molding the plurality of protrusions and a communication groove extending so as to communicate two adjacent forming recesses. When a direction orthogonal to both the thickness direction of the base portion and the arrangement direction of the two adjacent forming recesses is defined as the width direction, the length of the communication groove in the width direction is smaller than the length of the forming recess in the width direction. Mold.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

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Figure 8

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Figure 10

Figure 11

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Figure 13

Figure 14

Mode for Carrying Out the Invention

[0009] Hereinafter, a mold according to an embodiment will be described. First, a laminated composite part having an intermediate member which is a molding target of the mold of the present embodiment will be described.

[0010] As shown in FIG. 2, the laminated composite part (hereinafter, interior part 10) is, for example, an automobile door trim or the like. The interior part 10 includes a base material 11, a skin material 12, and an intermediate member 13.

[0011] The base material 11 has a plate shape. The base material 11 is formed of a hard resin material such as polypropylene. The skin material 12 has a plate shape that covers the base material 11. The skin material 12 is formed of a soft resin material such as soft polyvinyl chloride. The intermediate member 13 is provided between the base material 11 and the skin material 12. The intermediate member 13 is formed of a soft resin material such as soft polyvinyl chloride. The interior part 10 is formed by laminating the base material 11, the intermediate member 13, and the skin material 12. The mold 40 of the present embodiment is for molding the intermediate member 13 as a resin molded product. The structure of the mold 40 will be described in detail later.

[0012] <Intermediate member 13> As shown in FIGS. 2 to 4, the intermediate member 13 has a base portion 20, a plurality of protrusions 23, and a plurality of ribs 24. The base portion 20, the plurality of protrusions 23, and the plurality of ribs 24 are integrally molded.

[0013] The base portion 20 is plate-shaped. <Projection 23> The plurality of projections 23 project from the second surface 22 of the base portion 20 facing the base material 11. Each projection 23 is a quadrangular pyramid with all corners rounded. Here, the direction connecting the base end portion, which is the end portion on the second surface 22 side of the projection 23, and the tip end portion of the same projection 23 is defined as the protruding direction of the projection 23. The projection 23 has a substantially rectangular shape having a longitudinal direction DL1 and a short-side direction DS1 when viewed from the protruding direction. That is, the cross-sectional shape of the projection 23 in the direction orthogonal to the protruding direction is substantially rectangular. As shown in FIG. 2, in a state where no external force is acting on the skin material 12 (the state shown in the figure), the tip of each projection 23 is in contact with the base material 11. Further, in the above state, the first surface 21 of the base portion 20 facing the skin material 12 is overlapped with the outer surface of the skin material 12.

[0014] The arrangement of the projections 23 on the second surface 22 of the base portion 20 will be described in detail. As shown in FIG. 4, a virtual line forming a polygonal lattice (hereinafter, the first virtual lattice 30) is set on the second surface 22 of the base portion 20. As the polygonal lattice of the first virtual lattice 30, a regular hexagonal lattice composed of a plurality of regular hexagons (hereinafter, virtual hexagons 31) is adopted. Note that FIG. 4 shows only one of the plurality of virtual hexagons 31.

[0015] The projection 23 is provided at a position corresponding to the side (hereinafter, virtual side 32) of the virtual hexagon 31. Specifically, for one virtual hexagon 31, a total of six projections 23 are provided, one for each of the six virtual sides 32. Each projection 23 is provided such that the base end portion on the second surface 22 is located on the virtual side 32 of the virtual hexagon 31.

[0016] The protruding direction of the protrusions 23 is inclined with respect to the base portion 20. Specifically, the protruding directions of the plurality of protrusions 23 are all inclined toward the center of the virtual hexagon 31. Also, as shown in FIG. 2, the protruding direction of each protrusion 23 is inclined by a predetermined angle α with respect to the normal line L1 of the second surface 22. Further, as shown in FIG. 4, the protrusions 23 provided on two opposing virtual sides 32 in the same virtual hexagon 31 protrude in an inclined state in the same direction. Also, the protrusions 23 provided on adjacent virtual sides 32 protrude in an inclined state in different directions from each other.

[0017] <Rib 24> As shown in FIGS. 3 and 4, the rib 24 extends so as to connect two adjacent protrusions 23 among the plurality of protrusions 23 arranged linearly in the longitudinal direction DL1. In the present embodiment, the plurality of protrusions 23 arranged linearly in the longitudinal direction DL1 protrude in an inclined state in the same direction. The rib 24 extends so as to connect the protrusions 23 that protrude in an inclined state in the same direction.

[0018] The rib 24 protrudes from the second surface 22 of the base portion 20 so as to form a plate shape extending in the longitudinal direction DL1. The rib 24 is connected to a portion of the outer surface of the protrusion 23 that extends in the short-side direction DS1 of the protrusion 23, that is, a portion corresponding to the short side of the substantially rectangular shape when the protrusion 23 is viewed from the protruding direction.

[0019] The length of the rib 24 in the short-side direction DS1, that is, the width of the rib 24, is smaller than the length of the protrusion 23 in the short-side direction DS1, that is, the width of the protrusion 23. The protruding height of the rib 24 is relatively high at both end portions in the longitudinal direction DL1, which is the direction in which the rib 24 extends, that is, the portions connected to the protrusions 23, and is low at the intermediate portion in the longitudinal direction DL1.

[0020] Here, the direction connecting the base end portion, which is the end portion on the second surface 22 side in the rib 24, and the protruding end portion of the same rib 24 is defined as the protruding direction of the rib 24. As the protruding direction of the rib 24, the same direction as the protruding direction of the protrusion 23 to be connected (see Fig. 2) is defined. The intermediate member 13 has three types of protrusions 23 with different protruding directions. In the present embodiment, for each of the three types of protrusions 23, the rib 24 is provided such that the protruding direction of the protrusion 23 and the protruding direction of the rib 24 are the same. Specifically, the intermediate member 13 is provided with a rib 24 extending in the diagonally upward direction to the upper right in Fig. 4, a rib 24 extending in the diagonally downward direction to the lower right in Fig. 4, and a rib 24 extending in the left-right direction in Fig. 4.

[0021] <Mold 40> Hereinafter, the mold 40 of the present embodiment will be described. As shown in Fig. 5, the mold 40 has a first mold 50 and a second mold 60. In this mold 40, the intermediate member 13 (see Fig. 3) is molded by injecting the molten resin R into the cavity formed by the first molding surface 51 of the first mold 50 and the second molding surface 61 of the second mold 60.

[0022] <First mold 50> The first mold 50 constitutes the fixed mold in the mold 40. The first molding surface 51 of the first mold 50 is a molding surface for molding the portion on the base portion 20 side in the intermediate member 13, specifically, the portion on the first surface 21 side in the base portion 20. The first molding surface 51 has a recess 52. The inner shape of the recess 52 is the same as the outer shape of the portion on the first surface 21 side in the base portion 20. The portion for molding the first surface 21 of the base portion 20 on the inner surface of the recess 52 has a planar shape.

[0023] <Second mold 60> The second mold 60 constitutes the movable mold in the mold 40. The second molding surface 61 of the second mold 60 is a molding surface facing the first molding surface 51 of the first mold 50. The second molding surface 61 is a molding surface for molding the portion on the protrusion 23 side in the intermediate member 13, specifically, the portion on the second surface 22 side in the base portion 20, the plurality of protrusions 23, and the plurality of ribs 24.

[0024] <Second forming surface 61> As shown in FIGS. 1 and 6, the portion 62 that forms the second surface 22 of the base portion 20 on the second forming surface 61 has a planar shape.

[0025] <Forming recess 63> On the second forming surface 61, in the portion where a plurality of protrusions 23 are formed, recesses (hereinafter referred to as forming recesses 63) are provided respectively. The inner shape of the forming recess 63 is the same as the outer shape of the protrusion 23. Here, the direction connecting the opening portion of the forming recess 63 on the second forming surface 61 and the bottom of the forming recess 63 is defined as the depth direction of the forming recess 63. The forming recess 63 has a substantially rectangular shape having a longitudinal direction DL2 and a short-side direction DS2 when viewed from the depth direction of the forming recess 63. That is, the cross-sectional shape of the forming recess 63 in the direction orthogonal to the depth direction is substantially rectangular.

[0026] In the present embodiment, the plurality of forming recesses 63 are arranged with respect to the second forming surface 61 in the same arrangement as the arrangement of the plurality of protrusions 23 with respect to the base portion 20 so that the plurality of protrusions 23 are integrally formed with the base portion 20 in the above-described arrangement (see FIG. 4).

[0027] Specifically, as shown in FIG. 1, on the second forming surface 61, a virtual line (hereinafter referred to as the second virtual lattice 70) forming a regular hexagonal lattice composed of a plurality of regular hexagons (hereinafter referred to as virtual hexagons 71) is set. Note that only one of the plurality of virtual hexagons 71 is shown in FIG. 1. The forming recess 63 is provided at a position corresponding to the side (hereinafter referred to as the virtual side 72) of the virtual hexagon 71. Specifically, a total of six forming recesses 63 are provided, one for each of the six virtual sides 72 of one virtual hexagon 71. Each forming recess 63 is provided such that the opening portion on the second forming surface 61 is located on the virtual side 72 of the virtual hexagon 71.

[0028] The depth direction of the formed recesses 63 is inclined with respect to the normal line L2 of the portion 62 that forms the second surface 22 of the base portion 20 on the second forming surface 61. Specifically, the depth directions of the plurality of formed recesses 63 are all inclined toward the center of the virtual hexagon 71 with respect to the normal line L2.

[0029] Also, the depth direction of each formed recess 63 is inclined by a predetermined angle α with respect to the normal line L2. Further, the formed recesses 63 provided on two opposing virtual sides 72 in the same virtual hexagon 71 are recessed in an inclined state in the same direction. Also, the formed recesses 63 provided on adjacent virtual sides 72 are recessed in an inclined state in different directions from each other.

[0030] <Communication groove 64> As shown in FIGS. 1 and 6, on the second forming surface 61, grooves (hereinafter, communication grooves 64) are provided at positions corresponding to the plurality of ribs 24 (see FIG. 4), respectively.

[0031] Specifically, the communication groove 64 extends so as to connect two adjacent formed recesses 63 among the plurality of formed recesses 63 arranged linearly in the longitudinal direction DL2. As shown in FIG. 1, the plurality of formed recesses 63 arranged linearly in the longitudinal direction DL2 are recessed in an inclined state in the same direction. The formed recess 63 extends so as to connect the formed recesses 63 that are recessed in an inclined state in the same direction.

[0032] The communication groove 64 extends in the longitudinal direction DL2 with a constant width and a constant depth. As shown in FIG. 6, the depth of the communication groove 64 is the same as the depth of the formed recess 63. As shown in FIG. 1, the communication groove 64 is connected to a portion that extends in the short-side direction DS2 of the formed recess 63 on the inner surface of the formed recess 63, that is, a portion corresponding to the short side of the substantially rectangular shape when the formed recess 63 is viewed from the depth direction.

[0033] The length of the communication groove 64 in the short side direction DS2, that is, the width of the communication groove 64, is smaller than the length of the forming recess 63 in the short side direction DS2, that is, the width of the forming recess 63. In this embodiment, the short side direction DS1 of the rib 24 and the short side direction DS2 of the communication groove 64 correspond to the width direction which is perpendicular to both the thickness direction of the base portion 20 and the arrangement direction of the two adjacent forming recesses 63. The width of the communication groove 64 is determined as follows based on the results of various experiments and simulations by the inventors and the like. That is, as the width of the communication groove 64, a width of a dimension that allows air to flow smoothly into the communication groove 64 and a width of a dimension that makes it difficult for the molten resin R to flow into the communication groove 64 are set.

[0034] Here, the direction connecting the opening portion on the second molding surface 61 of the communication groove 64 and the bottom of the communication groove 64 is defined as the depth direction of the communication groove 64. In this embodiment, as the depth direction of the communication groove 64, the same direction as the depth direction of the forming recess 63 to be connected is defined. The second molding surface 61 of the second mold 60 has three types of forming recesses 63 with different depth directions. In this embodiment, for each of the three types of forming recesses 63, the communication groove 64 is provided so that the depth direction of the forming recess 63 and the depth direction of the communication groove 64 are the same. Specifically, a communication groove 64 extending in the upper right diagonal direction in FIG. 1, a communication groove 64 extending in the lower right diagonal direction in FIG. 1, and a communication groove 64 extending in the left-right direction in FIG. 1 are provided.

[0035] <Function> Hereinafter, the operation of the mold 40 of this embodiment will be described. As shown in FIG. 5, when molding the intermediate member 13, first, a mold clamping process is executed. In the mold clamping process, the mold clamping of the mold 40 is executed through the operation control of a driving device (not shown). As a result, a cavity is formed between the first mold 50 and the second mold 60 by the first molding surface 51 and the second molding surface 61. This cavity has a shape corresponding to the intermediate member 13.

[0036] Thereafter, a molding process is executed. In the molding process, through the operation control of an injection device (not shown), the molten resin R is injected into the cavity of the mold 40. The injection of the molten resin R into the mold 40 is performed through a passage provided in the first mold 50. Thereby, the intermediate member 13 is molded in the cavity.

[0037] Regarding the flow of the molten resin R inside the mold 40 in the molding process, it will be described with reference to FIGS. 7 and 8. As shown in FIG. 7, the molten resin R (indicated by dot hatching in FIG. 7) flows into a portion that forms the base portion 20 in the mold 40, specifically, a portion sandwiched between the recess 52 of the first molding surface 51 and the portion 62 of the second molding surface 61. Then, as indicated by arrow A in FIG. 7, the molten resin R spreads over the entire portion that forms the base portion 20. When the spreading molten resin R reaches the forming recess 63, as indicated by arrow B in FIG. 7, the molten resin R flows into the forming recess 63. And with the inflow of the molten resin R into the forming recess 63, air is pushed into the bottom of the forming recess 63.

[0038] In the present embodiment, a communication groove 64 that communicates the two forming recesses 63 is provided on the second molding surface 61 of the second mold 60. Therefore, as indicated by arrow C in FIG. 7, the air pushed into the bottom of the forming recess 63 with the inflow of the molten resin R into the forming recess 63 is discharged to the outside of the forming recess 63, specifically, into the communication groove 64. Thus, according to the present embodiment, the communication groove 64 can function as an air escape groove for allowing the air inside the forming recess 63 to escape to the outside. And thereby, it is difficult for air to accumulate inside the forming recess 63.

[0039] Also in the present embodiment, the depth of the forming recess 63 and the depth of the communication groove 64 are the same. Therefore, no step is formed at the boundary between the bottom of the forming recess 63 and the bottom of the communication groove 64. Thereby, the air pushed into the bottom of the forming recess 63 with the inflow of the molten resin R into the forming recess 63 is smoothly discharged into the communication groove 64 communicated with the forming recess 63. Therefore, it is difficult for air to accumulate at the bottom of the forming recess 63.

[0040] Furthermore, in the present embodiment, the communication groove 64 extends in the longitudinal direction DL2 of the forming recess 63 and communicates with a portion extending in the short-side direction DS2 on the inner surface of the forming recess 63. Therefore, compared with the case where the communication groove 64 communicates with the portion extending in the longitudinal direction DL2 on the inner surface of the forming recess 63, air and the molten resin R flow more easily in the longitudinal direction DL2, that is, toward the communication groove 64, inside the forming recess 63. As a result, air easily flows from the forming recess 63 into the communication groove 64, so that it is difficult for air to accumulate in the forming recess 63.

[0041] According to the present embodiment, since it is difficult for air to accumulate at the bottom of the forming recess 63 in this way, the molten resin R flows into the bottom of the forming recess 63 as shown in an example in FIG. 8. According to the present embodiment, the occurrence of short shots can be suppressed in this way.

[0042] Also, in the present embodiment, as shown in FIG. 1, the width of the communication groove 64 is smaller than the width of the protrusion 23. By reducing the width of the communication groove 64 in this way, it is possible to limit and suppress the inflow of the molten resin R into the communication groove 64 while allowing the inflow of air into the communication groove 64.

[0043] In the molding process, as shown in an example in FIG. 8, a small amount of the molten resin R flows into the communication groove 64 together with air. Then, the molten resin R that has flowed into the communication groove 64 constitutes the rib 24. Here, the amount of the molten resin R flowing into the communication groove 64 is not the same in each communication groove 64. Therefore, the shapes of the plurality of ribs 24 are not constant, and in some cases, the shape is interrupted between the two protrusions 23. FIGS. 3 and 4 show an example of the shape of such a rib 24.

[0044] After the molding process, a mold opening process is executed. In the mold opening process, the mold opening of the mold 40 is executed through the operation control of the driving device. Then, the intermediate member 13 is taken out from inside the mold 40 in the mold opened state.

[0045] <Actions and Effects of this Embodiment> The actions and effects of this embodiment will be described. (1) The mold 40 includes a first mold 50 having a first molding surface 51 and a second mold 60 having a second molding surface 61. The mold 40 molds an intermediate member 13 having a base portion 20 and a plurality of protrusions 23 protruding from a second surface 22 of the same base portion 20 between the first molding surface 51 and the second molding surface 61. The second molding surface 61 includes a plurality of forming recesses 63 for molding the plurality of protrusions 23, and a communication groove 64 extending with a width smaller than the width of the forming recess 63 so as to communicate the two forming recesses 63.

[0046] According to the above configuration, the air pushed into the bottom of the forming recess 63 as the molten resin R flows into the forming recess 63 can be discharged to the communication groove 64. As a result, it becomes difficult for air to accumulate inside the forming recess 63, so that the occurrence of short shots can be suppressed. Moreover, by reducing the width of the communication groove 64, the inflow of the molten resin R into the communication groove 64 can be restricted and suppressed while allowing the inflow of air into the communication groove 64.

[0047] (2) The depth of the forming recess 63 and the depth of the communication groove 64 are the same. Therefore, the air pushed into the bottom of the forming recess 63 as the molten resin R flows into the forming recess 63 can be smoothly discharged to the communication groove 64. As a result, it becomes difficult for air to accumulate at the bottom of the forming recess 63, so that the occurrence of short shots can be preferably suppressed.

[0048] (3) The communication groove 64 extends in the longitudinal direction DL2 of the forming recess 63 and is communicated with a portion extending in the short direction DS2 on the inner surface of the forming recess 63. As a result, air easily flows from the forming recess 63 into the communication groove 64, so that it becomes difficult for air to accumulate in the forming recess 63. Therefore, the occurrence of short shots can be preferably suppressed.

[0049] <Modification Example> Incidentally, the above-described embodiment can be implemented with the following modifications. The above-described embodiment and the following modification examples can be implemented in combination with each other within a technically consistent range.

[0050] · The communication groove 64 is not limited to having a constant width, and may have a shape that becomes narrower toward the bottom of the communication groove 64. · As shown in an example in FIG. 9, the depth of the communication groove 84 may be made smaller than the depth of the forming recess 83. Also in this case, the air pushed into the bottom of the forming recess 83 as the molten resin R flows into the forming recess 83 can be discharged to the communication groove 84.

[0051] · The depth of each part of the communication groove 64 is not limited to being constant, and the depth of each part of the communication groove 64 may be set such that the depth of the communication groove 64 in the middle part in the longitudinal direction DL2 is smaller than the depth of the communication groove 64 at both ends in the longitudinal direction DL2.

[0052] In this case, for example, the shape of the communication groove 64 may be determined so that the molten resin R does not fill the communication groove 64, etc., so that the inflow of air from the forming recess 63 to the communication groove 64 is not hindered by the molten resin R flowing into the communication groove 64.

[0053] In this case, in order to make it difficult for air to accumulate in the forming recess 63, it is preferable that the depth of the forming recess 63 and the depth of the communication groove 64 are the same at the connection part where the forming recess 63 and the communication groove 64 are connected.

[0054] · As shown in an example in FIG. 10, the depth direction of the forming recess 93 and the depth direction of the communication groove 94 may be the direction in which the normal line L2 (see FIG. 2) extends. In this case, in the intermediate member 13 formed by the mold 40, the protruding direction of the protrusion 23 and the protruding direction of the rib 24 coincide with the direction in which the normal line L1 of the second surface 22 extends.

[0055] · As shown in an example in FIG. 11, the depth direction of the forming recess 103 and the depth direction of the communication groove 104 may be set in different directions. Also in this case, the air pushed into the bottom of the forming recess 103 as the molten resin R flows into the forming recess 103 can be discharged to the communication groove 104.

[0056] In this case, in the intermediate member 13 formed by the mold 40, the protruding direction of the protrusion 23 and the protruding direction of the rib 24 are set in different directions. Therefore, the relationship between the protruding direction of the protrusion 23 and the protruding direction of the rib 24 can be set with a higher degree of freedom as compared with the case where the protruding direction of the protrusion 23 and the protruding direction of the rib 24 are the same. As a result, the ease of bending of the protrusion 23 of the intermediate member 13, and thus the touch feeling of the interior component 10 having the intermediate member 13, can be set with a higher degree of freedom.

[0057] · In addition to inclining the depth direction of the forming recess 63 toward the center of the virtual hexagon 71 in the second virtual grid 70 set on the second molding surface 61, it may be inclined toward a position slightly deviated from the center. In this case, in the intermediate member 13 formed by the mold 40, the protruding direction of the protrusion 23 is inclined toward a position slightly deviated from the center of the virtual hexagon 31.

[0058] · The outer shape of the protrusion 23 and the inner shape of the forming recess 63 are not limited to a quadrangular pyramid shape, and can be arbitrarily changed, such as to an elliptical cone shape or a cylindrical shape. · The first molding surface 51 of the first mold 50 may be a molding surface for molding a portion other than the second surface 22 in the base portion 20, and the second molding surface 61 of the second mold 60 may be a molding surface for molding the second surface 22, the protrusion 23, and the rib 24 of the base portion 20. It is also possible to make the first molding surface 51 of the first mold 50 a molding surface for molding the first surface 21 of the base portion 20, and the second molding surface 61 of the second mold 60 a molding surface for molding a portion other than the first surface 21 in the base portion 20, the protrusion 23, and the rib 24.

[0059] ·The first molding surface 51 of the first mold 50 may be a molding surface for forming so-called dimples such as leather patterns or geometric patterns on the first surface 21 of the base portion 20. In this case, the surface shape of the first molding surface 51 may be made the same as the surface shape of the first surface 21 of the base portion 20, that is, the concave and convex shape constituting the above-mentioned dimples. According to the above configuration, the portion on the first surface 21 side in the base portion 20 can function as a skin material covering the base material 11. In this case, it becomes possible to omit the skin material 12.

[0060] ·As the polygonal grids of the first virtual grid 30 and the second virtual grid 70, in addition to adopting a regular hexagonal grid, a square grid or a regular triangular grid can be adopted. When the first virtual grid 30 and the second virtual grid 70 are square grids, for example, the second molding surface 61 may be configured as follows.

[0061] In the example shown in FIG. 12, on the second molding surface 111 of the second mold 110, a virtual line forming a square grid (hereinafter, the third virtual grid 115) is set. And the forming recess 113 is provided at positions corresponding to each side of a square (hereinafter, the virtual square 116) constituting the square grid in the third virtual grid 115. Further, the communication groove 114 extends so as to form the same square grid as the third virtual grid 115. Note that only one of the plurality of virtual squares 116 is shown in FIG. 12.

[0062] When the first virtual grid 30 and the second virtual grid 70 are regular triangular grids, for example, the second molding surface 61 may be configured as follows. In the example shown in FIG. 13, on the second molding surface 121 of the second mold 120, a virtual line forming a regular triangular grid (hereinafter, the fourth virtual grid 125) is set. And the forming recess 123 is provided at positions corresponding to each side of a triangle (hereinafter, the virtual triangle 126) constituting the regular triangular grid in the fourth virtual grid 125. Further, the communication groove 124 extends so as to form the same regular triangular grid as the fourth virtual grid 125. Note that only one of the plurality of virtual triangles 126 is shown in FIG. 13.

[0063] ·The mold 40 according to the above embodiment can be applied not only to a mold for an injection molding machine but also to any mold such as a mold for roll forming. FIG. 14 shows an example of a mold when the mold 40 according to the above embodiment is applied to a mold for roll forming. As shown in FIG. 14, the mold 130 includes a first processing roll 131 as a first mold, a second processing roll 132 as a second mold, and a supply unit 133. Each of the processing rolls 131 and 132 has a cylindrical shape. The outer peripheral surfaces of the processing rolls 131 and 132 are arranged to face each other. The processing rolls 131 and 132 are rotationally driven in opposite directions about their respective central axes as the rotation centers.

[0064] The outer peripheral surface of the first processing roll 131 constitutes a first molding surface for molding the portion on the base portion 20 side in the intermediate member 13 (see FIG. 2). A recess (not shown) is provided on the outer peripheral surface of the first processing roll 131. Due to this recess, the portion on the first surface 21 side in the base portion 20 is molded.

[0065] The outer peripheral surface of the second processing roll 132 constitutes a second molding surface for molding the portion on the protrusion 23 side in the intermediate member 13 (see FIG. 2), specifically, the portion on the second surface 22 side in the base portion 20, the plurality of protrusions 23, and the plurality of ribs 24. A forming recess 1321 and a communication groove (not shown) are provided on the outer peripheral surface of the second processing roll 132. Then, the protrusion 23 is molded by the forming recess 1321, and the rib 24 is molded by the communication groove.

[0066] The supply unit 133 feeds the molten resin R between the outer peripheral surface of the first processing roll 131 and the outer peripheral surface of the second processing roll 132. When molding the intermediate member 13 with the mold 130, the molten resin R is fed from the supply unit 133 between the processing rolls 131 and 132 while the processing rolls 131 and 132 are rotationally driven. Thereby, the intermediate member 13 having the protrusion 23 and the rib 24 is extrusion-molded.

[0067] According to the above mold 130, similar to the above embodiment, when molding the intermediate member 13 using the mold 130, the occurrence of short shots can be suppressed. · The mold according to the above embodiment is also applicable to a mold for molding an intermediate member having protrusions and ribs provided on both surfaces of a plate-like base portion between a first molding surface and a second molding surface. In this case, a forming recess and a communication groove may be provided on both the first molding surface and the second molding surface.

[0068] · The material of the skin material 12 can be changed to a soft resin material other than soft polyvinyl chloride such as an elastomer, or a woven fabric. · The material of the intermediate member 13 can also be changed to a soft resin material other than soft polyvinyl chloride such as a polyester-based elastomer, an olefin-based elastomer, or a polystyrene-based elastomer.

[0069] · The mold according to the above embodiment is not limited to a mold for molding an intermediate member of a door trim which is a stacked composite part, but can also be applied to a mold for molding an intermediate member of other stacked composite parts such as a vehicle instrument panel or a glove box. Further, it is not limited to being applied to a mold for molding an intermediate member of a stacked composite part, and the mold according to the above embodiment can also be applied to a mold for molding an intermediate member of a panel part other than for vehicles.

[0070] <Supplementary Note> Describe the technical idea that can be grasped from the above embodiment and modification examples. [Appendix 1] A mold includes a first mold having a first molding surface and a second mold having a second molding surface facing the first molding surface. Between the first molding surface and the second molding surface, a resin molded product having a plate-shaped base portion and a plurality of protrusions protruding from the base portion is molded. At least one of the first molding surface and the second molding surface includes a plurality of forming recesses for molding the plurality of protrusions and a communication groove extending to communicate two adjacent forming recesses. When a direction orthogonal to both the thickness direction of the base portion and the arrangement direction of the two adjacent forming recesses is defined as the width direction, the length of the communication groove in the width direction is smaller than the length of the forming recess in the width direction.

[0071] [Appendix 2] In the connection portion where the forming recess and the communication groove are connected, the depth of the forming recess is the same as the depth of the communication groove. The mold according to [Appendix 1]. [Appendix 3] The forming recess has a shape (ellipse, square) having a longitudinal direction and a short transverse direction when viewed from the depth direction (open end side) of the forming recess. The communication groove extends in the longitudinal direction and is connected to a portion extending in the short transverse direction on the inner surface of the forming recess. The mold according to [Appendix 1] or [Appendix 2].

[0072] [Appendix 4] The depth direction of the forming recess and the depth direction of the communication groove are set in different directions. The mold according to any one of [Appendix 1] to [Appendix 3].

Explanation of Reference Numerals

[0073] 10… Interior component 11… Base material 12… Skin material 13… Intermediate member 20… Base portion 21… First surface 22… Second surface 23… Protrusion 24… Rib 30… First virtual grid 31… Virtual hexagon 32… Virtual side 40, 130… Mold 50…Type 1 51…First forming surface 52…Recess 60, 110, 120…Type 2 61, 111, 121…Second forming surface 62…Part 63, 83, 93, 103, 113, 123, 1321…Form recess 64, 84, 94, 104, 114, 124…Communication groove 70…Second virtual grid 71…Virtual hexagon 72…Virtual side 115…Third virtual grid 116…Virtual square 125…Fourth virtual grid 126…Virtual triangle 131…First processing roll 132…Second processing roll 133…Supply part

Claims

1. A mold comprising a first mold having a first molding surface and a second mold having a second molding surface facing the first molding surface, and molding a resin molded product having a plate-shaped base portion and a plurality of protrusions protruding from the base portion between the first molding surface and the second molding surface, At least one of the first molding surface and the second molding surface includes a plurality of forming recesses for molding the plurality of protrusions and a communication groove extending so as to communicate two adjacent forming recesses, When the direction orthogonal to both the thickness direction of the base portion and the arrangement direction of the two adjacent forming recesses is defined as the width direction, The mold in which the length of the communication groove in the width direction is smaller than the length of the forming recess in the width direction.

2. At the connection portion where the forming recess and the communication groove are connected, the depth of the forming recess and the depth of the communication groove are the same, The mold according to claim 1.

3. The forming recess has a shape (ellipse, square) having a longitudinal direction and a short side direction when viewed from the depth direction (open end side) of the forming recess, The communication groove extends in the longitudinal direction and is connected to a portion extending in the short side direction on the inner surface of the forming recess, The mold according to claim 1 or 2.

4. The depth direction of the forming recess and the depth direction of the communication groove are set in different directions, The mold according to claim 1 or 2.

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