Molding molds for foamed resins

Abstract

This facilitates the formation of slits in the inner wall surfaces of the male and female molds, particularly in recessed areas such as corners and recesses within the molding space. [Solution] A mold for molding foamed resin in which foamed beads filled in a molding space between a male mold and a female mold are foamed by steam discharged from a slit opening in the inner wall surface of the wall surrounding the molding space of at least one of the molds, wherein the mold comprises a main body mold having a first wall and a second wall that sandwich the corner of the molding space, and a divided mold formed by dividing a part or all of the first wall from the main body mold so as to include the inner wall surface of the end on the corner side, and the slit opening in the inner wall surface of the end of the divided mold.

Description

Technical Field

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[0001] The present invention relates to a mold for foamed resin molding.

Background Art

[0002] In Patent Document 1, as a mold for foamed resin molding in which foamed beads filled in a molding space formed between a core mold and a cavity mold are fused with steam to form a molded product, a metal saw (rotary blade) is inserted into an inner wall surface forming the molding spaces of the core mold and the cavity mold to form a plurality of slits, and steam is injected from these slits.

[0003] In this type of mold for foamed resin molding, since the degree of foaming of the foamed beads depends on the position of the slits, there is a requirement to form the slits at desired positions.

[0004] However, in the mold for foamed resin molding according to Patent Document 1, for example, when trying to form a slit on an inner wall surface at a deep position such as a corner or a recess of the molding space, the metal saw may also contact a portion where no slit is desired to be formed, and there is a problem that it is difficult to form the slit at a desired position.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] Therefore, the main problem of the present invention is to facilitate the formation of slits on the inner wall surface at a deep position such as a corner or a recess of the molding space in the male mold body or the female mold body.

Means for Solving the Problems

[0007] The foam resin molding die according to the present invention is a foam resin molding die that foams foam beads filled in a molding space between a male mold and a female mold with steam discharged from a slit opening in the inner wall surface of the wall surrounding the molding space of at least one of the molds, wherein the mold comprises a main body mold having a first wall and a second wall that sandwich the corner of the molding space, and a divided mold formed by dividing a part or all of the first wall from the main body mold so as to include the inner wall surface of the end on the corner side, and the slit is characterized in that it opens in the inner wall surface of the end of the divided mold.

[0008] According to the present invention, the mold is composed of a main mold having a first wall and a second wall that sandwich the corner of the molding space, and a divided mold formed by dividing a part or all of the first wall from the main mold so as to include the inner wall surface of the end on the corner side. For example, when forming a slit on the inner wall surface of the first wall and the second wall that sandwich the corner of the molding space using a rotary blade, the slit can be formed without damaging parts other than the divided mold by removing the divided mold from the main mold and working with it.

[0009] A specific embodiment of the slit is one in which, with the divided type attached to the main body type, the slit has an opening that extends along a virtual plane perpendicular to the first wall and the second wall, respectively. This slit is formed by inserting a rotating blade perpendicular to the first wall and the second wall, respectively.

[0010] Specific embodiments of the divided type include a case in which the divided type is formed by dividing the inner wall portion of the first wall from the outer wall portion, the main body type has ventilation holes penetrating inward and outward in either the first wall or the second wall, and when the divided type is attached to the main body type, the ventilation holes are configured to communicate with slits formed in the divided type.

[0011] Furthermore, a more specific embodiment of the divided type is one in which the first wall body has a convex inner wall portion at its end that protrudes inward more than the portion other than the end, and the divided type is formed by dividing the convex inner wall portion.

[0012] In the corners of the molding space, the steam discharged from the slits does not easily reach all corners, which can easily lead to poor fusion of the foam beads. In such cases, for example, when the divided mold is attached to the main body, a first gap connecting to the molding space may be formed between the divided mold and the wall on which the ventilation holes are formed, and the ventilation holes may be configured to communicate with the slits formed in the divided mold through the first gap.

[0013] With this configuration, steam is discharged not only from the slits but also from the first gap in the corners of the molding space, thus suppressing foaming defects.

[0014] Furthermore, when the divided type is attached to the main body type, a second gap connecting to the molding space and the first gap may be formed between the divided type and the wall body on which the ventilation holes are not formed.

[0015] With this configuration, steam is discharged in three directions from the slit, the first gap, and the second gap, which further suppresses foaming defects.

[0016] For example, if the thickness of the first wall is thin, forming the split type by separating the inner wall portion of the first wall from the outer wall portion would result in a thinner main body type and reduced strength. Therefore, the split type may be formed by dividing the end portion of the first wall, and the main body type may have mounting holes that penetrate from the inside to the outside at the end portion of the first wall, so that the split type can be fitted into these mounting holes for installation.

[0017] In addition, as the inner part of the mold body, not only the corner part but also, for example, a concave part can be considered. Therefore, the foam resin molding die according to the present invention is a foam resin molding die that foams foam beads filled in a molding space between a male mold body and a female mold body with steam discharged from a slit that opens to the inner wall surface of a wall surrounding the molding space of at least one of the mold bodies. The mold body includes a main body mold having a concave part that opens to the molding space, a pair of opposing wall bodies that form the concave part, and a bridging wall body that is bridged between the pair of opposing wall bodies, and a split mold formed by dividing a part or all of the bridging wall body from the main body mold so that the inner wall surface is included. The slit may be opened on the inner wall surface of the split mold.

Advantages of the Invention

[0018] According to the present invention, a slit having a desired shape can be formed at a desired position on a wall body sandwiching a corner part of a molding space of a foam resin molding die by using a rotary blade.

Brief Description of the Drawings

[0019] [Figure 1] It is an exploded perspective view schematically showing a foam resin molding die of the first embodiment. [Figure 2] It is a perspective view schematically showing a male mold body of a foam resin molding die of the first embodiment. [Figure 3] It is a cross-sectional view schematically showing a foam resin molding die of the first embodiment. [Figure 4] It is an enlarged cross-sectional view schematically showing a male mold body of a foam resin molding die of the second embodiment. [Figure 5] It is a perspective view schematically showing a male mold body of a foam resin molding die of the third embodiment. [Figure 6] It is a cross-sectional view schematically showing a male mold body of a foam resin molding die of the third embodiment. [Figure 7] It is a partial cross-sectional view schematically showing a modified example of a male mold body of a foam resin molding die of the third embodiment.

Modes for Carrying Out the Invention

[0020] Hereinafter, embodiments of the mold for foamed resin molding according to the present invention will be described based on the drawings.

[0021] <First Embodiment> The mold M for foamed resin molding according to this embodiment forms a box-shaped molded product that opens in a predetermined direction. As shown in FIG. 1, it includes a male mold body M1 and a female mold body M2. Then, as shown in FIG. 3, by fitting the male mold body M1 into the female mold body M2, a molding space X is formed between the male mold body M1 and the female mold body M2. A plurality of slits S that open on the inner wall surface of the wall body surrounding the molding space X are formed in the male mold body M1 and the female mold body M2. Steam is discharged into the molding space X from these slits S to fuse the foamed beads filled in the molding space X.

[0022] The male mold body M1 of this embodiment has a bottomed box shape that is surrounded by four side wall bodies 10 and a bottom wall body 20 and opens in a predetermined direction. A flange wall body 30 protrudes outward from the opening edge of each side wall body 10.

[0023] The female mold body M2 of this embodiment has a bottomed box shape that is surrounded by four side wall bodies 40 and a bottom wall body 50 and opens in a predetermined direction, and is sized slightly larger than the male mold body M1.

[0024] In this embodiment, the male mold body M1 is fitted into the female mold body M2, and the front end surface of the flange wall body 30 is brought into close contact with the inner surface of the side wall body 40, thereby forming the molding space X. That is, the male mold body M1 sandwiches the corner C of the molding space X with the flange wall body 30 and the side wall body 10. Therefore, the flange wall body 30 corresponds to the first wall body in the claims, and the side wall body 10 corresponds to the second wall body in the claims.

[0025] Thus, as shown in FIGS. 2 and 3, the male mold body M1 of this embodiment includes a main mold body M1a that forms the general shape of the male mold body M1, a split mold M1b formed by dividing a part of the main mold body M1a, and an attachment mechanism 60 that detachably attaches the split mold M1b to the main mold body M1a.

[0026] The main body type M1a has four side walls 10, a bottom wall 20, and four flange walls 30, and the corners C of the molding space X are sandwiched between the side walls 10 and the flange walls 30 perpendicular to the side walls 10.

[0027] The divided type M1b is formed by dividing the end of the flange wall 30 on the corner C side along the side wall 10, and has a long block shape. In this embodiment, as shown in Figure 3, the inner wall portion 30a at the end of the flange wall 30 on the corner C side is divided from the outer wall portion 30b. More specifically, the flange wall 30 in this embodiment has a convex inner wall portion 30a at the end on the corner C side that protrudes inward more than the rest of the body, and the divided type M1b is formed by dividing this convex inner wall portion 30a.

[0028] The split type M1b has a slit S formed on its inner wall surface. This slit S has an opening along a virtual plane perpendicular to the inner wall surfaces of the flange wall 30 and the side wall 10. Specifically, this slit S is formed by inserting a rotating blade having a predetermined diameter along the virtual plane, and has a bottom surface along the circumference of a circle of the predetermined diameter. In other words, it is formed by cutting perpendicular to the flange wall 30 and the side wall 10. Multiple slits S are formed in the longitudinal direction of the split type M1b. In this embodiment, they are formed at equal intervals. This slit S is formed with a rotating blade having the same diameter as the rotating blade used to form other slits S formed in the main body type M1a and the female mold body M2. Furthermore, if the split type M1b is attached to the main body type M1a, it is not possible to insert and form the slit without the rotating blade contacting the side wall 10 and the flange wall 30 that sandwich the corner C. In other words, when attempting to form a shape with the rotating blade while the split-type M1b is attached to the main body-type M1a, the rotating blade is designed in such a way that it will inevitably come into contact with the side wall 10 or the flange wall 30.

[0029] The mounting mechanism 60 includes screw holes 61 formed at both longitudinal ends of the split-type M1b, a through hole 62 formed in the flange wall 30 to which the split-type M1b is attached and communicating with the screw holes 61, and a screw 63 that is inserted into the through hole 62 and screwed into the screw holes 61. Therefore, the split-type M1b can be removed from the main body type M1a by removing the screw 63, making maintenance such as preventing clogging of the slit S easy.

[0030] The main body type M1a has a flange wall 30, specifically the outer wall portion 30b of the flange wall 30, which has a ventilation hole 70 that penetrates from the inside to the outside of the molded interior. When the split type M1b is attached, the slit S communicates with the ventilation hole 70. In this embodiment, the split type M1b has an intermediate hole 71 (see Figure 3) that opens on the surface facing the flange wall 30 and connects to the slit S internally, and this intermediate hole 71 communicates with the ventilation hole 70.

[0031] Furthermore, when the split type M1b is attached to the main body type M1a, a first gap G1 is formed between the split type M1b and the main body type M1a. In this embodiment, both ends of the split type M1b protrude slightly compared to the intermediate part between them, thereby forming the first gap G1 between the split type M1b and the flange wall 30. The first gap G1 is connected to the molding space X and opens in a direction along the inner wall surface of the flange wall 30.

[0032] Furthermore, in this embodiment, with the split type M1b attached to the main body type M1a, a second gap G2 is formed between the split type M1b and the side wall body 10. The second gap G2 is connected to the molding space X and the first gap G1, and in this embodiment, it opens in a direction along the inner wall surface of the side wall body 10.

[0033] Therefore, the slit S and the ventilation hole 70 are in communication with each other through the first gap G1. As a result, when the steam supplied to the ventilation hole 70 passes through the first gap G1, it is divided into three parts: one discharged from the first gap G1 to the molding space X, one discharged from the slit S to the molding space X, and one discharged from the second gap G2 to the molding space X.

[0034] According to this embodiment, the male mold M1 is composed of a main mold M1a having a flange wall 30 and a side wall 10 that sandwich the corner C of the molding space X, and a divided mold M1b formed by dividing a part of the flange wall 30 from the main mold M1a so as to include the inner wall surface of the end on the corner C side. For example, when forming a slit S by inserting a rotating blade perpendicular to the inner wall surfaces of the flange wall 30 and the side wall 10 that sandwich the corner C of the molding space X, the divided mold M1b can be removed from the main mold M1a for the work, so that the slit S can be formed in the desired position and shape without damaging the part other than the divided mold M1b (main mold M1a).

[0035] Furthermore, since the steam supplied to the ventilation holes 70 is discharged from the slits S, the first gap G1, and the second gap G2, respectively, the steam can easily reach every corner C of the molding space X, thereby suppressing foaming defects.

[0036] Furthermore, since the split-type M1b can be removed from the main body type M1a, maintenance is easier even if the slit S or the gaps G1 and G2 become clogged.

[0037] <Second Embodiment> This embodiment is a modified version of the male mold M1 of the first embodiment. The male mold M1 of this embodiment includes a split mold M1b formed by dividing the end of the flange wall 30 on the corner C side that sandwiches the corner C of the molding space X. The main body mold M1a has a mounting hole 80 that penetrates in the inward and outward direction at the end of the flange wall 30, and the split mold M1b is fitted into this mounting hole 80 for installation.

[0038] Even in this embodiment, the split type M1b can be removed from the main body type M1a for work, so the slit S can be formed without damaging parts other than the split type M1b.

[0039] In this embodiment, the split type M1b is fitted and installed without any gaps on the side surface of the mounting hole 80. However, as shown in Figure 4(b), the split type M1b may be installed with a gap G between it and the inner surface of the mounting hole 80. In this case, this gap G can also be used as a vent to allow steam to pass through.

[0040] <Third Embodiment> As shown in Figures 4 and 5, the male mold body M1 of this embodiment has a recess 21 in the bottom wall body 20 that opens toward the molding space X. This recess 21 is surrounded by a pair of opposing wall bodies 21a that face each other and a bridging wall body 21b that spans between the pair of opposing wall bodies 21a. In other words, the bridging wall body 21b forms the bottom of the recess 21. The spacing between the pair of opposing wall bodies 21a is narrower than the diameter of the rotating blade that forms the other slit S formed in the male mold body M1.

[0041] In this embodiment, the divided type M1b is formed by dividing the entire bridge wall 21b from the main body type M1a. Therefore, this divided type M1b has the same width as the spacing between the pair of opposing wall bodies 21a, and the slit S is open along its entire width. This slit S has an opening along a virtual plane perpendicular to the pair of opposing wall bodies 21a and the bridge wall 21b, respectively.

[0042] In this embodiment, the split type M1b is attached to the main body type M1a by welding or the like in a way that prevents it from being detached, but this is not limited to this. For example, as in the first embodiment, it may be configured to be detachably attached via a mounting mechanism.

[0043] In this embodiment, the recessed bottom surface of the recess 21 of the male mold M1 can be removed as a split type M1b, so that the slit S can be formed without damaging the parts of the recess 21 other than the bottom surface.

[0044] The following are examples of modifications of the third embodiment. For example, as shown in Figures 7(a) and 7(b), the inner wall portion 21bx of the bridge wall 21b may be separated from the outer wall portion 21by, and the inner wall portion 21bx may be made into a divided type M1b. In this case, a ventilation hole 70 that penetrates from the inside to the outside is formed in the outer wall portion 21by of the bridge wall 21b that constitutes the main body type M1a, and when the divided type M1b is installed on the main body type M1a, the slit S formed in the divided type M1b is configured to communicate with the ventilation hole 70. The shape of this ventilation hole 70 is not particularly limited, and may be, for example, a plurality of small holes formed in the outer wall portion 21by (see Figure 7(a)), or an elongated hole extending in the longitudinal direction of the outer wall portion 21by (see Figure 7(b)).

[0045] Furthermore, as shown in Figures 7(c) and 7(d), the segmented M1b may be attached to the tip surfaces of a pair of opposing wall bodies 21a. In addition, in each of these embodiments, the segmented M1b is formed by dividing the entire bridge wall body 21b, but it may also be formed by dividing a part of the bridge wall body 21b.

[0046] <Other Embodiments> The mold for molding foamed resin according to the present invention is not limited to that of the above embodiment. The divided mold of the first embodiment is formed by dividing the corner end of the flange wall, but is not limited thereto. For example, the entire flange wall may be formed by dividing it from the side wall.

[0047] Furthermore, although the divided mold is detachably attached to the main mold in each of the above embodiments, the invention is not limited to this. For example, a slit may be formed in the divided mold and then it may be attached to the main mold in a way that prevents it from being detached. In addition, if the female mold body forms a corner of the molding space, the female mold body may be divided into a divided mold and a main mold.

[0048] Furthermore, various combinations or modifications of parts of the embodiments are permitted, as long as they do not contradict the spirit of the present invention. [Explanation of Symbols]

[0049] M Molding mold for foamed resin S-slit M1 Male M1a main body type 10. Side wall (second wall) 20 Bottom wall 30 Flange wall (first wall) 70 ventilation holes M1b split type G1 First Gap G2 Second Gap M2 female body 21a Opposing wall 21b Bridge wall

Claims

1. A mold for molding foamed resin, wherein foamed beads filled in a molding space between a male mold and a female mold are foamed by vapor discharged from a slit opening in the inner wall surface of the wall surrounding the molding space of at least one of the molds, The mold comprises a main mold having a first wall and a second wall that sandwich the corner of the molding space, and a divided mold formed by dividing the main mold so that a part or all of the first wall is included in the inner wall surface of the end on the corner side. A mold for molding foamed resin, characterized in that the slit is open in the inner wall surface of the end portion of the divided type.

2. The mold for foamed resin molding according to claim 1, wherein, with the divided mold attached to the main mold, the slit has an opening that extends along a virtual plane perpendicular to the first wall and the second wall, respectively.

3. The aforementioned divided type is formed by separating the inner wall portion of the first wall body from the outer wall portion. The main body type has ventilation holes that penetrate inward and outward in either the first wall or the second wall, The mold for molding foamed resin according to claim 1, wherein, when the divided mold is attached to the main mold, the ventilation holes are configured to communicate with slits formed in the divided mold.

4. The first wall has a convex inner wall portion at its end that protrudes inward more than the portion other than the end, The mold for molding foamed resin according to claim 3, wherein the divided mold is formed by dividing the convex inner wall portion.

5. With the split type attached to the main body, a first gap connecting to the molded space is formed between the split type and the wall on which the ventilation holes are formed. The mold for molding foamed resin according to claim 3 or 4, wherein the ventilation holes are configured to communicate with slits formed in the divided mold through the first gap.

6. The mold for molding foamed resin according to claim 5, wherein, with the divided mold attached to the main mold, a second gap connected to the molding space and the first gap is formed between the divided mold and the wall body on which the ventilation holes are not formed.

7. The aforementioned divided type is formed by dividing the end portion of the first wall body, The mold for molding foamed resin according to claim 1, wherein the main body mold has a mounting hole that penetrates inward and outward at the end of the first wall body, and the divided mold is fitted into the mounting hole and attached.

8. A mold for molding foamed resin, wherein foamed beads filled in a molding space between a male mold and a female mold are foamed by vapor discharged from a slit opening in the inner wall surface of the wall surrounding the molding space of at least one of the molds, The mold comprises a main mold having a recess formed therein that opens into the molding space, a pair of opposing wall bodies forming the recess, and a bridging wall body spanning between the pair of opposing wall bodies, and a divided mold formed by dividing the main mold so that a part or all of the bridging wall body is included in the inner wall surface, A mold for molding foamed resin, characterized in that the slit is open in the inner wall surface of the divided type.

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