Mold, method of manufacturing composite molded product using same, and spacer

Abstract

To provide a molding tool capable of suppressing generation of a weld line even while being capable of suppressing positional deviation of a sheet body to a resin molding; and to provide a manufacturing method of a composite molded article using the same, and a spacer.SOLUTION: Provided is a molding tool 1 to be used when a composite molded article 10 in which one surface of a sheet body 11 goes along a resin molding 13 is integrally formed. The molding tool comprises: a positioning projection 8 that is inserted into a hole 12 formed on the sheet body, and arranged to form a space through which a molten resin can flow between a tip end surface 8a and an opposite side; and an induction part 4 that induces to the tip end surface side of the positioning projection the molten resin that is supplied from a resin supply port 3 into a cavity 9, and flows toward the positioning projection.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a molding die used for integrally molding a composite molded product, a manufacturing method of the composite molded product using the same, and a spacer. [Background technology]

[0002] A molding die is known which is used for integrally molding a composite molded product in which one surface of a sheet body is aligned with a resin molded body. When molding such a composite molded product, it is desirable to position the sheet body in the cavity of the molding die so that it does not shift. For example, Patent Document 1 listed below discloses a molding die provided with protrusions that fit into through-holes provided in a sheet-like porous body. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-112156 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, if a molding die is provided with the above-described protrusions, the resin injected from the gate portion will flow around the protrusion along the outer peripheral surface of the protrusion, that is, the resin will be divided by the protrusion and join downstream of the protrusion in the resin flow direction, which raises the concern that weld lines may easily occur.

[0005] The present invention has been made in consideration of the above-mentioned situation, and aims to provide a molding tool that can suppress the misalignment of a sheet body relative to a resin molding while suppressing the occurrence of weld lines, a manufacturing method for a composite molded product using the same, and a spacer. [Means for solving the problem]

[0006] In order to achieve the above object, the molding die according to the present invention is a molding die used when integrally molding a composite molding in which one surface of a sheet body is aligned with a resin molding, and is provided with a positioning protrusion that is inserted into a hole formed in the sheet body and is arranged with a gap between its tip surface and an opposing side through which molten resin can flow, and a guide portion that guides the molten resin that is supplied from a resin supply port into a cavity and flows toward the positioning protrusion, toward the tip surface side of the positioning protrusion. On the opposing side of the positioning projection, a projection receiving recess is provided which receives the positioning projection and forms, on the resin molded body, a tip covering portion which covers the tip surface of the positioning projection and an outer circumferential covering portion which covers the outer circumferential surface of the positioning projection, and a guide groove which extends from the projection receiving recess toward the upstream side in the flow direction of the molten resin and constitutes the guide portion. It is characterized by the fact that In order to achieve the above-mentioned object, the molding die of the present invention is a molding die used when integrally molding a composite molded product in which one side of a sheet body is aligned with a resin molding, and is provided with a positioning protrusion that is inserted into a hole formed in the sheet body and is arranged with a gap between its tip surface and the opposing side through which molten resin can flow, and a guide portion that guides the molten resin that is supplied from a resin supply port into a cavity and flows toward the positioning protrusion toward the tip surface side of the positioning protrusion, and on the opposing side of the positioning protrusion, two guide protrusions that constitute the guide portion are provided so as to sandwich the positioning protrusion from both sides in a direction approximately perpendicular to the flow direction of the molten resin from the resin supply port toward the positioning protrusion, and is formed so that when the positioning protrusion is inserted between the two guide protrusions, the dimension between the tip surface of the positioning protrusion and the opposing surface opposite it is larger than the gap dimension from the outer peripheral surface of the positioning protrusion to the mutually facing side surfaces of each guide protrusion.

[0007] In order to achieve the above-mentioned object, the manufacturing method of a composite molded product of the present invention is a manufacturing method of a composite molded product that uses a molding die of the present invention to integrally mold a composite molded product in which one side of a sheet body is aligned with a resin molded body, and is characterized in that it includes a process of positioning the sheet body by inserting a positioning protrusion provided on the molding die into a hole formed in the sheet body, and a process of supplying molten resin into a cavity of the molding die to mold the resin molded body including a tip covering portion that covers the tip surface of the positioning protrusion.

[0008] In order to achieve the above object, the spacer according to the present invention is a spacer that is arranged in a cooling water flow path provided in a cylinder block of an internal combustion engine and regulates the flow of cooling water, and includes a sheet body having a hole penetrating in a thickness direction, and a spacer body made of synthetic resin along which one surface of the sheet body is aligned, and the spacer body includes a bottomed cylindrical protrusion that is provided to define a recess communicating with the hole of the sheet body and protrudes toward one side in the thickness direction, and a protruding strip that is provided to extend continuous with the protrusion and protrudes toward one side in the thickness direction. The width of the protrusion is smaller than the diameter of the protrusion. It is characterized by the above.

[0009] In order to achieve the above object, the spacer according to the present invention is a spacer that is arranged in a cooling water flow path provided in a cylinder block of an internal combustion engine and regulates the flow of cooling water, and includes a sheet body having a hole penetrating therethrough in a thickness direction, and a spacer body made of synthetic resin to which one side of the sheet body is aligned, and the spacer body is provided with a sheet body side recess communicating with the hole of the sheet body, and two anti-sheet body side recesses located on both sides of the sheet body side recess on a side different from the side to which the sheet body is aligned in the thickness direction. A surface of a cover portion defining a bottom surface of the sheet body side recess, which faces a side other than the side along which the sheet body is aligned, is formed flush with a surface of another portion of the spacer body, which faces a side other than the side along which the sheet body is aligned. It is characterized by the fact that Effect of the Invention

[0010] The molding die, the manufacturing method of a composite molded product using the same, and the spacer of the present invention are configured as described above, so that it is possible to suppress the misalignment of the sheet body relative to the resin molded body while also suppressing the occurrence of weld lines. [Brief description of the drawings]

[0011] [Figure 1] 1(a) and 1(b) are schematic, partially cutaway, longitudinal sectional views illustrating an example of a molding die according to one embodiment of the present invention and an example of a method for producing a composite molded product using the same. [Diagram 2] 1A to 1C are schematic views of an example of a spacer as an example of a composite molded product molded using the same mold, where (a) is a partially cutaway schematic front view, (b) is a partially cutaway schematic vertical cross-sectional view corresponding to the X1-X1 line arrow view in (a), and (c) is a partially cutaway schematic horizontal cross-sectional view corresponding to the Y1-Y1 line arrow view in (a). [Diagram 3] 2 is a schematic plan view, with parts omitted, showing an example of a state in which the spacer is disposed in a cooling water flow passage of an internal combustion engine. FIG. [Figure 4] 4(a) and (b) are schematic cross-sectional views, partly cut away, corresponding to part Z in FIG. [Diagram 5]1A is a schematic front view, partially cut away, showing an example of a molding die for a first modified example and an example of a spacer molded using the same; FIG. 1B is a schematic front view, partially cut away, showing an example of a molding die for a second modified example and an example of a spacer molded using the same; and FIG. 1C is a schematic longitudinal sectional view, partially cut away, corresponding to the X2-X2 line arrow view in FIG. 1B. [Figure 6] 1A is a schematic partially cutaway front view showing an example of a molding die for a third modified example and an example of a spacer molded using the same; FIG. 1B is a schematic partially cutaway longitudinal sectional view corresponding to the X3-X3 line arrows in FIG. 1A; FIG. 1C is a schematic partially cutaway front view showing an example of a molding die for a fourth modified example and an example of a spacer molded using the same; and FIG. 1D is a schematic partially cutaway longitudinal sectional view corresponding to the X4-X4 line arrows in FIG. [Figure 7] 10(a) is a schematic front view, partially cut away, showing an example of a molding die for the fifth modified example and an example of a spacer molded using the same, and (b) is a schematic cross-sectional view, partially cut away, corresponding to the Y2-Y2 line arrow view in (a). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In some drawings, some of the detailed reference numerals used in other drawings are omitted. 1 to 4 are diagrams that diagrammatically show an example of a molding die according to the first embodiment, an example of a method for producing a composite molded product using the same, and an example of a spacer.

[0013] The molding die 1 according to this embodiment is used when integrally molding a composite molded product 10 in which one surface of a sheet body 11 is aligned with a resin molded body 13, as shown in Figs. In this embodiment, as shown in FIG. 3, the composite molded product 10 is a spacer that is disposed in a cooling water flow passage 24 provided in a cylinder block 21 of an internal combustion engine 20 and regulates the flow of cooling water. With this configuration, the spacer that is disposed in the cooling water flow passage 24 and regulates the flow of cooling water can be molded by using the mold 1, which will be described in detail later, while suppressing the occurrence of weld lines. The composite molded product 10 molded by using the mold 1 according to this embodiment is not limited to such a spacer, but as an example, the composite molded product 10 will be described below as a spacer 10, and the resin molded body 13 will be described below as a spacer main body 13. An example of a specific configuration of the mold 1 will be described later.

[0014] FIG. 3 illustrates a cylinder block 21 in which a plurality of (three in the illustrated example) cylinder bores 27, 27, 27, each housing a reciprocating piston 28, 28, 28, are arranged adjacent to each other in series, as an example of an internal combustion engine 20 such as an automobile engine. A cylinder head (not shown) is attached to the cylinder block 21 via a gasket. An open deck type cooling water flow path (water jacket) 24 is formed in a continuous (annular) groove shape around the cylinder bores 27, 27, 27. The cooling water flow path 24 is provided with an arc-shaped portion 24a that is arc-shaped so as to surround the cylinder bore 27, and a pair of constricted portions 24b that are constricted in a manner such that the portions between the adjacent cylinder bores 27, 27 are close to each other. Both sides of the groove width direction of the cooling water flow path 24 are partitioned by an inner peripheral side wall surface 26 on the cylinder bore 27 side and an outer peripheral side wall surface 25 on the opposite side to the cylinder bore 27. The cylinder block 21 is provided with a cooling water (including antifreeze) inlet 22 and a cooling water outlet 23 which communicate with the cooling water flow path 24. The cooling water outlet 23 is connected by piping to a radiator (not shown), and the outlet side of the radiator is connected by piping to the cooling water inlet 22 via a water pump (not shown). This allows the cooling water to circulate between the cooling water flow path 24 and the radiator.

[0015] As shown in Fig. 4(a) and (b), the spacer 10 includes a sheet body 11 having a hole (through hole) 12 penetrating in the thickness direction, and a spacer body 13 made of synthetic resin along which one surface of the sheet body 11 is aligned. In the illustrated example, a plurality of spacers 10, 10 are arranged in the cooling water flow passage 24. These spacers 10, 10 are provided over substantially the entire circumference of the cooling water flow passage 24. These spacers 10, 10 are divided into two in a direction perpendicular to the cylinder bore arrangement direction (approximately divided into two equal parts in the illustrated example). The sheet bodies 11, 11 and spacer bodies 13, 13 of these spacers 10, 10 have the same configuration, so one of them will be described below as an example.

[0016] 3, the spacer body 13 is in the form of a thin plate arranged such that the thickness direction coincides with the groove width direction of the cooling water flow path 24. The spacer body 13 includes an arc-shaped portion 18 formed in an arc shape corresponding to the arc-shaped portion 24a of the cooling water flow path 24, and a connecting portion 19 formed in a bent shape corresponding to the constricted portion 24b of the cooling water flow path 24 and connecting adjacent arc-shaped portions 18, 18 to each other. 2(a) to 2(c), the spacer body 13 includes a bottomed cylindrical protrusion 15 that is provided to define a recess 16 communicating with the through hole 12 of the sheet body 11 and protrudes toward one side in the thickness direction, and a protrusion 14 that is provided to extend continuously from the protrusion 15 and protrudes toward one side in the thickness direction. With this configuration, the flow of cooling water can be effectively regulated by the protrusion 15 and the protrusion 14 that is connected to it. In this embodiment, the protrusion 15 and the protrusion 14 are provided to be located approximately in the circumferential center of the surface of each arc-shaped portion 18 that faces the outer circumferential wall surface 25. An example of a specific configuration of the protrusion 15 and the protrusion 14 will be described later.

[0017] The sheet body 11 is flexible and is provided along a surface facing the inner peripheral wall surface 26 of the arc-shaped portion 18 of the spacer body 13. The dimension of the sheet body 11 along the circumferential direction of the cooling water flow passage 24 and the dimension of the sheet body 11 along the depth direction of the cooling water flow passage 24 are smaller than the dimension of the arc-shaped portion 18 of the spacer body 13 along the circumferential direction and the dimension of the cooling water flow passage 24 of the arc-shaped portion 18 along the depth direction. In the illustrated example, an example is shown in which the sheet bodies 11, 11, 11 are provided on each of the multiple (three in the illustrated example) arc-shaped portions 18, 18, 18 of the spacer body 13. These sheet bodies 11, 11, 11 are provided so that their respective circumferential central portions coincide with the circumferential central portions of the arc-shaped portions 18, 18, 18, but are not limited to such an example. These sheet bodies 11, 11, 11 have the same configuration, so that only one of them will be described below as an example. An example of a specific configuration of the through holes 12 in the sheet body 11 will be described later.

[0018] In this embodiment, the sheet body 11 has a characteristic of expanding in the thickness direction from a compressed state due to a predetermined external factor. With this configuration, the spacer 10 in which the sheet body 11 having the characteristic of expanding in the thickness direction from a compressed state is integrally molded with the spacer body 13 can be molded while suppressing the occurrence of weld lines. The sheet body 11 may be a cellulose sponge that can be restored (expanded) in the thickness direction by absorbing water as a predetermined external factor. When the cellulose sponge is dried in a compressed state by applying pressure, hydrogen bonds are formed between cellulose molecules, and the compressed state is maintained, while when the sponge is exposed to water or the like and absorbs water, the water molecules dissociate the hydrogen bonds between cellulose molecules, and the sponge is restored from the compressed state.

[0019] With the above-described configuration including the sheet body 11, the sheet body 11 is in a compressed state when the spacer 10 is inserted into the cooling water flow path 24, and therefore the ease of insertion can be improved. On the other hand, as shown in Fig. 4(b), if the sheet body 11 swells due to water absorption, the sheet body 11 and the spacer body 13 can effectively regulate the flow of cooling water. In the illustrated example, the sheet body 11 is in a state where it is in abutment with the inner peripheral wall surface 26 and the protrusion 15 of the spacer body 13 is in abutment with the outer peripheral wall surface 25 when it is in an swelled state, but the present invention is not limited to such an example. The sheet body 11 is not limited to the cellulose-based sponge described above, but may be a rubber-based foam or a synthetic resin-based foam compressed with a water-soluble or heat-meltable binder, or may have various other configurations.

[0020] As shown in Figs. 1(a) and 1(b), the forming die 1 is provided with a positioning protrusion 8 which is inserted into a through hole 12 formed in the sheet body 11 and is arranged with a gap between a tip surface 8a and the opposing side through which molten resin can flow. With this configuration, it is possible to suppress the positional deviation of the sheet body 11 with respect to the spacer body 13. In other words, it is possible to suppress the sheet body 11 from moving within the cavity 9 of the forming die 1. Furthermore, as shown in Figs. 2(a) to 2(c), the spacer body 13 is formed including a tip cover portion 15a which covers the tip surface 8a of the positioning protrusion 8, and while it is possible to position the sheet body 11, no through hole is formed in the spacer body 13 by the positioning protrusion 8. The molding die 1 is provided with a guide portion 4 that guides the molten resin, which is supplied from the resin supply port 3 into the cavity 9 and flows toward the positioning protrusion 8, toward the tip surface 8a of the positioning protrusion 8. With this configuration, the molten resin flowing toward the positioning protrusion 8 is guided toward the tip surface 8a of the positioning protrusion 8 by the guide portion 4, so that it is possible to prevent the molten resin from becoming difficult to flow on the tip surface 8a side. As a result, the molten resin flowing around the positioning protrusion 8 along the outer peripheral surface 8b of the positioning protrusion 8 and the molten resin flowing along the tip surface 8a of the positioning protrusion 8 tend to flow at approximately the same timing on the downstream side of the positioning protrusion 8 in the resin flow direction, so that it is possible to prevent weld lines from being generated. This makes it possible to prevent cracks due to localized strength reduction and poor appearance in the manufactured spacer body 13.

[0021] In this embodiment, the opposite side of the positioning protrusion 8 of the mold 1 is provided with a protrusion receiving recess 5 that receives the positioning protrusion 8 and forms a tip covering portion 15a covering the tip surface 8a of the positioning protrusion 8 and an outer peripheral covering portion 15b covering the outer peripheral surface 8b of the positioning protrusion 8 on the spacer body 13, and a guide groove 4 that extends from the protrusion receiving recess 5 toward the upstream side in the flow direction of the molten resin and constitutes a guide portion. With this configuration, the tip covering portion 15a covering the tip surface 8a of the positioning protrusion 8 received in the protrusion receiving recess 5 and the outer peripheral covering portion 15b covering the outer peripheral surface 8b can be formed. As a result, the tip covering portion 15a and the outer peripheral covering portion 15b can form a bottomed cylindrical protrusion 15 that protrudes from one side of the spacer body 13. In addition, since the guide groove 4 extending from the protrusion receiving recess 5 toward the upstream side in the flow direction of the molten resin is provided, it is possible to more effectively prevent the weld line from occurring. In other words, the molten resin can be effectively guided toward the tip surface 8a of the positioning protrusion 8 along the guide groove 4 that constitutes the guide portion.

[0022] In this embodiment, as shown in Figs. 2(a) and (b), the mold 1 is provided with a plurality of positioning protrusions 8,8, a plurality of protrusion receiving recesses 5,5, and a guide groove 4 that connects the plurality of protrusion receiving recesses 5,5. With this configuration, the sheet body 11 can be more reliably positioned by the plurality of positioning protrusions 8,8. In addition, the guide groove 4 that connects the plurality of protrusion receiving recesses 5,5 can effectively guide the molten resin toward the tip surfaces 8a,8a of each positioning protrusion 8,8. The guide groove 4 is formed linearly between the plurality of protrusion receiving recesses 5,5. With this configuration, the linear guide groove 4 can more effectively guide the molten resin toward the tip surfaces 8a,8a of each positioning protrusion 8,8. The resin supply port 3 opens at the groove bottom 4a of the guide groove 4 or in the vicinity of the guide groove 4. With this configuration, the molten resin supplied from the resin supply port 3 can be easily caused to flow along the guide groove 4.

[0023] Specifically, as shown in Figs. 1(a) and 1(b), the molding die 1 includes a first die 2 provided with a resin supply port 3, a guide groove 4, and a protrusion receiving recess 5, and a second die 7 provided with a positioning protrusion 8. The first die 2 and the second die 7 are formed so that the cavity 9 defined by them has a shape corresponding to the above-mentioned spacer body 13. The resin supply port 3, the guide groove 4, and the protrusion receiving recess 5 of the first die 2, and the positioning protrusion 8 of the second die 7 are provided in the circumferential center (circumferential direction of the cooling water flow path 24) of each part forming each of the arc-shaped parts 18, 18, 18 of the spacer body 13. In the following, the resin supply port 3, the guide groove 4, and the protrusion receiving recess 5 of the first die 2, and the positioning protrusion 8 of the second die 7 will be described using a part forming one arc-shaped part 18 as an example.

[0024] In this embodiment, the positioning protrusion 8 is cylindrical (see also FIG. 2(a)). In this embodiment, the two positioning protrusions 8,8 are provided at an interval in the depth direction of the cooling water flow path 24. These two positioning protrusions 8,8 are provided at a position equidistant from the resin supply port 3. These two positioning protrusions 8,8 have the same protrusion dimension and diameter W1. The sheet body 11 described above is provided with through holes 12,12 through which these two positioning protrusions 8,8 are inserted. The inner diameter of these through holes 12,12 is set to a diameter corresponding to the diameter W1 of the positioning protrusions 8,8 so that each positioning protrusion 8,8 can be inserted. The protrusion dimension of the positioning protrusions 8,8 is made larger than the thickness dimension of the sheet body 11. In this embodiment, the protrusion receiving recess 5 corresponds to the positioning protrusion 8 and has a circular shape concentric with the positioning protrusion 8 when viewed in the recess depth direction (see also FIG. 2(a)). In this embodiment, the two protrusion receiving recesses 5, 5 are spaced apart in the depth direction of the cooling water flow path 24 so as to be equidistant from the resin supply port 3. The two protrusion receiving recesses 5, 5 have the same depth dimension D2 (see FIG. 1(a)) and diameter.

[0025] The guide groove 4 is provided to extend in the depth direction of the cooling water flow path 24 so as to communicate with these two protrusion receiving recesses 5, 5. The resin supply port 3 is provided to open at a groove bottom 4a of the guide groove 4. 1(a), in this embodiment, the groove depth dimension D1 of at least the portion of the guide groove 4 on the protrusion receiving recess side is equal to or greater than the depth dimension D2 of the protrusion receiving recess 5. With this configuration, the molten resin can be more effectively guided along the guide groove 4 toward the tip surface 8a of the positioning protrusion 8, compared to, for example, a configuration in which the groove depth dimension D1 of the guide groove 4 is smaller than the depth dimension D2 of the protrusion receiving recess 5. In the illustrated example, the groove depth dimension D1 of the guide groove 4 between the two protrusion receiving recesses 5, 5 is set to a uniform dimension over the entire length and is set to the same dimension as the depth dimension D2 of the protrusion receiving recess 5, but is not limited to this embodiment. 2(a), the groove width W2 of the guide groove 4 is smaller than the diameter W1 of the positioning protrusion 8. With this configuration, the molten resin is less likely to flow along the outer circumferential surface 8b of the positioning protrusion 8, so that the molten resin can be more effectively guided toward the tip surface 8a of the positioning protrusion 8. In the illustrated example, the groove width W2 of the guide groove 4 is a uniform dimension over the entire length and is about 1 / 2 the diameter W1 of the positioning protrusion 8, but is not limited to this example.

[0026] As shown in FIG. 1(b), when the positioning protrusion 8 is inserted into the protrusion receiving recess 5, the dimension (tip side gap dimension) G1 between the tip surface 8a of the positioning protrusion 8 and the opposing bottom surface 5a of the protrusion receiving recess 5 is larger than the dimension (outer peripheral side gap dimension) G2 along the radial direction from the outer peripheral surface 8b of the positioning protrusion 8 to the inner peripheral surface 5b of the protrusion receiving recess 5. With this configuration, the molten resin is less likely to flow along the outer peripheral surface 8b side of the positioning protrusion 8, so that the molten resin can be more effectively guided toward the tip surface 8a side of the positioning protrusion 8. In the illustrated example, the tip side gap dimension G1 is about 1.2 times the outer peripheral side gap dimension G2, but the present invention is not limited to this example.

[0027] A manufacturing method of a composite molded product using the mold 1 configured as above to integrally mold a spacer 10 with one side of a sheet body 11 aligned with a spacer body 13 includes a step of positioning the sheet body 11 by inserting a positioning protrusion 8 provided on the mold 1 into a through hole 12 formed in the sheet body 11, and a step of supplying molten resin into a cavity 9 of the mold 1 to mold a spacer body 13 including a tip cover portion 15a that covers a tip surface 8a of the positioning protrusion 8. Specifically, as shown in FIG. 1(a), in a state where the first mold 2 and the second mold 7 are opened, the positioning protrusion 8 of the second mold 7 is inserted into the through hole 12 of the sheet body 11 to position the sheet body 11 with respect to the second mold 7. Then, as shown in FIG. 1(b), the first mold 2 and the second mold 7 are closed, and molten resin is supplied into the cavity 9 through a resin supply port 3.

[0028] The molten resin supplied from this resin supply port 3 flows between the mold surface of the first mold 2 and the mold surface of the second mold 7, also flows along the guide groove 4, and flows along the tip faces 8a, 8a and outer peripheral faces 8b, 8b of the positioning protrusions 8, 8 on both sides and the bottom faces 5a, 5a and inner peripheral faces 5b, 5b of the protrusion receiving recesses 5, 5 on both sides. In this way, the molding die 1 is configured so that the molten resin flowing from the resin supply port 3 along the outer peripheral faces 8b of the positioning protrusions 8 so as to go around the positioning protrusions 8 and the molten resin flowing along the tip faces 8a of the positioning protrusions 8 flow at approximately the same timing downstream of the positioning protrusions 8 in the resin flow direction. Then, by appropriately maintaining pressure, opening the mold, and releasing the mold, the spacer 10 is formed with one surface of the sheet body 11 aligned with the spacer body 13.

[0029] In this embodiment, two protrusions 15, 15 are provided at the circumferential center of the arc-shaped portion 18 of the spacer body 13 of the spacer 10, spaced apart in the depth direction of the cooling water flow path 24, and a protrusion 14 is provided extending to connect these protrusions 15, 15. These protrusions 15, 15 are provided so as to protrude radially outward from the arc-shaped portion 18. These protrusions 15, 15 are generally cylindrical with a bottom, with tip cover portions 15a, 15a as the bottom surface and outer circumferential cover portions 15b, 15b as the side surface. These protrusions 15, 15 have the same protrusion dimension and diameter. The thickness dimension (dimension along the protrusion protruding direction) of the tip cover portions 15a, 15a of these protrusions 15, 15 is larger than the thickness dimension (dimension along the protrusion radial direction) of the outer circumferential cover portions 15b, 15b of these protrusions 15, 15.

[0030] Recesses 16, 16 are provided so as to open on the sheet body 11 side of the protrusions 15, 15. The bottom surfaces of the recesses 16, 16 are defined by the tip cover portion 15a, and the inner peripheral surfaces are defined by the outer peripheral cover portion 15b and the spacer body 13 except for the protrusions 15, 15. The recesses 16, 16 are substantially circular when viewed in the depth direction. The diameter of the recesses 16, 16 is substantially the same as the diameter of the through holes 12, 12 of the sheet body 11. The protrusion 14 is provided so as to protrude radially outward from the arc-shaped portion 18. The protrusion 14 is formed like a wall whose width direction corresponds to the circumferential direction of the cooling water flow passage 24. The protrusion dimension of the protrusion 14 is the same as the protrusion dimension of the protrusions 15, 15. In other words, the tip surface of the protrusion 14 and the tip surfaces of the protrusions 15, 15 are flush with each other. The width dimension of the protrusion 14 (the dimension along the circumferential direction of the cooling water flow passage 24) is smaller than the diameter of the protrusions 15, 15.

[0031] Next, modified examples of the molding die and an example of a spacer as a composite molded product molded using each modified example will be described with reference to the drawings. In the following modified examples, differences from the previously described example will be mainly described, and the same configurations will be given the same reference numerals and their description will be omitted or briefly described. Also, explanations of the effects achieved similarly to the previously described example will be omitted or briefly described. Also, the manufacturing method using the mold according to each modified example will be omitted because it is the same as above.

[0032] FIG. 5(a) is a diagram showing a schematic diagram of an example of a molding die according to a first modified example and an example of a spacer molded using the same. This modification is different from the above-mentioned example mainly in that the guide groove 4A of the first die 2A of the molding die 1A is not linear but is bent midway. In this modification, the two protrusion receiving recesses 5,5 of the first die 2A and the two positioning protrusions 8,8 of the second die 7A are provided at positions shifted from the resin supply port 3 in the circumferential direction of the cooling water flow path 24. These two protrusion receiving recesses 5,5 and the two positioning protrusions 8,8 are provided at positions that coincide with each other in the circumferential direction of the cooling water flow path 24 and at positions equidistant from the resin supply port 3. The guide groove 4A is bent at the portion where the resin supply port 3 is provided and is provided so as to extend from that portion toward each of the protrusion receiving recesses 5,5.

[0033] The resin supply port 3 may be provided so as to be located at the circumferential center of the portion forming the arc-shaped portion 18, or the two protrusion receiving recesses 5, 5 and the two positioning protrusions 8, 8 may be provided so as to be located at the circumferential center of the portion forming the arc-shaped portion 18. A spacer body 13A of a spacer 10A molded using this molding die 1A is provided with a protrusion 14A that is bent midway. In the spacer body 13A, similarly to the above, two protrusions 15, 15 are provided so as to be aligned with each other in the circumferential direction of the cooling water flow path 24. The protrusions 14A are provided so as to extend from the bent portion toward each of the protrusions 15, 15.

[0034] 5(b) and (c) are diagrams showing an example of a molding die according to a second modified example and an example of a spacer molded using the same. In this modification, one protrusion receiving recess 5 is provided in the first die 2B of the molding die 1B, and one positioning protrusion 8 is provided in the second die 7B. The protrusion receiving recess 5, the positioning protrusion 8, and the resin supply port 3 are provided so as to be aligned with each other in the circumferential direction of the cooling water flow path 24. In this modification, the resin supply port 3 opens not at the groove bottom 4a of the guide groove 4B, but in the vicinity of the guide groove 4B. Here, the vicinity of the guide groove 4B may be within a distance of 20 mm from the resin supply port 3 to the guide groove 4B, depending on the diameter of the resin supply port 3 and the size of the spacer 10 to be molded. In the illustrated example, the resin supply port 3 opens in the vicinity of the end of the guide groove 4B extending toward the protrusion receiving recess 5 on the opposite side to the end of the protrusion receiving recess 5, but is not limited to this example.

[0035] 5(c), in this modification, guide groove 4B does not have a uniform groove depth over its entire length, but has a uniform groove depth D1 at its portion on the protrusion receiving recess 5 side. The portion of guide groove 4B on the resin supply port 3 side is formed so that the groove depth gradually increases from the end on the resin supply port 3 side toward the protrusion receiving recess 5 side. The groove depth D1 at the portion of guide groove 4B on the protrusion receiving recess 5 side is smaller than the depth D2 of protrusion receiving recess 5. A spacer body 13B of a spacer 10B molded using this molding die 1B is provided with one protrusion 15 and a protruding streak 14B extending from this protrusion 15 in the depth direction of the cooling water flow path 24. The protruding dimension of the protruding streak 14B at the protrusion 15 side is smaller than the protruding dimension of the protrusion 15. The protruding dimension of the protruding streak 14B at the portion away from the protrusion 15 is formed so that it gradually decreases with increasing distance from the protrusion 15. In this modified example, an example in which one protrusion receiving recess 5 and one positioning protrusion 8 are provided is shown, but further protrusion receiving recesses 5 and positioning protrusions 8 may be provided symmetrically on either side of the resin supply port 3. In this case, guide grooves 4B may be provided so as to extend from the vicinity of the resin supply port 3 toward both sides in the depth direction of the cooling water flow path 24.

[0036] 6(a) and (b) are schematic diagrams showing an example of a molding die according to a third modified example and an example of a spacer molded using the same. As in the second modification, this modification shows an example in which one protrusion receiving recess 5 is provided in the first die 2C of the forming die 1C, and one positioning protrusion 8 is provided in the second die 7C. In this modification, the groove depth dimension D1 of the guide groove 4C at the protrusion receiving recess 5 side portion is set to be larger than the depth dimension D2 of the protrusion receiving recess 5, as shown in FIG. 6(b). This modification shows an example in which this guide groove 4C is provided so as to reach a part of the protrusion receiving recess 5. In the illustrated example, an example in which the guide groove 4C is provided so as to reach approximately the center of the protrusion receiving recess 5 is shown. A spacer body 13C of a spacer 10C molded using this molding die 1C is provided with one protrusion 15 and a protrusion 14C extending from this protrusion 15 in the depth direction of the cooling water flow path 24. The protrusion dimension of the protrusion 14C at the protrusion 15 side portion is set to be larger than the protrusion dimension of the protrusion 15. This protrusion 14C is provided so as to reach a part of the protrusion 15. In the spacer 10C configured in this manner, the protrusion 14C may be in contact with an outer circumferential wall surface 25 of the cooling water flow path 24 when the sheet body 11 is in an expanded state.

[0037] 6(c) and (d) are diagrams showing an example of a molding die according to a fourth modified example and an example of a spacer molded using the same. In this modification, as in the second modification, one protrusion receiving recess 5 is provided in the first die 2D of the molding die 1D, and one positioning protrusion 8 is provided in the second die 7D. In this modification, the groove width W2 of the guide groove 4D is larger than the diameter W1 of the positioning protrusion 8. In this modification, the groove width W2 of the guide groove 4D is the same as the inner diameter of the protrusion receiving recess 5. The groove depth dimension D1 of this guide groove 4D is the same as the depth dimension D2 of the protrusion receiving recess 5. In other words, the guide groove 4D is configured such that a series of approximately semicircular protrusion receiving recesses 5 are provided in the end portion on the side different from the resin supply port 3 side when viewed in the recess depth direction. The resin supply port 3 is provided so as to open at the groove bottom 4a of the end portion on the side different from the protrusion receiving recess 5 side of this guide groove 4D. A spacer body 13D of a spacer 10D molded using this molding die 1D is provided with a rib 14D extending continuously from a substantially semi-cylindrical protrusion 15 in the depth direction of the cooling water flow path 24. In other words, a substantially semi-cylindrical protrusion 15 is provided continuously at one end of the rib 14D. The protrusions 15 and the rib 14D have the same protruding dimensions. The diameter of the protrusion 15 and the width of the rib 14D are the same.

[0038] 7(a) and (b) are diagrams showing an example of a molding die according to a fifth modified example and an example of a spacer molded using the same. In this modification, the configuration of the guide portion provided in the molding die 1E is mainly different from the above-mentioned examples. In this modification, two guide protrusions 6, 6 constituting the guide portion are provided on the opposing side of the positioning protrusion 8 of the second die 7E so as to sandwich the positioning protrusion 8 from both sides in a direction substantially perpendicular to the flow direction of the molten resin from the resin supply port 3 toward the positioning protrusion 8. Even with this configuration, it is possible to make it difficult for a weld line to occur. That is, the two guide protrusions 6, 6 constituting the guide portion make it difficult for the molten resin to flow on the outer peripheral surface 8b side of the positioning protrusion 8, so that the molten resin can be more effectively guided toward the tip surface 8a side of the positioning protrusion 8. In addition, since the protrusion receiving recess 5 forming the outer peripheral covering portion 15b as described above is not provided, the surface of the tip covering portion 15A covering the tip surface 8a of the positioning protrusion 8 can be made flush with the surrounding surface without forming the protrusion 15 as described above.

[0039] In this modified example, a plurality of positioning protrusions 8,8 (two in the illustrated example) are provided, and guide protrusions 6,6,6,6 are provided to be positioned on both sides of each of these positioning protrusions 8,8. That is, in the illustrated example, four guide protrusions 6,6,6,6 are provided. With this configuration, the sheet body 11 can be positioned more reliably by the plurality of positioning protrusions 8,8. In addition, the guide protrusions 6,6,6,6 located on both sides of each of these positioning protrusions 8,8 can effectively guide the molten resin toward the tip surfaces 8a,8a of each positioning protrusion 8,8. Specifically, the resin supply port 3 of the first die 2E of the molding die 1E and the two positioning protrusions 8,8 of the second die 7E are provided so as to be aligned with each other in the circumferential direction of the cooling water flow path 24. The resin supply port 3 and the two positioning protrusions 8,8 may be provided so as to be located at the circumferential center of the portion forming the arc-shaped portion 18. The two positioning protrusions 8,8 are provided so as to be equidistant from the resin supply port 3. The guide protrusions 6,6,6,6 on both sides of each positioning protrusion 8,8 have the same configuration, so the guide protrusions 6,6 on both sides of one of the positioning protrusions 8 will be described below as an example.

[0040] These guide protrusions 6, 6 are provided so as to be located on both sides of the positioning protrusion 8 in the circumferential direction of the cooling water flow path 24. As shown in Fig. 7(a), these guide protrusions 6, 6 are substantially rectangular when viewed in the groove width direction of the cooling water flow path 24, and the dimension along the depth direction of the cooling water flow path 24 is larger than the diameter of the positioning protrusion 8. In the first type 2E, a groove portion extending in the depth direction of the cooling water flow path 24 is formed by these guide protrusions 6, 6, and the groove bottom of this groove portion becomes the opposing surface 5A with which the tip surface 8a of the positioning protrusion 8 faces. 7(b), in the present modified example, when the positioning protrusion 8 is inserted between these two guide protrusions 6, 6, the dimension (tip side gap dimension) G3 between the tip surface 8a of the positioning protrusion 8 and the opposing surface 5A facing it is larger than the gap dimension (outer peripheral side gap dimension) G4 from the outer peripheral surface 8a of the positioning protrusion 8 to the mutually facing side surfaces 6a, 6a of each guide protrusion 6, 6. With this configuration, the molten resin is less likely to flow on the outer peripheral surface 8b side of the positioning protrusion 8, so that the molten resin can be more effectively guided toward the tip surface 8a side of the positioning protrusion 8.

[0041] The spacer body 13E of the spacer 10E molded using this mold 1E is provided with a sheet body side recess 16A communicating with the through hole 12 of the sheet body 11, and two counter-sheet body side recesses 17, 17 located on both sides of the sheet body side recess 16A on a side different from the side along which the sheet body 11 is aligned in the thickness direction. With this configuration, weight reduction can be achieved by the sheet body side recess 16A and the counter-sheet body side recesses 17, 17 on both sides. In addition, since the spacer body 13E is configured without the above-mentioned protrusion 15 protruding in the thickness direction, interference with the inner wall (outer peripheral side wall surface 25) of the cooling water flow path 24 can be suppressed.

[0042] In this example, the anti-seat body side recesses 17, 17 are provided so as to be positioned on both sides of the sheet body side recess 16A in the circumferential direction of the cooling water flow path . This spacer body 13E is provided with two sheet body side recesses 16A, 16A spaced apart in the depth direction of the cooling water flow path 24, and anti-sheet body side recesses 17, 17, 17, 17 are provided to be located on both sides of these sheet body side recesses 16A, 16A. Since the sheet body side recesses 16A, 16A and the anti-sheet body side recesses 17, 17, 17 on both sides thereof have the same configuration, the following description will be given taking one sheet body side recess 16A and the anti-sheet body side recesses 17, 17 on both sides thereof as an example.

[0043] The sheet body side recess 16A is generally similar to the recess 16 in the above-mentioned example, and opens on the sheet body 11 side (the inner peripheral wall surface 26 side) and has a substantially circular shape when viewed in the recess depth direction. The bottom surface of this sheet body side recess 16A is defined by the tip cover portion 15A. The surface of this tip cover portion 15A facing the outer peripheral wall surface 25 is flush with the surface of the other portion of the spacer main body 13E facing the outer peripheral wall surface 25. The counter-sheet body side recesses 17, 17 open on a side (the outer peripheral wall surface 25 side) different from the side where the sheet body 11 is provided, and are substantially rectangular when viewed in the depth direction of the recess. The dimension of the walls 15B, 15B provided to separate the counter-sheet body side recesses 17, 17 from the sheet body side recess 16A along the circumferential direction of the cooling water flow path 24 is smaller than the thickness dimension of the tip cover portion 15A.

[0044] The different configurations of the molding dies 1, 1A to 1E and the spacers 10, 10A to 10E according to the above-mentioned respective examples may be partially rearranged or combined for application. In the above examples, the sheet body 11 has a characteristic of expanding in the thickness direction from a compressed state due to a predetermined external factor, but it may have a configuration that does not have such a characteristic. The sheet body 11 may be, for example, leather, cloth, textile, wood veneer, resin sheet, cork sheet, etc. In each of the above examples, a composite molded product in which one side of the sheet body 11 is aligned with a resin molded body is used as the spacer 10, 10A to 10E to be placed in the cooling water flow path 24, but it may also be used to form various parts and components used in automobile interior trim and garnishes, industrial machinery, electronic devices, building materials, etc. The configurations of the components constituting the molding dies 1, 1A to 1E and the spacers (composite molded products) 10, 10A to 10E according to the above-mentioned examples are not limited to the above-mentioned examples, and various other modifications are possible. [Explanation of symbols]

[0045] 1,1A~1E Mold 3 Resin supply port 4,4A~4D Guide groove (guide part) 4a Groove bottom 5 Protrusion receiving recess 5a Bottom (opposite side) 5b Inner surface 5A Opposite surface (opposite side) 6 Guiding protrusion (guiding part) 6a side 8 Positioning protrusion 8a Tip surface 8b Outer surface 9 Cavity 10, 10A~10E Spacer (composite molding) 11 Sheet body 12 Through hole (hole) 13, 13A to 13E Spacer body (resin molded body) 14,14A~14D protrusion 15 Protrusion 15a, 15A Tip cover 15b Outer cover 16 Recess 16A Seat side recess 17 Recess on opposite side of seat body 20 Internal Combustion Engine 21 Cylinder block 24 Cooling water flow path D1 Groove depth dimension (groove depth dimension of the guide groove on the protrusion receiving recess side) D2 Depth dimension (depth dimension of protrusion receiving recess) G1 Tip side clearance dimension (dimension between the tip surface of the positioning protrusion and the bottom surface of the opposing protrusion receiving recess) G2 Outer circumference clearance dimension (diameter dimension from the outer circumference of the positioning protrusion to the inner circumference of the protrusion receiving recess) G3 Tip side clearance dimension (dimension between the tip face of the positioning protrusion and the opposing face) G4 Outer gap dimension (gap dimension from the outer surface of the positioning protrusion to the opposing side surfaces of each guide protrusion) W1 diameter (diameter of positioning protrusion) W2 Groove width (guide groove width)

Claims

1. A molding die used for integrally molding a composite molded product in which one surface of a sheet body is aligned with a resin molded body, a positioning protrusion that is inserted into a hole formed in the sheet body and that is disposed with a gap between its tip surface and an opposing side through which molten resin can flow; and a guide portion that guides the molten resin that is supplied from a resin supply port into the cavity and flows toward the positioning protrusion, toward the tip surface side of the positioning protrusion, A molding die is provided on the opposite side of the positioning protrusion, with a protrusion receiving recess that receives the positioning protrusion and forms, on the resin molded body, a tip covering portion that covers the tip surface of the positioning protrusion and an outer peripheral covering portion that covers the outer peripheral surface, and a guide groove that extends from the protrusion receiving recess toward the upstream side in the flow direction of the molten resin and constitutes the guide portion.

2. In claim 1, A molding die characterized in that a groove depth dimension of at least a portion of said guide groove on said projection receiving recess side is equal to or greater than a depth dimension of said projection receiving recess.

3. In claim 1 or 2, A molding die characterized in that, when the positioning protrusion is inserted into the protrusion receiving recess, the dimension between the tip surface of the positioning protrusion and the opposing bottom surface of the protrusion receiving recess is larger than the radial dimension from the outer peripheral surface of the positioning protrusion to the inner peripheral surface of the protrusion receiving recess.

4. In any one of claims 1 to 3, A molding die, wherein a groove width of the guide groove is smaller than a diameter of the positioning protrusion.

5. In any one of claims 1 to 4, A molding die comprising: a plurality of said positioning projections; a plurality of said projection receiving recesses; and said guide groove connecting said plurality of projection receiving recesses.

6. In claim 5, The molding die is characterized in that the guide groove is formed linearly between the plurality of projection receiving recesses.

7. In any one of claims 1 to 6, The molding die is characterized in that the resin supply port opens at a bottom of the guide groove or in the vicinity of the guide groove.

8. A molding die used in integrally molding a composite molded product in which one surface of a sheet body is aligned with a resin molded body, a positioning protrusion that is inserted into a hole formed in the sheet body and that is disposed with a gap between its tip surface and an opposing side through which molten resin can flow; and a guide portion that guides the molten resin that is supplied from a resin supply port into the cavity and flows toward the positioning protrusion, toward the tip surface side of the positioning protrusion, On the opposing sides of the positioning protrusion, two guide protrusions that constitute the guide section are provided so as to sandwich the positioning protrusion from both sides in a direction generally perpendicular to the flow direction of the molten resin from the resin supply port toward the positioning protrusion, and the molding die is formed so that when the positioning protrusion is inserted between the two guide protrusions, the dimension between the tip surface of the positioning protrusion and the opposing surface facing it is larger than the gap dimension from the outer peripheral surface of the positioning protrusion to the mutually facing side surfaces of each guide protrusion.

9. In claim 8, A molding die comprising a plurality of positioning projections, each of the positioning projections being provided with a guide projection disposed on both sides thereof.

10. In any one of claims 1 to 9, The molding die is characterized in that the composite molded product is a spacer that is placed in a cooling water flow passage provided in a cylinder block of an internal combustion engine and regulates the flow of cooling water.

11. In any one of claims 1 to 10, The mold is characterized in that the sheet has a property of expanding in a thickness direction from a compressed state in response to a predetermined external factor.

12. A method for producing a composite molded product, comprising the steps of: using the mold according to any one of claims 1 to 11; and integrally molding a composite molded product by aligning one surface of a sheet body with a resin molded body, the method comprising the steps of: A method for manufacturing a composite molded product, comprising the steps of: inserting a positioning protrusion provided on the molding die into a hole formed in the sheet body to position the sheet body; and supplying molten resin into a cavity of the molding die to mold the resin molded product including a tip cover portion that covers the tip surface of the positioning protrusion.

13. A spacer that is disposed in a cooling water flow passage provided in a cylinder block of an internal combustion engine and regulates the flow of cooling water, The spacer includes a sheet body having a hole formed therethrough in the thickness direction, and a spacer body made of synthetic resin, one surface of which is aligned with the sheet body. The spacer body is provided with a bottomed cylindrical protrusion that protrudes toward one side in the thickness direction so as to define a recess that communicates with the hole in the sheet body, and a protrusion streak that is connected to the protrusion and protrudes toward one side in the thickness direction, and the width dimension of the protrusion streak is smaller than the diameter of the protrusion.

14. A spacer that is disposed in a cooling water flow passage provided in a cylinder block of an internal combustion engine and regulates the flow of cooling water, The spacer includes a sheet body having a hole formed therethrough in the thickness direction, and a spacer body made of synthetic resin, one surface of which is aligned with the sheet body. A spacer characterized in that the spacer body is provided with a sheet body side recess that communicates with a hole in the sheet body, and two anti-sheet body side recesses located on both sides of the sheet body side recess on a side in the thickness direction other than the side to which the sheet body is aligned, and the surface of a covering portion that defines the bottom surface of the sheet body side recess facing the side other than the side to which the sheet body is aligned is formed flush with a surface of another portion of the spacer body facing the side other than the side to which the sheet body is aligned.

Images