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 simplifying a structure; 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 flexible sheet body 11 goes along a resin molding 13 is integrally formed. The molding tool comprises a first mold 2 dividing a space in which the sheet body is arranged, and having a first mold surface 4 facing one surface of the sheet body, and a second mold 7 having a second mold surface 9 facing the first mold surface. The first mold comprises a press projection 6 that is brought into contact with the sheet body at a position separated from a resin supply port 3 opening on the first mold surface so as to form a space between the first mold surface and the sheet body around thereof, and disposed fixedly so that a resin layer 14 is formed between a tip end surface 6a and the sheet body. A side surface 6c on a downstream side in a flowing direction of a molten resin at the press projection is set as an inclined surface on a downstream side as being separated from the tip end surface.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] Conventionally, a molding die is known that is used for integrally molding a composite molded product in which one side of a sheet body is aligned with a resin molded body. When molding such a composite molded product, when the sheet body is aligned with the surface of the mold on the side where the resin supply port is provided, the sheet body becomes a resistance to the molten resin, so a pin may be provided to press the sheet body against the mold surface. In this case, the resin injected from the gate flows around the pin along the outer peripheral surface of the pin, that is, the resin is divided by the pin and merges on the downstream side of the pin in the resin flow direction, so there is a concern that weld lines are likely to occur. For example, Patent Document 1 below discloses an insert molding die consisting of a movable mold to which an insert film is fixed, a fixed mold having an injection outlet for molten resin, and a fixed pin that protrudes from the fixed mold into a cavity to press the insert film against the movable mold and is pressed into the fixed mold by the injection pressure of the molten resin injected into the cavity. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 8-267504 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the insert molding die described in Patent Document 1, it was necessary to provide an ejection means such as a spring or an air cylinder at the rear end of the fixed pin, and it was also necessary to set the ejection force so that the fixed pin was pushed into the fixed mold by the injection pressure.

[0005] The present invention has been made in consideration of the above-mentioned circumstances, and aims to provide a molding die that can suppress the occurrence of weld lines while simplifying the structure, 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 of the present invention is a molding die used for integrally molding a composite molded product in which one side of a flexible sheet body is fitted to a resin molded body, and is provided with a first die having a first mold surface that defines a space in which the sheet body is disposed and that faces one side of the sheet body, and a second die having a second mold surface that faces the first mold surface, the first die being abutted against the sheet body at a position spaced from a resin supply port that opens in the first mold surface so as to form a space between the first mold surface around the first die and the sheet body, and being fixedly provided so that a resin layer is formed between the tip surface and the sheet body. Multiple The presser protrusion has a downstream side in the flow direction of the molten resin, and the downstream side of the presser protrusion is an inclined surface which becomes more downstream as it moves away from the tip surface. an edge portion between the tip surface of the pressing protrusion and the inclined surface downstream in the flow direction of the molten resin is curved, and an edge portion between both side surfaces of the pressing protrusion along the flow direction of the molten resin and the inclined surface downstream in the flow direction of the molten resin is curved. It is characterized by the above.

[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 mold of the present invention to integrally mold a composite molded product by aligning one side of a sheet body with a resin molded body, and is characterized in that it includes a process of placing the sheet body between the first mold surface and the second mold surface, and closing the mold so that the pressing protrusion forms a space between the sheet body and the first mold surface around the pressing protrusion, and a process of supplying molten resin from the resin supply port to mold the resin molded body so that a resin layer is formed between the tip surface of the pressing protrusion and the sheet body.

[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 passage provided in a cylinder block of an internal combustion engine and regulates the flow of cooling water, the spacer including a flexible sheet body and a spacer body made of synthetic resin along which one surface of the sheet body is aligned, and on a side of the spacer body other than the side on which the sheet body is provided in a thickness direction thereof, A cylindrical protrusion with a bottom and a plurality of bottomed recesses sandwiching the protrusion At least one of the inner surfaces of the recess on both sides in the direction of the flow of the cooling water is an inclined surface inclined to the side that widens the opening of the recess. The recess has a curved corner between the inner side surfaces on both sides in the water flow direction and the bottom surface, and the recess has a curved corner between the inner side surfaces on both sides in the water flow direction and the inclined surface. It is characterized by the above. Effect of the Invention

[0009] The molding die, the manufacturing method of a composite molded product using the same, and the spacer according to the present invention are configured as described above, and thus can suppress the occurrence of weld lines while simplifying the structure. [Brief description of the drawings]

[0010] [Figure 1] 1(a) and 1(b) are schematic cross-sectional views, partially cut away, 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] 1(a) to (c) are schematic diagrams showing an example of a spacer as an example of a composite molded product molded using the molding die, in which (a) is a schematic partially cutaway front view, (b) is a schematic partially cutaway cross-sectional view corresponding to the view of the XX line in (a), (c) is a schematic partially cutaway oblique view of the spacer, and (d) is a schematic partially cutaway plan view showing an example of the molding die as seen in the direction of the V arrow in FIG. 1(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 Y in FIG. [Diagram 5] 5(a) and 5(b) are schematic cross-sectional views, partly cut away, illustrating a schematic diagram of another example of a method for producing a composite molded product using the example of the molding die. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] 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 5 are diagrams that typically show an example of a molding die according to the first embodiment, one and another example of a method for producing a composite molded product using the same, and an example of a spacer.

[0012] The molding die 1 according to this embodiment is used when integrally molding a composite molded product 10 in which one surface of a flexible 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.

[0013] 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.

[0014] As shown in Figures 4(a) and (b), the spacer 10 includes a sheet body 11 and a spacer body 13 made of synthetic resin, to which one surface of the sheet body 11 is aligned. In the illustrated example, a plurality of spacers 10 are arranged in the cooling water flow passage 24. These spacers 10 are provided over substantially the entire circumference of the cooling water flow passage 24. These spacers 10 are divided into two in a direction perpendicular to the cylinder bore arrangement direction (approximately equal in the illustrated example). The sheet bodies 11 and spacer bodies 13 of these spacers 10 have the same configuration, so one of them will be described below as an example.

[0015] 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. As shown in Figs. 2(a) and 2(b), a bottomed recess (outer peripheral recess) 17 is provided on the side of the spacer body 13 different from the side on which the sheet body 11 is provided in the thickness direction. With this configuration, the outer peripheral recess 17 is provided, so that the weight can be reduced. In this embodiment, as shown in Figs. 2(a) and 4(a), the spacer body 13 includes a bottomed cylindrical protrusion 15 that is provided to define a recess (inner peripheral recess) 16 that communicates with a hole (through hole) 12 that is provided through the sheet body 11 in the thickness direction and protrudes toward one side in the thickness direction. In this embodiment, the protrusion 15 is provided so as to be located approximately in the circumferential center of the surface of each arc-shaped portion 18 that faces the outer peripheral wall surface 25, and the outer peripheral recess 17 is provided at a position spaced apart from the protrusion 15 in the circumferential direction. An example of a specific configuration of the protrusion 15 and the outer peripheral recess 17 will be described later.

[0016] The sheet body 11 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 centers coincide with the circumferential centers of the respective 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 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.

[0017] 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.

[0018] 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.

[0019] As shown in Figs. 1(a) and 1(b), the mold 1 includes a first mold 2 having a first mold surface 4 facing one side of the sheet body 11, and a second mold 7 having a second mold surface 9 facing the first mold surface 4. The first mold 2 includes a pressing protrusion 6 fixedly provided at a position away from a resin supply port 3 opening in the first mold surface 4, which is in contact with the sheet body 11 so as to form a space between the first mold surface 4 and the sheet body 11 around the first mold surface 4, and a resin layer 14 is formed between the tip surface 6a and the sheet body 11 (see also Fig. 2(b)). With this configuration, the sheet body 11 is less likely to resist the molten resin, and the fluidity of the molten resin supplied from the resin supply port 3 can be improved. In addition, since the pressing protrusion 6 is fixedly provided on the first mold 2, the structure of the mold 1 can be simplified compared to a mold in which a fixing pin is freely movable. This allows the pressing protrusion 6 to be easily shaped in various ways so as to have good fluidity, and makes it difficult for weld lines to occur with a simple structure. In addition, since the resin layer 14 is provided between the tip surface 6a of the pressing protrusion 6 and the sheet body 11, it is possible to prevent the portion where the pressing protrusion 6 was provided from becoming only the sheet body 11 or only burr-like resin. In the case where the portion where the pressing protrusion 6 was provided becomes only the sheet body 11 without the resin layer 14 being formed, for example, if the sheet body 11 has water permeability, there is a concern that cooling water will pass through that portion and an unintended water flow will occur, but this can be prevented by the above configuration.

[0020] The side surface (downstream side surface) 6c of the pressing protrusion 6 downstream in the flow direction of the molten resin is an inclined surface that becomes more downstream as it moves away from the tip surface 6a. With this configuration, it is possible to make it difficult for weld lines to occur. In other words, the molten resin flows along the tip surface 6a of the pressing protrusion 6, and the molten resin flowing along the tip surface 6a is easily flowed along the downstream side surface 6c that is an inclined surface, so that the molten resin that flows around the pressing protrusion 6 along the outer peripheral surface (side surface) 6d of the pressing protrusion 6 can be reduced, making it difficult for weld lines to occur. This makes it possible to suppress the occurrence of cracks due to localized strength reduction in the spacer 10 as a molded composite molded product, and the occurrence of poor appearance. The specific configuration of the pressing protrusion 6 will be described later.

[0021] In this embodiment, the second die 7 is provided with a positioning protrusion 8 that is inserted into a through hole 12 formed in the sheet body 11. With this configuration, it is possible to suppress misalignment 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 of the molding die 1. This positioning protrusion 8 is disposed with a gap between its tip surface 8a and the opposite side through which the molten resin can flow. With this configuration, the spacer body 13 including a portion covering the tip surface 8a of the positioning protrusion 8 is molded, 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 (see FIG. 4(a)). In this embodiment, the first die 2, which is the opposing side of the positioning protrusion 8 of the molding die 1, is provided with a protrusion receiving recess 5 that receives the positioning protrusion 8 and forms a protrusion 15 that covers the tip surface 8a and the outer circumferential surface 8b of the positioning protrusion 8 on the spacer main body 13. With this configuration, it is possible to form a cylindrical protrusion 15 with a bottom that protrudes from one surface of the spacer main body 13.

[0022] In this embodiment, the forming die 1 is provided with a plurality of positioning protrusions 8, 8 and a plurality of protrusion receiving recesses 5, 5 (see FIG. 2(a)). With this configuration, the sheet body 11 can be more reliably positioned by the plurality of positioning protrusions 8, 8. The first die 2 and the second die 7 of the molding die 1 are formed so that the cavity defined by them has a shape corresponding to the above-mentioned spacer body 13. The resin supply port 3 and the projection receiving recess 5 of the first die 2 and the positioning projection 8 of the second die 7 are provided at the center in the circumferential direction (circumferential direction of the cooling water flow path 24) of each part forming the arc-shaped parts 18, 18, 18 of the spacer body 13. In this embodiment, the pressing projection 6 of the first die 2 is provided at a plurality of positions (two positions in the illustrated example) at intervals in the circumferential direction of each part forming the arc-shaped parts 18, 18, 18 of the spacer body 13. In the following, the resin supply port 3, the projection receiving recess 5, and the pressing projection 6 of the first die 2 and the positioning projection 8 of the second die 7 will be described using a part forming one arc-shaped part 18 as an example.

[0023] 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 protruding dimension and diameter. 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 of the positioning protrusions 8,8 so that each positioning protrusion 8,8 can be inserted. The protruding dimension of the positioning protrusions 8,8 is larger than the thickness dimension T1 of the sheet body 11.

[0024] In this embodiment, the protrusion receiving recess 5 is circular and concentric with the positioning protrusion 8 when viewed in the depth direction of the recess to correspond to the positioning protrusion 8. In addition, in this embodiment, the two protrusion receiving recesses 5, 5 are provided at an interval 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 and diameter.

[0025] The two pressing protrusions 6, 6 are provided at positions spaced apart from the resin supply port 3 in the circumferential direction so as to be aligned in the depth direction of the cooling water flow path 24 and equidistant from the resin supply port 3. The two pressing protrusions 6, 6 have the same protruding dimension, the dimension along the depth direction of the cooling water flow path 24, and the dimension along the circumferential direction. As shown in FIG. 1(a), the pressing protrusions 6, 6 are provided so as to protrude from the first mold surface 4, which is a concave curved surface, toward the second mold surface 9. The pressing protrusions 6, 6 are provided at positions spaced apart from the resin supply port 3 so that the flexible sheet body 11 does not come into close contact with the resin supply port 3 or the first mold surface 4 around it. The positions and number of the pressing protrusions 6, 6 are not limited to those shown in the figures, and may be appropriately positioned and numbered so that the entire or almost entire sheet body 11 is not in contact with the first mold surface 4. For example, the pressing protrusions 6, 6 may be provided so that 70% or more of one side of the sheet body 11 in the thickness direction as a whole is not in contact with the first mold surface 4. Since these pressing protrusions 6, 6 have the same configuration, the specific configuration will be described below by taking one pressing protrusion 6 as an example.

[0026] 1(a) and 1(b), in the present embodiment, the dimension (gap dimension) G1 between the tip surface 6a of the pressing protrusion 6 and the opposing second mold surface 9 in the mold closed state is set to be larger than the thickness dimension T1 of the sheet body 11. With this configuration, the sheet body 11 is pressed against the second mold surface 9 by the molten resin supplied from the resin supply port 3 so as to be separated from the tip surface 6a of the pressing protrusion 6, and a resin layer 14 can be provided between the tip surface 6a of the pressing protrusion 6 and the sheet body 11. The protrusion dimension and gap dimension G1 of the pressing protrusion 6 and the thickness dimension of the resin layer 14 may be appropriately set depending on the thickness dimension T1 and size of the sheet body 11 and the shape of the spacer 10, as well as from the viewpoint of strength and from the viewpoint of preventing the sheet body 11 from sticking to the first mold surface 4. In the illustrated example, the thickness dimension of the resin layer 14 is slightly larger than the thickness dimension T1 of the sheet body 11, and the protruding dimension of the pressing protrusion 6 is slightly larger than the thickness dimension of the resin layer 14, but this is not limited to this example.

[0027] In this embodiment, the pressing protrusion 6 is formed in an elongated shape along the flow direction of the molten resin, as shown in Figures 1 and 2(d). With this configuration, it is possible to reduce resistance to the flow of the molten resin, and it is possible to prevent the molten resin from flowing in an unintended direction and to prevent insufficient filling of the molten resin. In the illustrated example, the pressing protrusion 6 is formed in a roughly rectangular shape when viewed in the protruding direction (thickness direction of the spacer 10). The tip surface 6a of the pressing protrusion 6 is generally rectangular when viewed in the protruding direction, and is a curved surface (in this embodiment, a concave curved surface) generally parallel to the first die surface 4. The tip surface 6a is a gently curved surface, and is generally flat.

[0028] 2(b), the downstream side surface 6c of the pressing protrusion 6 is an inclined surface that is inclined from a downstream edge portion 6ac, which is an edge portion on the downstream side in the flow direction of the molten resin with respect to the tip surface 6a, toward the first mold surface 4 so that the angle formed with the tip surface 6a is an obtuse angle. The angle formed between the tip surface 6a and the downstream side surface 6c may be an appropriate angle from the viewpoint of suppressing weld lines, for example, may be about 100 degrees to 170 degrees, and in the illustrated example, an angle of about 120 degrees is shown. As shown in Fig. 2(d), the downstream edge 6ac is curved. With this configuration, the molten resin can flow smoothly toward the downstream side, and weld lines on the downstream side are less likely to occur. In the illustrated example, the downstream edge 6ac is curved and convex (chamfered). The rising portion (downstream side rising portion) 6ce from the first mold surface 4 on the downstream side surface 6c is curved. With this configuration, the molten resin can flow smoothly toward the downstream side, and weld lines on the downstream side are less likely to occur. In the illustrated example, the downstream side rising portion 6ce is curved in a concave shape.

[0029] The side surface (upstream side surface) 6b of the pressing protrusion 6 on the upstream side in the flow direction of the molten resin is an inclined surface that becomes more upstream as it moves away from the tip surface 6a. With this configuration, the molten resin can be made to flow smoothly toward the tip surface 6a of the pressing protrusion 6, and it is possible to make it more difficult for weld lines to occur on the downstream side. The angle between this upstream side surface 6b and the tip surface 6a may be, for example, about 100 degrees to 170 degrees, as described above. The edge 6ab (upstream edge) between the upstream side surface 6b and the tip surface 6a is curved (convex curved in the illustrated example) as described above. With this configuration, the molten resin can flow smoothly toward the downstream side as described above. The rising portion (upstream rising portion) 6be on the upstream side surface 6b rising from the first mold surface 4 is curved (concavely curved in the illustrated example) as described above. With this configuration, the molten resin can easily flow smoothly toward the downstream side as described above.

[0030] The edges (downstream side edges) 6cd, 6cd between the side surfaces 6d, 6d on both sides along the flow direction of the molten resin and the downstream side surface 6c of the pressing protrusion are curved. With this configuration, the molten resin can flow smoothly toward the downstream side, and weld lines on the downstream side are less likely to occur. In the illustrated example, these downstream side edges 6cd, 6cd are curved (chamfered). The edges (upstream edges) 6bd, 6bd between the side surfaces 6d, 6d on both sides and the upstream side surface 6b are also curved (convex curved in the illustrated example). With this configuration, the molten resin can flow smoothly toward the downstream side, as described above. These side surfaces 6d, 6d on both sides are inclined surfaces that move away from each other as they move away from the tip surface 6a. With this configuration, the molten resin can flow more smoothly.

[0031] The edges (tip side edges) 6ad, 6ad between the side surfaces 6d, 6d on both sides and the tip surface 6a are curved (convex curved in the illustrated example) as described above. With this configuration, the molten resin can flow smoothly and easily as described above. The rising portions (side rising portions) 6de, 6de on the side surfaces 6d, 6d on both sides extending from the first mold surface 4 are curved (concavely curved in the illustrated example) as described above. With this configuration, the molten resin can flow smoothly and easily as described above. That is, in this embodiment, the pressing protrusion 6 is tapered from the base end in the protruding direction on the first mold surface 4 side toward the tip end in the protruding direction. In addition, the peripheral edge portion (four peripheral edges in this embodiment) 6ab, 6ac, 6ad, 6ad of the tip surface 6a of the pressing protrusion 6 is curved. With this configuration, it is possible to prevent the sheet body 11 pressed by the pressing protrusion 6 from being scratched. In addition, the rising portions 6be, 6ce, 6de, 6de of the pressing protrusion 6 in the entire circumferential direction (all four peripheries in this embodiment) are curved. In addition, the edges 6bd, 6bd, 6cd, 6cd between the side surfaces (four periphery side surfaces in this embodiment) of the pressing protrusion 6 are curved.

[0032] 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 main body 13 includes a step of placing the sheet body 11 between the first mold surface 4 and the second mold surface 9, and closing the mold so that the pressing protrusions 6, 6 form a space between the sheet body 11 and the first mold surface 4 around the pressing protrusions 6, 6, and a step of supplying molten resin from the resin supply port 3 to mold the spacer main body 13 so that a resin layer 14 is formed between the tip surfaces 6a, 6a of the pressing protrusions 6, 6 and the sheet body 11. In this embodiment, the manufacturing method includes a step of inserting a positioning protrusion 8 provided on the mold 1 into a through hole 12 formed in the sheet body 11 to position the sheet body 11.

[0033] Specifically, as shown in Fig. 1(a), with the first mold 2 and the second mold 7 open, the positioning protrusions 8 of the second mold 7 are inserted into the through holes 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 so that a space is formed between the sheet body 11 and the first mold surface 4 around the pressing protrusions 6, 6 by the pressing protrusions 6, 6, and molten resin is supplied into the cavity through the resin supply port 3. The molten resin supplied from the resin supply port 3 flows between the first mold surface 4 of the first mold 2 and the sheet body 11 separated from the first mold surface 4 by the pressing protrusions 6, 6, and flows along the tip surfaces 6a, 6a of the pressing protrusions 6, 6. The molten resin also flows along the tip surfaces 8a, 8a and outer peripheral surfaces 8b, 8b of the positioning protrusions 8, 8 on both sides, and the bottom surfaces and inner peripheral surfaces of the protrusion receiving recesses 5, 5 on both sides. 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.

[0034] At least one of the inner surfaces 17b, 17c on both sides in the water flow direction of the cooling water in the outer circumferential recess 17 provided in the spacer body 13 of the spacer 10 is an inclined surface inclined toward the side that widens the opening of the outer circumferential recess 17. With this configuration, it is possible to reduce the weight by providing the outer circumferential recess 17, but since at least one of the inner surfaces 17b, 17c on both sides in the water flow direction is an inclined surface, it is possible to reduce the influence on the water flow of the cooling water and to reduce damage to the spacer body 13 due to the water flow. In this embodiment, the inner surfaces 17b, 17c on both sides in the water flow direction are inclined surfaces inclined toward the side that widens the opening of the outer circumferential recess 17. With this configuration, it is possible to more effectively reduce the influence on the water flow of the cooling water. In this embodiment, the outer circumferential recess 17 is formed in an elongated shape along the circumferential direction of the arc-shaped portion 18, which is the water flow direction of the cooling water. With this configuration, it is possible to more effectively reduce the influence on the water flow of the cooling water and damage to the spacer body 13.

[0035] In this embodiment, as shown in Figures 2(a) and 4(a), two protrusions 15, 15 are provided in the circumferential center of the arc-shaped portion 18 of the spacer body 13, spaced apart in the depth direction of the cooling water flow path 24, and outer circumferential recesses 17, 17 are provided at positions spaced apart on both sides of the circumferential direction from the midpoint between 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 formed in a substantially cylindrical shape with a bottom. These protrusions 15, 15 have the same protrusion dimension and diameter. Inner peripheral recesses 16, 16 are provided so as to open on the sheet body 11 side of these protrusions 15, 15. These inner peripheral recesses 16, 16 are formed in a substantially circular shape when viewed in the depth direction. The diameter of these inner peripheral recesses 16, 16 is substantially the same as the diameter of the through holes 12, 12 of the sheet body 11.

[0036] The outer circumferential recesses 17, 17 on both sides are provided so as to open radially outward from the arc-shaped portion 18. Since the outer circumferential recesses 17, 17 have the same configuration, the specific configuration will be described below by taking one of the outer circumferential recesses 17 as an example. The outer circumferential recess 17 is formed by the pressing protrusion 6 and has a shape corresponding to the pressing protrusion 6. That is, the outer circumferential recess 17 is generally rectangular when viewed in the depth direction (thickness direction of the spacer 10). The bottom surface 17a of the outer circumferential recess 17 is generally rectangular when viewed in the depth direction and is a curved surface (in this embodiment, a convex curved surface) that is generally parallel to the surface facing the outer circumferential wall surface 25 of the spacer body 13. The bottom surface 17a is a gently curved surface and is generally flat. Of the inner surfaces 17b, 17c on both sides of the outer circumferential recess 17 in the water flow direction, the first inner surface 17b on one side and the second inner surface 17c on the other side are both inclined surfaces that are inclined toward the side that widens the opening of the outer circumferential recess 17. The inner surfaces 17d, 17d on both sides along the water flow direction are also inclined surfaces that are inclined toward the side that widens the opening of the outer circumferential recess 17.

[0037] The inside corner (first bottom side inside corner) 17ab between the first inner surface 17b and the bottom surface 17a, the inside corner (second bottom side inside corner) 17ac between the second inner surface 17c and the bottom surface 17a, and the inside corners (side bottom side inside corners) 17ad, 17ad between the inner surfaces 17d, 17d on both sides and the bottom surface 17a are curved surfaces (concave curved surfaces in the example shown). The opening edge portion (first opening edge portion) 17be of the first inner surface 17b, the opening edge portion (second opening edge portion) 17ce of the second inner surface 17c, and the opening edge portions (side opening edge portions) 17de, 17de of the inner surfaces 17d, 17d on both sides are curved surfaces (convex curved surfaces in the example shown). The inside corners (first side inside corners) 17bd, 17bd between the first inner surface 17b and the inner surfaces 17d, 17d on both sides, and the inside corners (second side inside corners) 17cd, 17cd between the second inner surface 17c and the inner surfaces 17d, 17d on both sides, are curved surfaces (concavely curved surfaces in the example shown).

[0038] That is, in this embodiment, the outer circumferential recess 17 is formed to expand from the bottom side toward the opening side. In addition, the inner corners 17ab, 17ac, 17ad, 17ad of the entire circumferential direction of the bottom surface 17a of the outer circumferential recess 17 (in this embodiment, the entire four circumferences) are curved. In addition, the outer circumferential recess 17 has its opening peripheral edges (in this embodiment, the four peripheral edges) 17be, 17ce, 17de, 17de curved. In addition, the outer circumferential recess 17 has its inner corners 17bd, 17bd, 17cd, 17cd between its inner surfaces (in this embodiment, the four circumferential inner surfaces) 17b, 17d, 17d, 17c curved. The above-mentioned configuration can more effectively reduce the effect of the cooling water on the water flow, and compared to a configuration in which edges are formed on the inside corners and the opening periphery, it is possible to avoid the concentration of stress on the inside corners and the opening periphery due to expansion, deformation, etc. caused by the water flow, heat, or cooling water, and it is possible to prevent the occurrence of cracks. In the above example, 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., or may be something like the sheet body 11A described below.

[0039] Next, another example of a method for manufacturing a composite molded product using the above-mentioned molding die 1 will be described with reference to Fig. 5. 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, description of the actions and effects achieved similarly to the previously described example will be omitted or briefly described.

[0040] In this example, the sheet body 11A is configured to be compressible in the thickness direction, and the thickness dimension T2 before compression is set to be equal to or larger than the gap dimension G1 between the tip surface 6a of the pressing protrusion 6 and the second mold surface 9 facing it in the mold closed state, and the sheet body 11A is configured to be compressed by the molten resin supplied from the resin supply port 3. With this configuration, the sheet body 11A is held in a manner sandwiched between the tip surface 6a of the pressing protrusion 6 and the second mold surface 9 facing it in the mold closed state, so that the positional deviation of the sheet body 11A can be suppressed. The thickness dimension T2 of the sheet body 11A before compression may be set to an appropriate dimension so that the sheet body 11A is in a non-contact state with the first mold surface 4 over the entirety or almost the entirety in the mold closed state, as shown in FIG. 5(b). In other words, the thickness dimension T2 may be set to an appropriate dimension so that a gap is formed over the entirety or almost the entirety between the sheet body 11A and the first mold surface 4, and a space through which the molten resin from the resin supply port 3 flows is formed. The thickness T2 of the sheet 11A before compression may preferably be 1.0 to 1.2 times the gap dimension G1. The thickness of the sheet 11A after compression (in a state compressed by molten resin) may be 0.3 to 0.5 times the gap dimension G1. The sheet 11A may be any material having flexibility that allows for compressive deformation, and may be made of a resin foam such as urethane foam.

[0041] In the above example, the outer shape of the pressing protrusion 6 is substantially square when viewed in the protruding direction, but it may be elliptical, semi-elliptical, diamond-shaped, triangular, or other polygonal shapes. Also, instead of the form in which the tip surface 6a is substantially square, it may be circular, elliptical, semi-elliptical, diamond-shaped, triangular, or other polygonal shapes, and may further be linear, dot-shaped, or have an extremely small area. As long as at least the downstream side surface 6c is an inclined surface, the pressing protrusion 6 is not limited to the above shape and may be various other shapes. In the above example, the molding die 1 is configured to integrally mold the flexible sheet bodies 11, 11A by deforming them so as to fit the curved spacer body 13, but it may be configured to mold a flat composite molded product. In such a case, even if the sheet bodies 11, 11A are curved due to warping or the like, the composite molded product 10 can be suitably molded by providing the pressing protrusions 6 as described above. In each of the above-mentioned examples, the composite molded product 10 in which one surface of the sheet body 11, 11A is aligned with the resin molded body 13 is used as the spacer 10 arranged in the cooling water flow path 24, but it may also be used to form various parts and members used in interior trim and garnish of automobiles, industrial machinery, electronic devices, building materials, etc. The configurations of the parts that form the molding die 1 and the spacer (composite molded product) 10 described above are not limited to the above-mentioned examples, and various other modifications are possible. [Explanation of symbols]

[0042] 1 mold 2 Type 1 3 Resin supply port 4 1st mold surface 6 Presser protrusion 6a Tip surface 6ac downstream edge of tip (edge ​​between tip face and downstream side) 6b Upstream side (upstream side in the flow direction) 6c Downstream side (side downstream of flow direction) 6cd Downstream side edge of side (edge ​​between side and downstream side) 6ce Downstream side rising part (rising part from the first type surface on the downstream side) 6d Side (side along the flow direction) 7 Type 2 8 Positioning protrusion 9 Second mold surface 10 Spacer (composite molding) 11, 11A Sheet body 12 Through hole (hole) 13 Spacer body (resin molding) 14 Resin layer 17 Outer recess (recess) 17b First inner surface (inner surface facing the water flow direction) 17c Second inner surface (inner surface facing the water flow direction) 20 Internal Combustion Engine 21 Cylinder block 24 Cooling water flow path G1 Gap dimension (dimension between the tip surface of the pressing protrusion and the second mold surface facing it) T1, T2 Sheet thickness dimensions

Claims

1. A molding die used for integrally molding a composite molded product in which one surface of a flexible sheet body is aligned with a resin molded body, a first mold that defines a space in which the sheet body is placed and has a first mold surface that faces one side of the sheet body and a second mold that faces the first mold surface; the first mold has a plurality of pressing protrusions fixedly provided at a position spaced from a resin supply port opening in the first mold surface, the pressing protrusions being in contact with the sheet body so as to form a space between the first mold surface and the sheet body around the pressing protrusions, and a resin layer being formed between the tip end surface and the sheet body, and the downstream side of the pressing protrusions in the flow direction of the molten resin is an inclined surface which becomes more downstream as it moves away from the tip end surface, an edge between the tip end surface of the pressing protrusion and the inclined surface on the downstream side in the flow direction of the molten resin is curved, A molding die characterized in that the edges of both side surfaces of the pressing protrusion along the flow direction of the molten resin and the inclined surface downstream of the flow direction of the molten resin are curved.

2. In claim 1, A molding die characterized in that the dimension between the tip surface of said pressing protrusion and the opposing second die surface in a closed state is larger than the thickness dimension of said sheet body.

3. In claim 1, The sheet body is compressible in the thickness direction, and its thickness dimension before compression is equal to or greater than the dimension between the tip surface of the pressing protrusion and the second mold surface facing it in a closed mold state, and is compressed by molten resin supplied from the resin supply port.

4. In any one of claims 1 to 3, A molding die characterized in that a side surface of the pressing protrusion on the upstream side in the flow direction of the molten resin is an inclined surface which becomes more upstream as it moves away from the tip surface.

5. In any one of claims 1 to 4, A molding die, characterized in that a portion of the inclined surface on the downstream side in the flow direction of the molten resin rising from the first mold surface is curved.

6. In any one of claims 1 to 5, The molding die is characterized in that the pressing protrusion is formed in an elongated shape along the flow direction of the molten resin.

7. In any one of claims 1 to 6, The second die is provided with a positioning protrusion that is inserted into a hole formed in the sheet body.

8. In any one of claims 1 to 7, 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.

9. In any one of claims 1 to 8, 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.

10. In any one of claims 1 to 9, The molding die is characterized in that the multiple pressing protrusions are arranged on either side of the resin supply port.

11. In claim 10, The molding die is characterized in that the plurality of pressing protrusions are provided at positions equidistant from the resin supply port.

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: placing the sheet body between the first mold surface and the second mold surface; and closing the mold so that the pressing protrusion forms a space between the sheet body and the first mold surface around the pressing protrusion; and supplying molten resin from the resin supply inlet to mold the resin molded body so that a resin layer is formed between the tip surface of the pressing protrusion and the sheet body.

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 flexible sheet body and a spacer body made of synthetic resin, one surface of which is aligned with the flexible sheet body. a cylindrical protrusion with a bottom and a plurality of bottomed recesses are provided on either side of the protrusion in the thickness direction of the spacer body, the cylindrical protrusion having a bottom and the plurality of bottomed recesses being spaced apart from each other in the direction of the flow of the cooling water, and at least one of the inner surfaces of the recesses on both sides of the water flow direction of the cooling water is an inclined surface that is inclined toward a side that widens the opening of the recesses, The recess has a curved corner between the inner surface on both sides in the water flow direction and the bottom surface, A spacer, characterized in that the corners between the inner surfaces on both sides of the recess along the water flow direction and the inclined surface are curved.

14. In claim 13, The spacer is characterized in that the recess is formed in an elongated shape along a water flow direction of the cooling water.

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