Molding mold and method for manufacturing composite molded products using the same

Abstract

To provide a molding die for manufacturing a composite molded product in which gate marks are not noticeable and a sheet-shaped insert member can be integrally molded with high precision, a method for manufacturing a composite molded product using the same, and a composite molded product.SOLUTION: A molding die 10 used for integrally molding a composite molded product 1 including a flexible sheet-shaped first insert member 2 and a resin molded body 3 integrally molded on one side 2a of the first insert member, includes a first mold 11 and a second mold 12 which are oppositely arranged to be freely brought into / out of contact with each other and form a cavity 100 to be filled with a molten resin r when the molds are closed. The first mold includes: a protrusion 111 through which a through hole 2c formed in the first insert member is inserted to fix the first insert member; and a resin supply port 112 which is formed at a tip of the protrusion and injects the molten resin into the cavity.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a mold used when integrally molding a composite molded product including a sheet-like insert member and a resin molded body. and A method for manufacturing a composite molded product using the same In the law is concerned.

Background Art

[0002] Conventionally, a composite molded product including a sheet-like insert member and a resin molded body has been known. As a method for forming such a composite molded product, for example, a method using a mold 200 including a first mold 201 and a second mold 202 as shown in FIG. 8 is known. In this method, as shown in FIG. 8(a), a sheet-like insert member 302 having flexibility is placed on the cavity surface of the first mold 201, and as shown in FIG. 8(b), molten resin r is injected into the cavity 203 through the gate 204. After the molten resin r filled in the cavity 203 is solidified, it is脱模, and as shown in FIG. 8(c), if the gate residue portion 303 solidified in the gate 204 is cut, a composite molded body 300 including the insert member 302 and the resin molded body 301 can be integrally molded.

[0003] However, in this case, since the sheet-like insert member 302 is not positioned, the insert member 302 may be pushed by the injection pressure of the molten resin r, and phenomena such as displacement or the end of the insert member 302 being turned up may occur. Also, the molten resin r may flow between the insert member 302 and the cavity surface of the first mold 201. Further, in this case, as shown in FIG. 8(d), which is a view in the X direction (plan view) of FIG. 8(c), a cut mark (gate mark) 301aa remains on the outer surface 301a of the resin molded body 301. Therefore, when the outer surface 301a side is the design surface (front surface) of the product, the problem is that the appearance of the product is impaired. Further, not only those having an insert member only on one side as shown in FIG. 8, but also those having insert members on both sides of the resin molded body are required to have no noticeable gate marks and be integrally molded with high accuracy.

[0004] Patent documents 1 and 2 below disclose a method for manufacturing a composite molded product using a mold that has insert members on both sides of a resin molded body and supplies molten resin into the cavity through a through hole formed in one of the insert members. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2000-127198 [Patent Document 2] Japanese Patent Publication No. 2002-264167 [Overview of the project] [Problems that the invention aims to solve]

[0006] According to the manufacturing method disclosed in Patent Document 1, gate marks are not formed on the surface where an insert member without through holes is provided. However, on the surface where an insert member with through holes is provided, marks of positioning protrusions for positioning the insert member remain, separate from the through holes. Furthermore, if the insert member placed on the gate side is a flexible sheet, the injection pressure of the molten resin may cause the edges of the insert member to lift, potentially causing molten resin to leak between the insert member and the mold.

[0007] The manufacturing method disclosed in Patent Document 2 above relates to an EL insert molded product used in switch parts of home appliances, etc., in which insert members are arranged on both sides of a resin molded body. However, since the insert member with through holes is a three-dimensionally processed resin sheet, it is not intended to use a flexible sheet as the insert member.

[0008] The present invention has been made in view of the above circumstances, and is a mold for manufacturing a composite molded product in which gate marks are not noticeable and a sheet-like insert member can be integrally molded with high precision. and A method for manufacturing composite molded products using this. Law The purpose is to provide it. [Means for solving the problem]

[0009] To achieve the above objective, the mold of the present invention 、 A mold used for integrally molding a composite molded product comprising a flexible sheet-like first insert member and a resin molded body integrally molded on one side of the first insert member, comprising a first mold and a second mold provided to be able to move toward and away from each other and to form a cavity into which molten resin is filled when the mold is closed, wherein the first mold comprises a projection that is inserted through a through hole formed in the first insert member and fixes the first insert member, and a resin supply port formed at the tip of the projection for injecting the molten resin into the cavity, and the first mold and the second mold form the cavity The second mold comprises a first cavity surface and a second cavity surface, and a second insert member is disposed on the second cavity surface side of the second mold, which is positioned opposite the resin supply port, and the second insert member is a flexible sheet-like material positioned along the second cavity surface of the second mold, and the second mold has a pair of second protrusions that project toward the first cavity surface side of the first mold and fix the second insert member, and the pair of second protrusions are characterized in that the end faces of the second insert member abut against the outer circumferential surfaces of the second protrusions to position the second insert member.

[0010] Furthermore, in order to achieve the above objective, the present invention provides a method for manufacturing a composite molded product using the mold, characterized by comprising: a first positioning step of inserting the projection of the first mold into the through hole of the first insert member to position the first insert member; and an injection step of injecting the molten resin into the cavity from the resin supply port to form the resin molded body. [Effects of the Invention]

[0012] Because the mold of the present invention has the above-described configuration, gate marks are not noticeable, and it is possible to manufacture composite molded products in which sheet-like insert members can be integrally molded with high precision.

[0013] Furthermore, because the manufacturing method for the composite molded product of the present invention has the above-described configuration, it is possible to manufacture a composite molded product in which gate marks are not noticeable and a sheet-like insert member can be integrally molded with high precision. [Brief explanation of the drawing]

[0015] [Figure 1] Figures (a) to (c) are explanatory diagrams (cross-sectional views) showing a method for manufacturing a composite molded product using a mold according to the first embodiment, where (a) shows the positioning step of placing the first insert member in the first mold, (b) shows the injection step of filling the cavity with molten resin, and (c) shows the composite molded product obtained after demolding. [Figure 2] (a) is a flowchart showing an outline of the manufacturing method of a composite molded product using a mold according to the first embodiment, and (b) is a flowchart showing an outline of the manufacturing method of a composite molded product using a mold according to the second embodiment. [Figure 3] (a) is an explanatory diagram (cross-sectional view) showing a mold according to the second embodiment, and (b) to (d) are explanatory diagrams (cross-sectional views) showing modified examples of the second embodiment. [Figure 4] (a) is an explanatory diagram (cross-sectional view) showing a mold according to the third embodiment, and (b) shows a modified example of the third embodiment. [Figure 5] An explanatory diagram (cross-sectional view) showing a mold according to the fourth embodiment is shown. [Figure 6] (a) is a schematic perspective view showing a toilet seat, which is an example of a composite molded product, and (b) is a cross-sectional view taken along the line A-A' in (a). [Figure 7] (a) to (c) are explanatory diagrams showing examples of composite molded products. [Figure 8] (a) to (c) are explanatory diagrams (cross-sectional views) showing a conventional method for manufacturing composite molded products, and (d) is an explanatory diagram showing a composite molded product in the view of (c) in the X direction (plan view).

BEST MODE FOR CARRYING OUT THE INVENTION

[0016] <Molding die> Hereinafter, embodiments of the present invention will be described with reference to the drawings. First, the molding die 10 according to the first embodiment will be described. The molding die 10 shown in FIG. 1(a) is used when integrally molding a composite molded product 1 including a flexible sheet-like first insert member 2 and a resin molded body 3 integrally formed on one surface 2a of the first insert member 2. The molding die 10 includes a first die 11 and a second die 12 that are provided so as to be relatively separable and form a cavity 100 into which molten resin r is filled when the dies are closed. The first die 11 includes a protrusion 111 through which a through hole 2c formed in the first insert member 2 is inserted to fix the first insert member 2, and a resin supply port 112 formed at the tip of the protrusion 111 for injecting molten resin r into the cavity 100. Details will be described below. In the following description, the state where the first die 11 and the second die 12 are clamped will be described with the second die 12 side as one side and the first die 11 side provided with the resin supply port 112 as the other side. Also, in some of the drawings, some of the detailed reference numerals attached to other drawings are omitted.

[0017] Fig. 1(a) shows the positioning process of the first insert member 2, which is a process before the molding die 10 is closed. As shown in Fig. 1(a), the first die 11 and the second die 12 are each provided with a first cavity surface 110 and a second cavity surface 120 that form a cavity 100 (see Fig. 1(b)). The first cavity surface 110 of the first die 11 has a planar shape. A protrusion 111 is arranged at a substantially central position on the first cavity surface 110 of the first die 11. The protrusion 111 is cylindrical and has a resin supply port 112 at its tip. A through hole 2c of the flexible sheet-like first insert member 2 is inserted through the protrusion 111. As shown in the explanatory diagram of the injection process in Fig. 1(b), the resin supply port 112 injects external molten resin r into the cavity 100 through a resin supply path 113. The second cavity surface 120 of the second die 12 is formed in a concave shape, and when the first die 11 and the second die 12 are closed, a cavity 100, which is a space filled with molten resin r, is formed. The cavity 100 in the present embodiment is formed as a substantially rectangular parallelepiped-shaped space. The resin molded body 3 integrally molded with the first insert member 2 manufactured by the molding die 10 of the present embodiment is formed in a substantially rectangular parallelepiped shape with the first insert member 2 embedded in the other surface 3b as shown in Fig. 1(c). In the present embodiment, the first die 11 is a fixed die, and the second die 12 is a movable die that can move away from and contact the first die 11 freely.

[0018] The first insert member 2 is not particularly limited in terms of material, shape, etc., as long as it is a flexible sheet. If the first insert member 2 is used as an exposed design surface of the composite molded product 1, decorative materials such as a decorative sheet, a leather sheet, a wood grain sheet, a cork sheet, etc. provided with patterns, colors, etc. may be used. When the first insert member 2 is a decorative material, one surface 2a in contact with the resin molded body 3 is the lining side, so it does not need to be provided with patterns, colors, etc.

[0019] Furthermore, the first insert member 2 may also enhance the functionality of the composite molded product 1. Examples of functional sheet materials include electromagnetic interference prevention sheets that block radio waves to prevent skimming, heat conduction sheets that efficiently transmit heat from a heat source, and antibacterial, antiviral, or stain-resistant sheets that take hygiene and ease of cleaning into consideration.

[0020] The molten resin r can be of various types depending on the shape, application, and function of the resin molded body 3 in the composite molded product 1. For example, it may be a thermoplastic resin such as polyethylene, polypropylene, ABS, acrylic, polycarbonate, polyamide, polyacetal, polyphenylene sulfide, or polyetheretherketone. Alternatively, it may be a thermosetting resin such as phenolic resin, epoxy resin, or polyurethane resin. Furthermore, various resin composite materials may be used as the molten resin r, such as those with additives such as silver-based antibacterial agents, or those containing reinforcing fibers such as carbon fiber or glass fiber.

[0021] According to the mold 10 of this embodiment, the first insert member 2 can be positioned at a desired location by inserting the through hole 2c of the first insert member 2 into the projection 111 of the first mold 11. Furthermore, since the molten resin r is injected from near the area where the through hole 2c is formed, the flow of the molten resin r makes it less likely for the first insert member 2 to be pushed and displaced, or for the edges of the first insert member 2 to peel off. In addition, according to this embodiment, a resin supply port 112 from which the molten resin r is injected is formed at the tip of the projection 111. Therefore, the molten resin r is prevented from flowing between the first cavity surface 110 of the first mold 11 and the first insert member 2, and the first insert member 2 and the resin molded body 3 are integrally molded with high precision. Furthermore, in this embodiment, the projection 111 of the first mold 11 is formed at approximately the center position on the first cavity surface 110, and the through hole 2c is formed at approximately the center position of the first insert member 2. When the first insert member 2 is placed on the first cavity surface 110, the molten resin r injected from the resin supply port 112 at the tip of the protrusion 111 flows from the center to the edge of the first insert member 2. As a result, the first insert member 2 is evenly pressed by the molten resin, which further suppresses misalignment and peeling caused by pressing in one direction. When the composite molded product 1 integrally molded using the mold 10 of this embodiment is demolded, as shown in Figure 1(c), a convex portion 32, which is a gate mark, is formed at the bottom of the recess 31 formed in the resin molded body 3 by the protrusion 111. Since the bottom of the recess 31 is formed in a recessed position on the center side (one side) of the resin molded body 3 than one side 2a of the first insert member 2, the convex portion 32 formed at the bottom of the recess 31 is not very noticeable in the appearance of the composite molded product 1.

[0022] <Manufacturing method> Next, the manufacturing method of the composite molded product 1 will be explained with reference to Figures 1 and 2(a). Figures 1(a) to 1(c) are cross-sectional views showing the manufacturing method of the composite molded product 1 using the mold 10, where (a) shows the positioning step of placing the first insert member 2 in the first mold 11, (b) shows the injection step of filling the cavity 100 with molten resin r, and (c) shows the composite molded product 1 obtained after demolding. Figure 2(a) is a flowchart of the manufacturing method of the composite molded product 1 of this embodiment, and the explanation below will follow the flowchart shown in steps S101 to S105. In the following explanation, the manufacturing steps in Figure 2 will be abbreviated as "Sxxx" instead of "step Sxxx".

[0023] First, as shown in Figures 1(a) and 2(a), the through hole 2c of the first insert member 2 is inserted into the projection 111 of the first mold 11 to position the first insert member 2 (S101). As a result, the other surface 2b of the first insert member 2 contacts the first cavity surface 110 of the first mold 11. Also, since the projection dimension of the projection 111 from the first cavity surface 110 is greater than the thickness dimension of the first insert member 2, the resin supply port 112 is exposed from one surface 2a of the first insert member 2.

[0024] Next, as shown in Figures 1(b) and 2(a), the first mold 11 and the second mold 12 are combined in a mold closing process to form a cavity 100 (S102). Then, molten resin r is injected into the cavity 100 from the resin supply port 112, filling the cavity 100 with molten resin r and molding the resin molded body 3 (S103). After the molten resin r filled in the cavity 100 is cooled and solidified under holding pressure, the first mold 11 and the second mold 12 are separated in a mold opening process (S104). Then, the resin molded body 3 is removed from the first mold 11, and a demolding process is performed to cut the remaining gate portion 1a that has solidified in the resin supply passage 113 (S105). By manufacturing as described above, a composite molded product 1 as shown in Figure 1(c) is obtained.

[0025] <Second Embodiment> Next, the mold 10A according to the second embodiment will be described with reference to Figures 3(a) and 2(b). Note that the explanation of the configuration and effects common to the mold 10 of the first embodiment shown in Figure 1 and the manufacturing method using the mold 10 of the first embodiment shown in the flowchart of Figure 2(a) will be omitted.

[0026] In the mold 10A shown in Figure 3(a), the second insert member 4, which is integrally molded with the resin molded body 3, is positioned on the second cavity surface 120 side of the second mold 12, which is positioned opposite the resin supply port 112 of the first mold 11. Therefore, by using the mold 10A of this embodiment, a composite molded product 1 can be obtained in which sheet-like insert members are arranged on both sides of the resin molded body 3, one side 3a and the other side 3b. In this embodiment, the second insert member 4 is made of a flexible sheet-like material and is fixed to a desired position on the second cavity surface 120 of the second mold 12 by vacuum adsorption by adsorption holes (not shown) provided in the second mold 12, or by protrusions (not shown), etc. The material of the second insert member 4 is not limited, similar to the first insert member 2 in the first embodiment.

[0027] When manufacturing a composite molded product 1 using a mold 10A in which the second insert member 4 shown in Figure 3(a) is positioned, the manufacturing process follows the flowchart shown in Figure 2(b). That is, after performing the first positioning step (S201) as in the first embodiment, a second positioning step is performed in which the second insert member 4 is positioned on the second cavity surface 120 of the second mold 12 (S202). Note that the order in which the first and second positioning steps are performed may be reversed. After performing the first and second positioning steps, the mold closing step (S203), injection step (S204), mold opening step (S205), and demolding step (S206) are performed as in the manufacturing method of the first embodiment. As a result, a composite molded product 1 is manufactured in which the first insert member 2, the second insert member 4, and the resin molded body 3 are integrally molded. By using the mold 10A shown in Figure 3(a), a composite molded product 1 is manufactured in which the second insert member 4 is embedded so as to be substantially flush with one surface 3a of the resin molded body 3, and the first insert member 2 is embedded so as to be substantially flush with the other surface 3b.

[0028] If a sheet-like insert member (first insert member 2) is present only on the other side 3b of the resin molded body 3, the cooling rate of the other side 3b with the first insert member 2 and the one side 3a without the insert member may differ during the cooling of the mold 10. If the cooling rate changes, the amount of shrinkage due to the solidification of the molten resin r on both sides of the resin molded body 3 will change, which may result in poor release from the mold 10. In addition, if the thermal expansion coefficients of the molten resin r and the first insert member 2 are different, the resin molded body 3 may deform, which may result in poor release from the mold 10. However, if sheet-like insert members with equivalent thermal conductivity and thermal expansion coefficients are present on both sides, poor release can be suppressed. Furthermore, by having sheet-like insert members with equivalent thermal conductivity and thermal expansion coefficients on both sides of the resin molded body 3, warping of the resin molded body 3 due to the shrinkage of the molten resin r and the sheet-like insert members can be suppressed.

[0029] <Modified form of the second embodiment> Next, with reference to Figures 3(b) to 3(d), various modifications of the mold 10A of the second embodiment shown in Figure 3(a) will be described. Note that the explanation of the configuration and effects of parts common to the above-described embodiments will be omitted. In the mold 10A' shown in Figure 3(b), the projection 111 of the first mold 11 is approximately 9 to 10 times larger in diameter than that of the mold 10A in Figure 3(a), and the diameter of the through hole 2c of the first insert member 2 is also sized to correspond to the diameter of the projection 111. Therefore, when a composite molded product 1 is manufactured using the mold 10A' of Figure 3(b), a recess 31 is formed on the other surface 3b of the resin molded body 3, with a diameter approximately 9 to 10 times larger than that when the mold 10A of Figure 3(a) is used. The other configurations of the mold 10A' are substantially the same as those of the mold 10A in Figure 3(a).

[0030] The mold 10A'' shown in Figure 3(c) is used to manufacture a composite molded product 1 equipped with a three-dimensional second insert member 4. The second mold 12 differs from the mold 10A in Figure 3(a) in that it has a configuration for positioning the three-dimensional second insert member 4. In the second mold 12, the position opposite the resin supply port 112 of the first mold 11 is approximately the center position of the second cavity surface 120. At approximately the center position of the second cavity surface 120, a recess 121 is provided for fixing the cylindrical second insert member 4 to the second cavity surface 120. Inside the recess 121, a cylindrical projection 122, which has approximately the same diameter as the inner circumferential surface 4b of the second insert member 4, is provided so as to protrude from the bottom surface 121a of the recess 121.

[0031] In the mold 10A'' shown in Figure 3(c), the second insert member 4 is a three-dimensional object positioned on the second cavity surface 120 side of the second mold 12. In this modified example, the second insert member 4 is cylindrical with a bottom surface 4a. When the second insert member 4 is placed in the recess 121 of the second cavity surface 120, it fits into the projection 122 within the recess 121 and is positioned accordingly. Furthermore, when the second insert member 4 is positioned on the second cavity surface 120, its bottom surface 4a is configured to be substantially flush with the second cavity surface 120.

[0032] The composite molded product 1 manufactured by the mold 10A'' shown in Figure 3(c) comprises a first insert member 2 embedded in the other surface 3b of the resin molded body 3, and a second insert member 4 protruding from one surface 3a of the resin molded body 3. The second insert member 4 may be configured such that, when placed in the recess 121 of the second cavity surface 120, its bottom surface 4a protrudes further towards the cavity 100 than the second cavity surface 120. In this configuration, a portion of the bottom surface 4a of the second insert member 4 is embedded in one surface of the resin molded body 3, resulting in a more integral molding of the second insert member 4 and the resin molded body 3.

[0033] In the mold 10A'' shown in Figure 3(d), the configuration of the first mold 11, the second mold 12, and the second insert member 4 differs from that in Figure 3(a). The projection 111 of the first mold 11 is formed with a projection dimension such that, when the through hole 2c of the first insert member 2 is inserted through it, the tip of the projection 111 and one side 2a of the first insert member 2 are substantially flush.

[0034] In the second type 12 of Figure 3(d), the position opposite the resin supply port 112 of the first type 11 is approximately the center position of the second cavity surface 120. At this approximately center position of the second cavity surface 120, a cylindrical fitting projection 123 is provided, which protrudes from the second cavity surface 120 for fixing the second insert member 4. The fitting projection 123 is formed with a protrusion size such that, when the cylindrical second insert member 4, which will be described later, is positioned, the opening 4c of the second insert member 4 contacts and closes the second cavity surface 120.

[0035] The second insert member 4 is cylindrical in shape and has a bottom surface 4a, which is fitted and fixed into a fitting projection 123 formed protruding from the second cavity surface 120. The mold 10A''' is configured such that when the mold is closed with the second insert member 4 fitted into the fitting projection 123, a gap is created between the bottom surface 4a of the second insert member 4 and the resin supply port 112.

[0036] With the first insert member 2 and the second insert member 4 positioned within the cavity 100, the first mold 11 and the second mold 12 are closed, and molten resin r is injected into the cavity 100. The injected molten resin r flows around the outer surface 4d of the second insert member 4 and fills the cavity 100. Then, as the molten resin r solidifies, a resin molded body 3 is formed, thereby forming the composite molded product 1. The composite molded product 1 manufactured by the mold 10A''' shown in Figure 3(d) has an opening 4c of the second insert member 4 on one side 3a of the resin molded body 3.

[0037] <Third Embodiment> Next, with reference to Figure 4(a), the molding die 10B according to the third embodiment will be described. In the mold 10B shown in Figure 4(a), the first cavity surface 110 of the first mold 11 is formed in a convex curved shape with a cross-sectional shape that protrudes toward the second cavity surface 120. Furthermore, the projection 111 of the first cavity surface 110 is located approximately at the center of the first cavity surface 110 and is positioned at the point that protrudes most toward the second mold 12.

[0038] The second cavity surface 120 of the second type 12 is formed in a concave, curved shape in cross-section. The second type 12 also has a pair of cylindrical second protrusions 124, 124 that project toward the first cavity surface 110 of the first type 11 and fix the second insert member 4. The second protrusions 124, 124 are provided at positions approximately equidistant from the center of the second cavity surface 120, and their tips 124a, 124a are positioned approximately parallel to the first cavity surface 110. In this embodiment, the second insert member 4 is fixed by the second protrusions 124, 124 by positioning the sheet-like second insert member 4 between the second protrusions 124, 124 with its end faces 4e, 4e in contact with the outer circumferential surfaces 124b, 124b of the second protrusions 124, 124. Furthermore, the tip portion 124a of the second projection 124 is configured to contact the first insert member 2 when the mold is closed.

[0039] When the first mold 11 and the second mold 12 of the mold 10B are closed, an arc-shaped cavity 100 is formed. The mold 10B shown in Figure 4(a) is used to manufacture a composite molded product 1 having an arc-shaped cross-section. Furthermore, the composite molded product 1 is manufactured with the first insert member 2 curved flush with the other surface 3b of the resin molded body 3, and the second insert member 4 curved flush with one surface 3a. An example of such a composite molded product 1 is a spacer used by being assembled in the cooling water passage of a cylinder block that constitutes an internal combustion engine.

[0040] When manufacturing a composite molded product 1 using the mold 10B shown in Figure 4(a), the first insert member 2 is positioned by inserting the projection 111 of the first mold into the through hole 2c of the first insert member 2. At this time, the other side 2b of the first insert member 2 does not need to be aligned with the first cavity surface 110. Then, the second insert member 4 is positioned along the second cavity surface 120. At this time, the end faces 4e, 4e of the second insert member 4 are positioned in contact with the outer circumferential surfaces 124b, 124b of the second projections 124, 124, so that the second insert member 4 is fixed to the second cavity surface 120.

[0041] Then, the first mold 11 and the second mold 12 are closed. As the second mold 12 approaches the first mold 11, the tips 124a, 124a of the second projections 124, 124 come into contact with one surface 2a of the first insert member 2. As the mold closing proceeds with the tips 124a, 124a of the second projections 124, 124 in contact with one surface 2a of the first insert member 2, the other surface 2b of the first insert member 2 is positioned along the first cavity surface 110. The subsequent manufacturing process proceeds substantially the same as the flowchart in Figure 2(b), and the composite molded product 1 is manufactured.

[0042] When manufacturing a spacer using the mold 10B shown in Figure 4(a), the first insert member 2 and the second insert member 4 are preferably sheet-like porous materials that are flexible and have the property of expanding in the thickness direction from a compressed state when certain external factors are applied. A suitable porous material for this purpose is a cellulose sponge, which, when it comes into contact with water, expands in the thickness direction from a compressed state and returns to its pre-compression state. A cellulose sponge is made of natural materials consisting of cellulose derived from pulp and natural fibers such as cotton added as reinforcing fibers, and has an open-cell structure with excellent water absorption. Cellulose has hydrophilic groups (OH) and is chemically compatible with water. When a cellulose sponge is dried under pressure, hydrogen bonds form between cellulose molecules, maintaining it in a compressed state. However, when exposed to moisture from this state, water molecules break the hydrogen bonds between cellulose molecules, restoring it from the compressed state.

[0043] <Modified form of the third embodiment> Next, with reference to Figure 4(b), a modified form of the mold 10B of the third embodiment, mold 10B', will be described. Note that the explanation of the configuration and effects of parts common to the embodiment in Figure 4(a) will be omitted. The mold 10B' in Figure 4(b) differs from that in Figure 4(a) in the configuration of the second projection 124 of the second mold 12 and the second insert member 4. The second projections 124, 124 are inserted through through holes 4f, 4f of the second insert member 4, which are located closer to the center of the second cavity surface 120 than those in Figure 4(a). The tips 124a, 124a of the second projections 124, 124 come into contact with one surface 2a of the first insert member 2 when the mold is closed. The second insert member 4 is positioned and fixed on the second cavity surface 120 by the insertion of its through holes 4f, 4f into the second projections 124, 124.

[0044] In the molds 10B and 10B' shown in Figures 4(a) and 4(b), the second insert member 4 can be molded while fixed in the desired position by the second projection 124 of the second mold 12. Furthermore, when the molten resin r is injected into the cavity 100, the second insert member 4 is fixed by the second projection 124, while its tip 124a comes into contact with the first insert member. As a result, lifting, peeling, etc., of the first insert member 2 and the second insert member 4 due to the injection pressure of the molten resin r and resin flow are suppressed.

[0045] <Fourth Embodiment> Next, with reference to Figure 5, the mold 10C according to the fourth embodiment will be described. The first mold 11 of the mold 10C in Figure 5 is configured such that the second mold 12 in Figure 4(a) is provided with a projection 111 having a resin supply port 112. More specifically, the first mold 11 has a first cavity surface 110 with a concave curved cross-sectional shape. Approximately at the center of the first cavity surface 110, there is a projection 111 that protrudes toward the second mold 12 and has a resin supply port 112 at its tip. Furthermore, the first mold 11 has a pair of cylindrical first protrusions 115, 115 that protrude toward the second cavity surface 120 of the second mold 12 and fix the first insert member 2. The pair of first protrusions 115, 115 are provided at positions approximately equidistant from the projection 111, and their tips 115a, 115a are configured to be approximately parallel to the second cavity surface 120. Furthermore, the tips 115a, 115a of the first projections 115, 115 are configured to contact the second insert member 4 when the mold is closed. In this embodiment, the first insert member 2 is positioned between the first projections 115, 115. The first insert member 2 is positioned and fixed to the first cavity surface 110 by having the projection 111 inserted through the through hole 2c and a part of the end face 2d contacting the outer circumferential surfaces 115b, 115b of the first projections 115, 115. The projection 111 and the first projections 115, 115 prevent the first insert member 2 from shifting position or its edges from curling due to the injection pressure and resin flow of the molten resin r during the injection process.

[0046] The second mold 12 has a second cavity surface 120 with a convex curved cross-sectional shape that protrudes toward the first cavity surface 110. The second insert member 4 is positioned at the center of the second cavity surface 120. The second insert member 4 is a flexible sheet-like material positioned along the second cavity surface 120. When the first mold 11 and the second mold 12 are closed with the second insert member 4 positioned along the second cavity surface 120, molten resin r is injected into the cavity 100 with the tips 115a,115a of the first projections 115,115 in contact with the second insert member 4. Because the tips of the first projections 115,115 are in contact with the second insert member 4, displacement of the second insert member 4 and curling of its edges are suppressed by the injection pressure and resin flow of the molten resin r.

[0047] In the molds 10A to 10C shown in Figures 3 to 5, the second insert member 4 can be placed on the second cavity surface 120 facing the resin supply port 112. Therefore, by using these molds 10A to 10C, the second insert member 4 can be provided on one side 3a of the resin molded body 3 and the first insert member 2 on the other side 3b, thereby expanding the range of structures and designs for the composite molded product 1.

[0048] <Example of a composite molded product> Next, with reference to Figures 6 and 7, an example of a composite molded product manufactured by the molding die and manufacturing method described above will be explained. Note that composite molded product 1 is not limited to those shown in Figures 6 and 7. The composite molded product 1A shown in Figures 6(a) and 6(b) is the upper component of the toilet seat 5 of a Western-style toilet. Figure 6(a) is a schematic perspective view of the toilet seat 5, and Figure 6(b) is a cross-sectional view taken along the line A-A' in (a). In Figures 6(a) and 6(b), the dashed line indicates the base body 6, which is positioned opposite the first insert member 2 and below the composite molded product 1A. The toilet seat 5 is formed by combining the composite molded product 1A and the base body 6.

[0049] In the composite molded product 1A, the second insert member 4 is the exposed surface and comes into contact with the skin of the user sitting on the toilet seat 5. Therefore, suitable materials for the second insert member 4 include sheet materials with various functionalities such as antibacterial / antiviral sheets or stain-resistant sheets, considering hygiene and ease of cleaning, or cork sheets that have moderate elasticity and do not feel cold. If a metal sheet with high thermal conductivity is used as the first insert member 2, heat from a heat source such as a heater (not shown) in the toilet seat 5 can be efficiently transferred to the second insert member 4 via the resin molded body 3. Furthermore, as shown in Figure 6(b), the first insert member 2 is located on the inner surface side of the toilet seat 5 that is not exposed, and the convex portion 32, which is the gate mark, protrudes from within the recessed portion 31 of the resin molded body 3 and is located within the through hole 2c of the first insert member 2. As a result, the gate mark is not visible from the outside of the toilet seat 5, and the second insert member 4 can be made to look aesthetically pleasing with high precision and integral molding. Alternatively, the first insert member 2 may be a flexible, planar heater with a heating function that can warm the toilet seat 5.

[0050] Next, the composite molded product 1B shown in Figure 7(a) will be described. Figure 7(a) is a schematic longitudinal cross-sectional view of the composite molded product 1B, which is a roughly cylindrical insulator that is attached to the legs of audio equipment such as speakers to suppress vibrations. The second insert member 4 of the composite molded product 1B is an insert nut having a screw hole for fastening to the screw part of the audio equipment. Since the second insert member 4 is embedded in one surface 3a of the resin molded body 3, the composite molded product 1B can be attached to the legs of audio equipment such as speakers. The first insert member 2 is provided along the other surface 3b of the resin molded body 3, and in this case, the first insert member 2 may be a vibration-damping material that suppresses vibrations from the audio equipment. Furthermore, since the convex portion 32 of the composite molded product 1B is located on one side of the one surface 2a of the first insert member 2 and is formed within the recessed portion 31, it can be made inconspicuous in appearance.

[0051] Next, the composite molded product 1C shown in Figure 7(b) will be described. Figure 7(b) is a schematic perspective view showing a cross-section of the composite molded product 1C. The composite molded product 1C is used as a storage compartment for a storage box 7 equipped with an openable and closable lid 7a. The composite molded product 1C is a rectangular tubular box with an open top and a closed bottom. The first insert member 2 is the inner surface of the composite molded product 1C, and the second insert member 4 is the outer surface of the composite molded product 1C. In this case, an electromagnetic interference prevention sheet that suppresses electromagnetic interference may be used as the first insert member 2. As for the second insert member 4, a sheet material with design appeal such as a wood grain sheet or a leather sheet is preferable. The storage box 7 shown here is suitable for storing items that may be affected by electromagnetic interference, such as electronic locks for vehicles, mobile devices such as smartphones, credit cards, and luxury watches. This suppresses electromagnetic interference and protects the contents from electromagnetic interference such as relay attacks, hacking, and skimming. Furthermore, in this composite molded product 1C, the convex portion 32, which is the gate mark, is formed on the inner surface side of the housing box 7 and is located on one side of one surface 2a of the first insert member 2 and formed within the recessed portion 31, so that it is not noticeable in appearance.

[0052] Next, the composite molded product 1D shown in Figure 7(c) will be described. Figure 7(c) is a schematic cross-sectional view of the composite molded product 1D. The composite molded product 1D is an arc-shaped spacer used by being assembled in the cooling water passage of the cylinder block that constitutes an internal combustion engine. The resin molded body 3 is formed with one surface 3a in a concave curve and the other surface 3b in a convex curve. The first insert member 2 and the second insert member 4 are flexible sheet materials made of cellulose sponge that, when in contact with water, expand in the thickness direction from a compressed state and return to their pre-compression state. The first insert member 2 and the second insert member 4 are embedded and provided so as to be substantially flush with the other surface 3b and one surface 3a of the resin molded body 3, respectively, when compressed. In the composite molded product 1D shown in Figure 7(c), the tip of the gate remaining portion 1a that has solidified in the resin supply passage 113 is exposed from the other surface 2b of the first insert member 2 in a compressed state. Furthermore, as shown by the dashed line in Figure 7(c), when the first insert member 2 enlarges, the remaining gate portion 1a fits within the through hole 2c of the first insert member 2 and is not exposed from the first insert member 2. Therefore, when used as a spacer, it is possible to prevent it from unintentionally obstructing the flow of the medium circulating in the cooling water channel or becoming a protrusion that restricts the flow of the medium.

[0053] The configuration and shape of the composite molded products 1,1A to 1D are not limited to those described above or shown in the figures. For example, the composite molded product 1A in Figures 6(a) and 6(b) may be assembled to the base body 6 with the gate remaining portion 1a not cut off. Also, in Figures 6(a) and 6(b), a part of one side 3a of the resin molded body 3 is part of the exposed surface of the toilet seat 5, but the entire surface 3a of one side of the resin molded body 3 may be covered by the second insert member 4 and not exposed.

[0054] Furthermore, other embodiments of the composite molded product 1 may include, for example, an exterior or cover for a chemical measuring instrument that incorporates electronic components such as electronic circuits and sensors. It is preferable that an electromagnetic interference prevention sheet, which suppresses noise caused by electromagnetic interference, be used as the second insert member 4 on the inner surface of the exterior or cover, and a heat insulating sheet, which suppresses measurement variations due to ambient temperature, be used as the first insert member 2 on the outer surface. Since functionality is more important than design for such composite molded products, the sheet shape and gate position (outer or inner side) should be determined according to the required functionality. Therefore, the first insert member 2 and the second insert member 4 may be reversed, resulting in an excellent exterior or cover that protects the built-in electronic components with the electromagnetic interference prevention sheet and heat insulating sheet.

[0055] Furthermore, the configuration and shape of the molds 10, 10A to 10C are not limited to those described above or shown in the figures. For example, although the first mold 11 is a fixed mold and the second mold 12 is a movable mold, the first mold 11 may be a movable mold, and the second mold 12 may be a fixed mold. Also, the first cavity surface 110 in Figures 1 and 3 may be formed in a concave shape, and the second mold 12 may be formed in a planar shape. In addition, in the mold 10 of Figure 1, in order to further suppress lifting and displacement of the end of the first insert member 2, the first mold 11 may be provided with suction holes for generating vacuum suction, and the first mold 11 and the second mold 12 may be provided with protrusions that contact the first insert member 2. Furthermore, in the molds 10B and 10B' shown in Figures 4(a) and 4(b), the tips 124a, 124a of the second projections 124, 124 are in contact with the first insert member 2 when the mold is closed, but they may be configured to be close to the first insert member 2 without contact. Even if the tips 124a, 124a of the second projections 124, 124 are close to the first insert member 2, lifting, peeling, etc., of the first insert member 2 and the second insert member 4 due to the injection pressure of the molten resin r and resin flow will be suppressed. Moreover, the shape of the second projections 124 is not limited; for example, they may be prism-shaped, and their number and position are not limited to those shown in the drawings. Furthermore, the tips 115a, 115a of the first projections 115, 115 of the mold 10C in Figure 5 may not contact the second insert member 4 when the mold is closed, but may be configured to be close to the second insert member 4, and their shape, number, position, etc., are not limited to those shown in the drawing. Even if the tips 115a, 115a of the first projections 115, 115 are configured to be close to the second insert member 4, lifting, peeling, etc., of the first insert member 2 and the second insert member 4 due to the injection pressure of the molten resin r and resin flow will be suppressed. In addition, the first insert member 2 in Figure 5 may be provided with an insertion hole through which the first projection 115 is inserted.

[0056] The shape and material of the first insert member 2 and the resin molded body 3, as well as the presence or absence of the second insert member 4, may be appropriately designed depending on the composite molded product 1 to be manufactured. The mold 10 should be provided with a cavity 100 that conforms to the shape of the composite molded product 1 to be manufactured, and a configuration that positions the first insert member 2 and the second insert member 4 at the desired positions. [Explanation of symbols]

[0057] 1,1A~1D composite molded product 2. First insert member 2a One side 2c through hole 3. Resin molded body 32 Convex portion 4. Second insert member 10,10A~10C mold 100 Cavity 11 Type 1 110 First cavity surface 111 Protrusion 112 Resin supply port 115 1st protrusion 115a Tip 12 Type 2 120 Second cavity surface 124 2nd protrusion 124a Tip r molten resin

Claims

1. A flexible, sheet-like first insert member and an integral part of one side of the first insert member. This is a mold used when integrally molding a composite molded product which comprises a resin molded body to be molded. hand, A cavity that is positioned to be able to move toward and away from each other, and is filled with molten resin when the mold is closed. It comprises a first type and a second type that form a tee, The first type comprises a projection that is inserted through a through hole formed in the first insert member and fixes the first insert member, and a resin supply port formed at the tip of the projection for injecting the molten resin into the cavity, The first type and the second type each comprise a first cavity surface and a second cavity surface that form the cavity, A second insert member, integrally molded with the resin molded body, is positioned on the second cavity surface side of the second mold, which is positioned opposite the resin supply port. The second insert member is a flexible sheet-like material that is positioned along the second cavity surface of the second type, The second type has a pair of second protrusions that project toward the first cavity surface side of the first type and fix the second insert member, The molding die is characterized in that the pair of second protrusions abut against the end faces of the second insert member on their outer circumferential surfaces to position the second insert member.

2. In claim 1, The molding die is characterized in that the tip of the second projection approaches or comes into contact with the first insert member when the mold is closed.

3. In claim 1 or claim 2, The molding die is characterized in that the projection is formed at approximately the center position on the first cavity surface of the first mold.

4. A method for manufacturing a composite molded article using a mold according to any one of claims 1 to 3, A first positioning step involves inserting the projection of the first mold into the through hole of the first insert member to position the first insert member, A method for manufacturing a composite molded product, comprising an injection step of injecting the molten resin into the cavity from the resin supply port to form the resin molded body.

5. In claim 4, A method for manufacturing a composite molded product, further comprising a second positioning step of arranging the second insert member on the second cavity surface of the second type.

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