Compression mold and method for manufacturing molded articles using a compression mold

Abstract

To provide a compression molding die capable of easily molding a desired convex face at an outer tip face of a curved portion of a molded article.SOLUTION: A compression molding die 6 comprises: a main inner mold 30 having an inside molding face 31a corresponding to an inner face of a curved portion 12 of a molded article 5, and an inside excess-flesh molding face 31b for molding an inner face of an excess flesh portion 101 positioned ahead of a tip of the curved portion 12; a main outer mold 40 configured to be relatively movable in a main direction Z with respect to the main inner mold 30 and having an outside molding face 41a corresponding to an outer face of a curved body portion 22 of the curved portion 12; and a sub-mold 51 configured to be relatively movable in sub-directions X and Y with respect to the main inner mold 30, and having a first sub-molding face 51a for molding an outer tip face 21a of the curved portion 12 and a second sub-molding face 51b for molding an outer face of the excess flesh portion 101.SELECTED DRAWING: Figure 8

Description

Technical Field

[0003]

[0001] The present invention relates to a compression molding die and a method for manufacturing a molded body using the compression molding die.

Background Art

[0002] Patent Documents 1 and 2 describe that a convex curved surface is compression-molded at the tip of a curved portion using an inner die and an outer die. In Patent Document 1, it is described that in the compression molding of the convex curved surface, the excess material of the material is molded so as to extend outward from the outer surface of the tip of the curved portion of the molded body. Patent Document 2 describes cutting off the excess material extending outward from the outer surface of the tip of the curved portion of the molded body.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

[0006] One aspect of the present invention relates to a molded body having a curved portion at its periphery, wherein the tip portion of the curved portion of A compression molding die for forming a convex curved surface on its outer surface, A main internal mold having an inner molding surface corresponding to the inner surface of the curved portion of the molded body, and an inner excess material molding surface for molding the inner surface of the excess material portion located ahead of the tip of the curved portion and separated from the curved portion, The main internal mold is configured to be movable relative to the main direction, and the outer surface of the curved portion of the molded body is the curved portion The aforementioned An outer molding surface corresponding to the outer surface of the curved main body portion excluding the tip portion, and having the outer molding surface facing a part of the inner molding surface of the main inner mold, The tip of the curved portion adjacent to the outer surface of the curved body portion is configured to be movable relative to the main internal mold in a secondary direction intersecting the main direction, and is configured to be movable relative to the main internal mold in a secondary direction intersecting the main direction. of A sub-mold having a first sub-molding surface for shaping the outer surface and the first sub-molding surface facing a part of the inner molding surface of the main inner mold, and a second sub-molding surface for shaping the outer surface of the excess material portion and the second sub-molding surface facing the inner excess material molding surface of the main inner mold, Equipped with, The aforementioned The material of the molded body is a plate member containing a compression-molded thermoplastic resin. The first sub-molding surface of the sub-mold is configured to be arranged continuously with the outer molding surface of the main outer mold. The tip portion of the curved portion corresponds to the tip portion of the curved portion The aforementioned material part Compressed between the main internal mold and the inner molding surface. By doing Thickness of the thermoplastic resin of By making it thinner, the material The aforementioned part The outer surface is configured to be able to form the aforementioned convex curved surface, The second sub-molding surface of the sub-mold is formed on the side opposite to the main outer mold relative to the first sub-molding surface, and in the sub-direction, it is located closer to the inner molding surface of the main inner mold than to the connection point between the outer molding surface of the main outer mold and the first sub-molding surface of the sub-mold, and compresses the leading edge of the material. By doing so, the compressed end of the material The thickness of the thermoplastic resin is the tip of the curved portion. The thickness of the thermoplastic resin after compression The compression mold is configured to allow the excess material to be molded by making it thinner than the original material.

[0007] Another aspect of the present invention is a molded body having a curved portion at its periphery, using the compression mold of the above aspect, wherein the curved portion The aforementioned tip of A method for manufacturing a molded body to form a convex curved surface on its outer surface, The material is placed between the inner molding surface of the main inner mold and the outer molding surface of the main outer mold. After arranging the material, the main internal mold and the main external mold are moved relative to each other in the main direction, thereby positioning a portion of the material by the main internal mold and the main external mold. With the material positioned by the main internal mold and the main external mold, the tip of the material is compressed by moving the sub-mold relative to the main internal mold in the sub-direction, thereby forming the tip of the curved portion and the excess material. The present invention relates to a method for manufacturing a molded body using a compression mold, wherein the body is cut at the boundary between the tip of the curved portion and the excess material portion, thereby separating the excess material portion from the tip of the curved portion. [Effects of the Invention]

[0008] The compression molding die includes a main inner mold, a main outer mold, and a secondary mold. The main inner mold and main outer mold are used to position the material, which is made of plate members, in preparation for forming a convex curved surface on the outer surface of the tip of the curved portion of the molded body. Specifically, the curved body portion of the material, excluding the tip, is positioned between a part of the inner molding surface of the main inner mold and the outer molding surface of the main outer mold. In other words, the inner surface of the curved body portion contacts a part of the inner molding surface of the main inner mold, and the outer surface of the curved body portion contacts the outer molding surface of the main outer mold.

[0009] The outer surface of the tip of the curved portion of the molded body is formed by a part of the inner molding surface of the main mold and the first secondary molding surface of the secondary mold. The outer surface of the tip of the curved portion of the molded body is formed by compression by a part of the inner molding surface of the main mold and the first secondary molding surface of the secondary mold, by moving the secondary mold in the secondary direction relative to the main mold.

[0010] Here, the main mold has an inner molding surface in addition to an inner excess material molding surface. The secondary mold has a first secondary molding surface in addition to a second secondary molding surface facing the inner excess material molding surface. As the secondary mold moves in the secondary direction, the outer surface of the tip of the curved portion of the molded body is formed. Simultaneously, as the secondary mold moves in the secondary direction, the inner excess material molding surface and the second secondary molding surface form the excess material located beyond the tip of the curved portion of the molded body.

[0011] The second sub-molding surface of the sub-mold for forming the excess material is located closer to the inner molding surface of the main inner mold than to the connection point between the outer molding surface of the main outer mold and the first sub-molding surface of the sub-mold in the sub-direction. Therefore, the excess material that is formed is not formed in the middle of the convex curved surface on the outer surface of the tip of the curved portion of the molded body.

[0012] If the excess material is formed while connected to the tip of the curved portion of the molded body, the molded body can be formed by cutting off the excess material in a later process. Here, the second sub-molding surface of the sub-mold is formed on the opposite side of the main outer mold from the first sub-molding surface. Therefore, since the excess material is not formed in the middle of the convex curved surface on the outer surface of the tip of the curved portion of the molded body, it is possible to form the convex curved surface on the outer surface of the tip into the desired shape. Furthermore, even if the excess material can be cut by moving the sub-mold, the second sub-molding surface of the sub-mold is formed on the opposite side of the main outer mold from the first sub-molding surface. Therefore, the second sub-molding surface of the sub-mold can form the convex curved surface on the outer surface of the tip into the desired shape.

[0013] As described above, according to the above embodiment, it is possible to provide a compression molding die that can easily form a desired convex curved surface on the outer surface of the tip of the curved portion of a molded body, and a method for manufacturing a molded body using the compression molding die. [Brief explanation of the drawing]

[0014] [Figure 1] It is a figure showing a rear perspective view of a vehicle seat to which a seat back board as an example of a molded body is attached. [Figure 2] It is a front view of a seat back board as an example of a molded body. [Figure 3] It is a cross-sectional view taken along line III-III of FIG. 2. [Figure 4] It is an enlarged view of a portion IV of FIG. 3. [Figure 5] (a) is a longitudinal cross-sectional view showing a compression molding die in the initial stage of molding (a cross-sectional view at a position corresponding to the cross-section line III-III of FIG. 2), and (b) is a cross-sectional view taken along line VB-VB of FIG. 5(a). [Figure 6] (a) is a longitudinal cross-sectional view showing a compression molding die during molding, and (b) is a cross-sectional view taken along line VIB-VIB of FIG. 6(a). [Figure 7] (a) is a longitudinal cross-sectional view showing a compression molding die at the final stage of compression molding, and (b) is a cross-sectional view taken along line VIIB-VIIB of FIG. 7(a). [Figure 8] It shows a method for manufacturing a molded body using the compression molding die of Embodiment 1, where (a) shows a material positioning step, (b) shows a main die moving step, (c) shows a sub-die moving step, and (d) is a figure showing the molded body. [Figure 9] It shows a method for manufacturing a molded body using the compression molding die of Embodiment 2, where (a) shows a material positioning step, (b) shows a main die moving step, (c) shows a sub-die moving step, and (d) is a figure showing the molded body. [Figure 10] It shows a method for manufacturing a molded body using the compression molding die of Embodiment 3, where (a) shows a material positioning step, (b) shows a main die moving step, (c) shows a sub-die moving step, and (d) is a figure showing the molded body. [Figure 11] It shows a method for manufacturing a molded body using the compression molding die of Embodiment 4, where (a) shows a material positioning step, (b) shows a main die moving step, (c) shows a sub-die moving step, and (d) is a figure showing the molded body. [Modes for carrying out the invention]

[0015] (Embodiment 1) 1. Configuration of vehicle seat 1 The configuration of the vehicle seat 1 will be described with reference to Figure 1. As shown in Figure 1, the vehicle seat 1 comprises, for example, a seat surface 2, a backrest 3, a headrest 4, and a seat backboard 5. The backrest 3 is rotatably supported at the rear end of the seat surface 2. The headrest 4 is supported on the upper surface of the backrest 3. The seat backboard 5 is attached to the rear surface of the backrest 3 and constitutes the design surface of the rear of the vehicle seat 1.

[0016] 2. Configuration of Seat Backboard 5 The structure of the seat backboard 5 will be explained with reference to Figures 2 to 4. The seat backboard 5 is molded from a compression-molded material, which will be described later. The seat backboard 5 is molded from a material that includes, for example, a thermoplastic resin. For example, the seat backboard 5 can be molded by including natural fibers or synthetic fibers in the thermoplastic resin. Examples of natural fibers include plant fibers such as kenaf and coconut.

[0017] As shown in Figure 2, the seat backboard 5 is formed in a substantially rectangular shape, for example, with chamfered corners. However, the shape of the seat backboard 5 can be arbitrarily determined. As shown in Figure 3, the seat backboard 5 is made of plate members. The seat backboard 5 has a central part 11 and curved parts 12, 13, and 14 around its periphery. In this embodiment, the seat backboard 5 has curved parts 12, 13, and 14 on the top, right, and left sides in Figure 2. Therefore, as shown in Figure 3, the seat backboard 5 forms a concave surface (inner surface) on the lower surface in Figure 3 and a convex surface (outer surface) on the upper surface in Figure 3.

[0018] As shown in Figure 4, the curved sections 12, 13, and 14 each comprise a tip section 21 located at the front end and a curved main body section 22 located at the base end. The tip section 21 comprises a tip outer surface 21a and a tip inner surface 21b. The tip outer surface 21a is formed into a convex curved surface in the longitudinal cross-section shown in Figure 4. The radius of curvature of the convex curved surface of the tip outer surface 21a is smaller than the overall radius of curvature of the curved sections 12, 13, and 14. The radius of curvature of the convex curved surface of the tip outer surface 21a is, for example, close to the thickness of the seat backboard 5.

[0019] The inner surface 21b of the tip is formed to be either planar or concave in the longitudinal cross-section shown in Figure 4. When the inner surface 21b of the tip is formed to be concave, the radius of curvature of the concave surface of the inner surface 21b of the tip is approximately the same as the overall radius of curvature of the curved sections 12, 13, and 14. Furthermore, the tangents at the boundary between the outer surface 21a of the tip and the inner surface 21b of the tip are discontinuous. Specifically, the boundary between the outer surface 21a of the tip and the inner surface 21b of the tip is formed to be acute in the longitudinal cross-section shown in Figure 4.

[0020] The curved main body portion 22 is the portion of the curved sections 12, 13, and 14 excluding the tip portion 21. The curved main body portion 22 comprises an outer surface 22a and an inner surface 22b. The outer surface 22a of the curved main body portion is approximately the same as the overall radius of curvature of the curved sections 12, 13, and 14. The outer surface 22a of the curved main body portion is the surface adjacent to the outer surface 21a of the tip portion 21. The outer surface 22a of the curved main body portion forms a smooth continuous surface with the outer surface 21a of the tip portion. In other words, the boundary between the outer surface 22a of the curved main body portion and the outer surface 21a of the tip portion has a common tangent.

[0021] The inner surface 22b of the curved main body is approximately the same as the overall radius of curvature of the curved sections 12, 13, and 14. The inner surface 22b of the curved main body is the surface adjacent to the inner surface 21b of the tip section 21. The inner surface 22b of the curved main body forms a smooth continuous surface with the inner surface 21b of the tip section. In other words, the boundary between the inner surface 22b of the curved main body and the inner surface 21b of the tip section has a common tangent.

[0022] 3. Compression mold 6 for molded body and method for manufacturing molded body The seat backboard 5 described above is used as a molded body and is compression-molded using a compression mold 6. In the following description, the seat backboard 5 will be used as the molded body, but the compression mold 6 is not limited to the seat backboard 5 and can be used for molded bodies having the curved portions 12, 13, and 14 described above.

[0023] In this embodiment, the compression mold 6 is used to compress and mold a convex curved surface onto the outer surface 21a of the tip portions 12, 13, and 14 of the seat backboard 5. Therefore, in the following description, the method for manufacturing a molded body using the compression mold 6 will be described as a method for molding only the outer surface 21a of the tip portion. Accordingly, the material W of the molded body is assumed to have the curved main body portion 22 already molded, and the outer surface 21a of the tip portion is molded onto the material W.

[0024] However, in addition to the above manufacturing method, the compression mold 6 can also be used to form a curved body portion 22 in addition to compression molding the tip portion 21 of a flat material W, for example. In this case, the manufacturing method of the molded body using the compression mold 6 involves bending the curved body portion 22 and compression molding the tip portion 21.

[0025] A compression mold 6 and a method for manufacturing a molded body 5 (e.g., a seat backboard 5) using the compression mold 6 will be described with reference to Figures 5 to 7. The compression mold 6 is composed of a main inner mold 30, a main outer mold 40, and sub-molds 51, 52, and 53.

[0026] As shown in Figures 5(a), 6(a), and 7(a), the main internal mold 30 comprises a convex portion 31 corresponding to the inner surface of the molded body 5 and a peripheral portion 32 that forms the periphery of the convex portion 31. The surface of the convex portion 31 of the main internal mold 30 is formed in a shape corresponding to the inner surface of the central portion 11 of the molded body 5 and the inner surfaces of the curved portions 12, 13, and 14 of the molded body 5. In other words, a part of the surface of the convex portion 31 of the main internal mold 30 is formed in a shape corresponding to the inner surface 21b of the tip portion 21 of the curved portions 12, 13, and 14 (shown in Figure 4) and the inner surface 22b of the curved body portion 22 (shown in Figure 4).

[0027] As shown in Figures 5(a), 6(a), and 7(a), the main outer mold 40 is positioned opposite the main inner mold 30 in the main direction Z and is configured to be movable relative to the main inner mold 30 in the main direction Z. In this embodiment, the case in which the main outer mold 40 is configured to be movable relative to the main inner mold 30 is given as an example, but a configuration in which the main inner mold 30 is movable can also be adopted.

[0028] The main outer mold 40 comprises a recess 41 corresponding to the outer surface of the molded body 5 and a peripheral portion 42 that forms the periphery of the recess 41. The recess 41 of the main outer mold 40 faces the main direction Z, which is the vertical direction in Figure 5, relative to the convex portion 31 of the main inner mold 30. The surface of the recess 41 of the main outer mold 40 is formed in a shape corresponding to the outer surface of the central portion 11 of the molded body 5 and the outer surface 22a (shown in Figure 4) of the curved main body portion 22 of the curved portions 12, 13, and 14 of the molded body 5. The peripheral portion 42 of the main outer mold 40 faces the main direction Z, relative to the peripheral portion 32 of the main inner mold 30.

[0029] In Figures 5(b), 6(b), and 7(b), the sub-mold 51 is positioned between the upper edge portion of the peripheral portion 32 of the main inner mold 30 and the upper edge portion of the peripheral portion 42 of the main outer mold 40 in the main direction Z. The sub-mold 51 is configured to be relatively movable with respect to the main inner mold 30 and the main outer mold 40 in a direction intersecting the main direction Z, and in this embodiment, in the sub-direction Y which is perpendicular to the main direction Z. In addition, in this embodiment, the sub-mold 51 is configured to be integrally movable with the main outer mold 40 in the main direction Z. In other words, the sub-mold 51 is configured to be relatively movable with respect to the main inner mold 30 in the main direction Z. Furthermore, the sub-mold 51 has a shape corresponding to the outer surface 21a of the tip portion 21 of the curved portion 12 of the molded body 5 (shown in Figure 4). Moreover, the sub-mold 51 functions as a part that molds the outer surface 21a of the tip portion 12 of the curved portion 12 by compressing the material W of the molded body 5.

[0030] In Figures 5(b), 6(b), and 7(b), the sub-mold 52 is positioned between the right-hand side of the peripheral portion 32 of the main inner mold 30 and the right-hand side of the peripheral portion 42 of the main outer mold 40 in the main direction Z. The sub-mold 52 is configured to be relatively movable with respect to the main inner mold 30 and the main outer mold 40 in a direction intersecting the main direction Z, and in this embodiment, in the sub-direction X which is perpendicular to the main direction Z. Furthermore, in this embodiment, the sub-mold 52 is configured to be integrally movable with the main outer mold 40 in the main direction Z. In other words, the sub-mold 52 is configured to be relatively movable with respect to the main inner mold 30 in the main direction Z. The sub-mold 52 has a shape corresponding to the outer surface 21a of the tip portion 21 of the curved portion 13 of the molded body 5 (shown in Figure 4). Moreover, the sub-mold 52 functions as a part that molds the outer surface 21a of the tip portion 13 of the curved portion 13 by compressing the material W of the molded body 5.

[0031] In Figures 5(b), 6(b), and 7(b), the sub-mold 53 is positioned between the left edge of the peripheral portion 32 of the main inner mold 30 and the left edge of the peripheral portion 42 of the main outer mold 40 in the main direction Z. The sub-mold 53 is configured to be relatively movable with respect to the main inner mold 30 and the main outer mold 40 in a direction intersecting the main direction Z, and in this embodiment, in the sub-direction X which is perpendicular to the main direction Z. Furthermore, in this embodiment, the sub-mold 53 is configured to be movable integrally with the main outer mold 40 in the main direction Z. In other words, the sub-mold 53 is configured to be relatively movable with respect to the main inner mold 30 in the main direction Z. The sub-mold 53 has a shape corresponding to the outer surface 21a of the tip portion 21 of the curved portion 14 of the molded body 5 (shown in Figure 4). Moreover, the sub-mold 53 functions as a part that molds the outer surface 21a of the tip portion 14 by compressing the material W of the molded body 5.

[0032] The manufacturing method for the molded body 5 is as shown in Figures 5(a) and 5(b), in which the main internal mold 30, the main external mold 40, and the sub-molds 51, 52, and 53 are initially positioned. At this time, the material W of the molded body 5 is placed between the main internal mold 30 and the main external mold 40 (material positioning step). The material W is formed from a compression-molded plate member. In this embodiment, the material W has a shape in which the curved main body portion 22 of the curved portions 12, 13, and 14 of the molded body 5 has been formed in advance.

[0033] After positioning the material W, as shown in Figures 6(a) and 6(b), the main outer mold 40 is moved relative to the main inner mold 30 in the main direction Z, so that the material W of the molded body 5 is sandwiched between the convex portion 31 of the main inner mold 30 and the concave portion 41 of the main outer mold 40 (main mold movement step). In other words, a portion of the material W of the molded body 5 is positioned by the convex portion 31 of the main inner mold 30 and the concave portion 41 of the main outer mold 40. It is also possible to bend the material W using the convex portion 31 of the main inner mold 30 and the concave portion 41 of the main outer mold 40 during this step.

[0034] With the material W of the molded body 5 positioned by the main inner mold 30 and the main outer mold 40, the sub-molds 51, 52, and 53 are moved relative to the main inner mold 30 in the sub-directions X and Y, as shown in Figures 7(a) and 7(b) (sub-mold movement process). Specifically, the sub-mold 51 moves relative to the main inner mold 30 in the sub-direction Y, compressing the tip of the material W of the molded body 5 and forming the outer surface 21a of the tip of the curved portion 12 of the molded body 5 (shown in Figure 4). The sub-mold 52 moves relative to the main inner mold 30 in the sub-direction X, compressing the tip of the material W of the molded body 5 and forming the outer surface 21a of the tip of the curved portion 13 of the molded body 5 (shown in Figure 4). The sub-mold 53 moves relative to the main inner mold 30 in the sub-direction X, compressing the tip of the material W of the molded body 5 and forming the outer surface 21a (shown in Figure 4) of the tip of the curved portion 14 of the molded body 5. The sub-molds 51, 52, and 53 move simultaneously.

[0035] 4. Detailed configuration of the compression mold 6 and the manufacturing method of the molded body 5 using the compression mold 6. The detailed configuration of the compression mold 6 in this embodiment will be explained with reference to Figure 8. Figure 8(a) corresponds to the state shown in Figure 5, Figure 8(b) corresponds to the state shown in Figure 6, and Figure 8(c) corresponds to the state shown in Figure 7. Figure 8(d) shows the molded member Wa removed from the compression mold 6. The molding of the curved portion 12 of the molded body 5 will be explained below. The same applies to the other curved portions 13 and 14 of the molded body 5.

[0036] In this embodiment, the compression mold 6 is used to form the molded member Wa shown in Figure 8(d) from the material W shown in Figure 8(a). The molded member Wa comprises a portion of the molded body 5 and an excess material portion 101 located beyond the tip of the molded body 5. In the molded member Wa of this embodiment, the excess material portion 101 is molded to be connected to the tip of the molded body 5 and to extend from the tip of the molded body 5 in the main direction Z.

[0037] The worker can cut off the excess material portion 101 of the molded member Wa from the molded body 5 by bending the excess material portion 101. The molded body 5 can be formed in this way. The curved portion 12 of the molded body 5 comprises a tip portion 21 and a curved body portion 22, as shown in Figure 8(d). The tip portion 21 comprises a tip portion outer surface 21a and a tip portion inner surface 21b. The curved body portion 22 comprises a curved body portion outer surface 22a and a curved body portion inner surface 22b.

[0038] As shown in Figure 8(a), the main mold 30 comprises a convex portion 31 corresponding to the inner surface of the molded body 5 and a peripheral portion 32 that forms the periphery of the convex portion 31. The convex portion 31 of the main mold 30 comprises an inner molding surface 31a and an inner excess material molding surface 31b. The inner molding surface 31a is the surface corresponding to the inner surface of the curved portion 12 of the molded body 5 (shown in Figure 8(d)). The inner excess material molding surface 31b is the surface for molding the inner surface of the excess material 101 located beyond the tip of the curved portion 12. The surface direction of the inner excess material molding surface 31b (equal to the direction of the surface line) coincides with the main direction Z and intersects with the secondary direction Y. The inner molding surface 31a and the inner excess material molding surface 31b constitute a smooth continuous surface. That is, the boundary between the inner molding surface 31a and the inner excess material molding surface 31b has a common tangent.

[0039] The main outer mold 40 comprises a recess 41 corresponding to the outer surface of the molded body 5 and a peripheral portion 42 that forms the periphery of the recess 41. The recess 41 of the main outer mold 40 has an outer molding surface 41a. The outer molding surface 41a is the surface corresponding to the outer surface 22a of the curved main body portion 22 of the curved portion 12 of the molded body 5. The outer molding surface 41a of the main outer mold 40 faces a part of the inner molding surface 31a of the main inner mold 30.

[0040] The sub-mold 51 is positioned between the peripheral portion 32 of the main inner mold 30 and the peripheral portion 42 of the main outer mold in the main direction Z. The sub-mold 51 is configured to be movable in the sub-direction Y relative to the main inner mold 30 and the main outer mold 40. The sub-mold 51 includes a first sub-molding surface 51a, a second sub-molding surface 51b, and an outer mold contact surface 51c.

[0041] As shown in Figure 8(c), the first sub-molding surface 51a is a molding surface for compression molding the outer surface 21a of the tip portion 21 of the curved portion 12 of the molded body 5. In other words, the first sub-molding surface 51a has a concave curved surface onto which the convex curved surface of the outer surface 21a of the tip portion of the molded body 5 is transferred. Furthermore, the first sub-molding surface 51a is configured to be positioned continuously with the outer molding surface 41a of the main outer mold 40 during compression molding of the outer surface 21a of the tip portion. In addition, the first sub-molding surface 51a faces a part of the inner molding surface 31a of the main inner mold 30. The first sub-molding surface 51a is configured to form a convex curved surface on the outer surface 21a of the tip portion of the material W by compressing the material W, which is formed from a plate member, with the inner molding surface 31a of the main inner mold 30.

[0042] As shown in Figure 8(c), the second sub-molding surface 51b is a molding surface for compression molding the outer surface of the excess material portion 101. In other words, the second sub-molding surface 51b is configured to allow molding of the excess material portion 101 by compressing the leading edge of the material W. The second sub-molding surface 51b is formed on the side opposite to the main outer mold 40 relative to the first sub-molding surface 51a. In this embodiment, the second sub-molding surface 51b is connected to the first sub-molding surface 51a. In other words, the second sub-molding surface 51b is continuous with the first sub-molding surface 51a. However, at the boundary between the first sub-molding surface 51a and the second sub-molding surface 51b, the tangents to each surface are discontinuous.

[0043] The second sub-molding surface 51b is located in the sub-direction Y closer to the inner molding surface 31a of the main inner mold 30 than the connection point between the outer molding surface 41a of the main outer mold 40 and the first sub-molding surface 51a of the sub-mold 51. The second sub-molding surface 51b faces the inner excess material molding surface 31b of the main inner mold 30. The surface direction of the second sub-molding surface 51b (equal to the direction of the surface line) coincides with the main direction Z and intersects with the sub-direction Y. Therefore, the second sub-molding surface 51b and the inner excess material molding surface 31b are configured to be moldable so as to extend in the main direction Z with the excess material portion 101 connected to the tip of the curved portion 12.

[0044] The outer mold contact surface 51c is the surface that contacts the peripheral portion 42 of the main outer mold 40. The outer mold contact surface 51c and the peripheral portion 42 of the main outer mold 40 are formed in a planar shape that is slightly inclined with respect to the secondary direction Y. Therefore, when the secondary mold 51 is moved in the secondary direction Y, as shown in Figure 8(c), the outer mold contact surface 51c of the secondary mold 51 and the peripheral portion 42 of the main outer mold 40 are positioned by surface contact.

[0045] As shown in Figure 8(a), the manufacturing method for the molded body 5 involves initially positioning the main internal mold 30, the main external mold 40, and the sub-molds 51, 52, and 53, and then placing the material W for the molded body 5 between the main internal mold 30 and the main external mold 40 (material positioning step).

[0046] Next, as shown in Figure 8(b), the main outer mold 40 is moved relative to the main inner mold 30 in the main direction Z, so that the material W of the molded body 5 is sandwiched between the inner molding surface 31a of the convex portion 31 of the main inner mold 30 and the outer molding surface 41a of the concave portion 41 of the main outer mold 40 (main mold movement step).

[0047] Next, as shown in Figure 8(c), the sub-mold 51 is moved relative to the main inner mold 30 in the sub-direction Y (sub-mold movement step). As a result, the first sub-molding surface 51a of the sub-mold 51 and a portion of the inner molding surface 31a of the main inner mold 30 compress the leading edge of the material W, forming the outer surface 21a of the leading edge of the curved portion 12 of the molded body 5 (shown in Figure 8(d)). Furthermore, the second sub-molding surface 51b of the sub-mold 51 and the inner excess material molding surface 31b of the main inner mold 30 compress the portion of the material W even further forward than the outer surface 21a of the leading edge, forming the excess material portion 101. In this way, the excess material portion 101 is formed to extend from the leading edge 21 of the curved portion 12 in the main direction Z. Then, the operator can cut the excess material portion 101 from the molded body 5 by bending the excess material portion 101 of the molded member Wa shown in Figure 8(d).

[0048] 5. Effects As described above, the compression mold 6 includes sub-molds 51, 52, and 53 in addition to the main inner mold 30 and the main outer mold 40. The main inner mold 30 and the main outer mold 40 are used to position the material W, which is made of plate members, in preparation for forming a convex curved surface on the outer surface 21a of the tip of the curved portion 12, 13, 14 of the molded body 5. Specifically, the curved body portion 22 of the material W, excluding the tip, is positioned between a part of the inner molding surface 31a of the main inner mold 30 and the outer molding surface 41a of the main outer mold 40. In other words, the inner surface 22b of the curved body portion 22 contacts a part of the inner molding surface 31a of the main inner mold 30, and the outer surface 22a of the curved body portion 22 contacts the outer molding surface 41a of the main outer mold 40.

[0049] The outer surfaces 21a of the tip portions 12, 13, and 14 of the molded body 5 are formed by a part of the inner molding surface 31a of the main mold 30 and the first sub-molding surfaces 51a of the sub-molds 51, 52, and 53. The outer surfaces 21a of the tip portions 12, 13, and 14 of the molded body 5 are formed by compression by a part of the inner molding surface 31a of the main mold 30 and the first sub-molding surfaces 51a of the sub-molds 51, 52, and 53, which are moved in the sub-directions X and Y relative to the main mold 30.

[0050] Here, the main internal mold 30 has an inner molding surface 31a and an inner excess material molding surface 31b. The sub-molds 51, 52, and 53 have a first sub-molding surface 51a and a second sub-molding surface 51b facing the inner excess material molding surface 31b. As the sub-molds 51, 52, and 53 move in the sub-directions X and Y, the outer surfaces 21a of the tip portions of the curved portions 12, 13, and 14 of the molded body 5 are formed. At the same time, as the sub-molds 51, 52, and 53 move in the sub-directions X and Y, the inner excess material molding surface 31b and the second sub-molding surface 51b form the excess material portion 101 located beyond the tip portions of the curved portions 12, 13, and 14 of the molded body 5.

[0051] The second sub-molding surfaces 51b of the sub-molds 51, 52, and 53 for forming the excess material portion 101 are located closer to the inner molding surface 31a of the main inner mold 30 than to the connection point between the outer molding surface 41a of the main outer mold 40 and the first sub-molding surfaces 51a of the sub-molds 51, 52, and 53 in the sub-directions X and Y. Therefore, the excess material portion 101 that is formed is not formed in the middle of the convex curved surface of the outer tip surface 21a of the curved portion 12, 13, and 14 of the molded body 5.

[0052] The excess material portion 101 is formed connected to the tips of the curved portions 12, 13, and 14 of the molded body 5, and the molded body 5 can be formed by cutting off the excess material portion 101 in a later process. Here, the second sub-molding surface 51b of the sub-molds 51, 52, and 53 is formed on the side opposite to the main outer mold 40 relative to the first sub-molding surface 51a. Therefore, since the excess material portion 101 is not formed in the middle of the convex curved surface of the tip outer surface 21a of the curved portions 12, 13, and 14 of the molded body 5, it is possible to form the convex curved surface of the tip outer surface 21a into a desired shape. Thus, a desired convex curved surface can be easily formed on the tip outer surface 21a of the curved portions 12, 13, and 14 of the molded body 5.

[0053] (Embodiment 2) The method for manufacturing the compression mold 6 and molded body 5 of Embodiment 2 will be described with reference to Figure 9. Note that, among the reference numerals used in Embodiment 2 and later, those that are the same as those used in previously described embodiments represent the same components as those in the previously described embodiments, unless otherwise specified.

[0054] Figure 9(a) corresponds to the state shown in Figure 5, Figure 9(b) corresponds to the state shown in Figure 6, and Figure 9(c) corresponds to the state shown in Figure 7. Figure 9(d) shows the molded member Wa removed from the compression mold 6. The molding of the curved portion 12 of the molded body 5 will be described below. The same applies to the other curved portions 13 and 14 of the molded body 5.

[0055] In this embodiment, the compression mold 6 is used to form the molded member Wa shown in Figure 9(d) from the material W shown in Figure 9(a). The molded member Wa comprises a portion of the molded body 5 and an excess material portion 102 located beyond the tip of the molded body 5. In the molded member Wa of this embodiment, the excess material portion 102 is molded to be connected to the tip of the molded body 5 and to extend from the tip of the molded body 5 in a direction different from the main direction Z. In this embodiment, the excess material portion 102 is molded to extend from the tip of the molded body 5 in a direction parallel to the secondary direction Y.

[0056] The worker can cut off the excess material portion 102 of the molded member Wa from the molded body 5 by bending the excess material portion 102. The molded body 5 can be formed in this way. The curved portion 12 of the molded body 5 comprises a tip portion 21 and a curved body portion 22, as shown in Figure 9(d). The tip portion 21 comprises a tip portion outer surface 21a and a tip portion inner surface 21b. The curved body portion 22 comprises a curved body portion outer surface 22a and a curved body portion inner surface 22b.

[0057] As shown in Figure 9(a), the main internal mold 30 comprises a protrusion 31 corresponding to the inner surface of the molded body 5 and a peripheral portion 32 that forms the periphery of the protrusion 31. The protrusion 31 of the main internal mold 30 comprises an inner molding surface 61a and an inner excess material molding surface 61b. The inner molding surface 61a is the surface corresponding to the inner surface of the curved portion 12 of the molded body 5 (shown in Figure 9(d)).

[0058] The inner excess material forming surface 61b is a surface for forming the inner surface of the excess material portion 102 located beyond the tip of the curved portion 12. The surface direction of the inner excess material forming surface 61b (equal to the direction of the surface line) is at an angle to the inner forming surface 61a and is formed to extend away from the outer forming surface 41a of the main outer mold 40 in the secondary direction Y. More specifically, the surface direction of the inner excess material forming surface 61b is formed to extend in a direction parallel to the secondary direction Y. In other words, the inner excess material forming surface 61b is continuous with the inner forming surface 61a. However, at the boundary between the inner forming surface 61a and the inner excess material forming surface 61b, the tangents to each are discontinuous.

[0059] The main outer mold 40 comprises a recess 41 corresponding to the outer surface of the molded body 5 and a peripheral portion 42 that forms the periphery of the recess 41. The recess 41 of the main outer mold 40 has an outer molding surface 41a. The outer molding surface 41a is the surface corresponding to the outer surface 22a of the curved main body portion 22 of the curved portion 12 of the molded body 5. The outer molding surface 41a of the main outer mold 40 faces a part of the inner molding surface 61a of the main inner mold 30.

[0060] The sub-mold 51 is positioned between the peripheral portion 32 of the main inner mold 30 and the peripheral portion 42 of the main outer mold in the main direction Z. The sub-mold 51 is configured to be movable in the sub-direction Y relative to the main inner mold 30 and the main outer mold 40. The sub-mold 51 includes a first sub-molding surface 62a, a second sub-molding surface 62b, and an outer mold contact surface 62c.

[0061] As shown in Figure 9(c), the first sub-molding surface 62a is a molding surface for compression molding the outer surface 21a of the tip portion 21 of the curved portion 12 of the molded body 5. In other words, the first sub-molding surface 62a has a concave curved surface onto which the convex curved surface of the outer surface 21a of the tip portion of the molded body 5 is transferred. Furthermore, the first sub-molding surface 62a is configured to be positioned continuously with the outer molding surface 41a of the main outer mold 40 during compression molding of the outer surface 21a of the tip portion. In addition, the first sub-molding surface 62a faces a part of the inner molding surface 61a of the main inner mold 30. The first sub-molding surface 62a is configured to form a convex curved surface on the outer surface 21a of the tip portion of the material W by compressing the material W, which is formed from a plate member, between the first sub-molding surface 62a and the inner molding surface 61a of the main inner mold 30.

[0062] As shown in Figure 9(c), the second sub-molding surface 62b is a molding surface for compression molding the outer surface of the excess material portion 102. In other words, the second sub-molding surface 62b is configured to mold the excess material portion 102 by compressing the leading edge of the material W. The second sub-molding surface 62b is formed on the side opposite to the main outer mold 40 relative to the first sub-molding surface 62a. In this embodiment, the second sub-molding surface 62b is connected to the first sub-molding surface 62a. In other words, the second sub-molding surface 62b is continuous with the first sub-molding surface 62a. However, at the boundary between the first sub-molding surface 62a and the second sub-molding surface 62b, the tangents to each surface are discontinuous.

[0063] The second sub-molding surface 62b is located in the sub-direction Y closer to the inner molding surface 61a of the main inner mold 30 than to the connection point between the outer molding surface 41a of the main outer mold 40 and the first sub-molding surface 62a of the sub-mold 51. The second sub-molding surface 62b faces the inner excess material molding surface 61b of the main inner mold 30. The surface direction (equal to the direction of the surface line) of the second sub-molding surface 62b is formed to extend in a direction parallel to the sub-direction Y. Therefore, the second sub-molding surface 62b and the inner excess material molding surface 61b are configured to be moldable so as to extend in a direction parallel to the sub-direction Y, with the excess material portion 102 connected to the tip of the curved portion 12.

[0064] The outer mold contact surface 62c is the surface that contacts the peripheral portion 42 of the main outer mold 40. The outer mold contact surface 62c and the peripheral portion 42 of the main outer mold 40 are formed in a planar shape that is slightly inclined with respect to the secondary direction Y. Therefore, when the secondary mold 51 is moved in the secondary direction Y, as shown in Figure 9(c), the outer mold contact surface 62c of the secondary mold 51 and the peripheral portion 42 of the main outer mold 40 are in contact, and both are positioned.

[0065] As shown in Figure 9(a), the manufacturing method for the molded body 5 involves initially positioning the main internal mold 30, the main external mold 40, and the sub-molds 51, 52, and 53, and then placing the material W for the molded body 5 between the main internal mold 30 and the main external mold 40 (material positioning step).

[0066] Next, as shown in Figure 9(b), the main outer mold 40 is moved relative to the main inner mold 30 in the main direction Z, so that the material W of the molded body 5 is sandwiched between the inner molding surface 61a of the convex portion 31 of the main inner mold 30 and the outer molding surface 41a of the concave portion 41 of the main outer mold 40 (main mold movement step).

[0067] Next, as shown in Figure 9(c), the sub-mold 51 is moved relative to the main inner mold 30 in the sub-direction Y (sub-mold movement step). As a result, the first sub-molding surface 62a of the sub-mold 51 and a portion of the inner molding surface 61a of the main inner mold 30 compress the leading edge of the material W, forming the outer surface 21a of the leading edge of the curved portion 12 of the molded body 5 (shown in Figure 9(d)). Furthermore, the second sub-molding surface 62b of the sub-mold 51 and the inner excess material molding surface 61b of the main inner mold 30 compress the portion of the material W even further forward than the outer surface 21a of the leading edge, forming the excess material portion 102. In this way, the excess material portion 102 is formed to extend from the leading edge 21 of the curved portion 12 in a direction parallel to the sub-direction Y. Then, the worker can cut the excess material portion 102 from the molded body 5 by processing such as bending the excess material portion 102 of the molded member Wa shown in Figure 9(d).

[0068] By manufacturing the molded body 5 using the compression mold 6 of this embodiment, the same effects as in Embodiment 1 are achieved.

[0069] (Embodiment 3) The manufacturing method of the compression mold 6 and molded body 5 of Embodiment 3 will be described with reference to Figure 10. Figure 10(a) corresponds to the state shown in Figure 5, Figure 10(b) corresponds to the state shown in Figure 6, and Figure 10(c) corresponds to the state shown in Figure 7. Figure 10(d) shows the molded member Wa removed from the compression mold 6. The molding of the curved portion 12 of the molded body 5 will be described below. The same applies to the other curved portions 13 and 14 of the molded body 5.

[0070] In this embodiment, the compression mold 6 is used to form the molded member Wa shown in Figure 10(d) from the material W shown in Figure 10(a). The molded member Wa comprises a portion of the molded body 5 and an excess material portion 103 located beyond the tip of the molded body 5. In the molded member Wa of this embodiment, the excess material portion 103 is molded to be connected to the tip of the molded body 5 and to extend from the tip of the molded body 5 in a direction different from the main direction Z. In this embodiment, the excess material portion 103 is molded to extend from the tip of the molded body 5 in a direction that has an angle with respect to the main direction Z and the secondary direction Y.

[0071] The worker can cut off the excess material portion 103 of the molded member Wa from the molded body 5 by bending the excess material portion 103. The molded body 5 can be formed in this way. The curved portion 12 of the molded body 5 comprises a tip portion 21 and a curved body portion 22, as shown in Figure 10(d). The tip portion 21 comprises a tip portion outer surface 21a and a tip portion inner surface 21b. The curved body portion 22 comprises a curved body portion outer surface 22a and a curved body portion inner surface 22b.

[0072] As shown in Figure 10(a), the main internal mold 30 comprises a convex portion 31 corresponding to the inner surface of the molded body 5 and a peripheral portion 32 that forms the periphery of the convex portion 31. The convex portion 31 of the main internal mold 30 comprises an inner molding surface 71a and an inner excess material molding surface 71b. The inner molding surface 71a is the surface corresponding to the inner surface of the curved portion 12 of the molded body 5 (shown in Figure 10(d)). The main external mold 40 comprises a recess 41 corresponding to the outer surface of the molded body 5 and a peripheral portion 42 that forms the periphery of the recess 41. The recess 41 of the main external mold 40 comprises an outer molding surface 41a.

[0073] The sub-mold 51 is positioned between the peripheral portion 32 of the main inner mold 30 and the peripheral portion 42 of the main outer mold in the main direction Z. The sub-mold 51 is configured to be movable in the sub-direction Y relative to the main inner mold 30 and the main outer mold 40. The sub-mold 51 includes a first sub-molding surface 72a, a second sub-molding surface 72b, and an outer mold contact surface 72c.

[0074] In this embodiment, the difference is that the inner excess material molding surface 71b of the main mold 30 and the second sub-molding surface 72b of the sub-mold 51 are at an angle to the inner excess material molding surface 61b of the main mold 30 and the second sub-molding surface 62b of the sub-mold 51 in Embodiment 2. By manufacturing the molded body 5 using the compression mold 6 of this embodiment, the same effects as in Embodiment 2 are achieved.

[0075] (Embodiment 4) The method for manufacturing the compression mold 6 and molded body 5 of Embodiment 4 will be described with reference to Figure 11. Figure 11(a) corresponds to the state shown in Figure 5, Figure 11(b) corresponds to the state shown in Figure 6, and Figure 11(c) corresponds to the state shown in Figure 7. Figure 11(d) shows the molded member Wa removed from the compression mold 6. The molding of the curved portion 12 of the molded body 5 will be described below. The same applies to the other curved portions 13 and 14 of the molded body 5.

[0076] In this embodiment, the compression mold 6 is used to form the molded member Wa shown in Figure 11(d) from the material W shown in Figure 11(a). The molded member Wa comprises the molded body 5 and an excess material portion 104 located beyond the tip of the molded body 5. In the molded member Wa of this embodiment, the excess material portion 104 is molded separately from the tip of the molded body 5. In other words, in this embodiment, the molded body 5 is formed without the operator separating the excess material portion 101 from the molded member Wa.

[0077] As shown in Figure 11(a), the main internal mold 30 comprises a convex portion 31 corresponding to the inner surface of the molded body 5 and a peripheral portion 32 that forms the periphery of the convex portion 31. The convex portion 31 of the main internal mold 30 comprises an inner molding surface 81a and an inner excess material molding surface 81b. The inner molding surface 81a is the surface corresponding to the inner surface of the curved portion 12 of the molded body 5 (shown in Figure 11(d)).

[0078] The inner excess material forming surface 81b is a surface for forming the inner surface of the excess material portion 104 located beyond the tip of the curved portion 12. The surface direction of the inner excess material forming surface 81b (equal to the direction of the surface line) is formed discontinuously from the inner forming surface 81a. Furthermore, in the secondary direction Y, the inner excess material forming surface 81b is formed at a position further from the outer forming surface 41a of the main outer mold 40 than the inner forming surface 81a. Here, the inner excess material forming surface 81b coincides with the main direction Z and intersects with the secondary direction Y. In other words, the inner forming surface 81a and the inner excess material forming surface 81b are formed in a stepped manner.

[0079] The main outer mold 40 comprises a recess 41 corresponding to the outer surface of the molded body 5 and a peripheral portion 42 that forms the periphery of the recess 41. The recess 41 of the main outer mold 40 has an outer molding surface 41a. The outer molding surface 41a is the surface corresponding to the outer surface 22a of the curved main body portion 22 of the curved portion 12 of the molded body 5. The outer molding surface 41a of the main outer mold 40 faces a part of the inner molding surface 31a of the main inner mold 30.

[0080] The sub-mold 51 is positioned between the peripheral portion 32 of the main inner mold 30 and the peripheral portion 42 of the main outer mold in the main direction Z. The sub-mold 51 is configured to be movable in the sub-direction Y relative to the main inner mold 30 and the main outer mold 40. The sub-mold 51 includes a first sub-molding surface 82a, a second sub-molding surface 82b, an outer mold contact surface 82c, and a non-molding surface 82d.

[0081] As shown in Figure 11(c), the first sub-molding surface 82a is a molding surface for compression molding the outer surface 21a of the tip portion 21 of the curved portion 12 of the molded body 5. In other words, the first sub-molding surface 82a has a concave curved surface onto which the convex curved surface of the outer surface 21a of the tip portion of the molded body 5 has been transferred. Furthermore, the first sub-molding surface 82a is configured to be positioned continuously with the outer molding surface 41a of the main outer mold 40 during compression molding of the outer surface 21a of the tip portion. In addition, the first sub-molding surface 82a faces a part of the inner molding surface 81a of the main inner mold 30. The first sub-molding surface 82a is configured to form a convex curved surface on the outer surface 21a of the tip portion of the material W by compressing the material W, which is formed from a plate member, between it and the inner molding surface 81a of the main inner mold 30.

[0082] As shown in Figure 11(c), the second sub-molding surface 82b is a molding surface for compression molding the outer surface of the excess material portion 104. In other words, the second sub-molding surface 82b is configured to mold the excess material portion 104 by compressing the leading edge of the material W. The second sub-molding surface 82b is formed on the side opposite to the main outer mold 40 relative to the first sub-molding surface 82a.

[0083] In this embodiment, the second sub-molded surface 82b is formed discontinuously from the first sub-molded surface 82a. That is, a non-molded surface 82d is interposed between the second sub-molded surface 82b and the first sub-molded surface 82a. The non-molded surface 82d is smoothly connected to the first sub-molded surface 82a, while it is connected to the second sub-molded surface 82b at an angle.

[0084] The second sub-molding surface 82b is located in the sub-direction Y closer to the inner molding surface 81a of the main inner mold 30 than the connection point between the outer molding surface 41a of the main outer mold 40 and the first sub-molding surface 82a of the sub-mold 51. The second sub-molding surface 82b faces the inner excess material molding surface 81b of the main inner mold 30. The surface direction of the second sub-molding surface 82b (equal to the direction of the surface line) coincides with the main direction Z and intersects with the sub-direction Y. Therefore, the second sub-molding surface 82b and the inner molding surface 81a of the main inner mold 30 are configured to cut the material W by shear. The second sub-molding surface 82b and the inner excess material molding surface 81b are configured to mold the excess material portion 104 so that it extends in the main direction Z at a position spaced apart from the tip of the curved portion 12.

[0085] The outer mold contact surface 82c is the surface that contacts the peripheral portion 42 of the main outer mold 40. The outer mold contact surface 82c and the peripheral portion 42 of the main outer mold 40 are formed in a planar shape that is slightly inclined with respect to the secondary direction Y. Therefore, when the secondary mold 51 is moved in the secondary direction Y, as shown in Figure 11(c), the outer mold contact surface 82c of the secondary mold 51 and the peripheral portion 42 of the main outer mold 40 are in contact, and both are positioned by this surface contact.

[0086] As shown in Figure 11(a), the manufacturing method for the molded body 5 involves initially positioning the main internal mold 30, the main external mold 40, and the sub-molds 51, 52, and 53, and then placing the material W for the molded body 5 between the main internal mold 30 and the main external mold 40 (material positioning step).

[0087] Next, as shown in Figure 11(b), the main outer mold 40 is moved relative to the main inner mold 30 in the main direction Z, so that the material W of the molded body 5 is sandwiched between the inner molding surface 81a of the convex portion 31 of the main inner mold 30 and the outer molding surface 41a of the concave portion 41 of the main outer mold 40 (main mold movement step).

[0088] Next, as shown in Figure 11(c), the sub-mold 51 is moved relative to the main inner mold 30 in the sub-direction Y (sub-mold movement step). When this is done, the second sub-molding surface 82b of the sub-mold 51 comes into contact with the outer surface of the material W. Then, the first sub-molding surface 82a of the sub-mold 51 and the inner molding surface 81a of the main inner mold 30 begin to compress the material W.

[0089] As the sub-mold 51 moves further relative to the sub-direction Y, the second sub-molding surface 82b of the sub-mold 51 reaches a position where it coincides with the inner molding surface 81a of the main inner mold 30. From this state, as the sub-mold 51 moves further relative to the sub-direction Y, the second sub-molding surface 82b of the sub-mold 51 and the inner molding surface 81a of the main inner mold 30 apply a shear force to the material W.

[0090] Then, the sub-mold 51 moves further relative to the sub-direction Y, and the first sub-molding surface 82a of the sub-mold 51 reaches a position where it is continuous with the outer molding surface 41a of the main outer mold 40. The first sub-molding surface 82a of the sub-mold 51 and a portion of the inner molding surface 81a of the main inner mold 30 compress the leading edge of the material W, forming the outer surface 21a of the leading edge of the curved portion 12 of the molded body 5 (shown in Figure 11(d)).

[0091] Furthermore, the second sub-molding surface 82b of the sub-mold 51 and the inner excess material molding surface 81b of the main inner mold 30 compress the material W even further towards the tip than the outer tip surface 21a, thereby forming the excess material 104. The inner excess material molding surface 81b of the main inner mold 30 and the second sub-molding surface 82b of the sub-mold 51 are configured to form the excess material 104 at a position separated from the tip of the curved portion 12 of the molded body 5. Therefore, as the molding of the outer tip surface 21a of the curved portion 12 of the molded body 5 is completed, the material W is cut by shear by the second sub-molding surface 82b of the sub-mold 51 and the inner molding surface 81a of the main inner mold 30, and the excess material 104 is separated from the tip of the curved portion 12.

[0092] As described above, the excess material 104 can be cut by moving the sub-mold 51, so that the molded body 5 can be formed with high precision and easily. In this case, the second sub-molding surface 82b of the sub-mold 51 is formed on the side opposite to the main outer mold 40 relative to the first sub-molding surface 82a. Therefore, the second sub-molding surface 82b of the sub-mold 51 can form the convex curved surface of the tip outer surface 21a into a desired shape.

[0093] Furthermore, as shown in Figure 11(c), when the outer surface 21a of the tip of the curved portion 12 is completed, the distance between the second sub-molding surface 82b of the sub-mold 51 and the inner molding surface 81a of the main inner mold 30 in the sub-direction Y is set to be shorter than the maximum opposing distance between the inner molding surface 81a of the main inner mold 30 and the first sub-molding surface 82a of the sub-mold 51. Therefore, the material W can be compressed by the inner molding surface 81a of the main inner mold 30 and the first sub-molding surface 82a of the sub-mold 51 before the material W is cut. This makes it possible to mold the outer surface 21a of the tip of the tip 21 of the molded body 5 with high precision. [Explanation of symbols]

[0094] 5 Molded body 6. Compression mold 12 Curved section 21 Tip 21a Tip outer surface 22 Curved main body 30 Main inner mold 31a,61a,71a,81a Inner molding surface 31b, 61b, 71b, 81b Inner side residual meat forming surface 40 Main Appearance 41a Outer forming surface Subtypes 51, 52, 53 51a, 62a, 72a, 82a First Forming Surface 51b, 62b, 72b, 82b Second Forming Surface 101, 102, 103, 104 Remaining Meat Section W material Wa Forming Post-Material

Claims

1. A compression mold for forming a convex curved surface on the outer surface of the tip of a curved portion in a molded body having a curved portion at its periphery, A main internal mold having an inner molding surface corresponding to the inner surface of the curved portion of the molded body, and an inner excess material molding surface for molding the inner surface of the excess material portion located ahead of the tip of the curved portion and separated from the curved portion, A main outer mold is configured to be movable relative to the main inner mold in the main direction, and has an outer molding surface that corresponds to the outer surface of the curved body portion of the molded body, excluding the tip of the curved portion, and the outer molding surface is facing a part of the inner molding surface of the main inner mold, A sub-mold is configured to be movable relative to the main internal mold in a sub-direction intersecting the main direction, and has a first sub-molding surface for forming the outer surface of the tip of the curved portion adjacent to the outer surface of the curved main body portion, the first sub-molding surface facing a part of the inner molding surface of the main internal mold, and a second sub-molding surface for forming the outer surface of the excess material portion, the second sub-molding surface facing the inner excess material molding surface of the main internal mold, Equipped with, The material of the molded body is a plate member containing a compression-molded thermoplastic resin, The first sub-molding surface of the sub-mold is configured to be positioned continuously with the outer molding surface of the main outer mold, and is configured to form the convex curved surface on the outer surface of the material by compressing the portion of the material corresponding to the tip of the curved portion between the inner molding surface of the main inner mold and the thermoplastic resin, thereby reducing the thickness of the thermoplastic resin. A compression mold wherein the second sub-molding surface of the sub-mold is formed on the opposite side of the main outer mold from the first sub-molding surface, and is located in the sub-direction closer to the inner molding surface of the main inner mold than the connection position between the outer molding surface of the main outer mold and the first sub-molding surface of the sub-mold, and is configured to form the excess material portion by compressing the tip of the material, thereby making the thickness of the thermoplastic resin after compression at the tip of the material thinner than the thickness of the thermoplastic resin after compression at the tip of the curved portion.

2. The main internal mold has a peripheral portion that faces the main direction outward from the inner excess material forming surface, The sub-type has a surface that faces the main direction with respect to the peripheral portion of the main internal type and has a gap in the main direction between it and the peripheral portion. The compression mold according to claim 1, wherein the main internal mold and the sub-mold are formed such that the end of the molded excess material has a gap in the main direction between it and the surrounding portion of the main internal mold.

3. The inner excess material forming surface of the main inner mold is formed in a shape that shares a common surface line at the boundary with the inner forming surface of the main inner mold. The second sub-molding surface of the sub-mold is connected to the first sub-molding surface of the sub-mold, The compression mold according to claim 1, wherein the inner excess material molding surface and the second sub-molding surface are configured to allow molding with the excess material connected to the tip of the curved portion of the molded body, and to allow molding so that the excess material extends in the main direction.

4. The inner excess material forming surface of the main inner mold is formed to be at an angle from the inner forming surface of the main inner mold and to extend in a direction away from the outer forming surface of the main outer mold in the secondary direction. The second sub-molding surface of the sub-mold is connected to the first sub-molding surface of the sub-mold, The compression mold according to claim 1, wherein the inner excess material molding surface and the second sub-molding surface are configured to allow molding with the excess material connected to the tip of the curved portion of the molded body, and to allow molding so that the excess material extends in a direction different from the main direction.

5. The compression mold according to claim 4, wherein the inner excess material molding surface and the second sub-molding surface are configured to mold the excess material portion so that it extends in a direction parallel to the sub-direction.

6. The compression mold according to claim 4, wherein the inner excess material molding surface and the second sub-molding surface are configured to mold the excess material portion in a direction having an angle with the main direction and the sub-direction.

7. The inner excess material forming surface of the main inner mold is formed discontinuously from the inner forming surface of the main inner mold, and is formed at a position further from the outer forming surface of the main outer mold than the inner forming surface in the secondary direction. The second sub-molding surface of the sub-mold is formed discontinuously from the first sub-molding surface of the sub-mold. The inner molding surface of the main mold and the second sub-molding surface of the sub-mold are configured to be cut by shearing the material. The compression mold according to claim 1, wherein the inner excess material molding surface and the second sub-molding surface are configured to mold the excess material at a position spaced apart from the tip of the curved portion of the molded body.

8. The compression mold according to claim 7, wherein, in the completed state of molding the outer surface of the tip of the curved portion, the distance between the second sub-molding surface and the inner molding surface in the sub-direction is set to be shorter than the maximum opposing distance between the inner molding surface and the first sub-molding surface.

9. A method for manufacturing a molded body having a curved portion at its periphery, using a compression mold according to any one of claims 1 to 6, for forming a convex curved surface on the outer surface of the tip of the curved portion, The material is placed between the inner molding surface of the main inner mold and the outer molding surface of the main outer mold. After arranging the material, the main internal mold and the main external mold are moved relative to each other in the main direction, thereby positioning a portion of the material by the main internal mold and the main external mold. With the material positioned by the main internal mold and the main external mold, the tip of the material is compressed by moving the sub-mold relative to the main internal mold in the sub-direction, thereby forming the tip of the curved portion and the excess material. A method for manufacturing a molded body using a compression mold, comprising cutting the curved portion at the boundary between the tip of the curved portion and the excess material portion, thereby separating the excess material portion from the tip of the curved portion.

10. A method for manufacturing a molded body having a curved portion on its periphery, using a compression mold according to claim 7 or 8, for forming a convex curved surface on the outer surface of the tip of the curved portion, The material is placed between the inner molding surface of the main inner mold and the outer molding surface of the main outer mold. After arranging the material, the main internal mold and the main external mold are moved relative to each other in the main direction, thereby positioning a portion of the material by the main internal mold and the main external mold. A method for manufacturing a molded body using a compression mold, wherein, with the material positioned by the main internal mold and the main external mold, the tip of the material is compressed by moving the sub-mold relative to the main internal mold in the sub-direction to form the tip of the curved portion and the excess material portion, and the sub-mold is cut at the boundary between the tip of the curved portion and the excess material portion by moving the sub-mold relative to the main internal mold in the sub-direction to separate the excess material portion from the tip of the curved portion.

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