Mold apparatus and method for manufacturing foamed resin molded products

Abstract

To provide a more compact mold device.SOLUTION: There is provided a mold device that has a first mold including a first surface extending in a first direction and a second surface extending in a second direction intersecting the first direction; and a second mold including a third surface extending in the first direction and a fourth surface extending in the second direction, and is configured to form a cavity by closing the first mold and the second mold. The mold device comprises: a first fixing member fixed to the third surface; and a first displacement portion displacing between a first pressing position that is rotatably supported by a first shaft extending in the first direction and presses the first fixing member in a third direction intersecting the first direction and the second direction, and a first release position for releasing the pressure. The first fixing member has a receiving portion that protrudes in the first direction beyond the second surface or the fourth surface. The first displacement portion has a pressing portion that swings along the second direction between the first pressing position and the first release position and presses the receiving portion at the first pressing position.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a mold device and a method for manufacturing a foamed resin molded product using this mold device.

Background Art

[0002] Conventionally, a mold device for a foam molding die having an upper die and a lower die divided in the vertical direction is known. Such a foam molding die manufactures a foam by foaming a foaming raw material in a cavity formed in a state where the upper die and the lower die are closed.

[0003] In such a mold device, the ends of the upper die and the lower die are clamped by a clamping mechanism (see, for example, Patent Document 1). By clamping the upper die and the lower die in this way, the gap around the cavity is closed, preventing the foamed resin raw material from flowing out around the cavity and generating burrs on the foam.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In such a mold mechanism, since the clamping mechanism swings, a space corresponding to the swing of the clamping mechanism is required. The present disclosure provides a more compact mold device.

Means for Solving the Problems

[0006] The mold apparatus according to this disclosure comprises a first mold including a first surface extending in a first direction and a second surface extending in a second direction intersecting the first direction, and a second mold including a third surface extending in the first direction and a fourth surface extending in the second direction, and is a mold apparatus that closes the first mold and the second mold to form a cavity. The mold apparatus comprises a first fixing member fixed to the third surface, and a first displacement part rotatably supported on a first axis extending in the first direction, which displaces between a first pressing position that presses the first fixing member in a third direction intersecting the first and second directions, and a first release position that releases the pressing. The first fixing member has a receiving portion that protrudes in the first direction more than the second surface or the fourth surface. The first displacement part swings along the second direction between the first pressing position and the first release position, and has a pressing portion that presses the receiving portion at the first pressing position.

[0007] Furthermore, the method for manufacturing a foamed resin molded product according to this disclosure involves introducing a foamed resin raw material into the cavity formed by the mold device, and displacing the first fixing member to the first pressing position to foam and harden the foamed resin raw material.

[0008] In this mold device, the first displacement part oscillates along the second direction in which the second surface extends, pressing against the receiving part. This allows for a more compact mold device. Furthermore, using such a mold device to manufacture foamed resin molded products, the more compact mold device can suppress the generation of burrs in the foamed resin molded products. [Effects of the Invention]

[0009] This disclosure provides a more compact mold apparatus and a method for manufacturing foamed resin molded products using this mold apparatus. [Brief explanation of the drawing]

[0010] [Figure 1] A side view of a mold apparatus in the first embodiment of this disclosure. [Figure 2] A top view of a mold apparatus in the first embodiment of this disclosure. [Figure 3] Front view of a mold apparatus in the first embodiment of this disclosure. [Figure 4] An enlarged view of the first lever portion in the first embodiment of the present disclosure. [Figure 5] An enlarged view of the second lever portion in the first embodiment of this disclosure. [Figure 6] A side view of a mold apparatus in a second embodiment of the present disclosure. [Figure 7] Front view of a mold apparatus in a second embodiment of the present disclosure. [Figure 8] An enlarged view of the third lever portion in the second embodiment of the present disclosure. [Figure 9] A side view of a mold apparatus in another embodiment of the present disclosure. [Modes for carrying out the invention]

[0011] <First Embodiment> Hereinafter, a first embodiment of the present disclosure will be described with reference to the drawings. As shown in Figures 1, 2, and 3, the mold apparatus 1 has a lower mold (an example of a first mold) 2 and an upper mold (an example of a second mold) 4. The mold apparatus 1 closes the lower mold 2 and the upper mold 4 to form a cavity 6. The mold apparatus 1 is an apparatus that injects foamed resin raw material into the cavity 6 and foams and hardens the foamed resin raw material to form a foamed resin molded body. In this embodiment, the foamed resin raw material is a foamed resin raw material obtained by mixing liquid A, which is mainly polyol, and liquid B, which is mainly isocyanate. The cavity 6 is formed in a shape that matches, for example, an energy absorber used in an automobile. However, the cavity 6 can be made into a variety of shapes.

[0012] The lower mold 2 and upper mold 4 are roughly rectangular parallelepiped structures that extend in the X direction (an example of the first direction), the Y direction (an example of the second direction), and the Z direction (an example of the third direction). The X, Y, and Z directions are orthogonal to each other. The lower mold 2 has a lower mold front (an example of the first surface) 2a and a lower mold back (an example of the first surface) 2b that extend in the X and Z directions and extend in the X direction, a lower mold right side (an example of the second surface) 2c and a lower mold left side (an example of the second surface) 2d that extend in the Y and Z directions and extend in the Y direction, and a lower mold top surface 2e and a lower mold bottom surface 2f that extend in the X and Y directions and extend in the Y direction. The upper mold 4 similarly has an upper mold front (an example of a third surface) 4a and an upper mold back (an example of a third surface) 4b that expand in the X and Z directions and extend in the X direction, an upper mold right side (an example of a fourth surface) 4c and an upper mold left side (an example of a fourth surface) 4d that expand in the Y and Z directions and extend in the Y direction, and an upper mold top surface 4e (and upper mold bottom surface 4f) that expands in the X and Y directions and extends in the Y direction. Figure 1 shows the lower mold left side surface 2d and the upper mold left side surface 4d. Figure 2 shows the upper mold top surface 4e. The cavity 6 is formed by recesses formed on either the lower mold top surface 2e and the upper mold bottom surface 4f, or both. When the mold is closed, the upper surface of the lower mold 2 comes into close contact with the lower surface of the upper mold 4, forming the cavity 6. Note that the direction of expansion and extension of each surface of the lower mold 2 and upper mold 4 are not limited to these. The direction in which each surface of the lower mold 2 and upper mold 4 expands and extends may be appropriately changed, for example, to match the shape of the cavity 6.

[0013] The mold apparatus 1 includes a frame 8 that supports the lower mold 2 and the upper mold 4. As shown in Figures 1 to 3, the frame 8 has a lower frame 8a and an upper frame 8b. The lower frame 8a extends in the Y direction along the lower surface 2f of the lower mold and supports the lower mold 2 by being fixed to the lower surface 2f of the lower mold. The upper frame 8b extends in the Y direction along the upper surface 4e of the upper mold and is fixed to the upper surface 4e of the upper mold.

[0014] The mold device 1 includes at least one hinge (an example of a hinge member) 10 that rotatably connects the lower mold 2 and the upper mold 4 via a frame 8. The hinge 10 is disposed at a position different from the first fixing member 14 described later. As shown in FIGS. 1 and 2, in the present embodiment, the hinge 10 is disposed at the rear end of the frame 8 that is farther in the Y direction than the rear surface 2b of the lower mold and the rear surface 4b of the upper mold. The hinge 10 has a hinge shaft (an example of a shaft member) 10a. The hinge 10 is disposed at a position different from the first fixing member 14. The hinge 10 rotatably supports the lower frame 8a and the upper frame 8b around the hinge shaft 10a. Thereby, the upper mold 4 rotates in the Z direction with respect to the lower mold 2 about the hinge 10.

[0015] As shown in FIG. 2, in the present embodiment, the upper frame 8b is formed of a plurality of metal pipes having a rectangular cross section. The upper frame 8b is formed by arranging two pipes extending in the Y direction at intervals in the X direction and connecting the two pipes with a pipe extending in the X direction. Two hinges 10 are provided at intervals in the X direction and are fixed to the pipe extending in the X direction. As shown in FIG. 3, the lower frame 8a may have the same shape as the upper frame 8b.

[0016] Also, as shown in FIGS. 1 to 3, the upper frame 8b may include an opening / closing device 12. The opening / closing device 12 may receive a force from a person or a machine to move the upper mold 4 up and down. A plurality of such mold devices 1 are arranged on a circulating conveyor (circle line) such that the hinge 10 is on the inner peripheral side of the circle line. The opening / closing device 12 may be configured to operate by receiving a force from a guide rail (an example of a machine) provided along the circle line.

[0017] As shown in FIGS. 1 to 3, the mold device 1 includes at least one first fixing member 14 that receives a force from a first lever 16 described later and presses the upper mold 4 against the lower mold 2. The first fixing member 14 is fixed to at least one of the front surface 4a and the back surface 4b of the upper mold. The first fixing member 14 has a receiving portion 14a that protrudes in the X direction from the right side surface 2c and the left side surface 2d of the lower mold, or from the right side surface 4c and the left side surface 4d of the upper mold.

[0018] As shown in FIGS. 1 and 2, in the present embodiment, one first fixing member 14 is provided on each of the front surface 4a and the back surface 4b of the upper mold. As shown in FIG. 2, the first fixing member 14 is a member including a cylindrical member 14b made of metal and a bracket 14c. By fixing the cylindrical member 14b to the front surface 4a and the back surface 4b of the upper mold via the bracket 14c, the first fixing member 14 is fixed to the upper mold 4. As shown in FIGS. 2, 3, and 4, the receiving portion 14a is a portion that protrudes in the X direction from this cylindrical member 14b and has a diameter slightly smaller than that of the cylindrical member.

[0019] As shown in FIGS. 1 to 3, the mold device 1 includes a first lever (an example of the first displacement portion) 16. In the present embodiment, the first lever 16 is disposed on both the front and back surfaces of the lower mold 2 and the upper mold 4. Further, the first lever 16 is disposed on the left and right surfaces of the lower mold 2 and the upper mold 4, respectively. Therefore, a total of four first levers 16 are disposed in the present embodiment. The first levers 16 disposed on the left and right side surfaces of the front surface and the first levers 16 disposed on the left and right side surfaces of the back surface have the same structure and operation. Therefore, in the present embodiment, the structure and operation of the first lever 16 disposed on the left side surface of the back surface will be described.

[0020] The first lever 16 is rotatably supported on a first shaft 16a that is supported by the front surface 2a and back surface 2b of the lower mold and extends in the X direction. As shown in Figures 1 and 4, the first lever 16 swings and displaces in the Y direction about the first shaft 16a. Specifically, as shown in Figure 4, the first lever 16 displaces between a first pressing position P1 and a first release position L1. When the first lever 16 is in the first pressing position P1, it presses the receiving portion 14a in the Z direction. When the first lever 16 is in the first release position L1, it releases the pressure.

[0021] Specifically, the first lever 16 has a first arm 16b having an upper end, a lower end, and an intermediate portion between the upper and lower ends. The first lever 16 is rotatably supported on a first shaft 16a at the intermediate portion of the first arm 16b. The first lever 16 further has a first pressing portion 16c formed at the upper end of the first arm 16b. When the first lever 16 is in the first pressing position P1, the first pressing portion 16c engages with the receiving portion 14a and presses the receiving portion 14a in the Z direction. When the first lever 16 is in the first release position L1, the first pressing portion 16c separates from the receiving portion 14a.

[0022] The first lever 16 further has a first rotation shaft 16d formed at the lower end of the first arm 16b. The first lever 16 is connected to the interlocking part 22, which will be described later, via the first rotation shaft 16d.

[0023] As shown in Figures 1 to 3 and Figure 5, the mold apparatus 1 includes a second fixing member 18. The second fixing member 18 is fixed to the right side 4c and left side 4d of the upper mold 4. As shown in Figures 1 and 2, in this embodiment, the second fixing member 18 is a cylindrical member having substantially the same shape as the receiving portion 14a that protrudes from the right side 4c and left side 4d of the upper mold. The position of the second fixing member 18 is near the center of the length of the upper mold 4 in the Y direction. This allows the first fixing member 14 and the second fixing member 18 to evenly press all four sides of the upper mold 4 in the Z direction.

[0024] The mold apparatus 1 further includes a second lever (an example of a second displacement part) 20. In this embodiment, one second lever 20 is positioned on both the right and left sides of the lower mold 2 and the upper mold 4. The second lever 20 positioned on the right side and the second lever 20 positioned on the left side have similar structures and operations. Therefore, in this embodiment, the structure and operation of the second lever 20 positioned on the left side will be described.

[0025] As shown in Figures 1 to 3, the second lever 20 is rotatably supported on a second shaft 20a that extends in the X direction and is supported on the right side 2c and left side 2d of the lower mold. As shown in Figures 1 and 5, the second lever 20 swings and displaces in the Y direction about the second shaft 20a. Specifically, as shown in Figure 5, the second lever 20 displaces between a second pressing position P2 and a second release position L2. When the second lever 20 is in the second pressing position P2, it presses the second fixing member 18 in the Z direction. When the second lever 20 is in the second release position L2, it releases the pressure.

[0026] Specifically, the second lever 20 has a second arm 20b having an upper end, a lower end, and an intermediate portion between the upper and lower ends. The second lever 20 is rotatably supported on a second shaft 20a at the intermediate portion of the second arm 20b. The second lever 20 further has a second pressing portion 20c formed at the upper end of the second arm 20b. When the second lever 20 is in the second pressing position P2, the second pressing portion 20c engages with the second fixing member 18 and presses the second fixing member 18 in the Z direction. When the second lever 20 is in the second release position L2, the second pressing portion 20c separates from the second fixing member 18.

[0027] The second lever 20 further has a second rotation shaft 20d formed at the lower end of the second arm 20b. The second lever 20 is connected to the interlocking part 22, which will be described later, via the second rotation shaft 20d. In this embodiment, the shape of the second lever 20 is the same as that of the first lever 16. This reduces the manufacturing cost of the mold device 1. Furthermore, the timing at which the first lever 16 presses the receiving part 14a and the timing at which the second lever 20 presses the second fixing member 18 are simultaneous. This allows all four sides of the upper mold 4 to be pressed simultaneously.

[0028] As shown in Figures 1 to 3, the mold apparatus 1 further includes the aforementioned interlocking section 22. The interlocking section 22 interlocks the first lever 16 and the second lever 20. As shown in Figures 2 and 3, in this embodiment, the interlocking section 22 has a right interlocking bar 22a extending in the Y direction, a left interlocking bar 22b extending in the Y direction, and a connecting bar 22c connecting the right interlocking bar 22a and the left interlocking bar 22b. The right interlocking bar 22a interlocks the first lever 16 and the second lever 20 located on the right side. The left interlocking bar 22b interlocks the first lever 16 and the second lever 20 located on the left side.

[0029] As shown in Figures 1 to 3, the interlocking section 22 is connected to the first lever 16 via a first rotating shaft 16d at its front and rear ends, and to the second lever 20 via a second rotating shaft 20d at its middle section. The connecting bar 22c is connected to an actuator 24, which will be described later. When the actuator 24 moves the connecting bar 22c in the Y direction, when the first lever 16 is in the first pressing position P1, the second lever 20 is in the second pressing position P2. When the first lever 16 is in the first release position L1, the second lever 20 is in the second release position L2.

[0030] The mold apparatus 1 further includes the actuator 24 described above. In this embodiment, the actuator 24 is a pneumatic cylinder. However, the actuator 24 may be of various types, such as electric. Also, in this embodiment, the actuator 24 is a device that moves the connecting bar 22c back and forth along the Y direction. However, any device that can operate the interlocking part 22 is acceptable as long as it is an actuator 24 of a type that can operate the interlocking part 22.

[0031] Next, the manufacturing method for the foamed resin molded product will be described. The foamed resin molded product is manufactured using the mold apparatus 1 described above.

[0032] As described above, the mold apparatus 1 has a cavity 6. First, the foamed resin raw material is put into the cavity 6 of the mold apparatus 1.

[0033] Next, the upper mold 4 is closed onto the lower mold 2.

[0034] Next, the actuator 24 is activated, moving the interlocking unit 22 so that the first lever 16 and the second lever 20 are set to the first pressing position P1 and the second pressing position P2, respectively. At this time, the first lever 16 and the second lever 20 move in conjunction with each other due to the action of the interlocking unit 22. In this embodiment, the timing of the first lever 16 moving to the first pressing position P1 and the timing of the second lever 20 moving to the second pressing position P2 are simultaneous.

[0035] The foamed resin raw material foams and hardens within cavity 6 to form a molded foamed resin article.

[0036] Next, the first lever 16 and the second lever 20 are set to the first release position L1 and the second release position L2, respectively.

[0037] Next, the upper mold 4 is opened from the lower mold 2, and the molded foamed resin body is removed from the cavity 6.

[0038] In this type of mold apparatus 1, the first lever 16 located on the back swings in the Y direction outward in the X direction of the right side 2c and left side 2d of the lower mold. By swinging in this manner, the first lever 16 can press the back of the upper mold 4 toward the lower mold 2. As a result, the required area on the back side of the mold apparatus 1 becomes more compact due to the space required for the swing of the first lever 16. Consequently, this mold apparatus 1 can be designed to be larger within the size of the frame 8, making it possible to handle larger molded products. As a result, a more compact mold apparatus 1 can be provided.

[0039] Furthermore, the second lever 20 also swings in the Y direction, similar to the first levers 16 on the back and front. That is, the first levers 16 on the back and front, and the second lever 20 swing in the same direction, allowing the four sides of the upper mold 4 to be pressed toward the lower mold 2. As a result, there are no levers that swing in the X direction, making the X-direction area of ​​the mold apparatus 1 more compact. Since the mold apparatus 1 for foamed resin molded products is placed in a row on a conveyor that forms a circular line, many mold apparatuses can be placed side by side by reducing the spacing between adjacent mold apparatuses 1. Therefore, this method of manufacturing foamed resin molded products using such a mold apparatus 1 can suppress the generation of burrs on the foamed resin molded products and improve production efficiency.

[0040] Furthermore, in this embodiment, the first lever 16 on the front is the same shape as the first lever 16 on the back. This reduces the manufacturing cost of the mold device 1.

[0041] <Second Embodiment> Hereinafter, a second embodiment of this disclosure will be described with reference to Figures 6, 7, and 8. In the second embodiment, only the differences from the first embodiment will be described. As shown in Figures 6 and 7, the structure of the first lever 216 on the front of the mold apparatus 201 differs from the first lever 16 of the first embodiment.

[0042] As shown in Figures 6 and 7, the mold apparatus 201 comprises a lower mold 202, an upper mold 204, a frame 208, a hinge 210, an opening / closing device 212, a first fixing member 214, a first lever 216, a second fixing member 218, a second lever 220, an interlocking unit 222, an actuator 224, a third fixing member 226, and a third lever 228. This embodiment differs from the first embodiment in that the first fixing member 14 and the first lever 16, which are located in front of the lower mold 2 and upper mold 4 in the first embodiment, are replaced by a third fixing member 226 and a third lever. Therefore, the configurations other than the third fixing member 226 and the third lever 228 are the same as in the first embodiment and will not be described.

[0043] The third fixing member 226 is a cylindrical member fixed to the upper mold front surface 204a of the upper mold 204. As shown in Figure 7, in this embodiment, two third fixing members 226 are arranged on the upper mold front surface 204a with a gap between them in the X direction.

[0044] As shown in Figures 6 and 7, the third lever 228 is fixed to the lower die front 202a and rotatably supported on a third axis 228a extending in the X direction. In this embodiment, two third levers 228 are arranged spaced apart in the X direction. The third lever 228 swings in the Y direction around the third axis 228a, similar to the first lever 216. As shown in Figure 8, the third lever 228 has a third arm 228b having an upper end, a lower end, and an intermediate portion between the upper and lower ends. The third arm 228b has two plate-like members and a plate-like third pressing portion 228c connecting these two plate-like members. The third lever 228 is rotatably supported on the third axis 228a at the intermediate portion of the third arm 228b. When the third lever 228 is in the third pressing position P3, the third pressing portion 228c engages with the third fixing member 226 and presses the third fixing member 226 in the Z direction. When the third lever 228 is in the third release position L3, the third pressing portion 228c separates from the third fixing member 226.

[0045] As shown in Figures 7 and 8, the third lever 228 further has a third pivot shaft 228d formed at the lower end of the third arm 228b. In this embodiment, the third pivot shaft 222d is a cylindrical member extending from the right interlocking bar 222a to the left interlocking bar 222b. The third lever 228 is connected to the right interlocking bar 222a and the left interlocking bar 222b via the third pivot shaft 228d.

[0046] Thus, even if the first lever 16 located on the front of the lower mold 2 and upper mold 4 is replaced with a third lever, the first lever 216, the second lever 220, and the third lever 228 will still swing in the same direction. This allows the four sides of the upper mold 4 to be pressed toward the lower mold 2 without the need for a lever that swings in the X direction.

[0047] As described above, this disclosure provides a more compact mold apparatus 1,201 and a method for manufacturing foamed resin molded products using this mold apparatus 1,201.

[0048] <Other Embodiments> Although embodiments of the present disclosure have been described above, the present disclosure is not limited to the embodiments described above, and various modifications are possible without departing from the spirit of the invention.

[0049] For example, in the first embodiment described above, an example in which two second levers 20 are arranged was used, but the number of second levers 20 may be appropriately changed according to the length of the lower mold 2 and the upper mold 4 in the Y direction.

[0050] Furthermore, in the first embodiment described above, the first lever 16 and the second lever 20 were actuated by the actuator 24, but the disclosure is not limited thereto. As shown in Figure 9, the mold device 1 may, for example, be provided with an input bar 300 extending in a direction intersecting the first arm 16b on the front first lever 16, and, similar to the opening and closing device 12, the input bar 300 may be actuated by force received from a person or a guide rail provided on the circle line. [Explanation of Symbols]

[0051] 1,201: Mold equipment 2,202: Lower mold 2a, 202a: Bottom mold front 2b: Back side of lower mold, 2c: Right side of lower mold, 2d: Left side, 2d: Left side of lower mold 2e: Upper surface of lower mold, 2f: Lower surface of lower mold 4,204: Upper mold 4a, 204a: Upper mold front, 4b: Upper mold back 4c: Right side of the upper mold, 4d: Left side of the upper mold, 4e: Top surface of the upper mold, 4f: Bottom surface of the upper mold 6: Cavity 10,210: Hinge 10a: Hinge axis 14,214: First fixing member 14a: Receiving part 16,216: First lever 16a: First axis, 16b: First arm, 16c: First pressing part, 16d: First rotation axis 18,218: Second fixing member 20,220: Second lever, 20a: Second axis, 20b: Second arm, 20c: Second pressing part, 20d: Second rotation axis 22,222: Interlocking part 24,224: Actuator L1: 1st release position, L2: 2nd release position P1: First pressing position, P2: Second pressing position

Claims

1. A mold apparatus comprising a first mold including a first surface extending in a first direction and a second surface extending in a second direction intersecting the first direction, a second mold including a third surface extending in the first direction and a fourth surface extending in the second direction, wherein the first mold and the second mold are closed to form a cavity, A first fixing member fixed to the third surface, A first displacement part is rotatably supported on a first shaft extending in the first direction, and displaces between a first pressing position that presses the first fixing member in a third direction intersecting the first and second directions, and a first release position that releases the pressing. Equipped with, The first fixing member has a receiving portion that protrudes in the first direction from the second surface or the fourth surface, The first displacement portion swings along the second direction between the first pressing position and the first release position, and has a pressing portion that presses the receiving portion at the first pressing position. Mold equipment.

2. A second fixing member fixed to the fourth surface, A second displacement part is rotatably supported on a second shaft extending in the first direction, and displaces between a second pressing position that presses the second fixing member in a third direction intersecting the first and second directions, and a second release position that releases the pressing. The first displacement part and the interlocking part that interlocks the second displacement part, Furthermore, The mold apparatus according to claim 1.

3. The system further includes an actuator for moving the aforementioned interlocking part. The mold apparatus according to claim 2.

4. The system further comprises a hinge member positioned at a different location from the first fixing member, having a shaft member, and supporting the first type and the second type so as to be rotatable around the shaft member. A mold apparatus according to any one of claims 1 to 3.

5. A method for manufacturing a foamed resin molded product, comprising introducing a foamed resin raw material into the cavity formed by the mold apparatus described in claim 1, and displacing the first fixing member to the first pressing position to foam and harden the foamed resin raw material.

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