Molds and molded products

Abstract

To provide a mold device that allows a nest to be replaced without reversing a mold and that can produce a molded product with various sizes and shapes by using one mold, and a molded product produced using the mold device.SOLUTION: There is provided a mold device, comprising: a pair of upper and lower molds; a first nest; and a second nest. The mold device is configured in that: the upper mold has a first through hole with a reversely convex cross section in which a first flat part forming a step is formed; the first nest includes a first enlarged diameter part that has a diameter wider than other parts and engages with the first flat part when placed in the first through hole; the second nest includes: a nest main body; a rod-shaped extrusion pin for extruding the molded product; a first extrusion plate for moving the extrusion pin; and a support member, and can be replaced integrally without removing the nest main body, the push-out pin, the first push-out plate, and the support member when attached to and detached from the lower mold.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a mold device capable of detachably attaching and detaching inserts, and a molded product molded using the mold device.

Background Art

[0002] Conventionally, as a mold device for molding a resin material, a mold device 102 as shown in FIG. 7 has been known. Here, the mold 104 includes an upper mold plate 104a and a lower mold plate 104b, and has a structure that can be opened and closed between a closed state shown in FIG. 7(a) and an open state shown in FIG. 7(b).

[0003] Also, inside the mold device 102, an insert 106 that can be detachably fitted into the mold device 102 as a separate part is arranged. Such an insert 106 is configured to form a molding space 108 for molding a molded product (not shown) between a concave insert 106a and a convex insert 106b in the closed state.

[0004] And extrusion pins 110 are arranged vertically through the lower mold plate 104b and the convex insert 106b. By raising the extrusion plate 112 in the open state, the molded product in the molding space 108 is extruded and taken out from the mold device 102.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, the conventional mold apparatus 102 described above had the problem that it was time-consuming to replace the insert 106. For example, when replacing the recessed insert 106a (see Figure 8(a)) fixed to the upper mold plate 104a, in order to prevent the recessed insert 106a from falling, it is necessary to first invert the upper mold plate 104a (mold inversion) as shown in Figure 8(b), and then remove the fixing bolts 114 as shown in Figure 8(c). Next, as shown in Figure 9(a), after removing the recessed insert 106a, a new recessed insert 106a' for molding a molded product of a different size or shape is fixed to the upper mold plate 104a, and then, as shown in Figure 9(b), the fixing bolts 114 are reattached and the mold is inverted again, requiring a series of operations.

[0007] On the other hand, when replacing the protrusion insert 106b (see Figure 10(a)) fixed to the lower mold plate 104b, first, as shown in Figure 10(b), the ejection pin 110 and fixing bolt 116 are removed from the lower mold plate 104b. Next, as shown in Figure 11(a), it is necessary to fix a new protrusion insert 106b' to the lower mold plate 104b for molding a product of a different size or shape.

[0008] Here, as shown in Figure 11(b), if another protrusion insert 106b' is newly fixed to the lower mold plate 104b, the position of the ejection pin 110 will not match that of the original protrusion insert 106b.

[0009] Therefore, with conventional mold devices 102, when molding molded products of different sizes and shapes, the lower mold plate 104b cannot be shared, and one lower mold plate 104b is required for each molded product of a single size and shape, which leads to increased costs. Furthermore, while cassette-type molds are known for small injection molding (see, for example, Patent Document 1), their strength is insufficient, making them difficult to apply to large-scale molding or press molding.

[0010] The object of the present invention is to provide a mold device that allows inserts to be replaced without mold inversion and that can produce molded products of various sizes and shapes with a single mold, and to provide molded products formed using the mold device. [Means for solving the problem]

[0011] According to the mold apparatus of this embodiment, A pair of upper and lower molds that can be opened and closed, A first insert that is interchangeably attached to the upper mold, A second insert that is interchangeably attached to the lower mold and A mold apparatus equipped with, The upper mold has a first through-hole with an inverted convex cross-section, in which a first planar portion forming a step is formed. The first insert has a wider diameter than the other parts and is provided with a first enlarged diameter portion that engages with the first flat portion when placed in the first through hole. The second insert comprises an insert body, a rod-shaped ejection pin for extruding a molded product, a first ejection plate for moving the ejection pin, and a support member, and is characterized in that the insert body, the ejection pin, the first ejection plate, and the support member can be replaced integrally without removing them when attaching or detaching it from the lower mold.

[0012] In other words, by designing the mold device in this way, inserts can be replaced without having to reverse the mold, and molded products of various sizes and shapes can be produced with a single mold. Furthermore, since the same mold can be used to produce molded products of various sizes and shapes, costs can be reduced. In addition, by adopting a simple structure in which the insert itself is replaced, sufficient strength can be maintained, making it applicable to large-scale molding and press molding requiring high pressure.

[0013] Furthermore, according to the mold apparatus of this embodiment, The first insert is characterized in that, when mounted on the upper mold, its upper end is exposed from the upper mold. This allows inserts to be replaced without having to reverse the mold.

[0014] Also, according to the mold device of the present embodiment, the lower mold includes a common extrusion plate formed by laminating a first extrusion plate that is exchanged together with the second nested member and a second extrusion plate that is not exchanged together with the second nested member. Thereby, the extrusion pin can be surely extruded by the second extrusion plate, and since there is no need to exchange the second extrusion plate, the burden of the nested member exchange work can be reduced.

[0015] Also, the mold device of the present embodiment is characterized by being used for press molding. That is, the present invention is preferably used for a press molding mold device.

[0016] The molded product of the present embodiment is obtained by press molding using the above-described mold device. Examples of the use of such a molded product include large flat-shaped members such as a bathroom floor pan, a bathtub apron, a bathroom counter, a wall panel, a ceiling material for a vehicle, an automobile under cover, a pedestal, a desk, and a bench.

Effect of the Invention

[0017] According to the present invention, it is possible to provide a mold device capable of exchanging the nested members without going through mold inversion and producing molded products of various sizes and shapes with a single mold, and to provide a molded product using the mold device.

Brief Description of the Drawings

[0018] [Figure 1] It is a schematic diagram showing the open / closed state of the press molding mold device according to the embodiment. [Figure 2] It is a diagram showing the process of removing the fixing bolts from the first nested member in the press molding mold device according to the embodiment. [Figure 3]In the mold device for press molding according to the embodiment, it is a diagram showing the process of exchanging the first insert with another first insert for molding molded products of different sizes and shapes. [Figure 4] In the mold device for press molding according to the embodiment, it is a diagram showing the preparation stage of removing the second insert from the lower mold. [Figure 5] In the mold device for press molding according to the embodiment, it is a diagram showing the process of exchanging the second insert with another second insert for molding molded products of different sizes and shapes. [Figure 6] In the mold device for press molding according to the embodiment, it is a schematic diagram explaining the state where the extrusion pins protrude above the second insert by raising the extrusion plate. [Figure 7] It is a schematic diagram showing the open and closed states of a conventional mold device. [Figure 8] In the conventional mold device, it is a diagram showing the process of removing the fixing bolts by inverting the upper mold. [Figure 9] In the upper mold of the conventional mold device, it is a diagram showing the process of exchanging the recessed insert with another recessed insert for molding molded products of different sizes and shapes. [Figure 10] In the conventional mold device, it is a diagram showing the process of removing the extrusion pins from the lower mold. [Figure 11] In the lower mold of the conventional mold device, it is a diagram showing the process of exchanging the protruding insert with another protruding insert for molding molded products of different sizes and shapes.

Embodiments for Carrying Out the Invention

[0019] Hereinafter, referring to the drawings, a mold device for press molding according to an embodiment of the present invention will be described. FIG. 1(a) is a schematic diagram showing the closed state of the mold device 2 for press molding, and FIG. 1(b) is a schematic diagram showing its open state. As shown in FIGS. 1(a) and 1(b), the mold device 2 for press molding includes a pair of mold halves 4 that can be opened and closed, consisting of an upper mold half 4a and a lower mold half 4b, and a pair of inserts 6 that are removably attached inside the mold halves 4 respectively and can be exchanged.

[0020] The insert 6 includes a first insert 6a, which is a concave insert fitted into the upper mold 4a, and a second insert 6b, which is a convex insert fitted into the lower mold 4b. In the closed state, a molding space 9 for molding a molded product (not shown) is formed between the first insert 6a and the second insert 6b.

[0021] The upper mold 4a has a first through-hole 5 in the center into which the first insert 6a is fitted, and this first through-hole 5 has an inverted convex cross-section with a wider diameter at its upper end. Therefore, a first flat portion 5a forming a step is formed above the first through-hole 5. In this embodiment, diameter does not necessarily refer to the diameter of a cylinder, but is a concept that also includes the width of a rectangular tube.

[0022] The first insert 6a penetrates the upper mold 4a through the first through hole 5, and its upper end is exposed above the press molding die device 2. The first insert 6a also has an inverted convex cross-section with a concave center, and above it is a first enlarged diameter portion 6x which has a wider diameter than the rest of the insert.

[0023] Therefore, the first insert 6a is attached to the upper mold 4a by engaging the first enlarged diameter portion 6x with the first flat portion 5a of the upper mold 4a and fixing the first enlarged diameter portion 6x to the first flat portion 5a with a bolt 8.

[0024] Furthermore, since the press molding die apparatus 2 requires a high mold temperature, steam temperature control is necessary. For this reason, the first insert 6a is provided with a connection part (not shown) for connecting a hose (circuit) of a steam temperature controller (not shown). As such a connection part, for example, one that can be connected by combining a socket (hose side) and a plug (insert 6 side) is used. Specifically, it is preferable to use a coupler (registered trademark) manufactured by Nitto Kohki as the connection part.

[0025] In this way, by connecting the socket and plug together, the sealing function of the connection can be completed within the range of the first insert 6a, and problems with deterioration of sealing performance can be prevented when replacing the first insert 6a.

[0026] The lower mold 4b comprises a lower mold body 10, a spacer block 12 that forms a space for moving the extrusion plate 20 (described later), and a base 14. The lower mold body 10 also has a second through-hole 16 in the center for fitting the second insert 6b. Because the second through-hole 16 has an inverted convex shape, a second flat portion 16a that forms a step is formed above the second through-hole 16.

[0027] The second insert 6b comprises a second insert body 17, a rod-shaped ejection pin 18 for extruding the molded product, a first ejection plate 20a (described later) for moving the ejection pin 18, and a support member 21 as a pressure receiving pin for supporting the second insert body 17.

[0028] Here, the second insert body 17 also penetrates the lower mold body 10 through the second through hole 16 and has a second enlarged diameter portion 6y that is wider in diameter than the other parts. For this reason, the second insert body 17 is attached to the lower mold body 10 by engaging the second enlarged diameter portion 6y with the second flat portion 16a of the lower mold body 10 and fixing the second enlarged diameter portion 6y to the second flat portion 16a with a bolt 8. The second insert body 17 also has a connection portion similar to that of the first insert 6a.

[0029] The extrusion plate 20 is constructed by stacking a first extrusion plate 20a through which the extrusion pin 18 passes and a second extrusion plate 20b that supports the lower end of the extrusion pin 18, both of which function as actuators for moving the extrusion pin 18 (see Figure 6). The first extrusion plate 20a is included in the second insert 6b and is replaced together with the second insert 6b, but the second extrusion plate 20b is not included in the second insert 6b and is not replaced together with the second insert 6b.

[0030] In this way, by making the extrusion plate 20 a double structure, the second extrusion plate 20b can reliably push out and retract the extrusion pin 18, and the need to replace the second extrusion plate 20b is eliminated, thereby reducing the burden of replacing the insert 6.

[0031] The support members 21 have the function of preventing the second insert body 17 from being distorted or broken by the molding pressure, and have a cylindrical shape with a diameter of approximately 50 mm to 150 mm. Furthermore, it is preferable to arrange the support members 21 in multiple locations in a balanced manner, for example, at intervals of approximately 100 mm to 300 mm, so as not to overlap with the positions of the ejection pins 18.

[0032] Next, the procedure for replacing the first insert 6a in the upper mold 4a will be described. First, as shown in Figure 2(a), the bolts 8 are removed from the upper mold 4a to which the first insert 6a is attached (see Figure 2(b)). Next, as shown in Figure 3(a), the first insert 6a is suspended by a crane (not shown) and lifted from the upper mold 4a.

[0033] Next, another first insert 6a' for molding a molded product of a different size or shape from the first insert 6a is suspended by a crane and lowered into the first through-hole 5 of the upper mold 4a. With the first enlarged diameter portion 6x engaged with the first flat portion 5a, the first insert 6a' is fixed to the upper mold 4a with bolts 8 (see Figure 3(b)). In Figure 3, an example is shown where the other first insert 6a' is a product used to manufacture a molded product of a smaller size or shape than the first insert 6a. However, the other first insert 6a' may also be a product used to manufacture a molded product of a larger size or shape than the first insert 6a.

[0034] Thus, because the first insert 6a has an inverted convex cross-section and the upper mold 4a has a first through-hole 5 with a step at its upper end where the diameter is widened, the first insert 6a can be easily replaced with another first insert 6a' without reversing the mold by engaging the first insert 6a with the step in the upper mold 4a.

[0035] Next, the procedure for replacing the second insert 6b in the lower mold 4b will be described. First, as shown in Figure 4(a), the bolts 8 are removed from the second insert 6b attached to the lower mold body 10 (see Figure 4(b)). Next, as shown in Figure 5(a), the second insert 6b is suspended by a crane (not shown) and lifted up from the lower mold body 10. The second insert 6b is lifted up as a single unit, including the second insert body 17, the ejection pin 18, the first ejection plate 20a, and the support member 21. Meanwhile, the second ejection plate 20b remains on the base 14 of the lower mold 4b.

[0036] Next, another second insert 6b' for molding a product of a different size or shape from the second insert 6b is suspended by a crane and lowered into the second through-hole 16 of the lower mold body 10. With the second enlarged diameter portion 6y engaged with the second flat portion 16a, the other second insert 6b' is fixed to the lower mold body 10 with bolts 8 (see Figure 5(b)). Although Figure 5 illustrates a case where the other second insert 6b' is used to manufacture a product of a smaller size or shape than the second insert 6b, the other second insert 6b' can be any product of a different size or shape from the second insert 6b, as explained in the case of the first insert 6a.

[0037] Thus, because the second insert 6b includes the second insert body 17, the ejection pin 18, the first ejection plate 20a, and the support member 21, the second insert 6b can be integrally replaced with another second insert 6b'. This eliminates the problem of misalignment of the ejection pin 18 when molding molded products of different sizes and shapes (see Figure 11(b)). As a result, the lower mold 4b can be shared, and molded products of various sizes and shapes can be manufactured with a single mold, thereby achieving cost savings.

[0038] Furthermore, after the second insert 6b is replaced and molding is complete, as shown in Figure 6, the extrusion plate 20 is raised, causing the extrusion pins 18 to protrude above the second insert 6b', and the molded product is removed from the second insert 6b'.

[0039] According to this embodiment of the invention, a press molding die device 2 can be provided that allows the insert 6 to be replaced without undergoing die inversion, and that can produce molded products of various sizes and shapes with a single die. Furthermore, by adopting a simple structure in which the insert 6 itself is replaced, the insert 6 and the die 4 can maintain sufficient strength, making it possible to apply the device to large-scale molding and press molding.

[0040] Furthermore, in conventional mold devices 102 for molding resin materials (see Figure 7), the connection part for connecting the hose (circuit) was provided on the outside of the insert 106, and the sealing function of the insert 106 was achieved by attaching an O-ring to the end of the insert 6. However, in this case, it was necessary to remove the water from the inlet and outlet of the hose (circuit) each time the insert 106 was replaced. In addition, there was a problem that the O-ring deteriorated as the mold temperature rose, reducing the sealing function of the insert 106.

[0041] However, according to the embodiment of the invention, by connecting the socket and plug together, the sealing function of the connection can be completed within the range of the insert 6, and the risk of O-ring deterioration is eliminated. Therefore, the sealing function when replacing the insert 6 can be improved. In addition, the effort of removing water can be eliminated, making it easier to replace the insert 6.

[0042] In the above-described embodiment, the upper mold 4a is shown as the fixed mounting plate and the lower mold 4b as the movable mounting plate. However, the upper mold 4a may be the movable mounting plate and the lower mold 4b may be the fixed mounting plate. Of course, either mold 4 can be the upper mold or the lower mold.

[0043] Furthermore, in the above-described embodiment, the support member 21 does not necessarily have to be cylindrical, and can be replaced with a rectangular prism or the like, as long as it has a supporting function. Also, the spacing between the support members 21 is not limited to a pitch of 100 mm to 300 mm.

[0044] Furthermore, although the above-described embodiment illustrates a press molding die device 2 as the die device, the present invention does not exclude injection molding dies. Furthermore, in the above-described embodiment, thermoplastic resins or thermosetting resins are used as the molding material. It is particularly suitable for sheet molding compound molding of large thermosetting resins.

[0045] Examples of applications for molded products manufactured using the above-described mold apparatus include large flat-shaped components such as bathroom floor pans, bathtub aprons, bathroom counters, wall panels, vehicle ceiling materials, automobile undercovers, pedestals, desks, and benches. [Explanation of Symbols]

[0046] 2. Press molding die apparatus 4 molds 4a upper mold 4b Lower mold 5. First through hole 5a 1st plane part 6 nesting 6a First nesting 6b Second nesting 6x First enlarged section 6y 2nd enlarged diameter section 8 volts 9 Molding space 10 Lower body 12 Spacer Blocks 14 Base 16. Second through hole 16a 2nd plane part 17. Second nesting body 18 Extrusion pins 20 Extrusion Plates 20a First extrusion plate 20b Second extrusion plate 21 Support member 102 Mold equipment 104 molds 104a Upper template 104b Lower template 106 nesting 106a Recessed insert 106b Convex nesting 108 molding space 110 Extrusion Pins 112 Extrusion Plate 114 Fixing bolts 116 Fixing bolts

Claims

1. A pair of upper and lower molds that can be opened and closed, A first insert that is interchangeably attached to the upper mold, A second nesting element that is interchangeably attached to the lower mold and A mold apparatus equipped with, The upper mold has a first through-hole with an inverted convex cross-section, on which a first flat portion constituting a step is formed. The first insert has a wider diameter than the other parts and is provided with a first enlarged diameter portion that engages with the first flat portion when placed in the first through hole, and the first insert can be attached and detached by moving it vertically without inverting the upper mold. The mold apparatus is characterized in that the second insert includes an insert body, a rod-shaped ejection pin for extruding a molded product, a first ejection plate for moving the ejection pin, and a support member, and that the insert body, the ejection pin, the first ejection plate, and the support member can be replaced integrally without removing them when attaching or detaching the insert to the lower mold.

2. The mold apparatus according to claim 1, characterized in that when the first insert is mounted on the upper mold, its upper end is exposed from the upper mold.

3. The mold apparatus according to claim 1 or 2, characterized in that the lower mold comprises a common extrusion plate formed by stacking the first extrusion plate, which is replaced together with the second insert, and the second extrusion plate, which is not replaced together with the second insert.

4. The mold apparatus according to claim 1, characterized in that it is used for press molding.

5. A molded product obtained by press molding using the mold apparatus described in claim 1.

Images