Molding device and method for manufacturing molded article

Abstract

A molding device (1A) comprises: a mold (10) that is for molding a molded article provided with a body and protrusions partially protruding from the body, and that has a space for molding the body and has first recesses (21-24) connected to the space and for molding the protrusions; and a plurality of pressure-application mechanisms that are disposed at places between the first recesses (21-24), and that, when a molten resin is loaded in the space and the first recesses (21-24), applies pressure to the molten resin to supplementarily load the first recesses (21-24) with the molten resin.

Description

Molding device and method for manufacturing molded product

[0001] The present disclosure relates to a molding apparatus and a method for manufacturing a molded product.

[0002] Some molded products are manufactured by filling a mold with molten resin and then hardening the molten resin. In such molded products, the hardened resin shrinks more than the molten resin, which can cause depressions called sink marks. To prevent this, various molding devices have been developed.

[0003] For example, Patent Document 1 discloses that in a molding device equipped with a mold for molding a molded product having a convex portion that partially protrudes from a main body portion, the mold is provided with a first recess for molding the convex portion, a second recess for accommodating a member that extrudes molten resin when the molten resin is filled near the first recess, and a groove that connects the first recess and the second recess.

[0004] Japanese Patent Application Publication No. 9-104035

[0005] In the molding device described in Patent Document 1, there is a groove that connects the first recess and the second recess, which results in the molded product having a shape that differs from the shape originally intended to be produced, thereby reducing the design quality.

[0006] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a molding device and a method for manufacturing a molded product that can suppress the occurrence of sink marks and produce molded products with high design quality.

[0007] To achieve the above object, a molding apparatus according to the present disclosure includes a mold and a plurality of pressure mechanisms. The mold is for molding a molded product having a main body and a protrusion partially protruding from the main body, and includes a space for molding the main body and a first recess connected to the space for molding the protrusion. The plurality of pressure mechanisms are arranged at positions where the first recess is located between them, and when molten resin has filled the space and the first recess, they pressurize the molten resin to refill the first recess.

[0008] According to the configuration of the present disclosure, the multiple pressure mechanisms are arranged at locations where the first recesses are located between them, and when the molten resin fills the space and the first recesses, they pressurize the molten resin to replenish the molten resin into the first recesses. Therefore, even if the molten resin shrinks as it hardens, the molten resin still fills the first recesses. As a result, the occurrence of sink marks is suppressed. Furthermore, because there are no grooves, recesses, etc. communicating with the first recesses, the molded product has a high designability.

[0009] a perspective view of an exterior panel manufactured by a molding apparatus according to embodiment 1 of the present disclosure, when the front surface is facing up; a perspective view of an exterior panel manufactured by a molding apparatus according to embodiment 1 of the present disclosure, when the back surface is facing up; a cross-sectional view of the molding apparatus according to embodiment 1 of the present disclosure; an enlarged cross-sectional view of a part of a mold included in the molding apparatus according to embodiment 1 of the present disclosure; a cross-sectional view showing an example of a sink mark that occurs in a molded product molded with a mold that does not have a second recess; a bottom view showing the positions of a first recess and a second recess when the molding space of a mold included in the molding apparatus according to embodiment 1 of the present disclosure is viewed from the bottom side; a perspective view of multiple pressure devices included in the molding apparatus according to embodiment 1 of the present disclosure; an enlarged view of region VIII shown in FIG. 7; a flowchart of a method for manufacturing an exterior panel using the molding apparatus according to embodiment 1 of the present disclosure; a cross-sectional view of the molding apparatus when molten resin is extruded by an extrusion member close to the gate in a molten resin refilling step included in the method for manufacturing an exterior panel using the molding apparatus according to embodiment 1 of the present disclosure; FIG. 1 is a cross-sectional view of a molding device when molten resin is extruded with all extrusion members in a molten resin refilling step included in a manufacturing method for an exterior panel using a molding device; FIG. 2 is a bottom view showing a first modified example of a first recess and a second recess of a mold included in the molding device according to embodiment 1 of the present disclosure; FIG. 3 is a bottom view showing a third modified example of a first recess and a second recess of a mold included in the molding device according to embodiment 1 of the present disclosure and their arrangement; FIG. 4 is a bottom view showing a fourth modified example of a first recess and a second recess of a mold included in the molding device according to embodiment 1 of the present disclosure and their arrangement;

[0010] A molding apparatus and a method for manufacturing a molded product according to an embodiment of the present disclosure will be described in detail below with reference to the drawings. In the drawings, identical or equivalent parts are designated by the same reference numerals. In the Cartesian coordinate system XYZ shown in the drawings, when the plate surface of a plate-shaped molded product is oriented horizontally, the horizontal plane is the XY plane and the vertical direction is the Z axis. This coordinate system will be referenced as appropriate below.

[0011] (Embodiment 1) The molding device according to embodiment 1 is a device for manufacturing a plate-shaped panel used for the exterior of equipment. The configuration of the molding device will be described in detail below, taking as an example a case in which the panel is a flat exterior panel used for an air conditioner. First, the configuration of the exterior panel to be molded by the molding device will be described with reference to Figures 1 and 2.

[0012] Fig. 1 is a perspective view of an exterior panel 100 manufactured by a molding device according to embodiment 1, with the front surface facing up. Fig. 2 is a perspective view of the same exterior panel 100 with the back surface facing up.

[0013] As shown in Figures 1 and 2, the exterior panel 100 is formed in a flat plate shape. The thickness of the exterior panel 100 is constant throughout, except for the edge portions and localized portions within the plate surface. As shown in Figure 1, the front surface of the exterior panel 100 is flat and smooth to enhance the design of the air conditioner. In contrast, as shown in Figure 2, the back surface of the exterior panel 100 is provided with fitting portions 101-105 for attaching the exterior panel 100 to the air conditioner main body. As a result, the fitting portions 101-105 of the exterior panel 100 partially protrude from the other flat plate portions. The thickness of the exterior panel 100 is locally increased at the fitting portions 101-105.

[0014] The exterior panel 100 having such a shape is molded from resin such as polystyrene (PS), polypropylene (PP), acrylonitrile butadiene styrene (ABS), etc. The exterior panel 100 is also molded by injection molding.

[0015] In the injection molding method, first, the resin described above is filled in a molten state into the space of a mold for molding the exterior panel 100. Next, the molten resin filled into the space of the mold is cooled and hardened. Then, the molded product formed into the shape of the mold by the hardened molten resin is removed from the mold. In this way, the exterior panel 100 is molded. In the injection molding method, when the molten resin hardens, the volume of the hardened resin is smaller than the volume of the molten resin. In other words, the resin shrinks. For this reason, sink marks may occur in the molded product. For example, the areas of the exterior panel 100 where the fitting portions 101-105 are provided are thicker than other flat plate portions, and therefore sink marks are more likely to occur. If sink marks occur on the front surface of the areas where the fitting portions 101-105 are provided, the design of the exterior panel 100 will be reduced.

[0016] Therefore, in order to suppress the occurrence of sink marks, a forming device according to embodiment 1 is used in the manufacture of the exterior panel 100. Next, the configuration of the forming device will be described with reference to Figs.

[0017] FIG. 3 is a cross-sectional view of the molding apparatus 1A. FIG. 4 is an enlarged cross-sectional view of a portion of the mold 10 provided in the molding apparatus 1A. FIG. 5 is a cross-sectional view showing an example of a sink mark 200 that occurs in a molded product molded with a mold 10 that does not have the second recesses 31-35 and 41-45. FIG. 6 is a bottom view showing the positions of the first recess 21-25 and the second recesses 31-35 and 41-45 when the molding space 20 of the mold 10 is viewed from the bottom side. FIG. 7 is a perspective view of multiple pressure devices 30 provided in the molding apparatus 1A. FIG. 8 is an enlarged view of region VIII shown in FIG. 7.

[0018] Note that Figure 3 shows a conceptual shape of the molding apparatus 1A for ease of understanding. Hatching of some components has been omitted. Also, Figure 4 shows only some of the first recesses 21-25 and second recesses 31-35 and 41-45 of the mold 10. Furthermore, Figure 6 also shows the conceptual shapes of the first recesses 21-25 and second recesses 31-35 and 41-45 for ease of understanding their positional relationships. Figure 7 shows only a portion of the configuration of the pressure device 30. Note that, like Figure 4, the first recesses 25 and second recesses 35 and 45 have been omitted in Figures 10, 11, 16, and 18, which will be described later.

[0019] As shown in Figure 3, the molding device 1A includes a mold 10 having a molding space 20 for molding the exterior panel 100, and a plurality of pressure devices 30 that replenish molten resin during molding to suppress sink marks 200.

[0020] The mold 10 includes a cavity 11 attached to a fixed platen and a core 12 attached to a movable platen. In the mold 10, a mold clamping cylinder (not shown) moves the movable platen toward or away from the fixed platen based on the output of a controller 50, thereby opening and closing the mold 10.

[0021] Here, the controller 50 has a CPU (Central Processing Unit) 56 and a memory 57 shown in FIG. 3, and the CPU 56 executes a program stored in the memory 57 to perform various operations such as control of the mold clamping cylinder.

[0022] To explain the operation of the mold 10 in more detail, in the mold 10, a mold clamping cylinder is controlled by a controller 50. Based on the output of the controller 50, the mold clamping cylinder switches between a state in which the core 12 is in contact with the cavity 11 and a state in which the core 12 is separated from the cavity 11.

[0023] In the mold 10, with the core 12 in contact with the cavity 11, the cavity 11 and the core 12 form a molding space 20 shown in Figure 4 for molding the exterior panel 100. When this molding space 20 is formed, an injection device (not shown) fills molten resin from a gate 26 connected to the molding space 20. Then, the mold 10 molds the exterior panel 100 by hardening the molten resin.

[0024] As the molten resin hardens, it shrinks, which can result in the occurrence of sink marks 200 as shown in Figure 5. As described above, the portions of the exterior panel 100 shown in Figure 2 where the mating portions 101-105 are provided are thicker than the other flat plate portions, making them more susceptible to sink marks 200. The portions of the mold 10 that form these mating portions 101-105 are the first recesses 21-25 formed in the core 12, which are connected to the molding space 20 shown in Figures 4 and 6. In order to prevent the occurrence of sink marks 200 when the mating portions 101-105 are formed using these first recesses 21-25, the mold 10 is provided with a plurality of pressure devices 30 as shown in Figure 4.

[0025] Each of the pressure devices 30 is a device that applies pressure to the molten resin when the molten resin fills the molding space 20 of the mold 10 and hardens, thereby replenishing the molten resin into the first recesses 21-25. In order to replenishing the molten resin into the first recesses 21-25, the same number of pressure devices 30 as the first recesses 21-25 are incorporated into the mold 10.

[0026] Specifically, as shown in FIG. 4, second recesses 31-34 and 41-44 are provided in the core 12 of the mold 10 at positions where the first recesses 21-24 are located between them. Also, as shown in FIG. 6, second recesses 35 and 45 are provided in the core 12 at positions where the first recess 25 is located between them. More specifically, as shown in FIG. 4, the core 12 has the second recesses 31-34 and the second recesses 41-44, respectively, disposed on either side of the first recesses 21-24. That is, the second recesses 31-34 are disposed on the left side of the first recesses 21-24, respectively, and the second recesses 41-44 are disposed on the right side of the first recesses 21-24, respectively. Also, as shown in FIG. 6, the core 12 has the second recess 35 and the second recess 45, disposed on either side of the first recess 25. That is, when viewed from the same side as in FIG. 4 , the second recess 35 is disposed to the left of the first recess 25 , and the second recess 45 is disposed to the right of the first recess 25 .

[0027] In the core 12, the distance from each of the first recesses 21-25 to each of the second recesses 31-35 and the distance from each of the first recesses 21-25 to each of the second recesses 41-45 are several millimeters, for example, 0.8 to 3 mm. In other words, if the thickness of the exterior panel 100 is 2 to 3 mm, the distance is approximately 1 time that thickness. As a result, each of the first recesses 21-25 and each of the second recesses 31-35 or 41-45 are adjacent to each other at a close distance. Note that it is desirable that the distance from each of the first recesses 21-25 to each of the second recesses 31-35 and the distance from each of the first recesses 21-25 to each of the second recesses 41-45 be the same, but these distances may not be the same depending on the amount of molten resin extruded by the extrusion member 36 described below, and one distance may be greater than the other.

[0028] Note that, because Fig. 6 is a bottom view, the left-right direction in the figure is opposite to that in Fig. 4. As a result, in Fig. 6, the second recesses 31-35 are disposed to the right of the first recesses 21-25, respectively, and the second recesses 41-45 are disposed to the left of the first recesses 21-25, respectively. This positional relationship is not limited to this, and the second recesses 31-35 and the second recesses 41-45 may be interchanged.

[0029] As shown in FIG. 6, each of the second recesses 31-35 and its corresponding second recesses 41-45 have the same shape. As a result, they are bilaterally symmetrical. Specifically, the second recesses 31-35 and 41-45 have a rectangular bottom view or cross-sectional shape as shown in FIG. 6. As shown in FIG. 4, the second recesses 31-35 and 41-45 extend in the vertical direction while maintaining their rectangular shape. As a result, each of the second recesses 31-35 and its corresponding second recesses 41-45 have the same rectangular prism shape as each of the second recesses 31-35 and 41-45, as shown in FIGS. 4 and 8. As shown in FIG. 4, a rectangular prism-shaped extrusion member 36 is housed in each of the internal spaces to pressurize the molten resin when it is filled into the molding space 20 of the mold 10.

[0030] Each of the ejection members 36 is formed in the shape of an elongated rectangular prism having a thickness sufficient to allow it to slide within the second recesses 31-35 and 41-45. Each of the ejection members 36 is housed within the second recesses 31-35 and 41-45 with one end surface facing toward the molding space 20, i.e., facing upward. Furthermore, the ejection members 36 provided in adjacent second recesses 31-35 and 41-45 are connected at their other end surfaces, i.e., their lower end surfaces, by a connecting plate 37, as shown in FIGS. 4 and 7 . The connecting plate 37 is connected to a rod 38 that moves up and down by a hydraulic cylinder 39 shown in FIG. 4 . As a result, the ejection members 36 provided in adjacent second recesses 31-35 and 41-45 can be simultaneously moved up and down by the hydraulic cylinder 39, and can move to the same vertical position within the second recesses 31-35 and 41-45. As a result, the extrusion member 36, together with the second recesses 31-35, 41-45, realizes a pressurizing mechanism that pressurizes the molten resin when the molten resin is filled into the molding space 20.

[0031] The hydraulic cylinder 39 moves the rod 38 up and down based on the output of the controller 50 shown in FIG. 3. When the molding space 20 is filled with molten resin and the molten resin is hardening, the controller 50 causes the hydraulic cylinder 39 to extend the rod 38 upward, causing the extrusion member 36 to slide in the column axis direction of the square pillar of the second recesses 31-35, 41-45 shown in FIG. 4. As a result, the extrusion member 36 extrudes the molten resin into the molding space 20 and pressurizes the molten resin. At this time, the upper end face of the extrusion member 36 is perpendicular to the column axis of the square pillar, and is therefore horizontal. Therefore, the extrusion member 36 extrudes the molten resin evenly and sufficiently pressurizes the molten resin.

[0032] As described above, the first recesses 21-25 are located between the second recesses 31-35 and the second recesses 41-45, respectively. Furthermore, the second recesses 31-35 and the first recesses 21-25, respectively, are close to each other. Similarly, the second recesses 41-45 and the first recesses 21-25, respectively, are also close to each other. As a result, the pressurized molten resin flows into the first recesses 21-25, respectively, and is supplied to the first recesses 21-25, respectively. In other words, the molten resin is replenished into the first recesses 21-25, respectively.

[0033] In the molding device 1A, the molten resin is pressurized in this manner until the molten resin is completely hardened, thereby suppressing the occurrence of sink marks 200. Next, a method for manufacturing an exterior panel 100 using this molding device 1A will be described in detail with reference to FIGS.

[0034] Fig. 9 is a flowchart of a method for manufacturing an exterior panel 100 using the molding apparatus 1A according to embodiment 1. Fig. 10 is a cross-sectional view of the molding apparatus 1A when molten resin is extruded by the extrusion member 36 closest to the gate 26 in a molten resin replenishing step included in the manufacturing method for the exterior panel 100. Fig. 11 is a cross-sectional view of the molding apparatus 1A when molten resin is extruded by all of the extrusion members 36 in the molten resin replenishing step.

[0035] In the manufacturing method of the exterior panel 100 using the molding device 1A, as shown in FIG. 9, first, the molding space 20 of the mold 10 is formed (step S1).

[0036] More specifically, a clamping cylinder (not shown) moves the movable platen toward the fixed platen to close the mold 10. This brings the core 12 into contact with the cavity 11 shown in FIG. 4, thereby forming the molding space 20.

[0037] 9, the molding space 20 is filled with molten resin (step S2). More specifically, an injection device (not shown) fills the molding space 20 with molten resin through a gate 26 connected to the molding space 20. This fills the molding space 20 with molten resin. Thereafter, the injection device maintains the molding space 20 at a relatively low injection pressure.

[0038] Next, the molten resin is cooled while being held under the injection pressure (step S3), thereby hardening the filled molten resin.

[0039] Furthermore, when the cooling of the molten resin begins, molten resin is replenished in parallel with the cooling of the molten resin (step S4). This is because the volume of the molten resin shrinks as the molten resin cools, which may cause sink marks 200 to form in the exterior panel 100 when the exterior panel 100 is molded. Furthermore, in order to mold an exterior panel 100 with high design quality, it is necessary to suppress the sink marks 200. As described above, this replenishment of molten resin is performed on the first recesses 21-25 that form the fitting portions 101-105, which are partial protruding portions of the exterior panel 100.

[0040] Specifically, the molten resin is replenished into the first recesses 21-25 in accordance with the distance from the gate 26 to each of the first recesses 21-25. More specifically, the replenishment is performed at a timing that depends on the distance from the gate 26 to each of the first recesses 21-25.

[0041] As described above, the second recesses 31-35 and the corresponding second recesses 41-45, which are provided on either side of the first recesses 21-25, are provided with extrusion members 36 for extruding the molten resin in their internal spaces. When replenishing the molten resin in the first recesses 21-25, the extrusion of the extrusion members 36 is performed at a timing based on the distance from the gate 26 to the first recesses 21-25 corresponding to the second recesses 31-35, 41-45 that house the extrusion members 36.

[0042] For example, when the molding space 20 starts to be held at the injection pressure, none of the ejection members 36 housed in any of the second recesses 31-35 and 41-45 are extruding as shown in Fig. 4, but immediately thereafter, the ejection members 36 in the second recesses 35 and 45 located closest to the gate 26 and sandwiching the first recess 25 as shown in Fig. 6 are pushed in. For example, the ejection members 36 are pushed in until the bottom end surfaces of the ejection members 36 are flush with the inner wall surface of the molding space 20.

[0043] After a certain period of time has elapsed, for example, one second, the pushers 36 located inside the second recesses 33 and 34, which are located next closest to the gate 26 and sandwich the first recesses 23 and 24, respectively, and the corresponding second recesses 43 and 44, respectively, are pushed in as shown in FIG. 10 . The pushing amount is the same as above. After that, after another certain period of time has elapsed, for example, one second, the pushers 36 located inside the second recesses 31 and 32, which are located farthest from the gate 26 and sandwich the first recesses 21 and 22, respectively, and the corresponding second recesses 41 and 42, respectively, are pushed in as shown in FIG. 11 . The pushing amount in this case is also the same as above.

[0044] In this manner, the extrusion members 36 are pushed into the second recesses 31-35 and the corresponding second recesses 41-45, which are arranged on either side of the first recesses 21-25, in order of distance from the gate 26. For example, the controller 50 described above controls each of the hydraulic cylinders 39 to push the extrusion members 36 in this order. The reason for pushing the extrusion members 36 in this order, i.e., at this timing, is that the molten resin fills the molding space 20 from the gate 26, and the closer to the gate 26, the sooner the filling of the molten resin is completed. The molten resin is then pressurized by pushing the extrusion members 36 at this timing. This causes the molten resin to be refilled into each of the first recesses 21-25 that are closest to the top end surface of the pushed-in extrusion members 36.

[0045] The distance from the first recesses 21-25 to the gate 26, which determines the timing of pushing the ejector member 36, may be measured in advance when the mold 10 is fabricated. When the controller 50 executes the above-described program, distance information measured in advance when the mold 10 is fabricated may be stored in the memory 57. In this case, the controller 50 may read out the distance information and determine the timing of pushing the ejector member 36 based on the distance information. The timing of pushing the ejector member 36 may be determined in advance based on the measured distance information, and the timing information may be stored in the memory 57. The controller 50 may read out and use the timing information.

[0046] Since the pressurization of the molten resin is performed in parallel with the cooling of the molten resin in step S3, the molten resin is replenished by the amount of shrinkage of the molten resin due to the cooling of the molten resin, thereby suppressing the occurrence of sink marks 200.

[0047] Returning to FIG. 9, when the molten resin is cooled and hardened throughout the molding space 20, the hardened resin, i.e., the molded exterior panel 100, is removed from the mold 10 (step S5).

[0048] More specifically, a clamping cylinder (not shown) moves the movable platen away from the fixed platen, thereby opening the mold 10. This separates the core 12 from the cavity 11 shown in Figure 4. Then, in this state, the molded exterior panel 100 is removed from the mold 10.

[0049] With the above steps, the exterior panel 100 is completed, and the manufacturing method for the exterior panel 100 is completed.

[0050] The exterior panel 100 is an example of a molded product as referred to in the present disclosure. The flat portion of the exterior panel 100 and the fitting portions 101-105 are an example of a main body portion and a protrusion portion partially protruding from the main body portion as referred to in the present disclosure. The molding space 20 is an example of a space for molding the main body portion as referred to in the present disclosure. Furthermore, the mechanisms formed by the second recesses 31-35, 41-45 and the extrusion members 36 housed in the second recesses 31-35, 41-45 are an example of a pressure mechanism as referred to in the present disclosure.

[0051] As described above, in the molding apparatus 1A according to the first embodiment, the second recesses 31-35 and the second recesses 41-45 are disposed at the locations where the first recesses 21-25 are located between them. Furthermore, the second recesses 31-35 and the second recesses 41-45 are provided with extrusion members 36. Furthermore, when the molding space 20, the first recesses 21-25, and the second recesses 31-35 and 41-45 are filled with molten resin, the extrusion members 36 pressurize the molten resin to replenish the molten resin into the first recesses 21-25. Therefore, even if the molten resin shrinks as it hardens, the molten resin still fills the first recesses 21-25, thereby suppressing the occurrence of sink marks in the molded product. As a result, the deterioration of the design of the molded product is suppressed.

[0052] Furthermore, in the molding device 1A, the second recesses 31-35 and the second recesses 41-45 are disposed at the locations where the first recesses 21-25 are located between them. Therefore, when the molding space 20, the first recesses 21-25, and the second recesses 31-35, 41-45 are filled with molten resin, the extrusion members 36 pressurize the molten resin, and the pressurized molten resin is effectively replenished into the first recesses 21-25. As a result, sink marks are less likely to occur in the molded product.

[0053] In the molding apparatus 1A, when the molding space 20, the first recesses 21-25, and the second recesses 31-35, 41-45 are filled with molten resin, each of the extrusion members 36 pressurizes the molten resin at a timing that depends on the distance from the gate 26 to the first recesses 21-25 corresponding to each of the extrusion members 36. For example, the shorter the distance from the gate 26, the earlier the extrusion members 36 pressurize the molten resin. This allows the molding apparatus 1A to preferentially replenish molten resin from areas where filling with molten resin has been completed. As a result, the molding apparatus 1A can suppress the occurrence of sink marks throughout the entire exterior panel 100, which is the molded product.

[0054] (Modification) In the first embodiment, the second recesses 31-35, the second recesses 41-45, and the first recesses 21-25 are arranged in a line. The first recesses 21-25 are located between the second recesses 31-35 and the second recesses 41-45, respectively, more specifically, in the middle of the second recesses 31-35 and the second recesses 41-45, respectively. However, the arrangement of the second recesses 31-35 and 41-45 is not limited to this.

[0055] The second recesses 31-35 and the second recesses 41-45 may be arranged at positions where the first recesses 21-25 are located between them. For example, the second recesses 31-35 and the second recesses 41-45 may be arranged at positions where the first recesses 21-25 are located in the center between them. Under these conditions, the second recesses 31-35, the second recesses 41-45, and the first recesses 21-25 do not have to be arranged in a line.

[0056] FIG. 12 is a bottom view showing a first modified example of the first recess and the second recess of the mold 10 of the molding apparatus 1A according to the first embodiment.

[0057] As shown in FIG. 12 , multiple second recesses 31-35 and 41-45 may surround the first recess 21-25. Specifically, the first recess 21-25 may be formed in a triangular shape in plan view, and second recesses 51-55 may be provided in addition to the second recesses 31-35 and 41-45. The second recesses 31-35, 41-45, and 51-55 may be arranged opposite each side of the triangle of the first recess 21-25 in plan view. In this case, the center of gravity of the triangle of the first recess 21-25 in plan view may be located at the center of the area surrounded by the second recesses 31-35, 41-45, and 51-55. In the mold 10, with this arrangement, the second recesses 31-35, 41-45, and 51-55 may be arranged at the locations where the first recesses 21-25 are located between them.

[0058] Furthermore, although not shown, the first recess 21-25 may be formed into a quadrangle in plan view, with four second recesses 31-35, 41-45, and 51-55 arranged opposite each side of the quadrangle in plan view. In this manner, the first recess 21-25 may be formed into a polygon in plan view, with the same number of second recesses 31-35, 41-45, and 51-55 arranged opposite each side of the polygon in plan view. In this case, the center of gravity of the polygon in plan view of the first recess 21-25 should be located at the center of the area surrounded by the second recesses 31-35, 41-45, and 51-55. This is because even with such a shape and arrangement, the molten resin can be sufficiently replenished into the first recess 21-25 when the molten resin is pressurized.

[0059] The number of second recesses 31-35, 41-45, 51-55 does not have to be the same as the number of sides of the polygon in plan view. In that case, it is preferable that multiple second recesses 31-35, 41-45, 51-55 surround the first recess 21-25.

[0060] Furthermore, although it has been explained that the second recesses 31-35 and the second recesses 41-45 may be located at positions where the first recesses 21-25 are located between them, the mold 10 may have the second recesses 31-35 without the second recesses 41-45. In that case, it is sufficient that the second recesses 31-35 surround the first recesses 21-25. In particular, the second recesses 31-35 may be formed in a shape that surrounds the first recesses 21-25. This is because even in such a configuration, the molten resin can be sufficiently replenished into the first recesses 21-25 when the molten resin is pressurized.

[0061] Fig. 13 is a bottom view showing a second modified example of the first recess and the second recess of the mold 10. Fig. 14 is a bottom view showing a third modified example of the first recess and the second recess of the mold 10 and its arrangement. Fig. 15 is a bottom view showing a fourth modified example of the first recess and the second recess of the mold 10 and its arrangement.

[0062] 13, each of the first recesses 21-25 may be formed in a circular shape in a plan view, and each of the second recesses 31-35 may be formed in a ring shape that surrounds and is concentric with each of the first recesses 21-25 in a plan view. In this case, the pusher member 36 housed in each of the second recesses 31-35 may be cylindrical. Note that the circle and ring referred to here may refer to a perfect circle, an oval, or an ellipse.

[0063] 14, when each of the first recesses 21-25 is formed in a rectangular shape in plan view, each of the second recesses 31-35 may be formed in a U-shape that surrounds three sides of the rectangular shape in plan view from three directions. In this case, the opening of the U-shape may face either inside or outside the molding space 20. In this case, each of the extrusion members 36 may be a rod with a U-shaped cross section that can be housed in the corresponding second recess 31-35.

[0064] 15, when each of the first recesses 21-25 is formed in a rectangular shape in plan view, each of the second recesses 31-35 may be formed in the shape of a rectangular frame that surrounds all sides of the rectangular shape in plan view. In this case, each of the push-out members 36 may be a rectangular tube that can be housed in the corresponding second recess 31-35.

[0065] (Embodiment 2) In Embodiment 1, the upper end surface of the extrusion member 36 is horizontal. In other words, the upper end surface of the extrusion member 36 is perpendicular to the column axis of the rectangular column-shaped recess of the second recesses 31-35, 41-45. However, the extrusion member 36 is not limited to this. Each of the extrusion members 36 is provided inside the second recesses 31-35, 41-45, and when molten resin is filled in the molding space 20, the first recesses 21-25, and the second recesses 31-35, 41-45, the extrusion member 36 extrudes the molten resin from the second recesses 31-35, 41-45 into the molding space 20. Therefore, to this extent, the shape of the extrusion member 36 is arbitrary.

[0066] In the molding apparatus 1B according to the second embodiment, the upper end surface of the extrusion member 36 is not horizontal but is inclined.

[0067] A molding apparatus 1B according to a second embodiment will be described below with reference to Figures 16 and 17. In the second embodiment, the configuration different from the first embodiment will be mainly described.

[0068] Fig. 16 is an enlarged cross-sectional view of a part of the mold 10 provided in the molding apparatus 1B according to embodiment 2. Fig. 17 is an enlarged cross-sectional view of a part of the second recesses 31-35, 41-45 of the mold 10 and the pushing member 66.

[0069] As shown in Figures 16 and 17, the upper end surface of each extrusion member 66 is inclined. Specifically, the upper end surface of each extrusion member 66 forms an inclined surface that approaches the bottom of the second recesses 31-35, 41-45 as it approaches the corresponding first recesses 21-25. That is, the upper end surface of each extrusion member 66 forms an inclined surface that becomes lower as it approaches the corresponding first recesses 21-25. As a result, when each extrusion member 66 is slid upward by the hydraulic cylinder 39 after molten resin has been filled into the molding space 20, the first recesses 21-25, and the second recesses 31-35, 41-45, the extrusion member 66 extrudes the molten resin not straight up but in a direction inclined toward the first recesses 21-25.

[0070] 17, the molten resin hardens slowly at the connection between the first recesses 21-25 and the molding space 20, resulting in uncured resin 250 remaining until later. Each extrusion member 66 extrudes the molten resin toward the uncured resin 250. As a result, the upper end surface of each extrusion member 66 replenishes the molten resin into the first recesses 21-25, suppressing the occurrence of sink marks 200.

[0071] Except for the shape of the upper end surface, the pusher member 66 has the same configuration as the pusher member 36 described in embodiment 1. Therefore, in embodiment 2, a description of the configuration of the pusher member 66 other than the upper end surface will be omitted.

[0072] The upper end surface of the push-out member 66 described above is an example of the inclined surface portion referred to in the present disclosure.

[0073] As described above, in the molding apparatus 1B according to the second embodiment, each of the extrusion members 66 has an inclined upper end surface that approaches the bottom of the second recesses 31-35 and 41-45 as it approaches the corresponding first recess 21-25. When the molding space 20, the first recess 21-25, and the second recesses 31-35 and 41-45 are filled with molten resin, the upper end surface of each of the extrusion members 66 extrudes the molten resin from the second recesses 31-35 and 41-45. As a result, the extruded molten resin flows into the first recess 21-25, replenishing the first recess 21-25 with sufficient molten resin. Therefore, the molding apparatus 1B can suppress the occurrence of sink marks 200.

[0074] (Embodiment 3) In Embodiments 1 and 2, the molding apparatuses 1A and 1B manufacture the exterior panel 100 by cooling the molten resin to harden the resin. The cooling is natural cooling or artificial cooling, for example, using a cooling device. However, the molding apparatuses 1A and 1B are not limited to this. The molding apparatuses 1A and 1B may also be equipped with a mechanism for adjusting the temperature of the molten resin when the molten resin is filled into the molding space 20 of the mold 10.

[0075] In the molding apparatus 1C according to the third embodiment, a plurality of temperature adjustment mechanisms 70 are provided in the mold 10.

[0076] A molding apparatus 1C according to a third embodiment will be described below with reference to Figures 18 and 19. In the third embodiment, the configuration different from the first and second embodiments will be mainly described.

[0077] Fig. 18 is an enlarged cross-sectional view of a portion of the mold 10 included in the molding apparatus 1C according to embodiment 3. Fig. 19 is an enlarged cross-sectional view of the second recesses 31-35, 41-45 of the mold 10 and the temperature adjustment mechanism 70 included in a modified example of the molding apparatus 1C according to embodiment 3.

[0078] 18, the molding apparatus 1C is equipped with a plurality of temperature adjustment mechanisms 70. Each temperature adjustment mechanism 70 has a heater 71 that heats a part of the mold 10 and a temperature sensor 72 that measures the temperature of the heated part of the mold 10.

[0079] As described in the first embodiment, in manufacturing the exterior panel 100 using the molding apparatus 1A, after forming the molding space 20 in the mold 10, the molding space 20 is filled with molten resin (step S2 in FIG. 9 ). The molten resin is then cooled (step S3 in FIG. 9 ) and refilled into the first recesses 21-25 (step S4 in FIG. 9 ). As a result, the molten resin hardens inside the molding space 20 to form the exterior panel 100. However, the hardening of the molten resin does not proceed solely from the cooling of the molten resin in step S3 above; it also begins when the molten resin comes into contact with the inner wall surface of the mold 10 during the filling of the molding space 20 of the mold 10 in step S2 above. As a result, when refilling the first recesses 21-25 with molten resin in step S4, a sufficient amount of molten resin may not be refilled, and the occurrence of sink marks 200 may not be sufficiently suppressed. Furthermore, the design of the exterior panel 100, which is a molded product, may be impaired. Therefore, in the molding apparatus 1C according to the third embodiment, a plurality of heaters 71 are incorporated into the mold 10.

[0080] More specifically, in the example of the mold 10 shown in FIG. 18 , the core 12 is formed with the first recesses 21-25. In this case, if sink marks 200 occur, they are likely to occur in the portions of the surface opposite the surface on which the mating portions 101-105 formed by the first recesses 21-25 are located, facing the mating portions 101-105. These facing portions are molded by the cavity 11. Therefore, heaters 71 are incorporated into the portions of the cavity 11 facing the first recesses 21-25 of the core 12. The number of heaters 71 incorporated into the cavity 11 is the same as the number of first recesses 21-25. When the molding space 20 of the mold 10 is filled with molten resin, each heater 71 heats the portion of the cavity 11 facing the first recesses 21-25. As a result, the heater 71 prevents the molten resin in contact with the portion of the cavity 11 facing the first recess 21-25 from hardening prematurely. This allows the heater 71 to easily replenish the molten resin and prevent the occurrence of sink marks 200. The heater 71 also prevents a deterioration in the design of the exterior panel 100.

[0081] On the other hand, in order to control the heating of each heater 71, temperature sensors 72 are provided in the same number as the heaters 71. Each temperature sensor 72 is provided in a portion of the cavity 11 close to the portion where the heater 71 is incorporated. The temperature sensor 72 is configured, for example, with a thermocouple, and measures the temperature of each portion of the cavity 11 that is heated by the heater 71 and faces each of the first recesses 21-25.

[0082] Although not shown, the molding apparatus 1C includes a controller 50, similar to the molding apparatus 1A according to embodiment 1. The controller 50 controls the power supplied to the heater 71 to adjust the heat generation timing and heat amount of the heater 71. The temperature sensor 72 transmits measured temperature data to the controller 50.

[0083] The controller 50 estimates the temperature of the molten resin based on the temperature data received from the temperature sensor 72 and adjusts the power supplied to the heater 71. For example, the controller 50 has a database in which the temperature measured by the temperature sensor 72 corresponds to the temperature of the molten resin at that time and the power required for the heater 71. The controller 50 applies the received temperature data to the database to determine the power of the heater 71 and supplies that power to the heater. As a result, the controller 50 controls the heater 71 to generate heat at an appropriate amount, thereby raising the temperature of the molten resin in contact with the portion of the cavity 11 facing the first recesses 21-25. This appropriate temperature is, for example, 80 to 200°C. As a result, the controller 50 adjusts the temperature of the molten resin to an appropriate temperature according to the timing of molding. Through this control, the controller 50 facilitates refilling of the molten resin and suppresses the occurrence of sink marks 200.

[0084] 19, the temperature adjustment mechanism 70 may be applied to the molding apparatus 1B according to the second embodiment, which includes the extrusion member 66 having an inclined upper end surface. This is because the temperature adjustment mechanism 70 can easily replenish the molten resin and suppress the occurrence of sink marks 200, regardless of the shape of the extrusion member 66.

[0085] As described above, the molding apparatus 1C according to the third embodiment includes a plurality of temperature adjustment mechanisms 70 provided in the mold 10, specifically the cavity 11. When the molten resin is filled into the molding space 20 and the first recesses 21-25, the temperature adjustment mechanisms 70 adjust the temperature of the molten resin filled into each of the first recesses 21-25 to delay the hardening of the molten resin. As a result, the temperature adjustment mechanisms 70 make it easier for the molten resin to be replenished into the first recesses 21-25, thereby suppressing the occurrence of sink marks 200. Furthermore, this also suppresses a decrease in the design quality of the molded product.

[0086] Each temperature adjustment mechanism 70 heats a portion of the mold 10 near each of the first recesses 21-25, specifically, a portion of the cavity 11 facing each of the first recesses 21-25, thereby delaying the hardening of the molten resin inside and near each of the first recesses 21-25. This makes it easier for the molten resin to be replenished into the first recesses 21-25, and makes it less likely that sink marks 200 will occur in the molded product.

[0087] Each temperature adjustment mechanism 70 includes a temperature sensor 72 that measures the temperature of a portion of the cavity 11 facing each of the first recesses 21-25, and adjusts the heat generation amount of the heater 71 based on the temperature data measured by the temperature sensor 72. Thus, each temperature adjustment mechanism 70 adjusts the molten resin to an appropriate temperature, making it easier to refill the molten resin into the first recesses 21-25.

[0088] It should be noted that a temperature adjustment mechanism 70 is provided corresponding to each of the first recesses 21-25. Therefore, the molding apparatus 1C is provided with the same number of temperature adjustment mechanisms 70 as the first recesses 21-25. However, the number of temperature adjustment mechanisms 70 is not limited to this, and does not have to be the same number as the first recesses 21-25. For example, the molding apparatus 1C may be provided with a number of temperature adjustment mechanisms 70 that is fewer than the number of first recesses 21-25. In that case, one temperature adjustment mechanism 70 may be provided corresponding to multiple first recesses 21-25. For this reason, the molding apparatus 1C may be provided with a single temperature adjustment mechanism 70 instead of multiple temperature adjustment mechanisms 70.

[0089] Although the molding apparatuses 1A-1C and the method for manufacturing a molded product according to the embodiment of the present disclosure have been described above, the molding apparatuses 1A-1C and the method for manufacturing a molded product are not limited to this.

[0090] In the embodiment 1-3, the first recess 21-25 is a portion for forming the fitting portion 101-105 of the exterior panel 100. However, the first recess 21-25 is not limited to this. The first recess 21-25 may be a portion for forming a convex portion that partially protrudes from the main body of the molded product. Therefore, the first recess 21-25 may be a portion for forming, for example, a rib or a locking portion of the exterior panel 100.

[0091] In the first to third embodiments, the push-out members 36, 66 are pushed out by the hydraulic cylinder 39. However, the push-out members 36, 66 are not limited to this. The push-out members 36, 66 may be pushed out by an air pressure cylinder in addition to the hydraulic cylinder 39.

[0092] In addition, in Embodiments 1-3, the lower end surfaces of the push-out members 36, 66 provided in the adjacent second recesses 31-35 and 41-45 are connected by a connecting plate 37. The connecting plate 37 is moved up and down by a hydraulic cylinder 39. However, the push-out members 36, 66 are not limited to this. The push-out members 36, 66 may each be moved up and down by a separate hydraulic cylinder 39.

[0093] In the embodiments 1-3, the cavity 11 of the mold 10 provided in the molding apparatus 1A-1C is disposed above the core 12, but the top-bottom, left-right, and front-back directions in the embodiments 1-3 are used for convenience of explanation. The orientation of the molding apparatus 1A-1C may be changed as long as the positional relationship of each component of the molding apparatus 1A-1C is maintained. For example, the cavity 11 and the core 12 of the mold 10 may be arranged in the left-right direction or the front-back direction.

[0094] In addition, in the embodiments 1-3, the molded product is the exterior panel 100, but the molded product is not limited to this. The molded product may be any product that includes a main body and a protrusion that partially protrudes from the main body. The molding devices 1A-1C are applicable to such molded products in general.

[0095] As described above, the molding apparatuses 1A-1C and the manufacturing method of the molded product are not limited to the above-described embodiment, and various modifications and substitutions can be made. Various embodiments of the present disclosure are described below as appendices.

[0096] (Supplementary Note 1) A molding device comprising: a mold for molding a molded product having a main body portion and a convex portion partially protruding from the main body portion, the mold having a space for molding the main body portion and a first concave portion connected to the space for molding the convex portion, and a plurality of pressure mechanisms arranged at locations where the first concave portion is located between them, and which pressurize the molten resin to replenish the molten resin into the first concave portion when the space and the first concave portion are filled with molten resin. (Supplementary Note 2) The molding device described in Supplementary Note 1, wherein the plurality of pressure mechanisms comprise: a plurality of second concave portions formed at locations where the first concave portion is located between them and connected to the space, and a plurality of extrusion members provided inside each of the second concave portions, and which extrude the molten resin from the second concave portions into the space when the space, the first concave portion, and the second concave portion are filled with molten resin. (Supplementary Note 3) The molding device according to Supplementary Note 2, wherein each of the extrusion members has an inclined surface portion inside each of the second recesses that approaches the bottom of the second recess as it goes toward the first recess, and when the space, the first recess, and the second recesses are filled with the molten resin, the inclined surface portion extrudes the molten resin from the second recesses into the space. (Supplementary Note 4) The molding device according to Supplementary Note 2 or 3, wherein each of the extrusion members is extruded by a hydraulic or pneumatic cylinder. (Supplementary Note 5) A molding device comprising: a mold for molding a molded product including a main body and a convex portion partially protruding from the main body, the mold having a space for molding the main body and a first concave portion connected to the space for molding the convex portion; and at least one pressurizing mechanism that, when the space and the first concave portion are filled with molten resin, pressurizes the molten resin to refill the first concave portion, the pressurizing mechanism surrounding the first concave portion alone or in combination.(Supplementary Note 6) The molding device described in Supplementary Note 5, wherein the at least one pressurizing mechanism comprises: at least one second recess formed in the mold, connected to the space, and formed in a shape surrounding the first recess, either surrounding the first recess alone or surrounding the first recess together; and extrusion members, the same number as the number of second recesses, provided inside each of the second recesses and configured to extrude the molten resin from the second recess into the space when the molten resin is filled in the space, the first recess, and the second recess. (Appendix 7) The molding apparatus according to any one of Appendices 1 to 6, wherein the molded product comprises a plurality of the convex portions, the mold comprises the same number of first concave portions as the convex portions, and further comprises a gate for filling the molten resin into the space, and in each of the first concave portions, when the molten resin has filled the space and the first concave portions, the pressurizing mechanism provided corresponding to each of the first concave portions pressurizes the molten resin at a timing according to the distance from the gate to the first concave portion corresponding to the pressurizing mechanism. (Appendix 8) The molding apparatus according to any one of Appendices 1 to 7, further comprising a temperature adjustment mechanism provided in the mold, and when the molten resin has filled the space and the first concave portions, adjusting the temperature of the molten resin filled in the first concave portions to delay hardening of the molten resin. (Appendix 9) A manufacturing method for manufacturing a molded product including a main body portion and a convex portion partially protruding from the main body portion, using a mold having a space for molding the main body portion, a first concave portion connected to the space for molding the convex portion, and a plurality of second concave portions connected to the space and between which the first concave portions are located, the method comprising: a step of filling the space, the first concave portion, and the second concave portions of the mold with molten resin; and a step of refilling the first concave portions with the molten resin by extruding the molten resin filled in the second concave portions from the second concave portions into the space and pressurizing the molten resin, while the space, the first concave portion, and the second concave portions are filled with molten resin.(Supplementary Note 10) A manufacturing method for manufacturing a molded product including a main body portion and a protrusion portion partially protruding from the main body portion using a mold having a space for molding the main body portion, a first recess portion connected to the space for molding the protrusion portion, and at least one second recess portion connected to the space and formed in a shape surrounding the first recess portion, the second recess portion either surrounding the first recess portion alone or surrounding the first recess in combination, the method comprising the steps of: filling the space, the first recess portion, and the second recess portion of the mold with molten resin; and, with the space, the first recess portion, and the second recess portion filled with molten resin, extruding the molten resin filled in the second recess portion from the second recess portion into the space to pressurize the molten resin, thereby refilling the first recess portion with the molten resin. (Appendix 11) The method for manufacturing a molded product according to Appendix 9 or 10, further comprising the step of extruding the molten resin filled in the second recess from the second recess into the space to pressurize the molten resin, and cooling the molten resin to harden the molten resin. (Appendix 12) The molded product comprises a plurality of the convex portions, and the mold comprises the same number of first recesses as the convex portions and further comprises a gate for filling the space with the molten resin, and the step of refilling the first recesses with the molten resin comprises pressurizing the molten resin filled in each of the second recesses corresponding to a first recess at a timing corresponding to each distance from the gate to the first recess corresponding to the second recess. (Appendix 13) The method for manufacturing a molded product according to any one of Appendix 9 to 12, further comprising the step of adjusting the temperature of the molten resin filled in the space, the first recess, and the second recess of the mold to delay hardening of the molten resin.

[0097] The present disclosure allows various embodiments and modifications without departing from the broad spirit and scope of the present disclosure. Furthermore, the above-described embodiments are intended to explain the present disclosure and do not limit the scope of the present disclosure. That is, the scope of the present disclosure is defined by the claims, not the embodiments. Various modifications made within the scope of the claims and within the meaning of the disclosure equivalent thereto are considered to be within the scope of the present disclosure.

[0098] This application is based on Japanese Patent Application No. 2024-105486, filed on June 28, 2024. The entire specification, claims, and drawings of Japanese Patent Application No. 2024-105486 are incorporated herein by reference.

[0099] 1A-1C molding apparatus, 10 mold, 11 cavity, 12 core, 20 molding space, 21-25 first recess, 26 gate, 30 pressure device, 31-35 second recess, 36 extrusion member, 37 connecting plate, 38 rod, 39 hydraulic cylinder, 41-45 second recess, 50 controller, 51-55 second recess, 56 CPU, 57 memory, 66 extrusion member, 70 temperature adjustment mechanism, 71 heater, 72 temperature sensor, 100 exterior panel, 101-105 fitting portion, 200 sink mark, 250 uncured resin.

Claims

1. A molding device comprising: a mold for molding a molded product having a main body and a protrusion that partially protrudes from the main body, the mold having a space for molding the main body and a first recess that is connected to the space and for molding the protrusion; and a plurality of pressure mechanisms that are arranged at locations where the first recess is located between them, and that pressurize the molten resin when the space and the first recess are filled with the molten resin to replenish the molten resin into the first recess.

2. The molding device described in claim 1, wherein the multiple pressure mechanisms comprise: multiple second recesses formed in the mold at locations between which the first recesses are located and connected to the space; and multiple extrusion members provided inside each of the second recesses and configured to extrude the molten resin from the second recesses into the space when the space, the first recesses, and the second recesses are filled with the molten resin.

3. The molding device according to claim 2, wherein each of the extrusion members has an inclined surface portion inside each of the second recesses that approaches the bottom of the second recess as it moves toward the first recess, and when the molten resin is filled into the space, the first recess, and the second recess, the inclined surface portion extrudes the molten resin from the second recess into the space.

4. The molding device according to claim 2 or 3, wherein each of the extrusion members is extruded by a hydraulic or pneumatic cylinder.

5. A molding device comprising: a mold for molding a molded product having a main body and a protrusion partially protruding from the main body, the mold having a space for molding the main body and a first recess connected to the space for molding the protrusion; and at least one pressure mechanism that, when molten resin has filled the space and the first recess, pressurizes the molten resin to replenish the molten resin into the first recess, the pressure mechanism surrounding the first recess alone or in combination.

6. The molding device according to claim 5, wherein the at least one pressure mechanism comprises: at least one second recess formed in the mold, connected to the space, and formed in a shape surrounding the first recess, either surrounding the first recess alone or surrounding the first recess together; and extrusion members, the same number as the number of second recesses, provided inside each of the second recesses and configured to extrude the molten resin from the second recess into the space when the molten resin has been filled into the space, the first recess, and the second recess.

7. A molding apparatus according to any one of claims 1 to 6, wherein the molded product comprises a plurality of the convex portions, the mold comprises the same number of first concave portions as the convex portions, and further comprises a gate for filling the molten resin into the space, and in each of the first concave portions, when the molten resin has filled the space and the first concave portions, the pressurizing mechanism provided corresponding to each of the first concave portions pressurizes the molten resin at a timing according to the distance from the gate to each of the first concave portions corresponding to the pressurizing mechanism.

8. A molding device according to any one of claims 1 to 7, further comprising a temperature adjustment mechanism provided in the mold, which, when the molten resin is filled into the space and the first recess, adjusts the temperature of the molten resin filled into the first recess to delay hardening of the molten resin.

9. A manufacturing method for manufacturing a molded product having a main body portion and a protrusion portion partially protruding from the main body portion, the mold having a space for molding the main body portion, a first recess portion connected to the space for molding the protrusion portion, and a plurality of second recess portions connected to the space and with the first recess portion located between each of the second recess portions, the manufacturing method for a molded product comprising the steps of: filling the space, the first recess portion, and the second recess portion of the mold with molten resin; and, with the space, the first recess portion, and the second recess portion filled with molten resin, extruding the molten resin filled in the second recess portion from the second recess portion into the space to pressurize the molten resin, thereby refilling the first recess portion with the molten resin.

10. A manufacturing method for manufacturing a molded product having a main body portion and a protrusion portion partially protruding from the main body portion, the mold having a space for molding the main body portion, a first recess portion connected to the space for molding the protrusion portion, and at least one second recess portion connected to the space and formed in a shape surrounding the first recess portion, either alone surrounding the first recess portion or together surrounding the first recess portion, the method comprising the steps of: filling the space, the first recess portion, and the second recess portion of the mold with molten resin; and, with the space, the first recess portion, and the second recess portion filled with molten resin, extruding the molten resin filled in the second recess portion from the second recess portion into the space to pressurize the molten resin, thereby refilling the first recess portion with the molten resin.

11. A method for manufacturing a molded product according to claim 9 or 10, further comprising a step of extruding the molten resin filled in the second recess from the second recess into the space to pressurize the molten resin, and then cooling the molten resin to harden the molten resin.

12. A method for manufacturing a molded product according to any one of claims 9 to 11, wherein the molded product comprises a plurality of the convex portions, the mold comprises the same number of first concave portions as the convex portions, and further comprises a gate for filling the space with the molten resin, and in the step of refilling the first concave portions with the molten resin, the molten resin filled in each of the second concave portions corresponding to the first concave portions is pressurized at a timing according to each distance from the gate to the first concave portion corresponding to the second concave portion.

13. A method for manufacturing a molded product according to any one of claims 9 to 12, further comprising a step of adjusting the temperature of the molten resin filled in the space, the first recess, and the second recess of the mold to delay hardening of the molten resin.

Images