Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – To produce composite – plural part or multilayered article
Reexamination Certificate
1999-11-09
2002-09-24
Ortiz, Angela (Department: 1722)
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
To produce composite, plural part or multilayered article
C264S266000, C264S275000, C264S277000, C264S328700, C425S112000, C425S123000, C425S125000, C425S577000
Reexamination Certificate
active
06454984
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a molding die of a laminated molding and manufacturing method of the laminated molding. More specifically, the present invention relates to a molding die of laminated molding having molding body made of synthetic resin with compressible surface member laminated thereto, and a manufacturing method of the laminated molding.
BACKGROUND ART
Conventionally, products made of synthetic resin are used for interior goods of an automobile, electric appliance components, household commodities etc.
Among the synthetic-resin-made products, an air-current control valve of an air conditioner for an automobile has flexible and compressible surface member for securing sealability thereof. Further, frame-shaped surface member as a sealing member is provided around an opening of an air-cleaner case for an automobile and peripheral portion of an inside of a refrigerator door in order to enhance air-tightness thereof
Such moldings having synthetic-resin-made molding body as a base and surface member integrated thereto can be manufactured by following methods:
(1) Attaching the surface member by adhesive or the like onto a surface of a molding body manufactured in advance by injection molding method or the like.
(2) Utilizing injection-molding method, where molten resin is injected into a die for molding the molding body integrally with the surface member after closing the die with the surface member being disposed therein (Japanese Patent Application Laid-open No. Hei 3-60297).
(3) Utilizing injection press molding method, where the surface member is disposed inside the die, and the molten resin is filled inside the die and is compressed by closing and clamping the die (Japanese Patent Application Laid-open No. Hei 5-83056).
(4) Enlarging clearance at a portion where the surface member is disposed in the internal space of the die (cavity) and providing a plurality of gate facing the enlarged portion. In molding the products, the surface member is disposed at the enlarged portion and molten resin is injected from the plurality of gate passing through the surface member to mold the molding body integrally with the surface member while controlling the molten resin flow (Japanese Patent Publication Laid-Open No. Hei 8-309786).
However, following disadvantages could occur according to the above methods.
According to the above (1) method, since the surface member has to be attached after shaping the molding products, lot of work is required and the productivity can be lowered.
According to method (2) and (3), since the surface member can be integrated simultaneously with the shaping step, the productivity can be enhanced.
However, when a surface member, especially compressible surface member such as polyurethane foamed sheet is partially laminated to the molding body, the molten resin flows toward a peripheral side of the surface member which is not abutted to inner surface of the die, i.e. exposed end of the surface member. Accordingly, the end of the surface member is likely to be caught in the molten resin, that is, the end of the surface member is turned over by the molten resin flow or buried in the resin and the entire surface member can cause position shift by being pushed off by the molten resin, thereby spoiling quality and appearance of the laminated moldings.
Since the method (4) is a multiple-gate type, molding failure such as weld mark and scorch is likely to be generated. And since the portion having the surface member of the molding body is made thick by enlarging inner space of the die, much resin is required thus being uneconomical, and generation of deformation and prolonged cooling time can be caused.
DISCLOSURE OF THE INVENTION
An object of the present invention is to provide a molding die of laminated molding and a manufacturing method of the laminated molding, where good quality and appearance can be obtained while improving productivity of the laminated molding and preventing molding failure.
The present invention is a molding die of a laminated molding for manufacturing a laminated molding having a molding body made of synthetic resin with a compressible surface member partially laminated thereonto. The present invention is characterized in having: a die body having a cavity for molding the laminated molding and being capable of attaching the surface member thereinside; a slide die structuring the die body and being advanceable and retractable relative to the cavity; and a flow-regulating portion provided to the die body for regulating a flow of a molten resin flowing toward the surface member.
In the present invention, since the flow-regulating portion for regulating the flow of the molten resin is provided to the die body, the molten resin can be prevented from directly flowing toward peripheral side of the surface member by making the flow-regulating portion regulate the flow of the molten resin flowing toward the surface member on the same plane as the surface member.
Accordingly, resin lap where the peripheral end of the surface member is turned over or buried in the resin by the flow of the molten resin, or position shift of the surface member by the resin flow can be prevented, thereby obtaining laminated moldings having good quality and appearance.
Further, since the flow of the molten resin can be controlled by the flow-regulating portion, it is not required to enlarge the portion of the cavity corresponding to the surface member as in the conventional method (method (4)), so that the portion of the molding body having the surface member laminated thereto can be prevented from being thick, thereby being economical for requiring fewer resin amount and being capable of preventing increase in cooling time and deformation of the molding body caused for becoming too thick.
Further, since a laminated molding having good quality can be obtained without employing multiple-gate method, molding failure such as weld mark and scorch can be prevented.
Since the surface member can be integrated simultaneously with the molding process of the molding body, the process for attaching the surface member can be omitted, thereby improving productivity.
Further, since the die body includes the slide die advanceable and retractable relative to the cavity, the resin pressure applied to the surface member can be lowered by retracting the slide die in filling the molten resin to prevent the molten resin from excessively permeating into the surface member, thereby preventing failures such as the surface member being fixed in a compressed condition and reducing damage caused on the surface member by the resin pressure.
Since the molten resin can be securely spread (filled) within the entire cavity by advancing the slide die after initiating to fill the molten resin, thereby obtaining molding body corresponding to the cavity configuration.
Foamed sheet made of resin such as polyurethane, polypropylene, polyethylene, laminated sheet having facing member such as other film integrated on at least one side of the foamed sheet etc. can be suitably used as the surface member.
The facing member to be integrated may be resin sheet or resin film made of PVC (polyvinyl chloride), thermoplastic elastomer etc., woven fabric and non-woven fabric.
The synthetic resin structuring the molding body as a base of the surface member may be thermoplastic resin such as polypropylene, polystyrene, polyethylene, ABS, polycarbonate, and compound of the thermoplastic resin with various additives.
The additives may be filler such as talc, mica, glass fiber, stabilizer for preventing deterioration by heat and light, coloring agent and so on.
In the above arrangement, the flow-regulating portion may preferably includes a plate-shaped flow-regulating plate, the flow-regulating plate being protrudable relative to the cavity.
By structuring the flow-regulating portion with the plate-shaped flow-regulating plate, the molten resin flowing toward the surface member can be introduced in a desired direction, thereby securely controlling the flow of the molten resin.
Since the flow-regul
Abe Tomokazu
Fukushima Terunobu
Saito Yoshiaki
Flynn ,Thiel, Boutell & Tanis, P.C.
Idemitsu Petrochemical Co. Ltd.
Ortiz Angela
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