Method for molding foamed resin molded article, mold, and foamed resin molded article

Patent metadata

Field	Value
Publication number	US-10493673-B2
Application number	US-201715459252-A
Country	US
Kind code	B2
Filing date	Mar 15, 2017
Priority date	Apr 26, 2016
Publication date	Dec 3, 2019
Grant date	Dec 3, 2019

Abstract

Provided are a method for molding a foamed resin molded article having a mounting hole which is formed with good dimensional precision without occurrence of shape sag and which has an improved load resistance, a mold therefor, and a foamed resin molded article thereby. A method for molding a foamed resin molded article 1 including a mounting section 11 and a non-mounting section 12, using a mold 3 including a first mold 31 having a non-mounting-section mold portion 31a and a mounting-section mold portion 31b, a second mold 32, and a cavity 4 having a non-mounting-section cavity portion 42 for molding the non-mounting section 12 and a mounting-section cavity portion 41 for molding the mounting section 11. The method includes: a filling step of filling a material to be molded into at least the mounting-section cavity portion 41; and a core-back step of moving at least one of the non-mounting-section mold portion 31a, the mounting-section mold portion 31b, and the second mold 32 so that a cavity width of the non-mounting-section cavity portion 42 is increased while a cavity width of the mounting-section cavity portion 41 is constant, the filling step and the core-back step being sequentially performed.

First claim

The invention claimed is:

1. A method for molding a foamed resin molded article including a mounting section and a non-mounting section other than the mounting section, the mounting section including a mounting hole for mounting the article to a counterpart member and an opening peripheral edge section of the mounting hole, wherein
a mold is used,
the mold includes a first mold, a second mold, and a cavity, the first mold including a non-mounting-section mold portion having a non-mounting-section mold surface and a mounting-section mold portion adjacent to the non-mounting-section mold portion and having a mounting-section mold surface, the second mold having a second mold surface, and the cavity having a non-mounting-section cavity portion for molding the non-mounting section and a mounting-section cavity portion for molding the mounting section, the non-mounting-section cavity portion being formed between the non-mounting-section mold surface and the second mold surface, the mounting-section cavity portion being formed between the mounting-section mold surface and the second mold surface and being continuous with the non-mounting-section cavity portion, and the cavity having respective cavity widths of the non-mounting-section cavity portion and the mounting-section cavity portion, and
the method comprises:
a filling step of filling a resin material containing a foaming agent into at least the mounting-section cavity portion of the cavity; and
a core-back step of moving at least one of the non-mounting-section mold portion, the mounting-section mold portion, and the second mold so that the cavity width of the non-mounting-section cavity portion is increased while the cavity width of the mounting-section cavity portion is constant; before the core-back step, the cavity width of the mounting-section cavity portion being greater than the cavity width of the non-mounting-section cavity portion, and the filling step and the core-back step being performed sequentially, and

the non-mounting section includes a porous foamed layer and a non-mounting-section skin layer formed on a surface of the foamed layer, and
the opening peripheral edge section of the mounting section includes a fine-foamed layer having a density higher than the foamed layer, and a mounting-section skin layer formed on a surface of the fine-foamed layer.

2. The method, for molding a foamed resin molded article, according to claim 1 , wherein
in the filling step, the non-mounting-section skin layer is molded in the non-mounting-section cavity portion, and the mounting-section skin layer and at least a portion of the fine-foamed layer, of the mounting section, are molded in the mounting-section cavity portion, and
in the core-back step, the foamed layer of the non-mounting section is molded in the non-mounting-section cavity portion, and the rest of the mounting section is molded in the mounting-section cavity portion.

3. The method, for molding a foamed resin molded article, according to claim 1 , wherein
in the mold in the filling step, the non-mounting-section mold surface is closer to the second mold surface than the mounting-section mold surface is, and the non-mounting-section mold portion has a step mold surface continuous with the non-mounting-section mold surface and intersecting the non-mounting-section mold surface and the mounting-section mold surface,
in the filling step, a step skin layer is additionally formed by the step mold surface in the mounting-section cavity portion, and
in the core-back step, a reinforcement section is formed, at a boundary between the mounting section and the non-mounting section, by the step skin layer being folded over.

4. The method, for molding a foamed resin molded article, according to claim 2 , wherein
in the mold in the filling step, the non-mounting-section mold surface is closer to the second mold surface than the mounting-section mold surface is, and the non-mounting-section mold portion has a step mold surface continuous with the non-mounting-section mold surface and intersecting the non-mounting-section mold surface and the mounting-section mold surface,
in the filling step, a step skin layer is additionally formed by the step mold surface in the mounting-section cavity portion, and
in the core-back step, a reinforcement section is formed, at a boundary between the mounting section and the non-mounting section, by the step skin layer being folded over.

Assignees

• Toyoda Gosei Kk

Inventors

• Fujisawa Hitoshi
• Hishida Yu
• Yamazaki Kunio
• Nakamura Yasuaki

Classifications

• B29K2105/043

  Skinned foam · CPC title

• B29K2023/12

  PP, i.e. polypropylene · CPC title

• B29C44/06 Primary

  Making multilayered articles {(B29C44/0407 - B29C44/0492 take precedence)} · CPC title

• B29L2031/30

  Vehicles, e.g. ships or aircraft, or body parts thereof {(vanes or blades B29L2031/08, air bags B29L2022/027)} · CPC title

• B29C44/583

  for making articles with cavities · CPC title