JP7541243B2 - Manufacturing method of the structure - Google Patents

Description

The present invention relates to a method for manufacturing a structure.

Patent Document 1 discloses a method for molding a resin panel using a mold having a pinch-off portion surrounding a cavity portion. In the molding method in Patent Document 1, a core material, for example made of a foam, a resin sheet covering the core material, and a skin material, for example made of a nonwoven fabric, are placed in the cavity portion and molded integrally within the cavity portion. The molded body molded in this manner has a molded body main body molded within the cavity portion and a flash portion disposed outside the cavity portion.

Patent document 1 discloses a method for cutting off burrs using a movable part attached to a mold. The movable part in Patent document 1 is configured to be driven so as to move away from the mold, thereby cutting off the burrs from the resin sheet that constitutes the molded body.

International Publication No. 2020/0269228

Depending on the configuration of the burr portion (e.g., material, shape, surface area, etc.), it may be difficult for the movable part of Patent Document 1 to engage with the burr portion. In such cases, when the movable part is driven, the burr portion does not move with the movable part, increasing the possibility that the burr portion will not be cut off from the resin sheet.

The present invention was made in consideration of these circumstances, and aims to provide a method for manufacturing a structure that can more reliably cut off burrs.

According to the present invention, there is provided a method for manufacturing a structure, comprising a molding step, a flash portion forming step, and a cutting step, in which a molded body is molded using a mold, the mold having a pair of first and second split molds and a movable part, each of the first and second split molds having a cavity part and a pinch-off part, the movable part being attached so as to be movable relative to the first and second split molds, and the movable part having a suction part and an engagement part, the molded body having a molded body main body, a cutting line, and a flash portion, and the molded body main body being molded within the cavity part in the molding step. The cutting line is pressed against the pinch-off portion in the molding process, the burr is connected to the molded body via the cutting line and is provided on the movable portion, the burr is shaped into the engaging portion by sucking the burr into the engaging portion via the suction portion in the burr forming process, and the burr is cut from the molded body along the cutting line by moving the movable portion relative to the first and second split molds while the burr is shaped into the engaging portion in the cutting process.

In the present invention, in the flash forming process, the flash is sucked into the engaging portion of the movable portion via the suction portion. This causes the flash to be formed into the movable portion, and the flash engages more reliably with the movable portion. Therefore, when the movable portion is moved relative to the first and second split molds, the flash is prevented from slipping against the movable portion, and the flash moves to follow the movable portion, resulting in the flash being more reliably cut off from the molded body.

Various embodiments of the present invention will be illustrated below.
Preferably, there is provided a method in which the first split mold has an end surface portion, the movable portion has an abutment surface portion, and in the flash portion forming step, the abutment surface portion is abutted against the end surface portion.
Preferably, there is provided a method wherein the mould further comprises a seal member, the seal member being attached to the end face portion or the abutment face portion.
Preferably, the method provides that the first split mold has a first outer portion, in which the pinch-off portion of the first split mold is formed and in which the end face portion is formed, and the second split mold has a second outer portion, in which the pinch-off portion of the second split mold is formed, and in which the second outer portion is arranged to face the first outer portion in the opening and closing direction of the first and second split molds.
Preferably, the molded body has a resin sheet and a skin material, and the skin material is disposed on the outside of the resin sheet.
Preferably, a method is provided in which a vacuum suction hole is formed in each of the first and second split molds, the vacuum suction hole is formed in the cavity portion, and the vacuum suction hole is formed so as to shape the resin sheet into the first and second split molds, and when the resin sheet is shaped into the first and second split molds, the skin material placed in the cavity portion is arranged to follow the first split mold, and the vacuum suction hole is not formed in a first outer portion of the first split mold.
Preferably, a skin escape space is formed between the first outer portion and the second outer portion, and an end of the skin is disposed in the skin escape space during the molding process.

Fig. 1A is a perspective view of a resin panel 1. Fig. 1B is a perspective view of a core material 3. Fig. 2A is an exploded perspective view of the core material 3. Fig. 2B is an enlarged view of region B in Fig. 2A. Fig. 2C is an end view of the reinforcing member 3c. 3 is a front view (cross-sectional views of first and second split molds 21, 22 and members in the vicinity thereof) showing the configuration of the molding machine 10. In Fig. 3, the illustration of the drive mechanism 24 shown in Fig. 5 is omitted. FIG. 4A is a perspective view of the insertion device 19, and FIG. 4B shows the state in which the core material 3 is attached to the insertion device 19. FIG. 5 is a perspective view showing a state in which the first and second split molds 21 and 22 are open. FIG. 6 is an enlarged view of area A shown in FIG. FIG. 7 is a perspective view of the first and second split molds 21 and 22 as viewed from a different direction than that of FIG. FIG. 8 is an enlarged view of area A shown in FIG. Fig. 9A is a perspective view of a pair of movable parts 23. Fig. 9B is an enlarged view of a region B shown in Fig. 9A. 10A and 10B are front views showing the operation of the movable part 23 when the first cutting step is performed. FIG. 11 is an explanatory diagram corresponding to FIG. 3 for explaining the molding process. 12 is an end view showing a state in which the first and second split molds 21, 22 are closed and the movable part 23 is located at the initial position. Fig. 12 corresponds to the end AA shown in Fig. 3. Fig. 13 shows a state after the engaging step (the flash forming step) and at the start of the first cutting step. Fig. 13 is an end view corresponding to the region A shown in Fig. 12. 14 is an explanatory diagram of the operation of the first cutting step, which shows the state in which the movable part 23 moves away from the first split mold 21, and the outer flash part 5bc2 is cut off from the inner flash part 5bc1. FIG. 15 shows a front view of the molded body 5 . Fig. 16 is a front view showing a state in which the outer burr portion 5bc2 of the molded body 5 shown in Fig. 13 is cut from the inner burr portion 5bc1. Fig. 16 shows a state in which the outer burr portion 5bc2 is pulled by the movable portion 23 and torn along the right line 5cr and the left line 5cl. Fig. 17 is an end view of the first and second split molds 21, 22 according to a modified example. Fig. 17 shows a state at the start of the first cutting step. FIG. 18 is an explanatory diagram of the operation of the first cutting step in the modified example. Fig. 19 is a cross-sectional view of first and second split molds 21 and 22 used when manufacturing a resin panel having a hinge portion. Fig. 19 is a cross-sectional view taken along a plane passing through the hinge portion of the resin panel and parallel to the direction in which the hinge portion extends. Fig. 20A is an exploded perspective view of the first split mold 21 and the movable part 23 according to the modified example 2. Fig. 20B is an exploded perspective view seen from a different direction from that of Fig. 20A. Fig. 20C shows a state in which the movable part 23 is supported by the support part 21f.

The following describes the embodiments of the present invention. The various features shown in the embodiments below can be combined with each other. In addition, each feature can be an invention independently.

1. Resin Panel 1 As shown in FIG. 1, a resin panel 1 (an example of a "structure") according to one embodiment of the present invention is a panel covered with a resin molded body 2 that is substantially rectangular in plan view.

1 and 2, a resin panel 1 includes a hollow resin molded body 2 and a core material 3, and the core material 3 is disposed within the resin molded body 2. A skin material 4 is attached to one side of the resin molded body 2 so as to extend to a parting line PL. The skin material 4 is, for example, a nonwoven fabric, and is molded integrally with the resin molded body 2 during molding.
Both sides of the core material 3 are in close contact with the resin molded body 2. The core material 3 is made up of base bodies 3a and 3b and a reinforcing member 3c that connects them. The reinforcing member 3c is a long and narrow member with a uniform cross-sectional shape. The base bodies 3a and 3b are made of, for example, foam.
The reinforcing member 3c is substantially H-shaped and is composed of an upper wall 3c1, a lower wall 3c2, and a column portion 3c3 connecting them. Both ends of the upper wall 3c1 in the width direction are provided with protrusions 3c11 protruding toward the lower wall 3c2. Both ends of the lower wall 3c2 in the width direction are provided with protrusions 3c21 protruding toward the upper wall 3c1. The protrusions 3c11 and 3c21 engage with the bases 3a and 3b, thereby integrating the bases 3a and 3b with the reinforcing member 3c. The ends of the bases 3a and 3b are provided with recesses 3a1 and 3b1 that are one step lower, and the upper and lower surfaces of the bases 3a and 3b and the reinforcing member 3c are substantially flush with each other as the upper wall 3c1 and the lower wall 3c2 are accommodated in the recesses 3a1 and 3b1.

2. Manufacturing method of resin panel 1 2-1. Description of manufacturing device As shown in Fig. 3, in the manufacturing method according to the embodiment, a molding machine 10 and an insertion device 19 are used to form a molded body 5 shown in Fig. 15. As shown in Figs. 3 to 9, the molding machine 10 includes a pair of sheet forming devices 14, first and second split molds 21, 22, a movable part 23, and a drive mechanism 24.

2-1-1 Configuration of the sheet forming apparatus 14 As shown in Fig. 3, the sheet forming apparatus 14 includes a hopper 12, an extruder 13, an accumulator 17, and a T-die 18. The extruder 13 and the accumulator 17 are connected via a connecting pipe 15. The accumulator 17 and the T-die 18 are connected via a connecting pipe 16. Each component will be described in detail below.

<Hopper 12, Extruder 13>
The hopper 12 is used to feed the raw resin 11 into the cylinder 13a of the extruder 13. The form of the raw resin 11 is not particularly limited, but is usually in the form of pellets. The raw resin is, for example, a thermoplastic resin such as polyolefin, and examples of polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-propylene copolymer, and mixtures thereof. The raw resin 11 may include recycled raw materials produced by crushing burrs with a crusher. After being fed from the hopper 12 into the cylinder 13a, the raw resin 11 is melted by heating in the cylinder 13a to become a molten resin. In addition, the raw resin 11 is transported toward the tip of the cylinder 13a by the rotation of a screw arranged in the cylinder 13a. The screw is arranged in the cylinder 13a, and conveys the molten resin while kneading it by its rotation. A gear device is provided at the base end of the screw, and the screw is rotated and driven by the gear device.

<Accumulator 17, T-die 18>
The raw resin is extruded from the resin extrusion port of the cylinder 13a and injected into the accumulator 17 through the connecting pipe 15. The accumulator 17 includes a cylinder 17a and a piston 17b that can slide inside the cylinder 17a, and the molten resin 11a can be stored in the cylinder 17a. After a predetermined amount of the molten resin 11a is stored in the cylinder 17a, the piston 17b is moved, whereby the molten resin 11a is extruded through a slit provided in the T-die 18 through the connecting pipe 16 and allowed to hang down to form the molten resin sheets p1 and p2.

2-1-2 First and second split molds 21, 22
As shown in Fig. 11, resin sheets p1, p2 are introduced between first and second split molds 21, 22. The first and second split molds 21, 22 are separable at a parting surface that comes into contact when the mold is closed, and the molded body 5 is formed by the first and second split molds 21, 22. That is, in the molding process, the molded body 5 is formed using a pair of separable first and second split molds 21, 22. In the embodiment, a skin relief space sp (see Fig. 13) is formed between the first and second split molds 21, 22. An end of the skin material 4 is placed in the skin relief space sp during molding.

<First split mold 21>
As shown in Figs. 7, 8, 13 and 14, the first split mold 21 includes a main body 21a1, a pair of first outer parts 21a2 and an end surface part 21a3. A cavity part CVT (see Fig. 12) is formed in the main body 21a1. When the first and second split molds 21 and 22 are closed, the cavity part CVT is a closed space formed between the first and second split molds 21 and 22, and is a space in which a molded body is molded. The first outer part 21a2 is connected to the ends (left and right ends) in the width direction of the main body 21a1. The width direction is a direction perpendicular to the opening and closing direction of the first and second split molds 21 and 22 and perpendicular to the up-down direction. The end surface part 21a3 has a surface against which the movable part 23 is abutted. In the embodiment, the end surface part 21a3 is formed on the side surface of the first outer part 21a2.

The first split mold 21 has a number of vacuum suction holes hl (see FIG. 13), which allow the resin sheet p1 to be suctioned under reduced pressure to be shaped to fit the inner surface 21b of the first split mold 21. The inner surface 21b faces the cavity portion cvt.

The first split mold 21 has a pinch-off portion 21d, which is provided so as to surround the cavity portion cvt. The pinch-off portion 21d is a protrusion formed so as to protrude from the first split mold 21 side to the second split mold 22 side. The pinch-off portion 21d has an inner pinch-off portion 21d1 and an outer pinch-off portion 21d2. As shown in FIG. 13, the inner pinch-off portion 21d1 and the outer pinch-off portion 21d2 are formed in the first outer portion 21a2.

The inner pinch-off portion 21d1 is provided so as to face the cavity portion cvt. The inner pinch-off portion 21d1 is formed in a shape corresponding to the shape of the resin panel 1. Specifically, in the embodiment, the inner pinch-off portion 21d1 has a flat top surface. Also, in the embodiment, the inner pinch-off portion 21d1 extends in a bent straight line.

The outer pinch-off portion 21d2 is provided at a position farther away from the cavity portion cvt than the inner pinch-off portion 21d1. The outer pinch-off portion 21d2 is formed in a shape that matches the shape of the movable portion 23. Specifically, the outer pinch-off portion 21d2 is formed in a shape that matches the shape of the engaging portion 23d (hereinafter referred to as the closest engaging portion 23d) of the movable portion 23 (see FIG. 8) that is closest to the first split mold 21. Specifically, the outer pinch-off portion 21d2 is formed so as to follow the closest engaging portion 23d when the first split mold 21 and the movable portion 23 are viewed in plan (when the first split mold 21 and the movable portion 23 are viewed from the direction of the arrow C2 in FIG. 11). In other words, the outer pinch-off portion 21d2 is formed parallel to the closest engaging portion 23d when the first split mold 21 and the movable portion 23 are viewed in plan. This prevents the cutting line of the burr from becoming distorted and makes it difficult to cut the burr.

In the embodiment, the closest engaging portion 23d is described as being located at the end of the opposing surface portion 23a of the movable portion 23 described later, but this is not limited to this. The closest engaging portion 23d may be located at a position inside the end of the opposing surface portion 23a in the driving direction of the movable portion 23.

The top surface of the outer pinch-off portion 21d2 also coincides with the top surface of the closest engaging portion 23d. In other words, when the top surface of the outer pinch-off portion 21d2 is extended, it overlaps with the top surface of the closest engaging portion 23d. Therefore, the top surface of the outer pinch-off portion 21d2 smoothly connects to the top surface of the closest engaging portion 23d. Therefore, in the embodiment, it is more effective to prevent the cutting line of the burr portion from becoming distorted, and it is effectively possible to prevent the burr portion from becoming difficult to cut.

In the embodiment, the shape of the inner pinch-off portion 21d1 corresponds to the shape of the closest engaging portion 23d, so the outer pinch-off portion 21d2 is formed parallel to the inner pinch-off portion 21d1. However, the shape of the outer pinch-off portion 21d2 does not have to be limited to the shape of the inner pinch-off portion 21d1. In other words, the shape of the outer pinch-off portion 21d2 only needs to be determined to match the shape of the movable portion 23. In other words, while the shape of the inner pinch-off portion 21d1 is limited by the shape of the resin panel 1, the outer pinch-off portion 21d2 is not limited to the shape of the resin panel 1 and can adopt a shape that matches the shape of the movable portion 23.

The first split mold 21 has a male protrusion 21e. The male protrusion 21e is provided in a position opposite a female protrusion 19c (described later) of the insertion device 19. The male protrusion 21e can slide relative to the first split mold 21 and be accommodated within the first split mold 21.

<Second split mold 22>
As shown in Fig. 13, the second split mold 22 includes a main body 22a1, a pair of second outer parts 22a2, and a pair of opposing parts 22a3. A cavity part CVT (see Fig. 12) is formed in the main body 22a1. The second outer parts 22a2 are connected to the ends (left and right ends) of the main body 22a1 in the width direction. In addition, each opposing part 22a3 is connected to an end of each second outer part 22a2 in the width direction. The opposing parts 22a3 are arranged to face the movable part 23.

The second split mold 22 is provided with a number of vacuum suction holes hl (see FIG. 13), which make it possible to vacuum suction the resin sheet p2 and shape it to fit the inner surface 22b of the second split mold 22. The inner surface 22b faces the cavity portion cvt.

The second split mold 22 has a pinch-off portion 22d, which is provided so as to surround the cavity portion cvt. The pinch-off portion 22d is a protrusion formed so as to protrude from the second split mold 22 side toward the first split mold 21 side. The pinch-off portion 22d has an inner pinch-off portion 22d1 and an outer pinch-off portion 22d2. As shown in FIG. 13, the inner pinch-off portion 22d1 and the outer pinch-off portion 22d2 are formed in the second outer portion 22a2.

The inner pinch-off portion 22d1 and the outer pinch-off portion 22d2 have the same configuration as the inner pinch-off portion 21d1 and the outer pinch-off portion 21d2. The inner pinch-off portion 22d1 is provided to face the cavity portion cvt. The inner pinch-off portion 22d1 is formed in a shape corresponding to the shape of the resin panel 1. Specifically, the top surface of the inner pinch-off portion 22d1 is a flat surface. The inner pinch-off portion 22d1 also extends in a bent straight line.

The outer pinch-off portion 22d2 is located farther away from the cavity portion CVT than the inner pinch-off portion 22d1. Like the outer pinch-off portion 21d2, the outer pinch-off portion 22d2 is formed in a shape that matches the shape of the movable portion 23. The top surface of the outer pinch-off portion 22d2 coincides with the top surface of the closest engaging portion 23d. Therefore, the top surface of the outer pinch-off portion 22d2 is smoothly connected to the top surface of the closest engaging portion 23d.

<Skin material relief space sp>
The skin escape space sp is a space in which excess skin material 4 is placed. An end of the skin material 4 is placed in the skin escape space sp. The skin escape space sp is formed between the first and second split molds 21, 22. Specifically, the skin escape space sp is a space between the first outer portion 21a2 and the second outer portion 22a2, and is also a space between the inner pinch-off portion 21d1 and the inner pinch-off portion 22d1 and the outer pinch-off portion 21d2 and the outer pinch-off portion 22d2.
The skin material 4 used during molding is larger than the size of the cavity portion cvt. Therefore, during molding, excess skin material 4 is generated. The excess skin material 4 is cut off by an operator in a later process. In addition, the raw material resin 11 constituting the flash portion can be reused, but if the excess skin material 4 adheres to the resin sheet p1 corresponding to the raw material resin 11, it may be firmly adhered and difficult to peel the skin material 4 from the resin sheet p1. If it is not possible to peel it off, the flash portion will be discarded, and the resin cannot be reused. Therefore, in the embodiment, a skin material escape space sp is formed in the first and second split molds 21 and 22.

Here, the width dimension w1 and depth dimension w2 of the skin material escape space sp shown in FIG. 13 will be described in the case where the thickness of the resin sheet p1 and the thickness of the resin sheet p2 are 0.6 (mm) to 1.7 (mm), respectively.
It is preferable that the width dimension w1 is set to, for example, 15.0, 15.5, 16.0, 16.5, 17.0, 17.5, 18.0, 18.5, 19.0, 19.5, 20.0, 20.5, 21.0, 21.5, 22.0, 22.5, 23.0, 23.5, 24.0, 24.5, or 25.0 (mm), and the width dimension w1 may be within a range between any two of the numerical values exemplified here.
In addition, the depth dimension w2 of the skin material relief space sp is preferably set to, for example, 4.0, 4.2, 4.4, 4.6, 4.8, 5.0, 5.2, 5.4, 5.6, 5.8, 6.0, 6.2, 6.4, 6.6, 6.8, 7.0, 7.2, 7.4, 7.6, 7.8, or 8.0 (mm), and the depth dimension w2 may be within a range between any two of the numerical values exemplified here.
By setting the width dimension w1 and the depth dimension w2 of the skin escape space sp in this manner, adhesion between the skin 4 and the resin sheet p1 can be suppressed.

In addition, the first outer portion 21a2 does not have a decompression suction hole hl. In other words, the cavity portions cvt of the first and second split molds 21, 22 have decompression suction holes hl, but the first outer portion 21a2 does not have a decompression suction hole hl. This effectively prevents the skin material 4 and the resin sheet p1 from adhering to each other. In the embodiment, the second outer portion 22a2 is described as having a decompression suction hole hl, but this is not limited to the above and may not be provided.

2-1-3 Configuration of the movable part 23 The movable part 23 has a function of engaging with and cutting off the burr portion. The movable part 23 is provided so as to be movable relative to the first and second separate molds 21, 22. As shown in Figures 9A to 10B and 13, the movable part 23 is provided on the side of the first outer part 21a2 of the first separate mold 21. The movable part 23 includes an opposing surface part 23a, an abutting surface part 23b, a suction part 23c, an engagement part 23d, and a seal member 23e.

As shown in FIG. 13, the opposing surface portion 23a is provided to face the opposing portion 22a3 of the second split mold 22. A plurality of engagement portions 23d are formed on the opposing surface portion 23a.

As shown in FIG. 14, the abutment surface portion 23b is formed so that it can abut against the end surface portion 21a3 of the first split mold 21. The abutment surface portion 23b is formed so as to fit the end surface portion 21a3. Therefore, when the abutment surface portion 23b is abutted against the end surface portion 21a3 and air is decompressed and sucked through the decompression suction hole hl, it is possible to prevent air from flowing between the abutment surface portion 23b and the end surface portion 21a3 into the portion where the resin is to be molded. The portion where the resin is to be molded is, for example, the inside of the cavity portion cvt or the gap between the flash portion and the surface of the engagement portion 23d.

As shown in FIG. 13, the suction portion 23c is a hole formed in the opposing surface portion 23a, and opens into the formation area of the engagement portion 23d. Air is sucked under reduced pressure through the suction portion 23c, so that the burr portion (outer burr portion 5bc2) is shaped into the engagement portion 23d. This allows the burr portion (outer burr portion 5bc2) to be more reliably caught by the movable portion 23, and prevents the burr portion from slipping relative to the movable portion 23 when the movable portion 23 is driven. As a result, in the embodiment, when the movable portion 23 is driven, the burr portion appropriately follows the movable portion 23, making it possible to more reliably cut the burr portion.

For example, if the suction section 23c is applying reduced pressure when the resin sheet p1 is being shaped in the cavity section cvt, wrinkles or the like may occur in the resin sheet p1, which may impair moldability. Therefore, the reduced pressure suction system in the suction section 23c is independent of the reduced pressure suction system of the reduced pressure suction hole hl of the first split mold 21. This makes it possible to separately control the timing of reduced pressure suction in the suction section 23c and the timing of reduced pressure suction in the reduced pressure suction hole hl, thereby preventing moldability from being impaired.

The engaging portion 23d has a function of engaging with the flash portion. The engaging portion 23d is a protrusion formed to protrude toward the second split mold 22. Since a plurality of engaging portions 23d are formed on the opposing surface portion 23a, the forming area of the engaging portions 23d on the opposing surface portion 23a is formed in an uneven shape. Note that, in the embodiment, the suction portion 23c is described as opening in the area between two adjacent engaging portions 23d on the opposing surface portion 23a, but this is not limited to this. The suction portion 23c may also open on the surface of the engaging portion 23d.

As shown in FIG. 9B, the seal member 23e is attached to the abutment surface portion 23b. Specifically, a groove portion is formed in the abutment surface portion 23b, and the seal member 23e is attached within the groove portion. This makes it possible to effectively prevent air from flowing into the portion where the resin is shaped from between the abutment surface portion 23b and the end surface portion 21a3. Note that, in the embodiment, the seal member 23e is described as being attached to the abutment surface portion 23b, but this is not limited thereto, and the seal member 23e may be attached to the end surface portion 21a3 of the first split mold 21.

2-1-4 Configuration of the drive mechanism 24 As shown in FIG. 5, the drive mechanism 24 is disposed on the rear part of the first split mold 21. The drive mechanism 24 is configured to drive the movable part 23. As shown in FIG. 5, the drive mechanism 24 includes a pair of upper drive mechanisms 24a and a pair of lower drive mechanisms 24b. Each of the upper drive mechanisms 24a and each of the lower drive mechanisms 24b can be configured, for example, with a cylinder or the like. Each of the upper drive mechanisms 24a and each of the lower drive mechanisms 24b is provided across the first split mold 21 and the movable part 23, and each of the upper drive mechanisms 24a and each of the lower drive mechanisms 24b is fixed to the first split mold 21 and the movable part 23. The movable part 23 moves when the cylinder of each of the upper drive mechanisms 24a and the cylinder of each of the lower drive mechanisms 24b are extended.
Each upper drive mechanism 24a and each lower drive mechanism 24b can be controlled independently. Therefore, as shown in Figures 10A and 10B, the drive mechanism 24 can move the upper part of the movable part 23 and then move the lower part of the movable part 23. This makes the force tearing the burr portion localized, and the movable part 23 can tear the burr portion smoothly.

2-1-5 Insertion device 19
The insertion device 19 is configured to be movable by a drive mechanism (not shown). As shown in Fig. 4A, the insertion device 19 includes a base 19a, a suction pad 19b, and a female projection 19c. Each member is held by the base 9a. The suction pad 9b is used to suction and hold the core material 3. The female projection 19c is capable of holding the skin material 4, and is used to attach the skin material 4 to the first split mold 21.

2-2 Molded body 5
The resin panel 1 is obtained by removing burrs from a molded body 5 (see FIG. 15 ) described below. In other words, the molded body 5 is a molded body in a state after being molded in a die and before the burrs are removed.

As shown in FIG. 15, the molded body 5 is configured by connecting the molded body main body 5a and the large burr portion 5b via a cutting line 5c that is provided to surround the molded body main body 5a. The cutting line 5c corresponds to the portion crushed by the pinch-off portions 21d and 22d. By cutting the molded body 5 along the cutting line 5c around the entire circumference of the molded body main body 5a, the molded body 5 can be separated into the molded body main body 5a and the large burr portion 5b.

15 and 16, the molded body 5a is composed of a portion (molded product 5d) corresponding to the above-mentioned resin panel 1, and a small flash portion 5e and an inner flash portion 5bc1 connected to the portion. In other words, the resin panel 1 can be obtained by removing the small flash portion 5e and the inner flash portion 5bc1 from the molded body 5a.
The large burr portion 5b is composed of an upper burr portion 5bu located at the upper part of the molded body main body 5a, a lower burr portion 5bb located at the lower part of the molded body main body 5a, and an outer burr portion 5bc2 located between the upper burr portion 5bu and the lower burr portion 5bb. The outer burr portion 5bc2 is connected to the inner burr portion 5bc1 before being cut into the movable portion 23.

As shown in FIG. 13, the inner burr portion 5bc1 is composed of resin sheets p1, p2 and a skin material 4. On the other hand, the outer burr portion 5bc2 is composed of resin sheets p1, p2. In other words, the outer burr portion 5bc2 does not include a skin material 4. In other words, the skin material 4 is positioned so that the end of the skin material 4 is located between the inner pinch-off portions 21d1, 22d1 and the outer pinch-off portions 21d2, 22d2.

The cutting line 5c includes a left line 5cl, a right line 5cr, an upper line 5cu, and a lower line 5cb. The left line 5cl, the right line 5cr, the upper line 5cu, and the lower line 5cb are respectively located on the left side, the right side, the upper side, and the lower side of the molded body main body 5a when the molded body 5 is viewed from the mold closing direction of the second split mold 22 shown in FIG. 11 (the direction of the arrow C2 in FIG. 11).

In this embodiment, a first cutting process is performed in which the molded body 5 is cut along the right line 5cr and the left line 5cl using the first and second split molds 21, 22 and the movable part 23. Then, after the molded body 5 is removed from the first and second split molds 21, 22, a second cutting process is performed in which the molded body 5 is cut along the remainder of the cutting line 5c (i.e., the upper line 5cu and the lower line 5cb).

The molded body main body 5a is composed of the molded product 5d (corresponding to the resin panel 1), the small flash portion 5e, and the inner flash portion 5bc1, which are connected via the parting line 5f. In other words, the molded body main body 5a has the molded product 5d, the small flash portion 5e, the inner flash portion 5bc1, and a part of the parting line 5f (the left line 5fl and the right line 5fr). Therefore, by cutting the molded body main body 5a along the parting line 5f around the entire circumference of the molded product 5d, the small flash portion 5e and the inner flash portion 5bc1 can be separated from the molded product 5d.

The parting line 5f includes a left line 5fl, a right line 5fr, an upper line 5fu, and a lower line 5fb. The left line 5fl, the right line 5fr, the upper line 5fu, and the lower line 5fb are respectively located on the left side, right side, upper side, and lower side of the molded body main body 5a when the molded body 5 is viewed from the mold closing direction (arrow C2) of the second split mold 22 shown in FIG. 11.

In the embodiment, a lower line 5cb of the cutting line 5c overlaps with a lower line 5fb of the parting line 5f.
Moreover, an upper line 5cu of the cutting line 5c is provided at a position adjacent to the upper side of an upper line 5fu of the parting line 5f, so that the molded product 5d and the small flash portion 5e are connected via the upper line 5fu.
Furthermore, the left line 5cl and the right line 5cr of the cutting line 5c are provided at positions adjacent to the sides of the left line 5fl and the right line 5fr of the parting line 5f, respectively. Therefore, the molded product 5d and the inner flash portion 5bc1 are connected via the left line 5cl and the right line 5cr.

The upper line 5fu of the parting line 5f is non-linear. For this reason, for example, an operator needs to use a cutter to cut the molded body 5 along the upper line 5fu. Therefore, in this embodiment, a linear upper line 5cu is provided at a position adjacent to the upper side of the upper line 5fu. In addition, in this embodiment, the lower line 5fb of the parting line 5f is also linear. Such a linear line can be cut using a cutter of the burr cutting device. In this way, after the left line 5cl and the right line 5cr are cut, the upper line 5cu and the lower line 5cb are cut, and the molded body main body 5a is separated from the large burr portion 5b.

2-3 Description of each step of the manufacturing method The manufacturing method of the resin panel 1 of this embodiment includes a skin material attachment step, a drooping step, a resin sheet shaping step, a core material welding step, a molding step, an engagement step, a first cutting step, a molded body removal step, a second cutting step, and a post-process.

2-3-1 Skin Attachment Process In the skin attachment process, the skin 4 is attached to the first split mold 21. Specifically, the female projection 19c is inserted in advance into a through hole formed in the skin 4, and the skin 4 is held by the insertion device 19 as shown in Fig. 3. In the skin attachment process, the female projection 19c and the male projection 21e are brought into opposition to each other, and then the two are engaged. In this state, the skin 4 is moved to the male projection 21e by pushing the skin 4 toward the male projection 21e. As a result, the skin 4 is attached to the first split mold 21 as shown in Fig. 11.

11, in the hanging process, the resin sheets p1, p2 extruded from the T-die 18 are hung between the first and second split molds 21, 22. The resin sheet p1 is hung between the core material 3 and the skin material 4. The resin sheet p2 is hung between the insertion device 19 and the second split mold 22. In this embodiment, direct vacuum molding is performed using the resin sheets p1, p2 extruded from the T-die 18 as they are, so the resin sheets p1, p2 are not cooled to room temperature and solidified before molding, and the solidified resin sheets p1, p2 are not heated before molding.

2-3-3 Resin Sheet Shaping Step In carrying out the resin sheet shaping step, the resin sheet p1 and the protruding portion (e.g., pinch-off portion) of the first split mold 21 are brought into close contact with each other in advance, and an airtight space is formed between the resin sheet p1 and the first split mold 21. The same applies to the resin sheet p2 and the second split mold 22. In addition, in forming the airtight space, an outer frame (not shown) separate from the first and second split molds 21 and 22 may be used. Each outer frame is disposed on the peripheral surface of the first and second split molds 21 and 22. Each outer frame is movable in the opening and closing direction of the first and second split molds 21 and 22, and has a vacuum suction hole formed therein. The outer frame of the first split mold 21 is brought into close contact with the resin sheet p1 by sucking it, and an airtight space is formed between the first split mold 21, the resin sheet p1, and the outer frame. The same applies to the outer frame of the second split mold 22.
Then, in the resin sheet shaping process, the air in the sealed space is decompressed and sucked through the decompression suction holes hl of the first and second split molds 21 and 22, and the resin sheets p1 and p2 are shaped into the first and second split molds 21 and 22. In the first split mold 21, the resin sheet p1 is shaped into a shape that follows the outline of the inner surface 21b of the cavity portion. The resin sheet p2 is shaped into a shape that follows the inner surface 22b of the cavity portion. The timing of shaping the resin sheets p1 and p2 may be shifted; for example, the resin sheet p2 may be shaped after the core material welding process, or the resin sheet p2 may be shaped in the mold clamping process.

The first outer portion 21a2 does not have a vacuum suction hole hl. Therefore, even if the resin sheet forming process is performed, adhesion between the skin material 4 and the resin sheet p1 is suppressed. Therefore, when the inner flash portion 5bc1 is removed from the molded body 5a, the resin that constitutes the inner flash portion 5bc1 can be reused.

2-3-4 Core Material Welding Step In the core material welding step, the core material 3 is welded to the resin sheet p1. As shown in Fig. 11, the insertion device 19 has attached the skin material 4 to the first split mold 21, so the core material 3 remains on the insertion device 19. In this state, the core material 3 can be welded to the resin sheet p1 by moving the insertion device 19 toward the resin sheet p1. After the core material 3 is welded to the resin sheet p1, the insertion device 19 is moved to a position outside the movement trajectory of the first and second split molds 21, 22.

The timing for placing the core material 3 between the resin sheets p1 and p2 is not limited, and the core material 3 may be placed between the resin sheets p1 and p2 during the hanging process or the shaping process. The core material 3 may also be welded to the resin sheet p2 first.

In the molding process, the first and second split molds 21, 22 are closed by moving the first and second split molds 21, 22 in the directions of arrows C1 and C2 in Fig. 11. As a result, the resin sheets p1, p2 are crushed and welded at the locations corresponding to the pinch-off portions 21d and 22d, and the molded body 5 shown in Fig. 15 is formed.

2-3-6 Engagement process (burr forming process)
The engagement step is a step (flash forming step) of forming the outer flash portion 5bc2 of the molded body 5 into the movable portion 23 and engaging the outer flash portion 5bc2 with the movable portion 23. That is, in the engagement step, as shown in Fig. 13, the outer flash portion 5bc2 is sucked into the engaging portion 23d via the suction portion 23c, so that the resin sheet p1 of the outer flash portion 5bc2 is formed to fit the engaging portion 23d.

In the molding process, when the first and second split molds 21, 22 are closed, the resins (resin sheets p1, p2) that make up the outer burr portion 5bc2 are welded together (see FIG. 13). In this state, the engagement process (burr shaping process) is performed, so that the non-welded portions of the resin sheets p1, p2 tend to separate, and as a result, the outer burr portion 5bc2 becomes hollow. As a result, even if the resin sheets p1, p2 are thin, the outer burr portion 5bc2 (resin sheet p1) clearly has unevenness along the engagement portion 23d, and the engagement portion 23d easily gets caught on the outer burr portion 5bc2 (resin sheet p1). As a result, the movable portion 23 can effectively tear the outer burr portion 5bc2 from the inner burr portion 5bc1.

As described above, the resin sheets p1 and p2 that make up the outer burr portion 5bc2 are welded together. This increases the rigidity of the outer burr portion 5bc2, which makes it easier for the force with which the engaging portion 23d pulls the outer burr portion 5bc2 to be transmitted to the outer burr portion 5bc2, making it easier to tear the outer burr portion 5bc2 from the inner burr portion 5bc1.

2-3-7 First Cutting Step After the engaging step, the molded body main body 5a is housed in the first and second split molds 21 and 22, and the large flash portion 5b is engaged with the engaging portion 23d provided on the movable portion 23 of the first split mold 21. In this state, as shown in Fig. 10A, when the upper side of the movable portion 23 is tilted away from the main body portion 22a1, the molded body 5 starts to be cut so as to tear from the upper side along the left line 5cl and the right line 5cr of the cutting line 5c. Next, as shown in Fig. 10B, when the movable portion 23 is moved so that the lower side of the movable portion 23 is separated from the first split mold 21, the tearing of the molded body 5 progresses downward, and the first cutting step is completed (see Fig. 15).

2-3-8 Molded Body Removal Process In the molded body removal process, the first and second split molds 21, 22 are opened while the burr portion, such as the upper burr portion 5bu, is clamped by a clamping device (not shown). The molded body 5 is then transported to a desired location for carrying out the next process by the clamping device. As shown in FIG. 16, the molded body 5 is cut along the left line 5cl and the right line 5cr of the cutting line 5c. On the other hand, the molded body 5 is not cut along the upper line 5cu and the lower line 5cb of the cutting line 5c. If the molded body 5 is cut along either the upper line 5cu or the lower line 5cb, the molded body main body 5a becomes easily shaken relative to the large burr portion 5b, making it difficult to handle. However, in this embodiment, the molded body 5 is cut only along the left line 5cl and the right line 5cr at this point, so that the molded body 5 is easy to handle.

2-3-9 Second Cutting Step In the second cutting step, the molded body 5 is cut along the upper line 5cu and the lower line 5cb to separate the molded body 5 into the molded body main body 5a and the large burr portion 5b. In the second cutting step, for example, a cutting device capable of recognizing the positions of the upper line 5cu and the lower line 5cb and automatically cutting the cutting lines can be used.

2-3-10 Post-Process In the post-process, the small flash portion 5e and the inner flash portion 5bc1 are removed to obtain the resin panel 1. This process can be performed by an operator.

3. Effects of the embodiment 3-1 Regarding the reduced pressure suction function of the movable part 23 In the engagement step (flash forming step) in the embodiment, the outer burr part 5bc2 is sucked into the engagement part 23d of the movable part 23 via the suction part 23c. As a result, the outer burr part 5bc2 is formed on the movable part 23, and the outer burr part 5bc2 is more reliably engaged with the movable part 23. Therefore, when the movable part 23 is moved relative to the first and second split molds 21, 22, the outer burr part 5bc2 is prevented from slipping with respect to the movable part 23, and the outer burr part 5bc2 moves to follow the movable part 23, and as a result, the outer burr part 5bc2 is more reliably cut off from the molded body main body 5a.

3-2 Double pinch-off portion In the embodiment, the first and second split molds 21, 22 have a double pinch-off structure. That is, each of the first and second split molds 21, 22 has an inner pinch-off portion 21d1, 22d1 connected to the cavity portion CVT, and an outer pinch-off portion 21d2, 22d2 provided at a position farther away from the cavity portion CVT than the inner pinch-off portion 21d1, 22d1. Here, the inner pinch-off portion 21d1, 22d1 needs to have a shape corresponding to the shape of the molded body main body 5a. On the other hand, the outer pinch-off portion 21d2, 22d2 is disposed at a position that divides the inner burr portion 5bc1 and the outer burr portion 5bc2. The inner burr portion 5bc1 and the outer burr portion 5bc2 are both cut off and are unnecessary parts in the product. That is, the outer pinch-off parts 21d2, 22d2 are not connected to the cavity part cvt, and separate the inner burr part 5bc1 and the outer burr part 5bc2 that are unnecessary for the product, so that the outer pinch-off parts 21d2, 22d2 are not required to have a shape that matches the molded body main body 5a, as the inner pinch-off parts 21d1, 22d1 are. Therefore, in the embodiment, the shape of the outer pinch-off parts 21d2, 22d2 can be easily set to a shape that takes into account the connection with the movable part 23. In other words, it is possible to prevent the cutting line of the burr part from becoming distorted, and to prevent the burr part from becoming difficult to cut.

In the embodiment, the inner pinch-off portions 21d1 and 22d1 are described as having flat top surfaces, but are not limited thereto. The inner pinch-off portions 21d1 and 22d1 may extend so that the top surfaces are uneven (wavy). In describing the shape of the inner pinch-off portions 21d1 and 22d1, a resin panel having a different shape from the resin panel described in the embodiment will be described as an example. That is, the resin panel may have a hinge portion disposed between two bases 3a and 3b covered with a resin sheet, the resin sheet being crushed by a mold. Here, the hinge portion is a thin portion formed by crushing the resin sheets p1 and p2 by the pinch-off portions 21dd and 22dd (see FIG. 19) of the first and second split molds 21 and 22, and the resin panel can be folded via this hinge portion. In addition, the hinge portion is formed so as to be closer to one side in the thickness direction of the resin panel. In this type of resin panel, the parting lines of the bases 3a and 3b are in the center of the thickness direction of the resin panel, whereas the parting line of the hinge portion is the hinge portion itself, and is closer to one side in the thickness direction of the resin panel. In other words, the parting line of the resin panel has a complicated configuration where the bases 3a and 3b are connected to the hinge portion. In other words, to manufacture such a resin panel, the pinch-off portions 21d and 22d of the first and second split molds 21 and 22 have complicated shapes. Specifically, as shown in FIG. 19, in the cross section of the first and second split molds 21 and 22 at the position of the hinge portion, the inner pinch-off portion 22d1 has a convex portion, and the inner pinch-off portion 21d1 has a concave portion.

This embodiment is suitable for a resin panel having such a hinge portion.
If a resin panel having the above-mentioned hinge portion is manufactured using a mold that does not have the outer pinch-off portions 21d2 and 22d2, as in the case of a conventional mold, the cutting line of the burr portion at the hinge portion becomes distorted and the mold design becomes complicated. In contrast, in the embodiment, the shape of the outer pinch-off portions 21d2 and 22d2 can be determined without being restricted by the shape of the inner pinch-off portions 21d1 and 22d1. Therefore, in the embodiment, the cutting line of the burr portion is prevented from becoming distorted, and it is possible to suppress the burr portion from becoming difficult to cut. In addition, since it is possible to avoid the configuration of the first and second split molds 21 and 22 becoming complicated, it is easy to design the mold.

In the conventional manufacturing method, the movable part cuts the part corresponding to the connecting part between the molded body main body 5a and the inner burr part 5bc1 in the embodiment. In such a manufacturing method, if the part cannot be completely cut, peeling and turning of the resin sheet may occur starting from the part when the molded body main body is removed from the mold, and the molded body main body may become a defective product. Since the embodiment cuts the connecting part between the inner burr part 5bc1 and the outer burr part 5bc2, even if the outer burr part 5bc2 cannot be completely cut from the inner burr part 5bc1, the part where peeling and turning occurs is the unnecessary inner burr part 5bc1. Therefore, the embodiment can prevent the molded body main body from becoming a defective product and can improve the yield. In addition, as described above, the embodiment adopts a double pinch-off structure, so that the burr part itself is less likely to be cut, and the effect of improving the yield is further enhanced.

In the conventional manufacturing method, the movable part cuts the skin material as well. However, there are cases where the skin material cannot be cut even if the resin sheet can be cut. In such cases, when the molded body is removed from the mold, the skin material may turn over from the part of the skin material that could not be cut, which may result in the molded body being defective.
In the embodiment, the end of the skin material 4 is located inside the outer pinch-off portions 21d2 and 22d2, and therefore the movable portion 23 does not cut the skin material 4 itself. Therefore, in the embodiment, it is possible to prevent the molded body 5a from becoming a defective product, and to improve the yield.
In addition, in the case where the skin material 4 extends to the outer burr portion 5bc, the portion where curling occurs is the unnecessary inner burr portion 5bc1 even if the skin material 4 is not cut by the movable portion 23. In other words, since the embodiment employs a double pinch-off structure, even if the skin material 4 extends to the outer burr portion 5bc, it is possible to prevent the molded body from becoming a defective product and improve the yield.

4. Modification 4-1 Modification 1
As shown in Fig. 17, the effect of the decompression suction function of the movable part 23 described in the embodiment can be obtained even if the outer pinch-off parts 21d2, 22d2 described in the embodiment are not provided in the first and second split molds 21, 22. In other words, even in the form shown in Fig. 17, the outer burr part 5bc2 is reliably engaged with the movable part 23, and the outer burr part 5bc2 is more reliably cut off from the molded body main body 5a.
In this modified example 1, since the first and second split molds 21 and 22 are not provided with the outer pinch-off portions 21d2 and 22d2, the inner burr portion 5bc1 and the outer burr portion 5bc2 are not cut in the cutting process, and the inner burr portion 5bc1 is cut from the molded body main body 5a, as shown in Fig. 18. At this time, since the first outer portion 21a2 does not have a decompression suction hole hl, the resin sheet p1 and the skin material 4 are prevented from being bonded to each other, and the skin material 4 is prevented from being cut together with the burr portion even when the movable portion 23 is driven. Therefore, when reusing the resin, it is possible to save the effort of peeling off the skin material 4 from the connected body of the cut inner burr portion 5bc1 and the outer burr portion 5bc2.

4-2 Modification 2
The first split mold 21 and the movable part 23 are connected via a drive mechanism 24. Here, if the stroke of the drive mechanism 24 is large or depending on the structure of the first split mold 21 and the movable part 23, there is a possibility that the movable part 23 falls off the first split mold 21 and the movable part 23 is difficult to return to the initial position. For example, if the stroke of the drive mechanism 24 is large, the movable part 23 will not contact the first split mold 21 and the movable part 23 will fall off the first split mold 21. At this time, since the movable part 23 is connected to the first split mold 21 via the drive mechanism 24, the movable part 23 will not fall to the floor. However, when the drive mechanism 24 is driven to return the movable part 23 to its original initial position, the movable part 23 may interfere with the side of the first split mold 21 and the movable part 23 may not be able to return to its initial position. In such a case, for example, an operator needs to move the movable part 23 to its initial position every time it falls off.

In this modified example 2, as shown in Figures 20A and 20B, the first split mold 21 has a support portion 21f, and the movable portion 23 has a supported portion 23f. Note that the drive mechanism 24 is not shown in Figures 20A and 20B.

The support portion 21f is configured to prevent the movable portion 23 from falling off the first split mold 21, and the support portion 21f is formed to protrude from the first split mold 21 in the direction toward the movable portion 23. The support portion 21f is connected to the lateral side of the first split mold 21. Specifically, in this modified example, the support portion 21f is connected to the first outer portion 21a2. Also, when the first split mold 21 and the movable portion 23 are viewed from the front side (when viewed from the direction of the arrow Ar in FIG. 20A), the support portion 21f is provided so as to protrude toward the movable portion 23 side from the end surface portion 21a3 of the first split mold 21. In other words, when viewed from the direction of the arrow Ar in FIG. 20A, the support portion 21f is provided so as to protrude toward the movable portion 23 side from the outermost pinch-off portion (outer pinch-off portion 21d2) in the width direction. Additionally, the support portion 21f is disposed on the rear side of the front portion of the first split mold 21 in the thickness direction Dr of the first split mold 21. Here, the front portion of the first split mold 21 is, for example, the portion where the inner pinch-off portion 21d1, the outer pinch-off portion 21d2, the inner surface 21b, etc. are formed.

The supported portion 23f is configured to be supported by the supporting portion 21f. The supported portion 23f is a concave portion into which the supporting portion 21f is inserted. As shown in FIG. 20C, since the supporting portion 21f is inserted into the supported portion 23f, when the movable portion 23 is driven, the supported portion 23f is supported on the upper surface of the supporting portion 21f. This makes it possible to prevent the movable portion 23 from falling off the first split mold 21.

As shown in Figs. 10A and 10B, the movable part 23 moves in a swinging manner, so the size of the supported part 23f is larger than the size of the supporting part 21f. This makes it possible to avoid interference between the supporting part 21f and the supported part 23f when the movable part 23 moves in a swinging manner, and the movable part 23 operates smoothly.

This modification 2 can also be applied to the form of modification 1.

1: Resin panel 2: Resin molded body 3: Core material 3a: Base body 3a1: Recess 3b: Base body 3b1: Recess 3c: Reinforcing member 3c1: Upper wall 3c11: Protrusion 3c2: Lower wall 3c21: Protrusion 3c3: Column portion 4: Skin material 5: Molded body 5a: Molded body main body 5b: Large flash portion 5bb: Lower flash portion 5bc: Outer flash portion 5bc1: Inner flash portion 5bc2: Outer flash portion 5bu: Upper flash portion 5c: Cutting line 5cb: Lower line 5cl: Left line 5cr: Right line 5cu: Upper line 5d: Molded product 5e: Small flash portion 5f: Parting line 5fb: Lower line 5fl: Left line 5fr: Right line 5fu: Upper line 9a: Base 9b: Suction pad 10 : Molding machine 11 : Raw resin 11a : Molten resin 12 : Hopper 13 : Extruder 13a : Cylinder 14 : Sheet forming device 15 : Connecting pipe 16 : Connecting pipe 17 : Accumulator 17a : Cylinder 17b : Piston 18 : T-die 19 : Insertion device 19a : Base 19b : Suction pad 19c : Female projection 21 : First split mold 21a1 : Main body 21a2 : First outer portion 21a3 : End face portion 21b : Inner surface 21d : Pinch-off portion 21d1 : Inner pinch-off portion 21d2 : Outer pinch-off portion 21dd : Pinch-off portion 21e : Male projection 21f : Support portion 22 : Second split mold 22a1 : Main body 22a2 : Second outer portion 22a3 : Opposing portion 22b : Inner surface 22d : Pinch-off portion 22d1 : Inner pinch-off portion 22d2 : Outer pinch-off portion 22dd : Pinch-off portion 23 : Movable portion 23a : Opposing surface portion 23b : Abutting surface portion 23c : Suction portion 23d : Engagement portion 23e : Sealing member 23f : Supported portion 24 : Drive mechanism 24a : Upper drive mechanism 24b : Lower drive mechanism A : Area Ar : Arrow B : Area C1 : Arrow C2 : Arrow Dr : Thickness direction PL : Parting line cvt : Cavity portion hl : Decompression suction hole p1 : Resin sheet p2 : Resin sheet sp : Space w1 : Width dimension w2 : Depth dimension

Claims (7)

A method for manufacturing a structure, comprising the steps of:
The method includes a molding step, a flash forming step, and a cutting step.
In the molding step, a molded body is molded using a mold,
The mold has a pair of first and second split molds and a movable part,
Each of the first and second split molds has a cavity portion and a pinch-off portion;
the movable portion is attached to the first and second split molds so as to be movable relative to the first and second split molds, and the movable portion has a suction portion and an engagement portion;
The molded body has a molded body main body, a cutting line, and a burr portion,
The molded body is molded in the cavity portion in the molding step,
The cutting line is crushed by the pinch-off portion in the forming process,
The burr portion is connected to the molded body via the cutting line and is provided on the movable portion,
In the flash portion forming step, the flash portion is formed on the engagement portion by sucking the flash portion to the engagement portion through the suction portion,
In the cutting process, the movable part is moved relative to the first and second split molds while the burr part is shaped into the engagement part, thereby cutting the burr part from the molded body along the cutting line. 2. The method of claim 1 ,
The first split mold has an end surface portion,
The movable portion has an abutment surface portion,
In the flash portion forming step, the abutment surface portion is abutted against the end surface portion. 3. The method of claim 2,
The mold further includes a seal member,
The method, wherein the seal member is attached to the end surface or the abutment surface. 4. The method according to claim 2 or claim 3,
The first split mold has a first outer portion;
The pinch-off portion of the first split mold is formed on the first outer portion, and the end surface portion is formed on the first outer portion;
the second split mold has a second outer portion;
The pinch-off portion of the second split mold is formed in the second outer portion, and the second outer portion is positioned to face the first outer portion in the opening and closing direction of the first and second split molds. The method according to any one of claims 1 to 4,
The molded body includes a resin sheet and a skin material,
The method, wherein the skin material is disposed on an outer side of the resin sheet. 6. The method of claim 5,
Each of the first and second split molds is formed with a decompression suction hole,
The decompression suction hole is formed in the cavity portion, and the decompression suction hole is formed so as to shape the resin sheet into the first and second split molds,
When the resin sheet is shaped in the first and second split molds, the skin material disposed in the cavity portion is provided so as to conform to the first split mold;
The vacuum suction holes are not formed in the first outer portion of the first part mold. 7. The method of claim 6,
A skin relief space is formed between the first outer portion and the second outer portion,
The method, wherein an end of the skin material is disposed in the skin material relief space in the molding step.