JP7812693B2 - Mold device and foam manufacturing method - Google Patents

Description

This disclosure relates to a mold apparatus and a method for manufacturing a foam using this mold apparatus.

Conventionally, mold assemblies for foam molding have been known, each having an upper mold and a lower mold that are vertically divided. Such foam molding dies produce foams by foaming the foaming raw material within a cavity formed when the upper and lower molds are closed.

In such a mold device, the ends of the upper and lower dies are clamped by a clamping mechanism (see, for example, Patent Document 1). By clamping the upper and lower dies in this way, the gap around the cavity is closed, preventing the foaming raw material from leaking around the cavity and causing burrs in the foam.

Publication number 3-15286

The present disclosure also provides a mold apparatus that prevents flash from forming on the foam.

The mold apparatus according to the present disclosure has a first mold and a second mold, and is configured to close the first mold and the second mold to form a cavity. The mold apparatus includes a hinge member and a first displacement portion. The hinge member has an axial member extending in a first direction and supports the first mold and the second mold rotatably around the axial member. The first displacement portion displaces between a first pressing position and a first release position, and when positioned at the first pressing position, presses the axial member in a second direction intersecting the first direction, and when positioned at the first release position, releases the pressure.

The present disclosure also provides a mold device that prevents burrs from forming on the foam.

FIG. 2 is a right side view of the mold device according to the first embodiment of the present disclosure. FIG. 2 is a top view of the mold device according to the first embodiment of the present disclosure. FIG. 2 is a rear view of the mold device according to the first embodiment of the present disclosure. FIG. 4 is a cross-sectional view of the mold device when the first lever is located at a first release position. FIG. 4 is a cross-sectional view of the mold device when the first lever is located at the first pressing position. FIG. 10 is a right side view of a mold device according to a second embodiment of the present disclosure.

A first embodiment of the present disclosure will be described below with reference to Figures 1 to 5. As shown in Figures 1, 2, and 3, mold apparatus 1 has a lower mold (an example of a first mold) 2 and an upper mold (an example of a second mold) 4. Mold apparatus 1 closes lower mold 2 and upper mold 4 to form a cavity 6. Mold apparatus 1 is an apparatus that injects a foaming raw material into cavity 6 and foams and hardens the foaming raw material to form a foam. In this embodiment, the foaming raw material is a foaming resin raw material that is a mixture of liquid A, which is mainly made of polyol, and liquid B, which is mainly made of isocyanate. Cavity 6 is formed into a shape that matches, for example, an energy absorbing material used in automobiles. However, the cavity 6 is not limited to this and can have a variety of shapes.

The lower mold 2 and upper mold 4 are roughly rectangular parallelepiped structures extending in the X, Y, and Z directions. The X, Y, and Z directions are perpendicular to one another. The lower mold 2 has a front, back, right side, left side, top, and bottom. The upper mold 4 similarly has a front, back, right side, left side, top, and bottom. Figure 1 shows the right side of the lower mold 2 and the right side of the upper mold 4. Figure 2 shows the top surface of the upper mold 4. The cavity 6 is formed by a recess formed in either or both the top surface of the lower mold 2 and the bottom surface of the upper mold 4. When the molds are closed, the top surface of the lower mold 2 comes into close contact with the bottom surface of the upper mold 4, forming the cavity 6.

The mold assembly 1 has at least one hinge member that rotatably connects the lower mold 2 and the upper mold 4. In this embodiment, as shown in Figure 2, the mold assembly 1 has hinge members 8a, 8b, and 8c arranged in the Y direction.

As shown in Figures 1 and 3, the hinge member 8a has a shaft member 10, a first member 12a, and a second member 14a. The shaft member 10 extends in the Y direction (an example of the first direction). The first member 12a is fixed to the lower mold 2 and supports the shaft member 10. More specifically, the first member 12a is fixed to the back surface of the lower mold 2. The second member 14a is fixed to the upper mold 4 and supports the shaft member 10. More specifically, the second member 14a is fixed to the back surface of the upper mold 4. The hinge members 8b and 8c have the same structure as the hinge member 8a. The shaft member 10 is shared by the three hinge members 8a, 8b, and 8c. The upper mold 4 is rotatable around the shaft member 10 relative to the lower mold 2 (arrow 9 in Figure 1).

The mold device 1 further includes first levers 16a and 16b (an example of a first displacement portion). The first lever 16a is provided on the right side (an example of a first surface) of the lower mold 2. The first lever 16b is provided on the left side of the lower mold 2. As shown in FIG. 1, the first lever 16a is displaceable between a first pressing position 26a and a first release position 28a. When the first lever 16a is located at the first pressing position 26a, it presses the shaft member 10 in the Z direction (an example of a second direction). When the first lever 16a is located at the first release position 28a, it releases the pressure.

Specifically, the first lever 16a has a first arm 18a having an upper end, a lower end, and an intermediate portion between the upper and lower ends. The lower mold 2 has a rotation shaft 22a on the right side of the lower mold 2. The first lever 16a is rotatably supported on the rotation shaft 22a at the intermediate portion of the first arm 18a. The first lever 16a also has an engagement portion 20a formed at the upper end of the first arm 18a. When the first lever 16a is positioned at the first pressing position 26a, the engagement portion 20a engages with the shaft member 10 and presses the shaft member 10 in the Z direction. When the first lever 16a is positioned at the first release position 28a, the engagement portion 20a disengages from the shaft member 10. The first lever 16b has the same structure as the first lever 16a. The first lever 16b is displaceable between the first pressing position 26b and the first release position 28b. The first lever 16b presses the shaft member 10 in the Z direction when it is located at the first pressing position 26b. The first lever 16b releases the pressure when it is located at the first release position 28b.

As shown in FIG. 2, the upper mold 4 and the lower mold 2 have a first length L1 in the Y direction. The shaft member 10 has a second length L2 in the Y direction that is greater than the first length L1. The first lever 16a is provided on the right side of the lower mold 2, rotates in the XZ plane, and is engageable with the right end of the shaft member 10. The first lever 16b is provided on the left side of the lower mold 2, rotates in the XZ plane, and is engageable with the left end of the shaft member 10.

As shown in FIG. 1, the first lever 16a further has a rotation shaft 24a formed at the lower end of the first arm 18a. The first lever 16a is connected to the interlocking part 50a via the rotation shaft 24a. Similarly, as shown in FIG. 2, the first lever 16b further has a rotation shaft 24b formed at the lower end of the first arm 18b. The first lever 16b is connected to the interlocking part 50b via the rotation shaft 24b.

The mold device 1 further includes second levers 34a and 34b (an example of a second displacement portion). The second levers 34a and 34b are provided on the front surface of the lower mold 2. As shown in FIG. 1, the second lever 34a is displaceable between a second pressing position 46a and a second release position 48a. When the second lever 34a is positioned at the second pressing position 46a, it presses the upper mold 4 toward the lower mold 2 in the Z direction. When the second lever 34a is positioned at the second release position 48a, it releases the pressure.

Specifically, the second lever 34a has a second arm 36a having an upper end, a lower end, and an intermediate portion between the upper and lower ends. The lower mold 2 has a rotation shaft 40a on the front surface of the lower mold 2. The second lever 34a is rotatably supported on the rotation shaft 40a at the intermediate portion of the second arm 36a. The second lever 34a also has an engagement portion 38a formed at the upper end of the second arm 36a. Meanwhile, the upper mold 4 has a receiving member 30a extending in the X direction on the front surface of the upper mold 4. The receiving member 30a has a receiving surface 32a that receives the engagement portion 38a. When the second lever 34a is positioned at the second pressing position 46a, the engagement portion 38a engages with the receiving member 30a and presses the upper mold 4 in the Z axis direction toward the lower mold 2. When the second lever 34a is positioned at the second release position 48a, the engagement portion 38a disengages from the receiving member 30a.

In the second lever 34a, the lower end of the second arm 36a is fixed to the connecting bar 68. As shown in Figures 1 and 2, the right end of the connecting bar 68 is connected to the interlocking part 50a via the rotation shaft 42a.

As shown in FIG. 2, the second lever 34b, like the second lever 34a, has a second arm 36b and an engaging portion 38b. The lower end of the second arm 36b is fixed to the connecting bar 68. The upper mold 4 has a receiving member 30b extending in the X direction on the front surface of the upper mold 4. When the second lever 34b is positioned at the second pressing position 46b, the engaging portion 38b engages with the receiving member 30b and presses the upper mold 4 in the Z axis direction toward the lower mold 2. When the second lever 34b is positioned at the second release position 48b, the engaging portion 38b disengages from the receiving member 30b. The left end of the connecting bar 68 is connected to the interlocking portion 50b via the rotation shaft 42b. The connecting bar 68 connects the second lever 34a and second lever 34b.

The mold device 1 further includes second levers 54a and 54b (an example of a second displacement portion). The second lever 54a is provided on the right side of the lower mold 2. The second lever 54b is provided on the left side of the lower mold 2. As shown in FIG. 1, the second lever 54a is displaceable between a second pressing position 64a and a second release position 66a. When the second lever 54a is located at the second pressing position 64a, it presses the upper mold 4 in the Z direction toward the lower mold 2. When the second lever 54a is located at the second release position 66a, it releases the pressure.

Specifically, the second lever 54a has a second arm 56a having an upper end, a lower end, and an intermediate portion between the upper and lower ends. The lower mold 2 has a rotation shaft 60a on the right side of the lower mold 2. The second lever 54a is rotatably supported on the rotation shaft 60a at the intermediate portion of the second arm 56a. The second lever 54a also has an engagement portion 58a formed at the upper end of the second arm 56a. Meanwhile, the upper mold 4 has a receiving member 52a extending in the Y direction on the right side of the upper mold 4. When the second lever 54a is positioned at the second pressing position 64a, the engagement portion 58a engages with the receiving member 52a and presses the upper mold 4 in the Z-axis direction toward the lower mold 2. When the second lever 54a is positioned at the second release position 66a, the engagement portion 58a disengages from the receiving member 52a.

The second lever 54a further has a rotation shaft 62a formed at the lower end of the second arm 56a. The second lever 54a is connected to the interlocking part 50a via the rotation shaft 62a.

As shown in FIG. 2, the second lever 54b has an engagement portion 58b and a rotation shaft 62b, similar to the second lever 54a. The upper mold 4 has a receiving member 52b extending in the Y direction on its left side. When the second lever 54b is positioned at the second pressing position 64b, the engagement portion 58b engages with the receiving member 52b, pressing the upper mold 4 in the Z direction toward the lower mold 2. When the second lever 54b is positioned at the second release position 66b, the engagement portion 58b disengages from the receiving member 52b. The second lever 54b is connected to the interlocking portion 50b via the rotation shaft 62b.

The mold device 1 further includes the interlocking units 50a and 50b described above. The interlocking unit 50a interlocks the first lever 16a, the second lever 34a, and the second lever 54a. The interlocking unit 50b interlocks the first lever 16b, the second lever 34b, and the second lever 54b.

For example, the interlocking portion 50a is a bar extending in the X direction. The interlocking portion 50a has a front end, a rear end, and an intermediate portion between the front and rear ends. The front end of the interlocking portion 50a is connected to the connecting bar 68 and thus to the second lever 34a via the rotation shaft 42a. The intermediate portion is connected to the second lever 54a via the rotation shaft 62a. The rear end is connected to the first lever 16a via the rotation shaft 24a. The interlocking portion 50a allows the first lever 16a to move together with the second levers 34a and 54a. When the first lever 16a is in the first pressing position 26a, the second levers 34a and 54a are in the second pressing positions 46a and 64a, respectively. When the first lever 16a is in the first release position 28a, the second levers 34b and 54b are in the second release positions 48a and 66a, respectively.

The mold device 1 further includes an operating lever 44. As shown in FIG. 2, the operating lever 44 is connected to the second levers 34a, 34b and interlocking portions 50a, 50b via a connecting bar 68. The operating lever 44 receives force from a person or machine to move the first levers 16a, 16b and second levers 34a, 34b, 54a, 54b.

Figure 4 is a cross-sectional view of the mold device when the first lever is in the first release position, showing the A-A, B-B, and C-C sections of Figure 3. Figure 5 is a cross-sectional view of the mold device when the first lever is in the first pressing position, showing the A-A, B-B, and C-C sections of Figure 3. As described above, the hinge member 8a has the shaft member 10, the first member 12a, and the second member 14a. As shown in Figures 4 and 5, the first member 12a has a first insertion hole 70 for inserting the shaft member 10. The second member 14a has a second insertion hole 72 for inserting the shaft member 10.

When the first lever 16a is in the first release position 28a, as shown in FIG. 4, the first lever 16a is not in contact with the shaft member 10. At this time, the lower end of the first insertion hole 70 is located a distance 71 below the lower end of the second insertion hole 72 in the Z direction. For example, the diameter of the first insertion hole 70 may be larger than the diameter of the second insertion hole 72. Alternatively, the diameter of the first insertion hole 70 may be the same as the diameter of the second insertion hole 72, and the central axis of the first insertion hole 70 may be located below the central axis of the second insertion hole 72 in the Z direction.

When the first lever 16a is located at the first pressing position 26a, as shown in Figure 5, the first lever 16 presses the shaft member 10 downward in the Z direction. As a result, the second member 14a is pressed toward the first member 12a. In other words, the upper mold 4 is pressed toward the lower mold 2.

As described above, the mold device 1 has second levers 34a, 34b that press the upper mold 4 toward the lower mold 2 at its front end. When the second levers 34a, 34b press the upper mold 4 toward the lower mold 2 at its front end, a reaction force is generated at the rear end of the upper mold 4 that lifts the upper mold 4 from the lower mold 2. In this embodiment, the first levers 16a, 16b press the upper mold 4 toward the lower mold 2 via the shaft member 10, preventing the upper mold 4 from lifting up from the lower mold 2 at its rear end. This prevents gaps from forming between the upper mold 4 and the lower mold 2 around the cavity, preventing burrs from forming in the foam.

Furthermore, the second levers 34a and 34b press the upper mold 4 toward the lower mold 2 at its front end, while the first levers 16a and 16b press the upper mold 4 toward the lower mold 2 at its rear end. At this time, the reaction between these forces generates a force that lifts the upper mold 4 from the lower mold 2 at its center. In this embodiment, the second levers 54a and 54b press the upper mold 4 toward the lower mold 2 at its center, preventing the upper mold 4 from lifting from the lower mold 2 at its center. This further prevents gaps from forming between the upper mold 4 and the lower mold 2 around the cavity, further preventing burrs from forming in the foam.

A second embodiment of the present disclosure will now be described with reference to Figure 6. In the first embodiment, the direction of movement (rotation) of the first levers 16a, 16b is the same as the direction of movement (rotation) of the second levers 34a, 34b. In the second embodiment, the direction of movement (rotation) of the first levers 16a, 16b is opposite to the direction of movement (rotation) of the second levers 34a, 34b.

The mold device 101 has an interlocking portion 73a. The interlocking portion 73a has a first bar 74a, a second bar 76a, and a third bar 78a. The first bar 74a has an upper end, a lower end, and an intermediate portion between the upper and lower ends. The intermediate portion is rotatably supported on the lower mold 2 via a rotation shaft 80a. The second bar 76a has a front end and a rear end. The front end of the second bar 76a is connected to the upper end of the first bar 74a via a rotation shaft 82a. The rear end of the second bar 76a is connected to the lower end of the first lever 16a via a rotation shaft 24a. The third bar 78a has a front end and a rear end. The front end of the third bar 78a is connected to the lower end of the second lever 34a via a rotation shaft 42a. The rear end of the third bar 78a is connected to the lower end of the first bar 74a via a rotation shaft 84a.

The second lever 34a is displaced between the second pressing position 46a and the second release position 48a in response to the movement of the operating lever 44. When the second lever 34a moves from the second release position 48a toward the second pressing position 46a, the second lever 34a rotates the first bar 74a clockwise via the third bar 78a. In response, the first bar 74a moves the first lever 16a from the first release position 28a toward the first pressing position 26a via the second bar 76a.

As shown in FIG. 6, the first levers 16a and 16b may be provided on the rear surface of the lower mold 2. Alternatively, the first levers 16a and 16b may be provided on the right and left sides of the lower mold 2, as in embodiment 1.

Next, we will explain the method for manufacturing a foam. The foam is manufactured using the mold apparatus 1, 101 described above.

As described above, mold device 1, 101 has cavity 6. First, the foaming raw material is poured into cavity 6 of mold device 1, 101.

Next, the upper mold 4 is closed onto the lower mold 2.

Next, the first levers 16a and 16b are set to the first pressing positions 26a and 26b, respectively. For example, a person or machine moves the operating lever 44, setting the second levers 34a and 34b to the second pressing positions 46a and 46b. At this time, the interlocking parts 50a, 50b, and 73a act to set the second levers 54a and 54b to the second pressing positions 64a and 64b, respectively. Then, the interlocking parts 50a and 50b act to set the first levers 16a and 16b to the first pressing positions 26a and 26b.

The foaming raw material foams and hardens within cavity 6 to form the molded foam.

Next, the first levers 16a and 16b are set to the first release positions 28a and 28b, respectively. For example, a person or machine moves the operating lever 44, which sets the second levers 34a and 34b to the second release positions 48a and 48b, respectively. At this time, the interlocking parts 50a, 50b, and 73a act to set the second levers 54a and 54b to the second release positions 66a and 66b, respectively. Then, the interlocking parts 50a and 50b act to set the first levers 16a and 16b to the first release positions 28a and 28b.

Next, the upper mold 4 is opened from the lower mold 2. The molded foam is removed from the cavity 6.

As described above, the present disclosure provides a mold device that prevents burrs from forming on foamed materials.

In the above embodiment, the second member 14a has a second insertion hole 72 for inserting the shaft member 10, but the present disclosure is not limited to this. The second member 14a only needs to support the shaft member 10, and for example, the second member 14a may be formed integrally with the shaft member 10. In this case, as shown in FIG. 4, the lower end of the first insertion hole 70 only needs to be located a distance 71 below the lower end of the shaft member 10 in the Z direction.

In the above embodiment, the mold device 1 is equipped with three hinge members 8a, 8b, and 8c, but the present disclosure is not limited to this. For example, the number of hinge members may be one, two, four or more.

In the above embodiment, the first lever 16a is linked to the second levers 34a and 54a via the linkage portion 50a, but the present disclosure is not limited to this. The first lever 16a may move independently of the second levers 34a and 54a.

REFERENCE SIGNS LIST 1, 101 mold device 2 lower mold 4 upper mold 6 cavity 8a, 8b, 8c hinge member 10 shaft member 12 first member 14 second member 16a, 16b first lever 26a first pressing position 28a first release position 34a, 34b, 54a, 54b second lever 46a, 64a second pressing position 48a, 66a second release position 50a, 73a interlocking portion

Claims (5)

A mold apparatus having a first mold and a second mold, the first mold and the second mold being closed to form a cavity,
a hinge member having a shaft member extending in a first direction and supporting the first die and the second die rotatably around the shaft member;
a first displacement portion that is displaceable between a first pressing position and a first release position, that presses the shaft member in a second direction intersecting the first direction when positioned at the first pressing position, and that releases the pressing force when positioned at the first release position;
Equipped with
The hinge member includes:
a first member fixed to the first die and having a first insertion hole through which the shaft member is inserted;
a second member fixed to the second die and supporting the shaft member;
and
The mold device has a first displacement portion that engages with the shaft member when positioned at the first pressing position and presses the shaft member in a direction from the second mold toward the first mold . the first mold has a first surface that intersects with the first direction,
The first displacement portion is provided on the first surface.
The mold apparatus according to claim 1 . the second member includes a second insertion hole through which the shaft member is inserted,
The diameter of the first insertion hole is larger than the diameter of the second insertion hole.
The mold apparatus according to claim 1 or 2. a second displacement unit that is displaceable between a second pressing position and a second release position, that presses the second mold against the first mold when positioned at the second pressing position, and that releases the pressing force when positioned at the second release position;
an interlocking portion that interlocks the first displacement portion and the second displacement portion;
The mold apparatus according to claim 1 , further comprising: A foaming material is poured into the cavity of the mold device according to any one of claims 1 to 4,
The first displacement portion is set to the first pressing position,
The foaming raw material is foamed and cured in the cavity to form a foam.
A method for producing a foam.