JP2000141467A - Method for molding laminated molded object - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the deformation strain in a high developing ratio area in a method for molding a laminated molded object by pressing a preheated and softened thermoplastic resin plate and a skin raw material to integrate them. SOLUTION: A slit 70 is preformed to the high developing ratio area of a skin raw material S and, at a time of press molding, the slit 70 is expanded in a lateral direction to deform the opening 70a of the slit to relax the tension applied to the skin raw material S. If cutting mechanisms 80, 81 are provided to press molds 40, 50 and slits (71, 72) are formed to the skin raw material S and a thermoplastic resin plate P before press molding, the slits (71, 72) are expanded in a lateral direction at a time of press molding to be formed into openings (71a, 72a) to relax the tension applied to the skin raw material S and the thermoplastic resin plate P. By the relaxing of this tension, the generation of deformation strain is effectively prevented.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a laminated molded product suitable for automobile interior parts, and more particularly to a method for molding a laminated molded product which does not cause deformation.

[0002]

2. Description of the Related Art Usually, various interior parts are installed inside a vehicle such as a passenger car. FIG. 13 is a cross-sectional view showing a configuration of an automobile door trim 1 provided in a door panel. The door trim 1 is provided with a door trim upper 2 and a door trim lower 3 in order to have an accent effect on appearance and enhance design. It consists of upper and lower halves.

The door trim upper 2 is formed by cold-pressing a thermoplastic resin plate subjected to a preheating softening treatment and a raw skin material, so that a skin material 2b is attached to a surface of a resin core material 2a pressed into a curved shape. The door trim lower 3 is made of an injection molded body of a synthetic resin such as a PP resin.

As a joint structure between the door trim upper 2 and the door trim lower 3, an ultrasonic boss 3a is protruded from the upper surface of the upper side of the door trim lower 3, and the door trim upper 2 corresponds to the ultrasonic boss 3a. After the ultrasonic boss 3a is inserted into the mounting hole 2c, the tip of the ultrasonic boss 3a is subjected to ultrasonic caulking to join the door trim upper 2 and the door trim lower 3. Fixed.

As a method of forming the door trim upper 2 in the door trim 1, considering the mass productivity of the door trim 1, as shown in FIG. Left and right symmetrical door trim upper 2A by press upper die 5,
The left and right door trim uppers 2A and 2B are separately formed by simultaneously forming the left and right door trim uppers 2A and 2B.

[0006]

As described above, when a thermoplastic resin plate subjected to a preheating softening treatment and a raw skin material are cold-pressed to form a laminated molded product, particularly in the high expansion ratio portion a, As shown in FIG. 15 (a), deformation tends to occur. As described above, when the laminated molded body is cut, as shown in FIG. 15 (b), the cut portion b tends to be further deformed. is there.

Therefore, when the lower portion of the door trim upper 2 formed by the conventional forming method is deformed, FIG.
As shown in FIG. 6, since a stress is applied in the direction of the arrow in the figure to control the deformation and the panel is mounted on the panel side, a gap indicated by a symbol c in the figure is formed at the joint between the door trim upper 2 and the door trim lower 3. However, it has been pointed out that a disadvantage arises in that the design property is deteriorated.

[0008] In addition to the joint between the door trim upper 2 and the door trim lower 3, a similar deformation tends to occur in a portion having a high deployment rate such as a door waist portion.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and is intended to provide a laminated molded article obtained by cold press molding a thermoplastic resin plate having been preheat-softened and a raw skin into a required shape using a press die. It is an object of the present invention to provide a method of forming a laminated molded body that does not cause deformation distortion and has improved molding accuracy.

[0010]

Means for Solving the Problems To achieve the above object, the invention according to claim 1 of the present application is to press-mold a thermoplastic resin plate which has been subjected to a preheating softening treatment and a raw skin material in a molding die. In the method of forming a laminated molded body comprising a resin core material and a skin material, a slit is opened in a high expansion rate portion of the raw skin material, and the slit expands in the width direction during press molding. When opened, the tension applied to the raw epidermis is reduced.

[0011] Next, a second aspect of the present invention is a laminate formed of a resin core material and a skin material by press-forming a thermoplastic resin plate subjected to a preheating softening treatment and a raw skin material in a molding die. In the method of molding a laminated molded body, a cutting mechanism is provided in the molding die, and a slit is formed in a raw material of the skin and a high expansion rate portion of the thermoplastic resin plate before clamping of the molding die. During the molding, the tension applied to the raw skin and the thermoplastic resin plate is relaxed by expanding the slit in the width direction.

Further, in the invention according to claim 3, the laminated molded body is a door trim upper in a vertically split two-part type door trim, and the molding die can simultaneously mold a pair of left and right door trim uppers, The slit forming portion is characterized in that it is set at a central portion that partitions both cavities.

Therefore, according to the first aspect of the present invention, a slit is previously formed in a high expansion rate portion of the raw skin material, and the thermoplastic resin plate subjected to the preheating softening treatment and the raw skin material are cold-pressed. As a result, when the press is integrated, the slits provided in the raw skin material expand in the width direction, so that the tension applied to the skin material during molding can be greatly reduced.

According to the second aspect of the present invention, when the press-molding die is clamped by the cutting mechanism provided in the press-molding die, a slit is formed in a high expansion rate portion of both the thermoplastic resin plate and the raw skin material. After forming, the press forming is performed, so that the slits formed on the raw skin and the thermoplastic resin plate expand in the width direction, so that the tension applied to the raw skin and the thermoplastic during the press forming. Both of the tension applied to the resin plate can be greatly reduced.

Next, according to the third aspect of the present invention, the lower side of the door trim upper in the left and right door trims is press-formed by a molding die while facing the lower side, and a slit is provided on the lower side of the door trim upper. Therefore, when joining the door trim upper and the door trim lower, there is no gap at the joining portion.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, an embodiment in which a molding method of a laminated molded article according to the present invention is applied to a door trim will be described in detail with reference to the accompanying drawings.

FIG. 1 is a front view showing a vehicle door trim manufactured by applying the method of the present invention, FIG. 2 is a sectional view showing the structure of the vehicle door trim, and FIG. 3 is used in a first embodiment of the method of the present invention. FIG. 4 is a plan view showing a press lower mold used in the method of the present invention, FIG. 5 is a cross-sectional view of a cold press forming step showing a first embodiment of the method of the present invention, and FIG. Is an explanatory view showing a slit shape at the time of cold press molding, and FIG. 7 is a cross-sectional view showing a trim cut step after molding in the first embodiment of the method of the present invention.

FIGS. 8 to 10 show a second embodiment of the method of the present invention. FIG. 8 is a sectional view showing a step of setting a raw skin and a thermoplastic resin plate, and FIG. FIG. 10 is a sectional view showing a cold press forming step.

FIGS. 11 and 12 show the contents of a measurement test of the laminated molded article according to the present invention. FIG. 11 is an explanatory view showing measurement points, and FIG. 12 is an explanatory view showing deformation distortion after molding. is there.

Referring to FIGS. 1 and 2, the structure of the door trim 10 for an automobile manufactured by the method of the present invention will be briefly described. The door trim upper 20 is made of a laminated molded body in which a skin material 22 is integrally adhered to a surface of a resin core material 21 molded into a desired curved surface shape. In consideration of the moldability, wood powder is mixed with polypropylene resin and extruded into a sheet shape. After preheating and softening, the sheet material is formed into a required shape by cold press molding. A laminated sheet material lined with polyethylene foam is used. The skin material 22 is integrated with the resin core material 21 during cold press molding. It is.

On the other hand, the door trim lower 30 is made of an injection molded body of a synthetic resin such as a PP resin, and has a door pocket opening 31 and a speaker grill 32 integrally formed.

The joint structure between the door trim upper 20 and the door trim lower 30 has the upper edge portion of the door trim lower 30 wrapped on the lower surface of the door trim upper 20 and is appropriately spaced on the upper edge rear surface of the door trim lower 30. The ultrasonic boss 33 is erected, and the ultrasonic boss 3
3 is inserted into the mounting hole 23 provided corresponding to the lower edge of the door trim upper 20, and then the front end of the ultrasonic boss 33 is caulked by ultrasonic processing to join and fix the door trim upper 20 and the door trim lower 30. Is done.

The vehicle door trim 10 is composed of the upper and lower divided parts of the door trim upper 20 and the door trim lower 30. The door trim upper 2 is formed along the joint line between the door trim upper 20 and the door trim lower 30.
0 and the door trim lower 30 are tightly joined to each other to ensure good design without any occurrence of skidding.

Next, a first embodiment in which the method of the present invention is applied to a method of forming the door trim upper 20 will be described with reference to FIGS.

As shown in FIG. 3, the cold press forming die is generally composed of a lower press die 40, an upper press die 50, and a raw skin material feeding device 60.
Door trim upper 20 of door trim 10 of right and left door
As shown in FIG. 4, a symmetrical cavity 41 is formed on the mold surface of the lower mold 40 so that A and 20B can be simultaneously molded.
a, 41b are formed.

A pair of left and right door trim uppers 2
In order to form 0A and 20B, a thermoplastic resin plate P preheated and softened is placed on the die surface of the lower press die 40, and the raw skin S is put into the upper and lower press dies 40 and 50. Although supplied via the device 60, the method of the present invention is characterized in that a slit 70 is previously formed in the raw skin S.

Therefore, as shown in FIG.
0 moves down by a predetermined stroke and presses up and down dies 40 and 5
When the mold is closed, the door trim upper 2 is symmetrical.
0A and 20B are formed into a desired curved surface shape. In particular, since the portion where the slit 70 is opened in the raw skin S is a high expansion rate portion, the slit 70 expands in the width direction as shown in FIG. Opening 70a.

Thereafter, as shown in FIG. 7, the central portion of the integrally molded product is cut, and each door trim upper 20 is cut.
A and 20B may be separated.

Therefore, in the present embodiment, the cut portion is a portion having a high expansion rate and is liable to be deformed and deformed. However, as described above, the slit 70 is previously formed in the raw skin S, and this slit is formed during press forming. Since 70 is expanded in the width direction of the slit to become the opening 70a, the tension applied to the raw skin S during press molding can be reduced, and deformation distortion generated in a high expansion rate portion can be effectively suppressed.

Although the cut portion exposes the resin core material 21, this portion is covered with the door trim lower 30, so that there is no problem with the design of the product.

Next, a second embodiment of the present invention will be described with reference to FIGS.

The second embodiment also employs a method of simultaneously forming a pair of left and right door trim uppers 20A and 20B. That is, as shown in FIG. 8, the cutting blade 80 is provided substantially at the center of the upper press die 50,
A receiving groove 81 is provided on the die surface of the press lower die 40 at a position corresponding to the cutting blade 80. The thermoplastic resin plate P as a material of the resin core material 21 is placed on the mold surface of the press lower die 40 as in the first embodiment. No slit processing is performed on the anti-S.

Then, the thermoplastic resin plate P and the raw skin material S
After being put into the press upper and lower molds 40 and 50, the press upper mold 50 is moved down by a predetermined stroke as shown in FIG. 9, and at this time, the height of the raw skin S and the thermoplastic resin plate P is reduced by the cutting blade 50. The expansion rate portion is cut, and slits 71 and 72 are formed before molding.

Further, as shown in FIG. 10, at the time of press molding, the slit 71 formed in the raw skin S is expanded in the width direction to be deformed into the opening 71a and formed on the thermoplastic resin plate P. The slit 72 also expands in the width direction and deforms to 72a, and the skin 71 and 72 formed in the high expansion rate portion of the skin raw material S and the thermoplastic resin plate P expand and deform in the width direction to form the skin. The tension applied to the raw fabric S and the thermoplastic resin plate P can be reduced.

Then, as in the first embodiment, the mold 40,
After opening the mold 50, the center of the molded product may be cut and separated into a pair of door trim uppers 20A and 20B.

Next, a comparison of the deformation strain between the laminated molded article formed by the conventional method and the laminated molded article formed by the first and second embodiments of the method of the present invention will be described below.

First, the conventional method, the method according to the first embodiment of the present invention (raw skin cut processing), and the method according to the second embodiment of the present invention (cutting both the raw skin and the thermoplastic resin plate) After forming each of the laminated molded articles having the shape shown in FIG. 11 based on the above, a sample is prepared. Show. FIG. 13 and Table 1 show a comparison of deformation strains at the measurement points a, b, and c of each sample.

[0038]

[Table 1]

Therefore, as is clear from Table 1 and FIG. 13, if the skin material S is cut in comparison with the conventional method, the deformation distortion can be suppressed to a small value.
If both the raw skin material S and the thermoplastic resin plate P are cut, deformation distortion can be more effectively suppressed.

In the above-described embodiment, the method of the present invention is applied to the lower edge portion of the door trim upper 20. However, if the method is applied to the waist portion of the door trim upper 20, the deformation of the waist portion of the door trim upper 20 can be suppressed. It is possible.

[0041]

As described above, the present invention has the following special functions and effects.

(1) The present invention according to claim 1 is a laminate formed by press-integrating a thermoplastic resin plate subjected to a preheating softening treatment with a raw skin material to form a laminated molded product comprising a resin core material and a skin material. In the molding method, a slit is formed in the skin raw material at a high expansion rate portion of the product, and at the time of press molding,
Since the slit expands in the width direction to reduce the tension applied to the raw skin material, it is possible to effectively suppress the deformation distortion generated in the high expansion rate portion of the laminated molded product, and to improve the product shape. This has the effect that the design can be maintained without generating gaps, gaps and the like between the mating parts.

(2) The invention according to claim 2 is a laminate molded article comprising a thermoplastic resin plate which has been subjected to a preheating softening treatment and a raw skin material, which are press-integrated to form a laminated molded product comprising a resin core material and a skin material. In the molding method, a cutting mechanism is installed in the press molding die, and a slit is formed by the above-mentioned cutting mechanism before molding on the raw skin material and the thermoplastic resin plate corresponding to the high expansion rate portion of the product, and the press is formed. During molding, the tension applied to the raw skin material and the thermoplastic resin plate can be reduced by expanding and deforming both the slits provided in the raw skin material and the thermoplastic resin plate in the width direction. Can be more effectively regulated, the initial shape of the product can be maintained in a good condition, and a product having a higher design can be provided without generating a gap or the like with a counterpart component.

(3) The invention according to claim 3 is applied to the door trim upper as a laminated molded article, and the slit is set at the lower edge portion of the door trim upper. Therefore, there is an effect that a beautiful joining line can be formed in the upper and lower two-part type automobile door trim.

[Brief description of the drawings]

FIG. 1 is a front view showing an automobile door trim having a door trim upper formed by the method of the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a configuration explanatory view of a press molding die used in the first embodiment of the method of the present invention.

FIG. 4 is a plan view of a lower press die in the press die shown in FIG. 3;

FIG. 5 is a sectional view showing a cold press forming step in the first embodiment of the method of the present invention.

FIG. 6 is an explanatory view showing a change in a slit shape at the time of cold press molding shown in FIG. 5;

FIG. 7 is a sectional view showing a trim cutting step in the first embodiment of the method of the present invention.

FIG. 8 is a sectional view showing a step of setting each material in a second embodiment of the method of the present invention.

FIG. 9 is a sectional view showing a precedent cutting step in a second embodiment of the method of the present invention.

FIG. 10 is a sectional view showing a cold press forming step in a second embodiment of the method of the present invention.

FIG. 11 is an external view showing a door trim upper.

FIG. 12 is an explanatory diagram showing deformation distortion of each sample at a measurement point a.

FIG. 13 is a sectional view showing a configuration of a conventional automobile door trim.

FIG. 14 is an explanatory view showing a cold press molding step of a door trim upper in a conventional door trim.

FIG. 15 (a) is an explanatory diagram showing deformation distortion of a conventional laminated molded product after molding, and FIG. 15 (b) is an explanatory diagram showing deformation distortion of a conventional laminated molded product after trim cutting.

FIG. 16 is an explanatory view showing a problem of a joint portion in a conventional upper and lower two-part type vehicle door trim.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Automotive door trim 20 (20A, 20B) Door trim upper 21 Resin core material 22 Skin material 30 Door trim lower 40 Press lower mold 41a, 41b Cavity 50 Press upper mold 60 Skin raw material input device 70, 71, 72 Slit 70a, 71a, 72a Opening 80 Cutting blade 81 Receiving groove S Raw skin P Thermoplastic resin plate

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI theme coat ゛ (Reference) // B29L 9:00 31:30 F term (Reference) 3D023 BA01 BB08 BC00 BD03 BE03 BE06 BE16 BE31 4F100 AJ02H AK01A AK04 AK07 AT00B BA02 BA03 CA23 DC13A DC13B DE01 DG12 DJ01 EH012 EJ202 EJ261 EJ262 EJ421 GB33 JB16A JL01 JL04 4F202 AD08 AD18 AD19 AD20 AG03 AH26 AM32 CA09 CB01 CB13 CB22 CK35 CK41 4F208 AD08 AD03 A19 MB22 AD08 AD03 A19 MB20

Claims (3)

[Claims] 1. A thermoplastic resin plate (P) subjected to a preheating softening treatment.
And the raw skin material (S) are press-molded in a molding die (40, 50) to form a laminate (20) composed of the resin core material (21) and the skin material (22). In the method for molding a body, a slit (70) is formed in a high expansion rate portion of the raw skin material (S).
A method of forming a laminated molded article, wherein, during press molding, the tension applied to the raw skin (S) is reduced by expanding the slit (70) in the width direction. 2. A thermoplastic resin plate (P) subjected to a preheating softening treatment.
And the raw skin material (S) are press-molded in a molding die (40, 50) to form a laminate (20) composed of the resin core material (21) and the skin material (22). In the method for molding a body, a cutting mechanism (80, 8) is provided on the molding die (40, 50).
1) is installed, and slits (71, 72) are formed in a high expansion rate portion of the raw skin material (S) and the thermoplastic resin plate (P) before the molds (40, 50) are clamped. During the molding, the slits (71, 72) are widened in the width direction to reduce the tension applied to the raw skin (S) and the thermoplastic resin plate (P). Method. 3. The laminated molded body is a door trim upper (20) in an upper and lower two-part type door trim, and the molding dies (40, 50) simultaneously mold a pair of left and right door trim uppers (20A, 20B). It is possible, and at the same time, the slit forming portion is formed in both cavities (4
3. The method according to claim 1, wherein the lamination is set at a central portion defining the lamination.