JP2001301017A - Method and apparatus for molding laminated molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To surely prevent an occurrence of a wrinkle at a skin material in a deeply drawing part in a method and an apparatus for molding a laminated molding to be applied to a roof trim or the like for an automobile. SOLUTION: The method for molding the laminated molding comprises the steps of heating to soften a foamed PPO base material 20 and a skin material 30, and then forming it in a required shape by die clamping pressing upper and lower dies 50 and 60. In this case, a tensioning mechanism 80 is provided at the die 50. A suitable tension is given to a molding material (the foamed PPO core material 20 and the skin material 30) by the mechanism 80 in the deeply drawing part 15. Thus, the deep drawing part 15 is satisfactorily formed by clamping the dies 50 and 60.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding method and a molding apparatus suitable for a roof trim for automobiles and the like, and more particularly to a molding method and a molding apparatus which can reliably prevent wrinkles from being generated on curved surfaces. The present invention relates to a molding method and a molding device.

[0002]

2. Description of the Related Art Roof trims for automobiles to be installed in roof panels of passenger cars are mainly formed by laminating a surface material having a shape-retaining property and a surface material having an excellent touch or a design. In particular, since it is desirable that the base material of the roof trim for automobiles is lightweight and has excellent rigidity and heat resistance, it has recently been used as foam P.
PO (abbreviation for polyphenylene oxide) base material tends to be frequently used.

FIG. 10 is a plan view of a roof trim for an automobile as viewed from the indoor side, and FIG. 11 is a cross-sectional view showing the structure of the roof trim. A skin material 3 is bonded and integrated via a hot melt film 3a, and sunroof openings 1a and 1b for opening and closing a sunshade panel are provided on the front and rear sides of the roof trim 1, respectively. Mounting holes 1c and 1d for mounting a room mirror and a room lamp are respectively provided at predetermined locations.

[0004] The foamed PPO base material 2 has a PPO skin layer 2b integrated with the front and back surfaces of a PPO foamed layer 2a. In particular, the peripheral edges of the sunroof openings 1a and 1b are enhanced in design and rigidity. In order to achieve this, a deep drawing portion (an uneven portion) is formed.

More specifically, as shown in FIG. 12, the foamed PPO base material 2 and the skin material 3 are press-integrated by clamping the press upper and lower dies 4 and 5. The mold surface is provided with a concave portion in the upper press die 4 and a corresponding convex portion 5a in the lower press die 5 in order to form a deep drawn portion (irregular portion) in the roof trim 1.

In order to form the roof trim 1 by using the press upper and lower dies 4, 5, the foamed PPO base material 2 and the skin material 3 are heated and softened by a heater device (not shown) and then opened. The upper and lower press dies 4 and 5 are supplied as shown in FIG. 13 by lowering the upper press die 4 and raising the lower press die 5 as shown in FIG. To form a roof trim 1 into a product shape, and then a sunroof opening 1
a, 1b is punched out and subjected to terminal treatment to make roof trim 1
Has been produced.

[0007]

As described above, in the conventional method of forming the roof trim 1 for an automobile, the heat-softened foamed PPO base material 2 and the skin material 3 are placed in the upper and lower press dies 4 and 5. The upper and lower press dies 4, 5 are supplied and molded by clamping, and in particular, the sunroof openings 1a, 1
By setting a deep drawing part (uneven part) on the periphery of b,
While avoiding skin wrinkles and strengthening rigidity,
If the angle indicated by θ in FIG. 11 is set to 135 ° or less, the surface material 3 is likely to be broken and wrinkled.
There was a problem that the degree of freedom in modeling was greatly restricted.

The present invention has been made in view of such circumstances, and is directed to a method and an apparatus for forming a laminated molded article in which a foamable base material and a skin material represented by an automobile roof trim are integrally laminated. It is another object of the present invention to provide a molding method and a molding apparatus for a laminated molded body having improved appearance performance without causing wrinkles in a skin material even in a deep drawing portion.

[0009]

In order to achieve the above-mentioned object, the present invention provides a foaming base material and a skin material which are heated and softened and then supplied into a press upper and lower mold of a required shape to partially form the foam base material and the skin material. In the method of molding a laminated molded body to form a laminated molded body having a deep drawing portion, after heating and softening the foamable base material and the skin material,
It is supplied to the press upper and lower molds and before the press upper and lower molds are clamped,
By the tension mechanism provided on one side of the press upper and lower mold,
The method is characterized in that the press upper and lower dies are clamped in a state where tension is applied to the molding material located in the deep drawing portion, and press molding is performed to a required shape.

Further, a molding apparatus according to the present invention is a molding apparatus for a laminated molded article formed by laminating and integrating a foamable base material and a skin material, wherein the molding apparatus has a press having a desired mold surface shape. It is characterized by comprising an upper and lower mold and a tension mechanism provided corresponding to the deep drawing portion of the laminated molded body and for applying a tension to the molding material.

As is apparent from the above configuration, since the tension mechanism is provided on one side of the press upper and lower molds,
With this tension mechanism, an appropriate tension can be applied to the molding material in the deep drawing portion, and no breakage wrinkles are generated in the skin material in the deep drawing portion during integral press molding of the foamable base material and the skin material. .

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a method and apparatus for forming a laminated molded product according to the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is a plan view of an automobile roof trim manufactured by applying the method of the present invention, as viewed from the interior side, FIG. 2 is a sectional view showing the structure of the automobile roof trim, and FIG. 3 is a laminate according to the present invention. FIG. 4 to FIG. 9 are schematic diagrams showing the configuration of an embodiment of a molding apparatus for moldings, and FIG. 4 to FIG. 9 are illustrations showing each step of molding a roof trim using the molding apparatus.

1 and 2, an automobile roof trim 10 has an occupied area substantially equal to the interior surface of a vehicle roof panel and is formed so that a product surface is slightly curved toward the interior. ing. In particular, in this embodiment, the sunroof openings 11a and 11
b has been opened, and the sunroof openings 11a, 1
A sunshade (not shown) is attached to 1b so as to be openable and closable. Further, a hole 12 for mounting a room mirror, a hole 13 for mounting a room lamp, and a mounting hole 14 for a switch for driving a sunshade are formed at the front edge of the roof trim 10 at the center, respectively.

The roof trim 10 for automobiles
Is a foamed PPO base material 20 having
And a skin material 30 such as a cloth adhered to the surface of the base material 20. More specifically, as shown in FIG. 2, the foamed PPO base material 20 has a configuration in which a PPO resin skin layer 22 is laminated and integrated on the front and back surfaces of a PPO resin foam layer 21, respectively. In the present embodiment, the PPO resin is Simple P
Instead of PO, a material modified with polystyrene is used in consideration of cost and the like.

As a specific embodiment, the basis weight of the PPO resin foam layer 21 is 500 to 600 g / m ² ,
The O-resin skin layer 22 has a thickness of 0.18 mm, and the foamed PPO base material 20 has a total thickness of 3 times at the time of raw material.
5 mm thing is heated and softened to 130 to 140 ° C.,
After the total thickness of the raw material is expanded to 6 to 8 mm, press forming is performed to a predetermined thickness by cold press forming described later.

On the other hand, as the skin material 30, a cloth such as velvet, moquette, or jersey is used, and a hot melt film 31 such as polyethylene is laminated on the back surface.
The foamed PPO base material 20 and the skin material 30 are overlapped with each other by heating and softening the foamed PPO base material 20 and the skin material 30 and cold-pressing the two, whereby the hot melt film 31 acts as an adhesive medium. Are firmly integrated. Note that a pad material having good cushioning properties such as polyurethane foam may be interposed between the skin material 30 and the hot melt film 31.

The feature of the present invention is that the sunroof openings 11a and 11b provided in the automobile roof trim 10 are provided.
4 corners (for example, one of them is indicated by reference symbol A in FIG. 1)
It is an object of the present invention to provide a molding method and a molding apparatus for a laminated molded article capable of providing an automobile roof trim 10 having good appearance performance without forming wrinkles.

That is, the surface material 30 in the deep drawing portion 15 in which the product surface of the automotive roof trim 10 is a curved concave surface does not have any wrinkles, and the angle α is set to a depth of 135 ° or less. It is characterized in that the deep drawing portion 15 is not formed with a wrinkle even if it is set in the drawing shape, and the deep drawing can be formed.

FIG. 3 shows a schematic configuration of a molding apparatus 40 according to the present invention. The molding apparatus 40 includes an upper press die 50, a lower press die 60, a clamp frame 70 capable of clamping the periphery when setting a material, In particular, it comprises a tension mechanism 80 that can apply a tension to a part of the molding material in order to eliminate a wrinkle in the skin material 30 at the deep drawing portion of the molded body.

More specifically, the press upper die 50 has a lift cylinder 52 connected to an upper table 51 and can move up and down by a predetermined stroke.
With respect to 0, the lifting cylinder 62 is connected to the lower table 61, and the press lower die 60 can also move up and down by a predetermined stroke.

The clamp frame 70 is provided with press upper and lower dies 50, 6
A conventional clamping device can be used as long as it has a function of sandwiching a trimmed material slightly larger than the zero mold surface shape from above and below.

Next, the foamed PPO base material 20 and the skin material 30
Tension mechanism 80 that can apply an appropriate tension to the
Are provided on the upper press die 50 in the present embodiment, and are provided at two locations on the left and right sides of the front side and the rear side, respectively, for a total of 4
An accommodation recess 53 for accommodating the tension mechanism 80 is formed at a location.

The tension mechanism 80 is used for the upper press die 5.
0, a bracket 81 fixed to the inner wall surface of the accommodation recess 53 by a screw or the like, an advance / retreat cylinder 82 such as an air cylinder supported by the bracket 81, and a support plate 83 attached to the rod end of the advance / retreat cylinder 82.
And a set pin 85 that can move forward and backward along the guide 84 in the direction of the arrow in the figure, and is attached to the support plate 83 so as to protrude downward. The tip of the set pin 85 is sharp, pierces the foamed PPO base material 20 and the skin material 30 in a penetrating manner, and extends along the direction perpendicular to the pressing direction of the press upper and lower dies 50, 60. 30 can be given a tension in a predetermined direction.

As the deep drawing portion in the press upper and lower dies 50 and 60, a concave portion 54 is provided in the upper press die 50 and a convex portion 63 is provided in the lower press die 60. In particular, in the die configuration shown in FIG. In order to punch out the sunroof opening 11a, this portion becomes an end material, and this portion is a non-molded portion so that no pressing pressure is applied.

Accordingly, since the tension mechanism 80 is provided in the non-molded portion, there is no hindrance to the molding of the molded body, and the set pin 8 in the tension mechanism 80 is not hindered.
5 can secure enough drive space, and the set pin 8
Even if traces of No. 5 remain, they become scraps and do not impair the product design.

Next, the molding process of the automobile roof trim 10 shown in FIGS. 1 and 2 will be sequentially described by using the molding apparatus 40 shown in FIG. 3. As shown in FIG. When the mold 60 is in the mold open state, the peripheral edges of the foamed PPO base material 20 and the skin material 30 are held by the clamp frame 70, and the foamed PP is
The O base material 20 and the skin material 30 are supplied into the press upper and lower dies 50 and 60 in a state where they are subjected to the heat softening treatment.

At this time, in the tension mechanism 80 provided in the upper press die 50, the cylinder 82 is in the extended state, and the set pin 85 is located closer to the outside in the accommodation recess 53.

Thereafter, as shown in FIG.
0 starts lowering by the operation of the raising / lowering cylinder 52 and also starts rising by the operation of the raising / lowering cylinder 62 in the press lower die 60, and before the press upper and lower dies 50, 60 are closed, as shown in FIG. The tip of the set pin 85 of the tension mechanism 80 penetrates vertically through the foamed PPO base material 20 and the skin material 30, and as shown in FIG. The sliding material 85 slides along the guide rail 84 in the direction of the arrow in the figure, that is, in the direction of the center of the mold.
Is given an appropriate tension.

Thereafter, as shown in FIG.
0, and the press lower die 60 is raised, the press upper and lower dies 50, 60 are clamped, and the sunroof opening 1 is closed.
The portions corresponding to 1a and 11b are non-molded portions where no press pressure is applied, and the other portions are subjected to a predetermined press pressure and are molded so as to maintain a desired wall thickness. At this time, since the deep drawing portion 15 formed along the periphery of the sunroof openings 11a and 11b is given an appropriate tension by the tension mechanism 80, no bending wrinkles are generated.

After the molding, as shown in FIG. 9, when the press upper die 50 is raised by the operation of the elevating cylinder 52 of the press upper die 50, the roof trim 10 which is a laminated molded product is moved from the press lower die 60. Then, the outer peripheral edge a of the product and the opening edge b for the sunroof are cut to complete the molding of the automotive roof trim 10.

As described above, according to the method of the present invention, the obtained automotive roof trim 10 is provided with a foamed PPO core material 20 and a skin material 30 at the deep drawing portion 15 as shown in FIG. With 80, an appropriate tension is applied, and the automotive roof trim 10 excellent in appearance performance in which the surface material 30 is not wrinkled in the deep drawing portion 15 can be obtained.

Further, the molding device 40 according to the present invention is provided with the respective sunroof openings 11a and 11b so that wrinkles do not occur at the four corners of the sunroof openings 11a and 11b.
The tension mechanism 80 is disposed on both the left and right sides of the roof trim 10a.
5, the tension mechanism 80 may be provided at an arbitrary position of the upper press die 50.
A recess is formed in the press lower die 60, and the tension mechanism 80 is formed.
May be accommodated and installed.

[0034]

As described above, the molding method and the molding apparatus of the laminated molded article according to the present invention provide the molding material at the deep drawing portion of the laminated molded article by providing the tension mechanism on one side of the press upper and lower molds. Since the foamable base material and the skin material are press-integrated while imparting an appropriate tension, the product surface can be improved without breaking wrinkles or the like on the product surface in the deep drawing portion. In addition, there is an effect that a free shape setting in which a deep drawing portion is set can be performed also on a molding surface.

Further, according to the preferred embodiment of the present invention, the deep drawn portion of the laminated molded body is set at the opening edge of the roof trim, and the tension mechanism is set to be accommodated in the non-molded portion which is a portion to be opened. There is an effect that the tension mechanism can be set without being restricted by the modeling of the upper and lower dies.

[Brief description of the drawings]

FIG. 1 is a plan view showing a roof trim for an automobile manufactured by applying the method of the present invention, as viewed from the inside of a room.

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

FIG. 3 is a schematic diagram showing a configuration of an embodiment of a molding device for a laminated molded product according to the present invention.

FIG. 4 is an explanatory view showing a material charging step in an embodiment in which the method of the present invention is applied to a roof trim molding method.

FIG. 5 is an explanatory diagram showing a state at the start of driving of an upper and lower mold in an embodiment in which the method of the present invention is applied to a method of molding a roof trim.

FIG. 6 is an explanatory view showing a state before operation of a set pin in an embodiment in which the method of the present invention is applied to a roof trim molding method.

FIG. 7 is an explanatory view showing a state after operation of a set pin in an embodiment in which the method of the present invention is applied to a method of forming a roof trim.

FIG. 8 is an explanatory view showing a press forming step in an embodiment in which the method of the present invention is applied to a method of forming a roof trim.

FIG. 9 is an explanatory diagram showing a roof trim removal process in an embodiment in which the method of the present invention is applied to a roof trim molding method.

FIG. 10 is a plan view of a conventional automobile roof trim as viewed from the indoor side.

11 is a sectional view taken along line XI-XI in FIG.

FIG. 12 is an explanatory view showing a material setting step in a conventional roof trim molding method.

FIG. 13 is an explanatory view showing a press forming step in a conventional roof trim forming method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Roof trim for vehicles 11a, 11b Opening for sunroof 15 Deep drawing part 20 Foamed PPO base material 21 PPO resin foam layer 22 PPO resin skin layer 30 Skin material 31 Hot melt film 40 Molding device 50 Press upper mold 51 Upper table 52 Elevation Cylinder 53 Housing recess 54 Deep drawing recess 60 Press lower die 61 Lower table 62 Elevating cylinder 63 Deep drawing projection 70 Clamp frame 80 Tension mechanism 81 Bracket 82 Cylinder 83 Support plate 84 Guide rail 85 Set pin a Product outer periphery Part b Sunroof opening edge

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI theme coat ゛ (Reference) B29L 31:30 B29L 31:30 F term (Reference) 4F202 AA32 AD05 AD08 AD17 AD20 AG03 AG20 AH23 AM32 CA17 CB01 CB26 CK90 CL02 CN01 4F208 AA32 AD05 AD08 AD17 AD20 AG03 AG20 AH23 AM32 MA05 MA06 MB01 MB22 MC03 MD10 MG05 MG13 MH06 MJ14 MJ22 MK01

Claims (4)

[Claims] After heating and softening a foamable base material (20) and a skin material (30), a press upper and lower mold (50, 6) having a required shape is formed.
In a method of forming a laminated molded product, which is supplied into the inside of 0) to form a laminated molded product partially having a deep drawn portion, the foamed base material (20) and the skin material (30) are heated and softened. The upper and lower press dies (50, 60) are supplied to the press upper and lower dies (50, 60), and the press upper and lower dies (5, 60)
(0, 60), the molding material (2) located in the deep drawing portion (15) by a tension mechanism (80) provided on one side.
A method of forming a laminated molded product, comprising clamping a press upper and lower mold (50, 60) in a state where tension is applied to (0, 30) and press-molding to a required shape. 2. The laminated molded product is an automobile roof trim (1).
0), and the deep drawing portion (15) is provided with the roof trim (1).
The method according to claim 1, wherein the edge is an edge of the sunroof opening (11) formed in (0). 3. An apparatus for forming a laminated molded body, comprising a foamed base material (20) and a skin material (30) laminated and integrated,
The molding device (40) includes a press upper and lower mold (50, 60) having a desired mold surface shape and a deep drawing part (1) of a laminated molded body.
And a tension mechanism (80) for applying tension to the molding material (20, 30). The tension mechanism (80) is provided with an advance / retreat cylinder (8) which is housed in the space of the upper press die (50).
2) and a set pin (8) that is driven by the reciprocating cylinder (82) to be able to reciprocate in the wrinkle eliminating direction of the skin material (30).
The apparatus for forming a laminated molded article according to claim 3, wherein the apparatus comprises: