JP2003191277A - Method and apparatus for manufacturing skin/resin substrate material integrated molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To manufacture a skin/resin substrate material integrated molded product having no gate and having a skin material of which the design surface has appearance free from damage. <P>SOLUTION: For the purpose of manufacturing the skin/resin substrate material integrated molded product, the skin material 21 is arranged in a mold (comprising mold members 2 and 3), and a molten resin material 22 is injected in the mold on the rear surface side of the skin material to form an integrated molded member. The resin substrate material is integrally molded on the skin material. In the injection of the molten resin material 22 at the time of formation of the integrated molded member, the molten resin material is injected inwardly from the gate 19 provided at the position on the outside (recessed parts 17 and 18) of the outer shape of the final product. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and apparatus for manufacturing a skin / resin base material integrally molded product in which a cloth or the like is used as a skin material and a resin base material is integrally formed on the back surface side by injection molding.

[0002]

2. Description of the Related Art A skin / resin base material integrally molded product obtained by integrally forming a resin base material by injection molding on the back side of a cloth or the like as a skin material is disclosed, for example, in JP-A-63-21252.
It is disclosed in Japanese Patent Publication No. The method of manufacturing an integrally molded product disclosed in this publication includes a step of disposing a skin material in a cavity of a mold, and a molten resin material is injected to the back surface side of the skin material in the mold to form a resin base material on the skin material. Forming an integrally formed member formed by integrally forming the material. The formed integrally molded member has a thin flange formed along the outer periphery at a portion on the outer periphery side of the outer shape of the final product. The integrally formed member thus formed further includes a step of cutting along the outer shape of the final product, thereby obtaining the final product. In this way, in the integral molding step, the integral molding member having the thin flange formed on the outer periphery is formed, and the flange portion only has to be cut, so that the end treatment of the final product can be easily performed.

[0003]

The above-described skin / resin base material integrally molded product has the advantage that the terminal treatment is simple,
When molding an integrally molded member, in order to obtain uniformity during molding, molten resin is injected into the mold through a gate from a position approximately at the center of the back surface of the skin material. When exposed to high temperature molten resin immediately after coming out of the gate, not only the back surface but also the front surface may be affected by the high temperature and the design surface may be damaged. Lowering the temperature of the molten resin reduces scratches, but the fluidity of the resin decreases and there is a risk that it will not flow evenly over the planned resin base material range, resulting in an unsatisfactory result. It is not desirable to keep the molten resin at low temperature.

When molten resin is injected into the central portion of the back surface of the skin material from the gate of the mold member, a protrusion-shaped gate portion is formed on the molded resin base material at a position corresponding to the gate. This gate part should be cut off in the final product and requires a cutting process. Japanese Patent Application Laid-Open No. 7-171847 discloses a manufacturing method for producing a skin / resin base material integrally molded product using a mold member in which a gate is arranged at a planned opening position. In this case, when the opening is punched in the integrally molded member after molding, there is an advantage that the gate portion at the opening can be removed together, and the step of cutting the gate portion can be omitted. However, JP-A-7-171847
Even in the manufacturing method of the issue, the adverse effect of high-temperature molten resin immediately after leaving the gate to the design surface of the skin material, that is, the damage to the design surface of the skin material cannot be prevented, and when the punched area of the opening is small, There is a fear that the design surface that has deteriorated the appearance will remain. Also, this method cannot be used for final products without openings. Further, if the gate portion is formed in the center of the integrally formed member, the degree of freedom in designing the final product may be reduced. For example, when a pair of locking legs are to be erected on the back side of the resin base material, if the gate portion is in the center,
It becomes difficult to remove the gate part, and if the gate part is left as it is, the bending of the locking leg is hindered and the insertion into the locking hole is hindered. When the gate is moved from the central position, the uniformity during molding is reduced.

Therefore, an object of the present invention is to provide a manufacturing method and apparatus in which a manufactured skin / resin base material integrally molded product has no gate portion and does not damage the outer appearance of the design surface of the skin material. To provide.

[0006]

To achieve this object, the present invention comprises the steps of placing a skin material in a mold.
A step of injecting a molten resin material into the back surface side of the skin material in the mold to form an integrally molded member in which a resin base material is integrally molded on the skin material; A method of manufacturing the method, characterized in that in the step of forming the integrally molded member, the integrally molded member is molded by injecting the molten resin material from the outside of the outer shape of the final product toward the inside. I will provide a.

According to the above-mentioned manufacturing method, since the molten resin material is injected from the outside of the outer shape of the final product toward the inside, the molten resin material is discharged from the gate to the final product portion of the skin material. Immediately after the high temperature does not flow directly, it is possible to prevent or reduce the adverse effect of the high temperature molten resin on the back surface of the skin material, and also to inject the molten resin material from the outside of the final product outline to the inside. Therefore, the gate is placed outside the outer shape of the final product, and the gate part on the back surface of the resin base material of the integrally molded member is outside the outer shape of the final product and is cut together when cutting the integrally molded member into the final product. It is possible to eliminate the step of cutting the gate part.

In the above method, the integrally molded member is
A surplus part is formed by injection on the outside of the outer shape of the final product,
The molten resin flows inward from the extra wall portion. The extra portion may be formed on a part of the outer side of the outer shape of the final product, or may be formed along the entire circumference.
Furthermore, a step of cutting the integrally molded member along the outer shape of the final product is provided, and the extra thickness portion and the extra thickness portion are formed,
The gate portion associated with the molten resin injection gate can be removed.

Further, according to the present invention, the molten resin material is injected through the gate to the back surface side of the skin material arranged in the mold, and the resin base material is integrally molded on the back surface of the skin material. An apparatus for manufacturing a skin / resin base material integrally molded product for forming a member, wherein the mold is composed of a pair of mold members, and the surfaces of the pair of mold members facing each other are provided for the integrally molded member. A concave member that forms a space is formed, and the concave member of the mold member includes a main portion corresponding to the final product and a surplus portion of a region on the outer peripheral side of the main member, and the mold member faces the back surface of the skin material. Is provided with the gate at a position corresponding to the surplus portion. Even with this device, the mold member is provided with a gate at a position corresponding to the surplus part, so that the molten resin material at a high temperature immediately after exiting the gate flows directly to the final product part of the skin material. It is possible to prevent or reduce adverse effects of high temperature molten resin on the back surface of the skin material, and the gate part on the back surface of the resin base material of the integrally molded member is outside the outer shape of the final product. It can be cut together with the cutting process, and the step of cutting the gate part is unnecessary.

The surplus portion of the mold member concave portion may be formed on a part of the outside of the outer shape of the final product, or may be formed along the entire outer periphery of the outer shape of the final product.
The recessed portion of the excess thickness portion includes a flange forming recessed portion that forms a thin flange on the outer peripheral side of the main portion, and a resin reservoir forming recessed portion that forms a thick resin reservoir portion on the outer peripheral side of the flange forming recessed portion. Can be formed as follows.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below.
A description will be given with reference to the drawings. 1 to 5 show steps of manufacturing a skin / resin base material integrally molded product according to the present invention. The illustrated skin / resin base material integrally-molded product is a decorative lid (garnish) that closes a hole in an automobile interior trim, as shown in FIG. This is an example for the purpose of explanation, and any other desired skin / resin base material integrally molded product can be produced.

In FIG. 1, an apparatus (not shown) for manufacturing a skin / resin base material integrally molded product according to the present invention has a mold 1. The mold 1 includes an upper mold member 2 and a lower mold member 3. The opposite surfaces of both mold members 2 and 3 are respectively
The skin / resin base material integrated molded product 1 is provided with a recess 5 and a recess 6 which form a space (cavity) having a predetermined shape. Further, in the upper mold member 2, a cavity for forming a locking hook 10 and a locking leg 11 which are engaged with the edge portion 9 of the hole of the trim 7 of FIG. 13 and 1
4 is also formed. In FIG. 1, the concave portion in the area 15 forms the main portion that becomes the final product, and the boundary portion forms the outer shape of the final product.

In the space formed by the recesses 5 and 6 in which the upper mold member 2 and the lower mold member 3 are in contact with each other, a thin outer peripheral flange is formed in a region on the outer peripheral side of the outer shape of the final product in the range 15 serving as the main part. Forming a shallow flange forming recess 1
7 is formed, and further, a wide and deep resin reservoir forming recess 18 for storing the molten resin is formed along the outer periphery of the flange forming recess 17. The flange forming concave portion 17 and the resin reservoir forming concave portion 18 are in the range 15
The outer part of the main part of the concave part inside is the excess thickness part. In the flange forming recess 17, a recess on the upper surface of the lower mold member 3 and a recess on the lower surface of the upper mold member 2 are formed shallow, and the recess of the upper mold member 2 is formed on the outer peripheral side thereof. The recess of the lower mold member 3 is deeply formed to form the resin reservoir forming recess 18 while keeping the same shape as the above. In the illustrated first embodiment, the recesses 17 and 18 are formed on the outer peripheral side of the final product outline line in the entire circumferential direction thereof.

In the present invention, the gate 19 for injecting the molten resin material on the back surface of the skin material is formed on the mold member (the upper mold member 2 in the illustrated embodiment) facing the back surface of the skin material, and the position thereof is a recess. Not the center of the main part of the
In the illustrated embodiment, it is formed at a position where the resin reservoir forming recess 18 is provided. Molten resin is injected from the gate 19. The number of gates 19 is one in the illustrated embodiment. However, for example, another gate may be provided at a position facing each other in the diametrical direction.

When a skin / resin base material integrally molded product is produced using the mold 1, first, a skin material 21 such as cloth is placed in the mold 1 as shown in FIG. The main portion 15 formed by 6 and the flange forming concave portion 17 and the resin reservoir forming concave portion 18 on the outer periphery thereof are formed and arranged in a size. After the arrangement, the upper mold member 2 and the lower mold member 3 are shown in FIG.
Fix it by firmly abutting it in the state of. Then, as shown in FIG. 2, the upper mold member 2 is provided on the back surface side of the skin material 21 in the mold 1.
The molten resin material 22 is injected through the gate 19 of FIG. As shown in FIG. 3, the injected molten resin material 22 flows so as to fill the entire circumference of the resin reservoir forming recess 18, and when the recess 18 is filled, adjacent shallow flanges are formed from each position of the recess 18. Through the recess 17, it flows all around the inside of the region 15. In this way, since the molten resin material flows in from the outer peripheral side of the final product portion 15 over the entire circumference, the uniformity of the product is maintained. Also, gate 1
Since the position of 9 is outside the final product portion 15 and that portion is a portion other than the final product, the front surface of the skin material is damaged at the portion directly receiving the resin material due to the high temperature of the molten resin material. However, it does not result in loss of the final product. This allows the melting temperature to be higher in order to increase the fluidity of the molten resin material, which further improves the homogeneity of the final product part inside the range 15.

The injected resin material 22 hardens with time and begins to bond to the back surface of the skin material 21. In that case, it is preferable that the molten resin material in contact with the skin material is in a state of maintaining a high melting temperature, and the subsequent bonding strength can be increased.
As shown in FIGS. 4 and 5, by allowing a certain period of time to elapse in the mold 1, the skin material 21 and the resin base material 22A fixed to the back surface side of the skin material 21 are integrally molded. The member 23 is formed. In the above integrally formed member forming step, the skin material 21 may be provided with a resin coating (not shown) on the back surface thereof in advance before the skin material 21 is placed in the mold 1. Alternatively, a resin film (not shown) may be further stacked on the back surface of the skin material 21 and placed in the mold 1. By providing these resin coatings or resin films between the skin material 21 and the resin base material 22A, it is possible to prevent the molten resin from seeping out to the front surface of the skin material 21 at the corners. The resin coating or resin film is also provided in the flange forming recess 17, and the flow of the high-temperature molten resin material 22 from the resin reservoir forming recess 18 causes the skin material 21 and the resin coating or resin film in the flange forming recess 17 to flow. And the resin base material 22A are strongly bonded.
Particularly, due to the high-temperature melting heat of the molten resin from the resin reservoir forming recess 18, the skin material 21 and the resin coating in the flange forming recess 17 or the resin film and the resin base material 22A can be more firmly bonded.

In FIG. 5, the integrally molded member 23 is shown in FIG.
Of the final product, that is, the final product part 15A corresponding to the main body part range 15, and the thin outer peripheral flange 25 formed by the flange forming recess 17 on the outer peripheral side of the part corresponding to the final product part 15A, and On the outer periphery of the outer peripheral flange 25, a thick resin reservoir 26 formed by accommodating the molten resin in the resin reservoir forming recess 18 is formed. High-temperature molten resin from the gate 19 flows into the thin-walled flange 25 formed by the flange forming recess 17 from the resin reservoir forming recess 18, and is sufficiently densely filled with the resin material. The resin base materials are tightly bonded and firmly fixed. Also, the skin material 2
Even when the resin coating or the resin film is provided on the back surface of No. 1, as described above, the resin material is sufficiently densely filled and the early curing is prevented.
1 and resin coating or resin film and resin substrate 22
A and A are closely joined and firmly fixed. Furthermore, as shown in FIGS. 4 and 5, when the molten resin material injected from the gate 19 is cured,
The protruding gate portion 27 is formed. In the present invention, since the gate 19 is provided in the extra thickness portion (the resin reservoir forming recess 18 in the embodiment) outside the final product portion 15A, the gate portion 27 is provided outside the final product portion 15A. A meat portion (resin reservoir portion 26 in the embodiment) is formed.

Further, in FIGS. 4 and 5, the outline line of the final product portion 15A of the integrally molded member 23 is shown by an inner broken line 29. A thin outer peripheral flange 25 is formed on the entire outer periphery of the line 29, and a thick resin reservoir portion 26 is formed on the outer peripheral of the line 29 along the entire outer periphery of the outer peripheral flange 25. The outer peripheral flange 25 and the resin reservoir portion 26 form a surplus portion 30. A locking hook 10 for mounting and a locking leg 11 are formed on the back surface of the center of the final product portion 15A. An elastic locking portion 31 is formed on the locking leg 11 to facilitate mounting and removal in the trim hole. The upper mold member 2 includes a cavity 13 for the locking hook 10 and a cavity 14 for the locking leg 11 in FIG.
Can be formed and split to allow removal of the shaped locking hooks and locking legs. The final product portion 15A of the integrally molded member 23 forms a design surface such as a fabric so that the front surface of the skin material 21 matches the design surface of the trim. The above-mentioned resin coating or resin film has the skin material 21 and the resin base material 22A shown in FIG.
And is formed as a skin material back surface coating layer, for example. In addition, although the excess thickness portion 30 is shown as consisting of the thin-walled outer peripheral flange and the thick resin reservoir portion, the invention is not limited to this, and the thin-walled outer peripheral flange may be used, or the thick resin reservoir portion alone. Of course, it may have another shape.

Next, as shown in FIG. 5, the integrally molded member 23 is cut along the outer shape of the final product portion 15A by using a cutting tool 33 such as a press die or a cutter blade. As a result, as shown in FIG.
The resin base material integrally molded product 8 is produced. As shown in FIG. 5, the cutting is performed along the final outer shape line 29 which is the inner circumference of the thin-walled flange 25, and the thin-walled flange 26 and the thick resin reservoir portion 26, that is, the extra-wall portion 30 are integrally molded member 23.
And the final product portion 15A remains to form the skin / resin base material integrated molded product 8. When the product 8 is formed in this way, it is only necessary to cut the flange portion and the resin reservoir portion, so that the end treatment of the final product can be easily performed.
Further, in the present invention, the gate portion 27 has the extra thickness portion 30.
Since it is in the resin reservoir 26 in the embodiment, the gate 27 can be removed by the cutting process. Therefore, it is not necessary to add a step of cutting the gate portion. Furthermore, the high-temperature molten resin is sufficiently flowing into the thin-walled flange portion, and the molten resin is sufficiently bonded to the back surface of the skin material in the thin-walled flange portion, and the skin material remains strong on the resin substrate even after the flange portion is cut. Since it is adhered to, the skin material does not peel off from the resin base material at the end portion. As shown in FIG. 6, the skin / resin base material integrally-molded product 8 thus produced, for example, serves as a lid that closes a mounting hole (service hole or the like) of the automobile interior trim 7, and the locking hook 10 and the engaging member. The elastic locking portion 31 of the locking leg 11 is attached using the stop leg 11.
This makes it easy to install and remove it. The skin material 22 on the front surface of the integrally molded product 8 is continuous with the skin material of the trim 7 to form a design surface that does not feel strange.

FIG. 7 shows an integrally molded member 34 formed by another mold (not shown). In this integrally molded member 34, the excess thickness portion 35 is formed only at the position corresponding to the gate of the mold member, and the excess thickness portion is not formed in the other portions. The mold is formed in a shape suitable for molding the integrally molded member 34. The excess thickness portion 35 includes the gate portion 3
7 is formed. The integrally molded member 34 having such a shape has an advantage that the small extra thickness portion 25 may be cut off in the cutting step for forming the final product. And
The gate portion 37 can also be cut from the final product by the cutting. In addition, the molten resin material from the gate is
Diffuses into the main recess of the mold, which is the final product part.

[0021]

According to the method of the present invention, the integrally molded member is injected from the outside of the outer shape of the final product to the inside thereof, so that the molten resin material is gated to the final product portion of the skin material. The high temperature material immediately after coming out of the product does not flow directly, so it is possible to prevent or reduce the adverse effect of the high temperature molten resin on the back surface of the skin material, and direct the molten resin material from the outside of the final product outline to the inside. Since the gate is placed outside the final product outline, the gate part on the back surface of the resin base material of the integrally molded member is outside the final product outline, and is integrated together when cutting the integrally molded member into the final product. It is possible to remove the gate part, and the step of cutting the gate part is unnecessary. Also in the apparatus of the present invention, since the mold member is provided with the gate at a position corresponding to the excess thickness portion, the molten resin material at a high temperature immediately after the molten resin material comes out from the gate is provided in the final product portion of the skin material. Does not flow directly, and it is possible to prevent or reduce the adverse effect of high temperature molten resin on the back surface of the skin material. The parts can be cut together when cutting into the final product, eliminating the step of cutting the gate.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a mold member showing a step of disposing a skin material in a method of manufacturing a skin-resin base material integrally molded product according to the present invention.

2 is a sectional view similar to FIG. 1, showing a step of injecting a molten resin material to form an integrally molded member after the disposing step of FIG. 1;

FIG. 3 is an explanatory view showing how the molten resin material flows in the step of forming the integrally molded member of FIG.

FIG. 4 is a plan view of a unitary molded member made by the step of forming the unitary molded member of FIG.

5 is a cross-sectional view taken along line VV of the integrally molded member of FIG.
It is a figure which shows a mode that the integrally molded member is cut.

6 is a cross-sectional view showing a state in which a skin / resin base material integrally molded product formed by subjecting the integrally molded member of FIG. 5 to an end treatment is mounted in a mounting hole of a trim.

FIG. 7 is a plan view of a modification of the integrally formed member formed by another mold.

[Explanation of symbols]

Type 1 2 Upper mold member 3 Lower mold member 5 Recess of upper mold member 6 Lower mold member recess 7 trim 8 skin / resin base material integrated molding products 9 Trim mounting hole edge 10 Locking hook 11 locking leg 13, 14 cavities 15, 15A Final product part 17 Flange forming recess 18 Resin Reservoir Forming Recess 19 gates 21 Skin material 22 Molten resin material 22A resin base material 23 integrally molded member 25 Peripheral flange 26 Resin Reservoir 27 Gate 29 Final product outline line 30 extra thickness 31 Elastic locking part 33 cutting tools 34 integrally molded member 35 extra thickness 38 Gate

Continued front page    (72) Inventor Yasushi Inoue             Hosoda, Noyori-cho, Toyohashi City, Aichi Prefecture (No street number)             Within Pop Rivet Fastener Co., Ltd. F-term (reference) 4F202 AD08 AG03 AH23 AH25 AH26                       CA11 CB01 CB13 CK06 CK83                 4F206 AD08 AG03 AH23 AH25 JA07                       JB13 JM04 JN11 JQ81 JW23

Claims (8)

[Claims] 1. A step of placing a skin material in a mold,
A step of injecting a molten resin material into the back surface side of the skin material in the mold to form an integrally molded member in which a resin base material is integrally molded on the skin material; A method of manufacturing the method, characterized in that, in the step of forming the integrally molded member, the integrally molded member is molded by injecting the molten resin material from the outside of the outer shape of the final product toward the inside. . 2. The method according to claim 1, wherein the integrally molded member has a surplus portion formed by the injection on the outside of the outer shape of the final product, and the molten resin inside from the portion of the surplus portion. A method characterized by being adapted to flow into the. 3. The method according to claim 2, wherein the extra thickness portion is formed along the entire circumference of the outer shape of the final product. 4. The method according to claim 2 or 3, wherein
Furthermore, the method includes a step of cutting the integrally molded member along the outer shape of the final product, wherein the excess thickness portion and the gate portion accompanying the molten resin injection gate formed in the excess thickness portion are formed by the cutting step. A method characterized by being removed. 5. A skin material in which a molten resin material is injected through a gate to the back surface side of a skin material disposed in a mold to form an integrally molded member in which a resin base material is integrally molded on the back surface of the skin material. An apparatus for manufacturing a resin base material integrally molded product, wherein the mold is composed of a pair of mold members, and a concave portion forming a space for the integrally molded member is formed on each surface of the pair of mold members facing each other. The concave portion of the mold member includes a main portion corresponding to the final product and a surplus portion of a region on the outer peripheral side of the main portion. A device, wherein the gate is provided at a position corresponding to a portion. 6. The apparatus according to claim 5, wherein the surplus portion of the mold member concave portion is formed along the entire outer periphery of the final product outer shape. 7. The device according to claim 5, wherein:
The recessed portion of the excess thickness portion has a flange forming recessed portion that forms a thin flange on the outer peripheral side of the main portion, and a resin reservoir forming recessed portion that forms a thick resin reservoir portion on the outer peripheral side of the flange forming recessed portion. Device characterized by including 8. The apparatus according to claim 5, wherein the surplus portion of the mold member recess is formed on a part of the outer side of the final product outer shape.