JP2006347083A - Molding method and mold of laminated molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molding method of a laminated molding made by integrating a skin and a surface of a resin core material into one body, the method capable of being easily conducted and holding the skin at proper clamping pressure, and to provide a mold for it. <P>SOLUTION: A skin holding apparatus 80 is mounted along an outer circumference of a cavity of upper and lower molds 50 and 60. The skin holding apparatus 80 has upper and lower plates 81 and 82 each holding the circumferential margin of the skin 30, a support shaft 83 supporting the lower plate 82, and a coil spring upwardly urging the support shaft 83. An adjusting mechanism is mounted to adjust effective length of the coil spring. Regarding the adjusting mechanism, an adjuster nut is screwed to a screw groove formed on the support shaft to adjust the effective length of the coil spring or an adjuster shim is fitted to either one of upper and lower sides of the support shaft 83. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for forming a laminated molded body in which a skin is integrally bonded to the surface of a resin core material and a molding die used therefor, and particularly, even if the material and thickness of the skin are changed, the skin is added. The present invention relates to a molding method and a molding die of a laminated molded body using a skin holding device capable of satisfactorily adjusting the tension.

  FIG. 12 is a front view showing an automotive door trim 1 that is installed on the interior surface of a door panel (not shown). The automotive door trim 1 is molded into a desired curved shape as shown in FIG. An outer skin 3 is integrally attached to the surface of the resin core material 2. As the molding method of the door trim 1, various molding methods such as a mold press molding method, a cold press molding method, and an injection molding method can be used.

  Hereinafter, a conventional manufacturing method of the door trim 1 will be described by illustrating a mold press molding method. First, as shown in FIG. 14, a mold press molding die 4 includes a molding upper die 5 that can move up and down by a predetermined stroke, a molding lower die 6 that is a fixed side located below the molding upper die 5, and a molding lower die 6. An injection machine 7 is connected to the mold 6 and supplies a molten resin as a material for the resin core material 2. And the skin holding | maintenance apparatus 8 which hold | maintains the skin 3 along the outer periphery of the product cavity of the shaping | molding upper / lower molds 5 and 6 is provided.

  As shown in FIG. 15, the skin holding device 8 is composed of an upper plate 8a, a lower plate 8b, and a support shaft 8c for supporting the lower plate 8b provided in the molding upper and lower molds 5, 6. A coil spring 8d is wound around the outer periphery of the support shaft 8c so as to be sandwiched between the upper plate 8a and the lower plate 8b along the peripheral edge of the skin 3 with a predetermined clamping pressure. At the time of mold press molding shown in FIG. 5, the peripheral portion of the skin 3 is devised so as to be satisfactorily held by the clamping pressure between the upper plate 8a and the lower plate 8b by the spring pressure of the coil spring 8d. The molding die 4 of such a mold press molding method and a molding method using the molding die 4 are described in detail in Patent Document 1.

JP 2001-225339 A

  As described above, in the conventional mold press molding method, the peripheral edge of the skin 3 that is set in advance is held at an appropriate clamping pressure by the skin holding device 8, but the molded shape of the molded product or the skin 3 It is necessary to change the clamping pressure between the upper plate 8a and the lower plate 8b in accordance with the thickness of the plate or the elongation characteristics. For this purpose, conventionally, the clamp pressure is varied depending on whether the coil spring 8d itself is replaced or the number of the coil springs 8d is increased or decreased. As an actual work, after loosening the fastening bolt 8e and removing the lower plate 8b from the shaft 8c, the coil spring 8d must be replaced or the number thereof must be increased or decreased, which complicates the troublesome work. It is a fact. Further, even if the spring pressure can be roughly adjusted by replacing or increasing or decreasing the coil spring 8d, it is difficult to finely adjust the clamp pressure, and there is still room for improvement in terms of fine-grained handling. there were.

  This invention was made in view of such circumstances, and improved the skin holding device used when integrally molding the resin core material and the skin, such as a mold press molding method, a cold press molding method, and an injection molding method. In addition, an object of the present invention is to provide a method for forming a laminated molded body in which the skin clamping pressure can be adjusted with a simple structure in consideration of the thickness and elongation characteristics of the skin, and a molding die used therefor.

  In order to solve the above problems, the method of the present invention sets the skin in a molding die and supplies the resin core material into a cavity defined between the molding upper and lower molds. In a method for forming a laminated molded body for forming a laminated molded body having a skin integrated on the surface, a skin holding device is provided along the outer periphery of the cavity of the molding upper and lower molds. The peripheral edge of the epidermis is sandwiched between the upper plate and the lower plate in the holding device, the lower plate is urged upward by a coil spring, and the peripheral edge of the epidermis is held at an appropriate clamping pressure. By attaching an adjuster mechanism that can change the spring pressure of the spring, the skin is held at an appropriate clamping pressure and integrated with the surface of the resin core.

  Furthermore, the molding die used in the molding method is a method of setting the resin core material by setting the skin in the molding die and supplying the resin core material into the cavity defined between the molding upper and lower molds. In a molding die for a laminated molded body for molding a laminated molded body having a surface integrated on the surface, the molding die is composed of a molding upper and lower mold capable of mutual clamping and mold opening, and a molding upper and lower mold. A skin holding device is provided along the outer periphery of the cavity, and this skin holding device supports the upper plate, the lower plate, and the lower plate that hold the peripheral edge of the skin from the upper and lower sides, and the outer periphery of the coil spring. And a clamping pressure is applied to the skin sandwiched between the upper plate and the lower plate by the spring pressure of the coil spring. Adjuster mechanism capable of adjusting the spring pressure of the ring, characterized in that is provided.

  Here, examples of the molding method include a mold press molding method, a cold press molding method, and an injection molding method. In the mold press molding method, after setting the skin in the molding die, the molten resin is supplied from the injection machine to the mold surface of the molding lower mold through the hot runner and gate, and the molding upper and lower molds are clamped. The core material and the skin are integrally formed. Further, in the cold press molding method, a thermoplastic resin plate such as polypropylene resin mixed with a filler such as wood powder is extruded as a resin core material into a sheet shape by a T-die extrusion molding machine, and this sheet raw material is heated. After heat-softening treatment, etc., it is placed on the lower mold, and then integrally molded by cold press molding together with the skin supplied into the mold. Further, in the injection molding method, after setting the skin in the molding die, the molding upper and lower molds are clamped, and then the molten resin is injected and filled into the cavity between the molding upper and lower molds from the resin core. What is necessary is just to integrally mold the skin on the surface of the material.

  Here, the skin holding device for holding the peripheral edge of the skin is provided with an upper plate and a lower plate on the molded upper and lower molds respectively along the outer periphery of the product cavity formed by the molded upper and lower molds. It is a mechanism to hold the peripheral edge of the epidermis between the plate. Further, the lower plate is supported by a support shaft, and the support shaft is inserted into the through hole of the molded lower mold in a state where a coil spring is wound around the outer periphery of the support shaft. Therefore, since the lower plate is always spring-biased upward by the spring pressure of the coil spring wound around the outer peripheral surface of the support shaft, the upper plate comes into contact with the lower plate when the upper mold is lowered. When the descent continues further, the peripheral edge of the skin sandwiched between the upper and lower plates is held at an appropriate clamping pressure by the spring pressure of the coil spring.

  Further, the adjuster mechanism in the skin holding device has a threaded groove formed on the outer peripheral surface of the support shaft, and an adjuster nut is screwed so as to be movable along the axial direction of the support shaft. The effective spring length of the coil spring can be adjusted by the operation.

  Therefore, according to the present invention, when changing the thickness and elongation characteristics of the skin to be used or the shape of the product, for example, the spring pressure of the coil spring is tightened by tightening the adjuster nut screwed to the support shaft. Since the spring pressure of the coil spring can be decreased by loosening the coil spring, the holding mechanism is disassembled every time the spring pressure is varied, or the coil spring is replaced. Alternatively, it is possible to deal with fine details such as saving time and increasing the number of coil springs and enabling fine adjustment with simple work.

  Further, in a preferred embodiment, the adjuster mechanism in the skin holding device can adjust the effective spring length of the coil spring by fitting an adjuster shim on at least one of the upper and lower sides of the support shaft that supports the lower plate. It is characterized by that.

  According to this embodiment, since the effective spring length of the coil spring can be easily adjusted by fitting the adjuster shim into the support shaft so as to contact at least one end of the coil spring, the thickness of the skin In order to increase the clamp pressure in consideration of the elongation characteristics, the adjuster shim may be fitted, and conversely, in order to reduce the clamp pressure of the coil spring, the fitted adjuster shim may be removed. As described above, regarding the clamp pressure of the skin when the skin variation is changed, it is only necessary to operate the adjuster mechanism.

  As explained above, according to the molding method of the laminated molded body and the molding die used therefor according to the present invention, the peripheral edge portion of the skin set in advance in the molding die is the upper plate and the lower side of the skin holding device. When the clamp pressure of the skin in the skin holding device is changed due to the thickness of the skin, the elongation characteristics, the shape of the molded product, etc., the operation of whether to tighten or loosen the adjuster nut, Alternatively, it can be handled by a simple operation such as attaching / detaching the adjuster shim, and the clamp pressure can be finely adjusted, so that the tension adjustment work applied to the skin can be carried out easily and inexpensively.

  Hereinafter, specific examples of a method for molding a laminated molded body and a molding die according to the present invention will be described in detail with reference to the accompanying drawings. It should be noted that the gist of the present invention is as described in the appended claims, and the embodiments described below are merely examples of the present invention.

  FIGS. 1 to 8 show a first embodiment of the present invention. FIG. 1 is a front view showing a door trim formed by the method of the present invention, FIG. 2 is a sectional view showing the structure of the door trim, and FIG. FIG. 4 is an explanatory diagram showing the configuration of the skin holding device in the molding die, FIG. 5 is an exploded perspective view showing the configuration of the skin holding device, and FIG. FIG. 7 and FIG. 8 are explanatory views showing a process of forming a door trim using the same molding die.

  1 and 2, the configuration of the door trim 10 manufactured by applying the method of the present invention will be briefly described. The door trim 10 is an interior part that is attached to the indoor surface side of a door panel (not shown), and includes various functional parts. For example, an inner handle escutcheon 11 is attached to a middle portion of the door trim 10. In addition, a power window switch escutcheon 13 and a pull handle 14 are attached to the upper surface of the armrest 12 that is formed in a bulging shape on the indoor side so that the occupant can rest on the elbow, and below the armrest 12. A door pocket 15 is opened, and a speaker grill 16 is attached to the front side of the door trim 10 as a unit or separately.

  As shown in FIG. 2, the door trim 10 is formed of a resin core 20 having a desired curved shape and having a mounting rigidity to the door panel, and a skin 30 adhered to the surface thereof. It is used for the purpose of improving touch feeling and surface texture. Here, the resin core material 20 is made of polypropylene resin mixed with talc, but the resin materials used are polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin. Vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, and the like can be used. Further, as the skin 30, thermoplastic resin sheets such as TPO (thermoplastic olefin), TPU (thermoplastic urethane), PVC sheet, etc., polyurethane foam, polypropylene foam, polyethylene foam on the back surface of a single sheet of these thermoplastic resin sheets A laminated sheet material lined with a cushion layer such as can be used. In this embodiment, a TPO sheet is used.

  Next, the structure of the molding die 40 used for molding the door trim 10 will be described with reference to FIGS. In this embodiment, since a mold press molding method is used, as shown in FIG. 3, a molding die 40 includes a molding upper mold 50 that can be moved up and down by a predetermined stroke, and a molding lower mold on the fixed side located below the molding upper mold 50. 60 and an injection machine 70 connected to the molded lower mold 60. More specifically, the molding upper die 50 is connected to an elevating cylinder 51 and is configured to be movable up and down by a predetermined stroke by driving the elevating cylinder 51. Further, the molding lower mold 60 is provided with a manifold 61 and a gate 62 as resin passages for the molten resin supplied from the injection machine 70.

  Further, in the present invention, the skin holding device 80 is provided along the outer periphery of the cavity C defined between the molding upper and lower molds 50, 60, and in particular, an adjuster mechanism is added to the skin holding device 80. This is a structural feature. That is, the skin holding device 80 is composed of an upper plate 81 attached to the mold surface of the molding upper mold 50 and a lower plate 82 which is paired with the upper plate 81 and is positioned below, and the lower plate 82 has a support shaft 83. Is supported by As shown in FIGS. 4 and 5, the support shaft 83 is inserted into the insertion hole 84 a of the base 84 attached to the molding lower mold 60 and the insertion hole 63 of the molding lower mold 60 so as to be movable up and down. A coil spring 85 is wound around the outer periphery of the support shaft 83, and the lower plate 82 is spring-biased upward by the spring pressure of the coil spring 85. When the upper mold 50 is lowered, the upper plate The peripheral edge of the epidermis 30 is appropriately held between the 81 and the lower plate 82 with a clamping pressure.

  Thus, the structural feature of the skin holding device 80 according to the present invention is that the clamping pressure acting between the upper plate 81 and the lower plate 82 is applied to the thickness of the skin 30, elongation characteristics, or the shape of the product. An adjuster mechanism is provided so that it can be adjusted appropriately according to the above. That is, a thread groove 83a is formed on the outer peripheral surface of the support shaft 83, and an adjuster nut 86 is screwed to the support shaft 83 as shown in the figure. Accordingly, the upper end 85 a of the coil spring 85 is in contact with the lower surface of the lower plate 82, and the lower end 85 b of the coil spring 85 is in contact with the adjuster nut 86.

  Next, the operation of the skin holding device 80 will be described with reference to FIG. 6. When the adjuster nut 86 is positioned at the lowest position, the effective spring length of the coil spring 85 is at the position shown in FIG. Is L0. For example, when it is desired to increase the clamping pressure of the skin 30 due to the thickness and elongation characteristics of the skin 30, the adjuster nut 86 is tightened to the support shaft 83 as shown in FIG. The lower end 85b of the coil spring 85 is positioned upward, and the effective spring length of the coil spring 85 is adjusted to L1, so that the clamping pressure of the skin 30 sandwiched between the upper plate 81 and the lower plate 82 can be increased. .

  In this way, the clamp pressure applied to the peripheral edge of the skin 30 can be easily adjusted by operating the adjuster nut 86 in consideration of the thickness of the skin 30 to be used, the elongation characteristics, or the shape of the door trim 10. Can do. Therefore, the conventional troublesome work such as removing the lower plate from the support shaft and replacing the coil spring or increasing / decreasing the number of coil springs as in the past can be eliminated, and the adjuster nut 86 can be loosened or tightened. Since it is possible to cope with this simple operation and fine adjustment is possible, the molding accuracy can be remarkably improved by a simple operation.

  For reference, a method for forming the door trim 10 using the molding die 40 using the skin holding device 80 will be briefly described. First, as shown in FIG. 7, when the upper mold 50 and the lower mold 60 of the molding die 40 are in the mold open state, the outer skin 30 is set. At this time, the peripheral edge of the skin 30 is placed on the upper surface of the lower plate 82. When the setting process of the skin 30 is completed, as shown in FIG. 8, when the lifting cylinder 51 is operated and the mold clearances of the upper and lower molds 50 and 60 reach a predetermined position, the injection machine 70 and the manifold 61 are arranged. The molten resin M is injected and filled into the cavity C through the gate 62, and the molding upper die 50 is continuously lowered to form the resin core 20 into a required shape, and the skin 30 is formed on the surface thereof. Are integrated.

  At this time, the peripheral edge portion of the skin 30 is sandwiched between the upper plate 81 and the lower plate 82, and is adjusted in advance so as to ensure a predetermined clamping pressure by operating the adjuster nut 86. Therefore, at the time of mold press molding, a part of the skin 30 is appropriately drawn into the cavity without causing wrinkles or sagging, so that the skin 30 is integrated with the surface of the resin core 20 in a good appearance. It will be stuck. In this embodiment, the skin holding device 80 is configured such that the adjuster nut 86 is screwed up and down on the lower end 85b side of the coil spring 85. However, the adjuster nut is mounted on the upper end 85a side of the coil spring 85. 86 may be set, and a coil spring 85 may be interposed between the base 84 and the adjuster nut 86. Further, in this embodiment, the present invention is applied to the mold press molding method, but can also be applied to the cold press molding method. In this case, the heat-softened sheet-shaped raw material is placed on the lower mold 60. After placement, the skin 30 may be set by applying the skin holding device 80 according to the present invention.

  9 to 11 show a second embodiment of the present invention. FIG. 9 is a sectional view showing a skin holding device in a molding die, FIG. 10 is a perspective view showing the configuration of the skin holding device, and FIG. It is explanatory drawing which shows the effect | action of the same skin holding | maintenance apparatus.

  In the second embodiment, the molding method used is a mold press molding method, and when the resin core material 20 and the skin 30 are integrated by mold press molding, an appropriate clamping pressure of the skin 30 can be secured. In the second embodiment, the structure of the adjuster mechanism in the skin holding device 80 is changed. That is, the skin holding device 80 is provided with upper and lower plates 81 and 82 that sandwich the peripheral end portion of the skin 30, a support shaft 83 that supports the lower plate 82, and a coil spring 85 that applies a clamping pressure. Although the point is the same as that of the first embodiment, the second embodiment is characterized in that an adjuster shim 87 is used as an adjuster mechanism for changing the spring pressure of the coil spring 85.

  That is, as shown in FIGS. 9 and 10, the coil spring 85 is wound around the outer periphery of the support shaft 83, and the adjuster shim 87 is positioned on the lower end 85 b side of the coil spring 85. 83. The thickness d of the adjuster shim 87 is determined in consideration of the thickness, elongation characteristics and cavity shape of the skin 30 to be used. When the clamp pressure applied to the skin 30 is strengthened, An effective spring length of the coil spring 85 (in FIG. 9) is set by increasing the thickness d of the shim 87 or by inserting a plurality of adjuster shims 87 having a predetermined thickness into the outer peripheral surface of the support shaft 83. (Indicated by L).

  Further, as shown in FIG. 11, the adjuster shim 87 is fitted into the support shaft 83 so as to contact the lower surface of the lower plate 82, and the coil spring 85 is held between the adjuster shim 87 and the base 84. You may do it. Also in this modified example, in order to vary the clamping pressure of the skin 30 depending on the thickness of the skin 30 to be used, the elongation characteristics, the shape of the door trim 10, etc., the adjuster shim 87 is connected to the upper end side and the lower end of the coil spring 85. The effective spring length of the coil spring 85 can be adjusted as appropriate by fitting into either or both of the sides, so that the parts can be disassembled and the coil spring replaced or the coil spring can be replaced as in the past. It is possible to abolish troublesome work such as increasing or decreasing the number of slabs, to properly adjust the clamping pressure of the skin 30 with a simple operation, and to provide the same effect as the first embodiment that can remarkably improve the molding performance. .

  Furthermore, in the second embodiment, since the adjuster shim 87 is only fitted into the outer peripheral surface of the support shaft 83, the adjustment of the effective spring length of the coil spring 85, that is, the fine adjustment of the clamp pressure, Although slightly inferior to the first embodiment, there is no need to form a screw groove on the outer peripheral surface of the support shaft 83, so that there is an advantage that the structure can be simplified and the cost can be reduced.

  In the first and second embodiments, the method for molding the door trim 10 and the molding die 40 used therefor have been described. However, as an applied laminated molded body, the skin 30 is integrally attached to the surface of the resin core material 20. If it is a structure, the use is not ask | required. The method of the present invention is applied to the mold press molding method, but can also be applied to a cold press molding method or an injection molding method.

It is a front view which shows the door trim for motor vehicles manufactured by applying the shaping | molding method of the laminated molded body which concerns on this invention. It is the II-II sectional view taken on the line in FIG. It is explanatory drawing which shows 1st Example of the shaping die of the laminated molded body which concerns on this invention. It is explanatory drawing which shows the structure of 1st Example of the skin holding | maintenance apparatus in the shaping die shown in FIG. It is a disassembled perspective view which shows the structure of the skin holding | maintenance apparatus shown in FIG. It is explanatory drawing which shows the effect | action of the skin holding | maintenance apparatus shown in FIG. It is explanatory drawing which shows the skin setting process in the shaping | molding method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows the mold press molding process in the shaping | molding method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows 2nd Example of the skin holding | maintenance apparatus in the shaping die of the laminated molded body which concerns on this invention. It is a disassembled perspective view which shows the structure of the skin holding | maintenance apparatus shown in FIG. It is explanatory drawing which shows the effect | action in the skin holding | maintenance apparatus shown in FIG. It is a front view which shows the conventional door trim. FIG. 13 is a sectional view taken along line XIII-XIII in FIG. 12. It is a schematic diagram which shows the shaping | molding method of the conventional door trim. It is explanatory drawing which shows the structure of the skin holding | maintenance apparatus used for the shaping | molding method of the conventional door trim.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Door trim 20 Resin core material 30 Skin 40 Molding die 50 Molding upper mold 60 Molding lower mold 61 Manifold 62 Gate 70 Injection machine 80 Skin holding device 81 Upper plate 82 Lower plate 83 Support shaft 83a Screw groove 84 Base 85 Coil spring 86 Adjuster Nut 87 Adjuster Shim C Cavity

Claims (4)

By setting the skin (30) in the molding die (40) and supplying the material of the resin core (20) into the cavity (C) defined between the molding upper and lower molds (50, 60), In the molding method of the laminated molded body for molding the laminated molded body (10) formed by integrating the skin (30) on the surface of the resin core material (20),
A skin holding device (80) is provided along the outer periphery of the cavity of the molding upper and lower molds (50, 60). In the setting step of the skin (30), the upper plate (81) in the skin holding device (80). The peripheral edge of the outer skin (30) is sandwiched between the lower plate (82) and the lower plate (82) is urged upward by the coil spring (85) so that the peripheral edge of the outer skin (30) is properly The surface of the resin core (20) can be held by holding the skin (30) with an appropriate clamping pressure by attaching an adjuster mechanism that can hold the coil spring (85) and change the spring pressure of the coil spring (85). A method for forming a laminated molded body, wherein the molded body is integrated. By setting the skin (30) in the molding die (40) and supplying the material of the resin core (20) into the cavity (C) defined between the molding upper and lower molds (50, 60), In the molding die (40) of the laminated molded body for molding the laminated molded body (10) formed by integrating the skin (30) on the surface of the resin core material (20),
The molding die (40) is composed of molding upper and lower molds (50, 60) capable of mutual clamping and mold opening, and a skin holding device ( 80), and the skin holding device (80) includes an upper plate (81), a lower plate (82), and a lower plate (82) that sandwich the peripheral edge of the skin (30) from above and below. And a skin (30) sandwiched between the upper plate (81) and the lower plate (82), and a support shaft (83) wound around the outer periphery of a coil spring (85). The laminated molded body is characterized in that a clamp pressure is applied by the spring pressure of the coil spring (85) and an adjuster mechanism capable of adjusting the spring pressure of the coil spring (85) is provided. Mold.   In the adjuster mechanism in the skin holding device (80), a screw groove (83a) is formed on the outer peripheral surface of the support shaft (83), and the adjuster nut (86) moves along the axial direction of the support shaft (83). 3. The laminated molded body according to claim 2, wherein the effective spring length of the coil spring (85) can be adjusted by adjusting the adjuster nut (86). Molding mold. The adjuster mechanism in the skin holding device (80) includes an adjuster shim (87) fitted on at least one of the upper and lower sides of the support shaft (83) that supports the lower plate (82), and the effective spring length of the coil spring (85). The molding die for a laminated molded body according to claim 2, wherein the thickness can be adjusted.

Images