JP2008173776A - Method for producing skin-integrated molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for easily producing a skin-integrated molding which is not provided with a substrate. <P>SOLUTION: The method for producing the skin-integrated molding 1 provided with a resin body 11 and the skin 20 adhered integrally to the surface of the body 11 includes a process of fitting the mouth part 21 of the bag-shaped skin 20 to a mouth part fitting jig 30, a process of packing a resin 12 into the bag-shaped skin 20, a cooling and holding process in which the injected resin 12 is cooled and held in a prescribed shape, and a process of detaching the cooled and held skin-integrated molding 1 from the jig 30. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing a skin-integrated molded product in which a skin is integrally adhered to the surface thereof.

Door trims, etc. (skin-integrated moldings), which are interior parts of automobiles, are provided with a skin such as fabric or leather on the surface in order to improve the texture and produce a high-class feeling.
Such a skin-integrated molded product has (1) a method of attaching a skin to the surface of a resin molded product obtained by injection molding, and (2) a skin arranged along the inner surface of a mold for injection molding. Later, it is manufactured by a method of injecting resin. For an armrest or the like having a hard base made of aluminum or the like, a technique has been proposed in which a foamed resin is injected into a gap between the base and the skin after the base is covered with the base (Patent Document 1). reference).
JP-A-6-23767

  However, the method of pasting the skin after injection and the method of arranging the skin on the inner surface of the mold are time-consuming and require a mold to be prepared for each skin-integrated molded product, resulting in a high manufacturing cost. was there. In addition, there was a problem that the delivery time of the prototype of the integral skin product had to be set long. Furthermore, Patent Document 1 does not disclose the production of a skin-integrated molded product that does not include a substrate.

  Then, this invention makes it a subject to provide the manufacturing method which can obtain easily the skin integral molding which is not provided with a base | substrate.

  As means for solving the above-mentioned problems, the present invention provides a method for producing a skin-integrated molded product comprising a resin-made main body and a skin integrally adhered to the surface of the main body. A method for producing a skin-integrated molded article, comprising: attaching a mouth part to a jig for attaching the mouth part; and filling a resin in the bag-like skin.

According to such a method for producing an integral skin product, for example, by forming a bag-like skin corresponding to the shape of the integral skin product after production by draping (draping, pattern making), Attach the mouth of the bag-shaped skin to a jig for attaching (fixing) the mouth.
Then, for example, by using an injection molding machine, a molten resin is injected into the bag-shaped skin from the mouth opening of the skin, and the resin is filled into the skin. The filling amount of the resin is not limited to the amount corresponding to the volume in the epidermis when it swells, and may be smaller than this.

  Then, after holding the shape by an appropriate method so that the bag-shaped skin and the filled resin have a predetermined shape, when taken out from the injection molding machine, the resin main body and the surface of the main body are in close contact with each other. A skin-integrated molded product having a skin can be obtained. Further, even if the skin-integrated molded product does not include a hard base such as aluminum, it can be manufactured by such a method.

  In this way, it is possible to obtain a skin-integrated molded article without using a mold, and without taking the trouble of attaching the skin after injection molding or arranging the skin on the mold before injection. Therefore, the manufacturing cost can be reduced. Moreover, since a mold is not used, a prototype of the integral skin product can be easily obtained. Furthermore, when the resin is filled in the skin, the melted and heat-resistant resin and the skin are welded and adhered, so there is no need to attach the skin with an adhesive or the like. The tactile sensation of the integrally molded product is not lowered.

Moreover, it is preferable that it is a manufacturing method of the skin integrated molding characterized by venting the gas in the bag-shaped skin before filling with the resin.
According to such a method for producing a skin-integrated molded product, after removing gas such as air in the bag-like skin, the resin is filled into the skin, so that it is difficult for gas to be mixed into the filled resin, that is, In other words, the so-called “air bite” is less likely to occur. Thereby, it becomes difficult for gas to mix in the main body after resin hardening, and a molding defect can be reduced.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method which can obtain easily the skin integral molding which is not provided with a base | substrate can be provided.

<< First Embodiment >>
Hereinafter, a first embodiment of the present invention will be described with reference to FIG.
As shown in FIG. 1, the manufacturing method of the skin integrated molding 1 which concerns on 1st Embodiment is the skin integrated molding 1 provided with the resin-made main body 11 and the skin 20 integrally_contact | adhered to the main body 11 integrally (FIG. 1). (See (d)). And the manufacturing method of the skin-integrated molded product 1 includes the step of attaching the mouth part 21 of the bag-like skin 20 to the jig 30 for attaching the mouth part, and injecting the resin 12 into the bag-like skin 20. An injection step of filling and filling, a cooling / holding step of cooling the injected resin 12 and holding it in a predetermined shape, and a removal step of removing and removing the skin-integrated molded article 1 after cooling and holding from the jig 30 Contains.

  In addition, although the specific kind of the skin integral molding 1 after manufacture does not limit this invention, For example, as an interior part for motor vehicles, an instrument panel, a console, roofing, a pillar garnish, a door trim, an armrest, a steering And grips such as shift knobs and side brakes, various pads, emblems attached to the center of the steering wheel, switches for air conditioning, and the like. Examples of exterior parts for automobiles include door handles, tailgate handles, and the like. In addition to automobile parts, for example, handles such as desks and lockers, door knobs, lighting shades, mouse housings, LCD monitor outer frames, stick grips, toys such as stuffed animals, Examples include low resilience pillows, body pillows, household cushions, mats, containers, etc. that absorb shock and easily deform.

<Skin>
First, the skin 20 will be described prior to the description of each process.
The skin 20 shown in FIG. 1A is formed into a bag shape by draping (draping, pattern making) corresponding to the shape of the skin 20 constituting the skin integrated molded article 1 after manufacture. The material of the skin 20 is not particularly limited, but the skin 20 is, for example, a cloth fabric (woven fabric), a nonwoven fabric, a rubber film or sheet, a resin film or sheet such as a thermoplastic resin, a metal film or sheet, It is formed from a paper having a sufficient strength (designed paper subjected to water-repellent finishing, Japanese paper). In addition, the skin 20 may be made of a woven fabric made of carbon fiber, and the appearance of the skin-integrated molded article 1 after manufacture may be carbon.

  Moreover, the skin 20 does not need to be formed from one sheet of cloth, film, or the like, and may be formed into a bag shape by sewing a plurality of cloths or bonding a plurality of films.

Furthermore, it is preferable that the skin 20 has air permeability. Thus, when the skin 20 has air permeability, as will be described later, when the resin 12 is injected into the skin 20 (see FIG. 1C), the air (gas) in the skin 20 passes through the skin 20. Thus, the resin 12 can be discharged to the outside, the resin 12 can be injected well, and the resin 12 can be suitably filled in the skin 20.
At the same time, the injected resin 12 enters the pores communicating with the inside and outside of the skin 20, that is, the resin 12 is inserted into the skin 20 and hardened, so that the adhesion between the cured resin main body 11 and the skin 20 is achieved. Can be increased. As a result, an air layer is unlikely to be formed at the interface between the main body 11 and the skin 20, and the skin 20 is difficult to peel off from the main body 11. Further, when air is discharged in this manner, the main body 11 is also prevented from being oxidized by air or the like after manufacturing.
However, it is preferable to set the air permeability (pore ratio) of the skin 20 so that the injected resin does not leak out of the skin 20.

  Furthermore, it is preferable that the skin 20 does not expand as much as possible due to the injection pressure of the resin 12 injected into the inside thereof. This is because the deformation of the skin 20 due to the injection pressure is suppressed and the skin-integrated molded product 1 having a precise shape is obtained.

<Mouth part installation process>
As shown in FIG. 1A, the skin 20 thus formed in a bag shape is attached to a mouth mounting jig 30. The jig 30 includes an upper jig 31 and a lower jig 32. The upper jig 31 is detachably attached to a nozzle 41 of an injection molding machine (injection molding machine) (not shown).
Specifically, the mouth portion 21 of the skin 20 is inserted into a through hole 32 a formed in the lower jig 32, and the mouth portion 21 is pushed along the upper surface 32 b of the lower jig 32. Next, as shown in FIG. 1B, the mouth portion 21 is sandwiched between the upper jig 31 and the lower jig 32, and the jig 30 is closed. Then, the skin 20 is attached to the jig 30.

<Injection process>
After attaching the skin 20 to the jig 30 in this way, as shown in FIG. 1C, the resin 12 is injected into the skin 20 through the mouth opening surrounded by the mouth portion 21. Is filled with resin.
The injection method of the injection molding machine is not particularly limited, and may be a plunger method, a screw method, or other methods. Further, in order to appropriately warm the resin 12 in the cylinder 42 to be injected, it is preferable to provide a hot water jacket (heating means). As such an injection molding machine, for example, SJA-50E manufactured by Yamashiro Seiki can be used. Furthermore, a degassing hole (not shown) may be appropriately formed in the jig 30 so that the air in the skin 20 can escape when injected.

  As the resin 12, for example, a thermoplastic resin such as PP (polypropylene), PE (polyethylene), PET (polyethylene terephthalate), PA (polyamide), PC (polycarbonate), ABS (acrylonitrile, butadiene, styrene) is used. Can do. That is, as the resin 12, an olefin-based, urethane-based, or styrene-based thermoplastic elastomer (TPO, TPU, TPS) can be used. In addition, a thermosetting resin can also be used. Specifically, for example, Santo Plain (registered trademark) manufactured by AES Japan can be used as the thermoplastic elastomer.

The molding temperature of the resin 12 (the kneading temperature of the resin 12 in the hopper that feeds the resin 12 into the cylinder 42), the temperature of the cylinder 42, and the like are set according to the type of the resin 12, and are, for example, 100 to 250 ° C. (preferably 180 ° C.). ~ 200 ° C).
Similarly, the injection pressure is set based on the type, viscosity, and the like of the resin 12, the cross-sectional area of the sprue 31a formed on the upper jig 31, the degree of elongation based on the material of the skin 20, and the like. It is set to about 98 to 9.8 MPa (10 to 100 kg / cm ² ). It is preferable to set the pressure as low as possible so that the resin 12 injected into the skin 20 does not leak through the skin 20 to the outside.
The injection time is set based on the volume in the skin 20, the viscosity of the resin 12, etc., and is set to 3 to 10 seconds, for example.
Further, the ambient temperature outside the skin 20 at the time of injection is set to, for example, 30 ° C. or less in order to cool the injected resin 12.

<Cooling and holding process>
Then, the resin 12 injected into the skin 20 is cooled in a predetermined cooling time (for example, 30 seconds or more) by an appropriate cooling method (air cooling, water cooling, leaving, etc.), and the injected resin 12 is formed into a predetermined shape. maintain. As a result, the temperature of the resin 12 is lowered and hardened to form the main body 11.

<Removal process>
Thereafter, the upper jig 31 is raised, the jig 30 is opened, and the skin integrated molded article 1 is removed from the jig 30. In addition, the runner 61 etc. are cut | disconnected and the skin integrated molding 1 is finished.

According to the manufacturing method of such a skin integrated molded product 1, the following effects can be mainly obtained.
Since the skin-integrated molded article 1 can be obtained without using a mold, the manufacturing cost of the mold can be suppressed. In addition, conventionally, it is necessary to prepare a mold for each skin-integrated molded article 1, and it usually takes a long time to produce the mold, but according to the present invention, the skin-integrated molded article 1 is obtained in a short period of time. be able to. Furthermore, since the skin 20 constitutes the skin-integrated molded product 1 after manufacture, the skin-integrated molded product 1 can be manufactured while using the skin 20 without waste. Furthermore, since it is not necessary to bond the main body 11 and the skin 20 or to arrange the skin 20 in the mold before injection, the productivity of the skin integrated molded article 1 can be increased.

  By injecting the resin 12 into the outer skin 20, the resin 12 (main body 11) and the outer skin 20 can be satisfactorily adhered by the heat of fusion of the resin 12. That is, since it is not necessary to adhere the main body 11 and the skin 20 with an adhesive, the touch of the skin-integrated molded article 1 is not reduced by the hard adhesive layer after curing.

Since the resin 12 is injected into the bag-shaped skin 20, even if the shape of the skin 20 is complicated, the resin 12 can be filled into the details of the skin 20. That is, the outer surface of the skin-integrated molded article 1 after manufacture protrudes locally. Correspondingly, even if the skin 20 protrudes locally, the protruding portion is filled with the resin 12. be able to.
In addition, when the shape of the skin 20 becomes complicated, the rigidity of the skin 20 itself becomes high, and it becomes difficult to be deformed by the injection pressure.

The first embodiment of the present invention has been described above. However, for example, the following modifications can be made without departing from the spirit of the present invention.
In the first embodiment described above, a case where a thermoplastic resin or a thermosetting resin is injected as the resin 12 into the skin 20 is exemplified. However, for example, as the resin 12, a silicon-based, olefin-based, or styrene-based resin is used. A gel elastomer (for example, Actimer (registered trademark) gel manufactured by Riken Technos) or liquid silicon may be used.

  In the first embodiment described above, the case where a resin 12 such as a thermoplastic resin is injected into the skin 20 using an injection molding machine (not shown) and the resin 12 is filled in the skin 20 is exemplified. Any method may be used as long as the resin 12 can be filled in the skin 20. For example, the resin 12 may be pushed and filled into the skin 20 using a transfer molding machine for molding rubber products, or the molten resin 12 may be poured into the skin 20 and filled.

  In the first embodiment described above, the case where the resin 12 is injected into the skin 20 from one nozzle 41 is exemplified. However, when the skin 20 is large and the volume in the skin 20 when swollen is large, a plurality of nozzles 41 is used. May be used to inject the resin 12. In this case, a plurality of mouth portions 21 are formed on the skin 20.

<< Second Embodiment >>
Next, a second embodiment of the present invention will be described with reference to FIG. Only parts different from the first embodiment will be described.
As shown in FIG. 2, the manufacturing method of the skin-integrated molded article 1 according to the second embodiment sprays the resin 12 into the skin 20 while blowing the cold air W (or mist) to the skin 20 and cooling the skin 20. It is characterized by doing.

  In this way, by blowing the cool air W and cooling the skin 20, the resin 12 injected into the skin 20 is appropriately cooled. Thereby, the resin 12 injected into the skin 20 and still having heat of fusion and having fluidity can be prevented from being deformed by its own weight. Therefore, it becomes easy to acquire the skin-integrated molded article 1 having a predetermined shape favorably.

<< Third Embodiment >>
Next, a third embodiment of the present invention will be described with reference to FIG. Only parts different from the first embodiment will be described.
As shown in FIGS. 3 (a) to 3 (d), the manufacturing method of the skin integrated molded product 1 according to the third embodiment is performed by immersing the skin 20 in a liquid 51 (for example, water) and molding the skin integrally in the liquid 51. The product 1 is manufactured.

  Thus, by manufacturing the skin integral molded product 1 in the liquid 51, the resin 12 injected into the skin 20 and still having heat of fusion and having fluidity is prevented from being deformed by its own weight. it can. The type and density (specific gravity) of the liquid 51 are preferably set as appropriate based on the density (specific gravity) of the resin 12. Further, as shown in FIGS. 3A to 3D, it is not necessary to perform all the steps in the liquid 51, and at least the injection step and the cooling / shape maintaining step shown in FIG. Preferably it is done.

  Moreover, if the liquid 51 is lower than the injection temperature of the resin 12, the injected resin 12 can be cooled by the liquid 51 as in the second embodiment. As such a liquid 51, for example, water can be used.

<< Fourth Embodiment >>
Next, a fourth embodiment of the present invention will be described with reference to FIG. Only parts different from the first embodiment will be described.

  As shown in FIG. 4 (b), the manufacturing method of the skin-integrated molded product 1 according to the fourth embodiment is to evacuate the air (gas) in the skin 20 before injecting the resin 12 into the skin 20. Features. As shown in FIG. 4, the upper jig 31 used in the fourth embodiment has a gas vent hole 31b communicating with the sprue 31a. The gas vent hole 31b is connected to the on-off valve 52 and a pump (not shown).

  4A to 4D, (open) indicates that the on-off valve 52 is open, and (closed) indicates that the on-off valve 52 is closed. The same applies to FIGS. 5 and 6 to be described later. Further, the on-off valve 52 is shown on the right outside of the upper jig 31 for the sake of clarity, but as shown in FIG. 4C, the injected resin is injected. 12 is arranged on the sprue 31a side of the gas vent hole 31b so as not to flow into the gas vent hole 31b from the sprue 31a. Further, the upper jig 31 is provided with an on-off valve (not shown) that appropriately opens and closes the upper opening of the sprue 31a.

As shown in FIG. 4A, when attaching the skin 20 to the jig 30, the on-off valve 52 is closed. And as shown in FIG.4 (b), the on-off valve 52 is opened, a pump (not shown) is operated, and the air in the skin 20 is attracted | sucked. If it does so, the air in the outer skin 20 will be extracted via the sprue 31a and the on-off valve 52, and the inside of the outer skin 20 will be pressure-reduced.
It should be noted that the air in the epidermis 20 is not limited to be evacuated as described above, but the epidermis 20 may be crushed and evacuated by manpower or a holding device, for example.

Next, as shown in FIG. 4C, the on-off valve 52 is closed and the resin 12 is injected into the skin 20. Thus, after the air in the skin 20 is evacuated, the resin is injected into the skin 20 so that the air is less likely to be mixed into the injected resin 12, that is, it is difficult to “catch the air”. In particular, when the air permeability of the skin 20 is low and the air in the skin 20 is difficult to escape, it is effective to vent the air before the resin 12 is injected.
In this manner, air can be prevented from being mixed into the main body 11 shown in FIG. 4D, and molding defects can be reduced. As a result, the productivity of the skin-integrated molded product 1 can be increased.

«Fifth embodiment»
Next, a fifth embodiment of the present invention will be described with reference to FIG. Only parts different from the fourth embodiment will be described.

  The fifth embodiment is characterized in that the skin-integrated molded product 2 having a hollow portion 13a therein is manufactured (see FIG. 5C). As in the fourth embodiment, after the air in the epidermis 20 is evacuated (see FIG. 4B), the volume in the epidermis 20 when the swells in the epidermis 20 as shown in FIG. 5A. A smaller amount (for example, 30 to 70% by volume) of the resin 12 is injected.

  Next, before the resin 12 is cured, air is fed into the skin 20 as shown in FIG. Then, the resin 12 is pushed and spread along the inner wall surface 20a of the skin 20 by the fed air, and the hollow portion 13a is formed.

  Then, when it takes out from the jig | tool 30, the skin integrated molding 2 provided with the main body 13 which has the hollow part 13a in the inside, and the skin 20 closely_contact | adhered to the surface of the main body 11 is obtained (refer FIG.5 (c)). . Such a skin-integrated molded product 2 has a hollow portion 13a and is lightweight. Further, since the amount of the resin 12 injected into the skin 20 is reduced, the manufacturing cost can be reduced.

<< Sixth Embodiment >>
Next, a sixth embodiment of the present invention will be described with reference to FIG. Only parts different from the fifth embodiment will be described.

  The sixth embodiment is characterized in that the main body 14 produces the skin-integrated molded product 3 having two resin layers 14a and 14b in the inner direction (see FIG. 6C). However, the number of resin layers 14a and 14b is not limited to this.

  As in the fifth embodiment, air is blown into the skin 20 to form the hollow portion 13a (see FIG. 5B), and then the skin 20 is attached to the jig 30 as shown in FIG. 6A. The jig 30 is attached to the nozzle 43 of another injection molding machine (not shown) (see FIG. 6B). Next, a resin 15 different from the resin 12 is injected into the hollow portion 13 a from the cylinder 44 and the nozzle 43. The injection amount, injection pressure, injection time and the like of the resin 15 are adjusted as appropriate.

  And after cooling and shape-retaining suitably, the skin integral molding 3 which has the two resin layers 14a and the resin layer 14b in the internal direction can be obtained. According to such a manufacturing method, the material (for example, hardness) of the resin layer 14a and the resin layer 14b can be changed.

<< Seventh Embodiment >>
Next, a seventh embodiment of the present invention will be described with reference to FIG. Only parts different from the fourth embodiment will be described.
The seventh embodiment is characterized in that the skin-integrated molded product 4 having a main body 16 that is foamed and includes bubbles 16a is manufactured (see FIG. 7C).

  Similarly to the fourth embodiment, after the gas in the skin 20 is removed (see FIG. 4B), the resin 12 containing the foamed capsule 17 is injected into the skin 20 as shown in FIG. 7A. To do. The injection amount of the resin 12 containing the foam capsule 17 is set in consideration of foaming the foam capsule 17. In addition, when the foamed capsule 17 is heated, the substance in the capsule is gasified. For example, Kureha's Microsphere (registered trademark) can be used.

  And as shown in FIG.7 (b), the foaming capsule 17 is heated to the foaming temperature by the heater 53 (heating means) from the exterior, or the oven (heating means) in which high frequency induction heating or microwave heating is possible, The foam capsule 17 is foamed to form a bubble 16a. The foam capsule 17 may be partially foamed. Further, when an oven capable of microwave heating or the like is used, since the injected one can be heated from the inside, the foamed capsule 17 can be uniformly foamed.

  Next, as shown in FIG. 7C, the jig 30 is opened, and the skin-integrated molded product 4 is taken out. Since the main body 16 of such a skin-integrated molded article 4 contains bubbles 16a by foaming, it is lightweight. In addition, since the gripping force and the like can be absorbed by the foamed main body 16, the flexibility (tactile feeling) of the skin-integrated molded article 4 is improved. In addition, by changing the foaming degree of the foam capsule 17 continuously, it is possible to impart a tactile sensation that changes in an inclined manner to the skin-integrated molded article 4.

It is a figure which shows the manufacturing method of the skin integrated molding which concerns on 1st Embodiment, (a) is the state which attached the skin to the jig | tool, (b) is the state which closed the jig | tool, (c) is in the skin. The state in which the resin is injected, (d) shows the state in which the skin-integrated molded product is removed from the jig. It is a figure which shows the manufacturing method of the skin integrated molding which concerns on 2nd Embodiment, and shows the state which is injecting resin in a skin, blowing cold air on a skin. It is a figure which shows the manufacturing method of the skin integral molding which concerns on 3rd Embodiment, (a) attached the skin to the lower jig | tool, the state which immersed the skin in the liquid, (b) the state which closed the jig | tool, (C) shows a state in which resin is injected into the epidermis while the epidermis is immersed in the liquid, and (d) a state in which the epidermis integrated product is removed from the jig. It is a figure which shows the manufacturing method of the skin integral molding which concerns on 4th Embodiment, (a) is the state which attached the skin to the lower jig | tool, and closed the jig | tool, (b) is extracting the air in a skin. The state, (c) shows the state where the resin is injected into the skin, and (d) shows the state where the skin-integrated molded product is removed from the jig. It is a figure which shows the manufacturing method of the skin integral molding which concerns on 5th Embodiment, (a) is the state which has injected resin in the skin, (b) blows air in the skin, and forms a hollow part. (C) shows a state in which the skin-integrated molded product is removed from the jig. It is a figure which shows the manufacturing method of the skin integral molding which concerns on 6th Embodiment, (a) is the state currently conveyed to another injection molding machine, attaching the skin integral molding which has a hollow part to a jig | tool. (B) shows the state in which resin is injected into the hollow portion, and (c) shows the state in which the skin-integrated molded product is removed from the jig. It is a figure which shows the manufacturing method of the skin integral molding which concerns on 7th Embodiment, (a) is the state which has injected the resin with a foam capsule in the skin, (b) forms a bubble by heating a foam capsule (C) shows a state in which the skin-integrated molded product is removed from the jig.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Skin integral molding 11 Main body 12 Resin 20 Skin 21 Mouth part 30 Jig

Claims (2)

A method for producing a skin-integrated molded article comprising a resin-made body and a skin that is integrally adhered to the surface of the body,
Attaching the mouth portion of the bag-like skin to a jig for attaching the mouth portion;
Filling the bag-shaped skin with resin;
The manufacturing method of the skin integral molding characterized by including this.   The method for producing a skin-integrated molded product according to claim 1, wherein the gas in the bag-like skin is vented before filling with the resin.

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