JP2013067022A - Method of molding laminated molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of molding a laminated molded article by which the surface texture and the soft feeling of the laminated molded article are kept, equipment is simplified, man-hours are reduced and a work environment is improved.SOLUTION: There is provided the method of molding the laminated molded article which comprises a resin core material 12 molded into a prescribed shape and a skin 13 stuck to the surface of the resin core material 12. The method comprises: a core material molding step of supplying a thermally-melted resin 12a into a cavity 26 of a upper and lower mold 23, 24 in a molding die 21 and molding the resin core material 12 along the shape of the cavity 26 into the prescribed shape; a skin supply step of opening the upper and lower mold 23, 24 while keeping the resin core material 12 before cooled on the lower mold 24 and supplying the skin 13 provided with a cobweb like hot melt sheet on the rear surface thereof to the resin core material 12 to laminate the skin thereon; and a pressing and cooling step of sticking the skin 13 to the outer surface of the resin core material 12 and cooling the skin.

Description

  The present invention relates to a molding method and molding apparatus for a laminated molded product, and more particularly to a molding method for a laminated molded product suitable for automobile interior parts such as a door trim, a rear parcel chef, a rear side trim, a luggage side trim, a room trim, and the like. The present invention relates to a molding apparatus.

  Various techniques relating to this type, molding method and molding apparatus for automobile interior parts have been proposed (see, for example, Patent Document 1 and Patent Document 2).

  FIG. 9 shows an automotive door trim 1 mounted on the interior surface of a vehicle door panel, and FIG. 10 is a cross-sectional view taken along the line CC in FIG. In FIG. 9, a door trim 1 for an automobile is molded into a required shape as shown in FIG. 9, and has a surface texture and soft feeling on the surface of a resin core 2 having shape retention and mounting rigidity to a door panel. In many cases, a laminated molded product to which the skin 3 to be applied is attached is used. Moreover, the skin 3 is often formed by applying urethane or the like to the back surface of a cloth or nonwoven fabric.

  FIG. 11 shows an example of the structure of a conventional molding apparatus for manufacturing a laminated molded product such as the door trim 1 and the like which is made by sticking the skin 3 on the surface of the resin core material 2. The molding apparatus shown in FIG. 11 includes a molding die 6 and an injection cylinder 7 as a material supply mechanism that supplies the material of the resin core material 2. The molding die 6 is composed of an upper die 4 connected to a functional press machine, and an upper die 4 and a lower die 5 that can be clamped and opened, as shown in FIG. An injection cylinder 7 is connected to the lower mold 5, and the molten resin 2 a is supplied from the injection cylinder 7 into the cavity 8 through a manifold 5 a and a gate 5 b provided in the lower mold 5.

  Next, a molding method using this molding apparatus will be described with reference to FIGS. First, the skin 3 is set and held on the lower mold 5 with the upper mold 4 in the mold 6 opened (a). Next, the upper die 4 is lowered and semi-closed, and in this state, from the injection cylinder 7 to the lower die 5 through the manifold 5a and the gate 5b, inside the cavity 8, that is, between the back surface of the skin 3 and the lower die 5. A required amount of molten resin 2a for forming the resin core material 2 is injected and supplied (b). Subsequently, the upper mold 4 is further lowered, and the molten resin 2a is spread between the skin 3 and the lower mold 5 to form the resin core material 2 having a required shape, and the resin core material is used without using an adhesive. The skin 3 is adhered to the surface of 2 (c). Further, when the resin core material 2 is cooled, the upper mold is opened (d), and then the door trim 1 having a required shape is produced when it is taken out.

JP 2001-287237 A. JP 2010-179485A.

  However, in the conventional molding method shown in FIG. 11, since the molten resin 2a is directly injected onto the back surface of the skin 3, a gate mark (resin leakage, resin omission, etc.) is made on the skin 3, and the appearance is poor. There was a problem to do.

  Moreover, the skin 3 receives an excessive pressure by the resin pressure at the time of molding of the resin core material 2. For this reason, in the case of the fabric specification, hair fall occurs, and in the case of the resin sheet, there are problems that it is easy to cause appearance defects such as squeezing outflow, and there is a problem that the soft feeling is impaired.

  Furthermore, there is a problem that the cost increases because it is necessary to use a skin material having a high basis weight in order to prevent the trace of the gate and the hair from falling down.

  Further, when the outer periphery of the skin is wound around, it is necessary to apply the adhesive around the outer periphery of the skin, and there is a problem that the work man-hour is increased and the working environment is deteriorated.

  Accordingly, the present invention has been made in view of the above problems, and while maintaining the surface texture and softness of the laminated molded product, the equipment can be simplified, the number of man-hours can be reduced, and the working environment can be maintained. It is an object of the present invention to provide a method for forming a laminated molded product that can improve the above.

  The present invention has been proposed in order to achieve the above object, and in a molding method of a laminated molded product comprising a resin core material molded into a required shape and a skin attached to the surface of the resin core material, A core material forming step of supplying a heat-melted resin material into the upper and lower mold cavities in the mold, and molding the resin core material into a required shape along the cavity shape, and the resin core material before cooling to the bottom A skin supply step of holding the mold on the mold and opening the upper and lower molds, and supplying and laminating the skin provided with a web-like hot melt sheet on the back surface; and the skin Are bonded to the outer surface of the resin core material and cooled and pressed.

  According to the molding method of the laminated molded product, after the molten resin is supplied into the upper and lower mold cavities to form the resin core material of the required shape, the upper and lower molds are opened, and the mold is placed on the resin core material. When a skin with a nest-like hot melt sheet is placed on the back surface, and then the upper and lower molds are closed and pressed and cooled, the hot melt sheet is melted by the heat of the resin core material, and the resin core material and the skin are adhered. Thereafter, the attached state is firmly held by cooling. Therefore, in this method, since the molten resin is not directly injected onto the back surface of the skin, a gate mark by injection molding is not formed on the skin. Further, the press pressure applied to the skin may be from no load to an ultra-low pressure required to contact the resin core material. Furthermore, since the resin core material and the skin can be adhered by melting the hot melt sheet with the heat of the resin core material, it is not necessary to use an adhesive or the like separately.

  In the molding method of the laminated molded product, the resin core material is formed in a short shot state in the core material molding step, and the resin material that is surplus by the thickness of the skin in the pressing / cooling step is short shot. It is possible to adopt a method in which the resin core material having the required shape is formed by fluid filling in the gaps.

  According to this method, when pressing in the pressing / cooling process, the resin material surplus by the thickness of the skin is fluidly filled into the gap portion in the short shot state to form a resin core material having a normal required shape can do. Therefore, when pressing in the pressing / cooling process, the resin material extruded by the press flows to the gap part where it is short shot and escapes, thereby reducing the force of crushing the skin and damaging the skin by the press. Can be reduced.

  In the method for molding a laminated molded product, a part of the upper mold in the molding die is movably provided outside, and the thickness of the skin is absorbed by the movement of a part of the upper mold in the pressing / cooling step. You can adopt the method you did.

  According to this method, when a surplus material is generated by the thickness of the skin when pressing in the pressing / cooling process, a part of the upper mold is moved outward to absorb the surplus volume. . Thereby, the force which crushes the skin at the time of pressing at a press and cooling process is reduced, and damage to the skin by press can be reduced.

  In the method for molding a laminated molded product, a method in which the outer surface of the resin core material is partially laminated and two-color molding is performed can be employed.

  According to this method, a two-color molded laminated molded product is obtained.

  In a molding apparatus for a laminated molded product in which a resin core material molded into a required shape and a skin is attached to the surface of the resin core material, a process of molding a resin material supplied in a hot melt state as the resin core material; And a molding die composed of upper and lower molds capable of sequentially performing the process of bonding the outer skin provided with a web-like hot melt sheet on the back surface to the outer surface of the resin core and cooling it. .

  According to the configuration of the molding apparatus of this laminated molded product, after supplying the molten resin into the cavity of the upper and lower molds and molding the resin core material of the required shape, the upper and lower molds are opened, and on the resin core material, When a skin provided with a web-like hot melt sheet is placed on the back surface, and then the upper and lower molds are closed and pressed and cooled, the hot melt sheet is melted by the heat of the resin core material, and the resin core material and the skin are adhered. Thereafter, the attached state is firmly held by cooling. Therefore, in this configuration, since the molten resin is not directly injected onto the back surface of the skin, no gate mark is formed by injection molding. Further, the press pressure applied to the skin may be from no load to an ultra-low pressure required to contact the resin core material. Furthermore, since the resin core material and the skin can be adhered by melting the hot melt sheet with the heat of the resin core material, it is not necessary to use an adhesive or the like separately.

  In the configuration of the molding apparatus for the laminated molded product, during the molding process of the resin core material, the resin material is supplied in a short shot state into the cavity formed by the upper and lower molds, and the processing in the pressing and cooling process is performed. At this time, it is possible to adopt a configuration in which the resin material that is surplus by the thickness of the outer skin is caused to flow into the gap in the short shot state to eliminate the gap.

  According to this configuration, when pressing in the pressing / cooling process, the resin material extruded by the press flows to the gap portion side where the short shot is performed and is released, thereby reducing the force of crushing the skin. Can reduce the damage of the epidermis.

  In the configuration of the molding apparatus for the laminated molded product, a part of the upper mold in the molding die is moved to the outside during the processing in the pressing / cooling step so as to absorb the pressing pressure on the skin. The configuration can be adopted.

  According to this configuration, when a surplus material is generated by the thickness of the skin when pressing in the pressing / cooling process, a part of the upper mold is moved to the outside, and the volume of the surplus material is reduced. Absorb. Thereby, the force which crushes the skin at the time of pressing at a press and cooling process is reduced, and damage to the skin by press can be reduced.

  According to the present invention, since no gate mark is produced by injection molding, the appearance can be improved. In addition, the press pressure applied to the skin can be from no-load to ultra-low pressure required to contact the resin core material, so that the surface texture and softness of the laminated molded product can be improved by reducing hair fall. Can do. Furthermore, since the resin core material and the skin can be adhered by melting the hot melt sheet with the heat of the resin core material, there is no need to use an adhesive, etc. Man-hours can be shortened and the work environment can be improved.

It is a front view which shows the door trim for motor vehicles manufactured by applying the molding method of the laminated molded product which concerns on this invention. It is the sectional view on the AA line of FIG. It is explanatory drawing which shows the schematic structure of the shaping | molding apparatus of the laminated molded product which implements one Embodiment of this invention, and the Example of a shaping | molding process. It is explanatory drawing which shows the schematic structure of the shaping | molding apparatus of the laminated molded product which concerns on this invention, and a modification of a shaping | molding process. It is explanatory drawing which shows the schematic structure of the shaping | molding apparatus of the laminated molded product which concerns on this invention, and the other modification of a shaping | molding process. It is a front view which shows other embodiment of the door trim for motor vehicles manufactured by applying the molding method of the laminated molded product which concerns on this invention. It is the BB sectional view taken on the line of FIG. It is explanatory drawing which shows schematic structure and a formation process of the shaping | molding apparatus of the laminated molded product shown in FIG. 6, FIG. It is a front view which shows the conventional door trim for motor vehicles. It is CC sectional view taken on the line of FIG. It is explanatory drawing which shows schematic structure and the example of a shaping | molding process of the shaping | molding apparatus of the conventional laminated molded product.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention (hereinafter referred to as “embodiments”) will be described in detail with reference to the accompanying drawings.

  FIG. 1 shows an automotive door trim 11 mounted on the interior surface of a vehicle door panel, and FIG. 2 is a cross-sectional view taken along line AA of FIG. In the same figure, the door trim 11 for motor vehicles is shape | molded by the required shape as shown in FIG. The automobile door trim 11 is formed as a laminated molded product in which a skin 13 that gives a surface texture and softness is pasted on the surface of a resin core 12 having shape retention and mounting rigidity to a door panel. To be served.

  Note that various functional parts such as an inside handle unit 14, an armrest 15, a pull handle unit 16, a power window switch unit 17, a door pocket 18, and a speaker grill 19 are attached to the door trim 11.

  In this embodiment, a material in which talc is mixed with polypropylene resin is used as the resin core material 12. Examples of the resin material that can be used include polyethylene resins, polypropylene resins, polystyrene resins, and polyethylene terephthalate resins. Resins, polyvinyl alcohol resins, vinyl chloride resins, polyamide resins, polyacetal resins, polycarbonate resins, ionomer resins, acrylonitrile / butadiene / styrene (ABS) resins, and the like.

  On the other hand, as the skin 13, for example, a TPO sheet is used as a top layer, and a polypropylene foam is used as a cushion layer backed on the back surface. It should be noted that a vinyl sheet, cloth, nonwoven fabric or other fabric sheet can be used as the top layer, and a polyethylene foam or polyurethane foam can be substituted for the cushion layer.

  The door trim 11 manufactured by applying the method of the present invention has a good surface texture of the outer skin 13, that is, the squeezed pattern formed on the top layer appears beautifully and the soft feeling of the cushion layer is utilized. It is possible to provide a door trim that achieves excellent cushion performance.

  Next, a more specific molding apparatus and method for manufacturing the door trim 11 as such a laminated molded product will be described.

  FIG. 3 shows a schematic configuration of a molding apparatus according to the present invention and a first embodiment of the molding process. The molding apparatus shown in FIG. 3 includes a molding die 21 and an injection cylinder 22 as a material supply mechanism that supplies a molten resin 12 a that forms the resin core material 12. The molding die 21 is composed of an upper die 23 connected to a function press (not shown), and an upper die 23 and a lower die 24 that can be clamped and opened, as shown in FIG. ), An injection cylinder 22 is connected to the lower mold 24, and the molten resin 12a is supplied from the injection cylinder 22 into the cavity 26 through a manifold 24a and a gate 24b provided in the lower mold 24. Yes.

  Next, a molding method using this molding apparatus will be described with reference to FIGS. First, the upper die 23 and the lower die 24 in the molding die 21 are closed (a), and then the resin core material 12 is formed in the cavity 26 through the manifold 24a and gate 24b provided in the lower die 24 from the injection cylinder 22. The required amount of molten resin 12a is injected and supplied (b). This step becomes a core material forming step, and the resin core material 12 having a substantially required shape is formed. In the core material forming step, the injected molten resin 12a is not cooled. Or cool it very little.

  Next, the process proceeds to the skin supplying step, and the upper mold 23 is raised to open the mold (c). When the mold is opened, the resin core material 12 is held on the lower mold 24. Moreover, this resin core material 12 is not solidified, and its surface temperature is 80 ° C. to 180 ° C. Subsequently, the skin 13 is laminated on the lower mold 24 from the top of the resin core 12 (d). Although not shown, the skin 13 is temporarily provided with a web-like hot melt sheet that serves as an adhesive on the back surface (joint surface side). This web-like hot melt sheet has a melting point (softening point) of 70 ° C. to 180 ° C. and is made of, for example, a deformed polyester fiber (deformed PET), and may be a film or a fiber. Moreover, a mesh-like hot melt may be used.

  Next, the process proceeds to a pressing / cooling step, and the upper mold 23 is again lowered and closed, the outer skin 13 and the resin core 12 are pressed against each other, and cooled to perform final molding (e). In this pressing / cooling step, since the surface temperature of the resin core 12 is higher than the melting point of the web-like hot melt sheet, when the skin 13 is pressed against the resin core 12, the web-like hot melt sheet is It melts and adhesively bonds between the resin core 12 and the skin 13. Moreover, it adheres strongly by cooling after that. Thereby, the door trim 11 having a required shape is formed.

  When the press / cooling process is finished, the upper mold 23 is raised again to open the mold, and the door trim 11 in which the resin core 12 and the skin 13 are integrated, that is, the laminated molded product is taken out from the molding die 21.

  As described above, according to the method and apparatus of the present invention, the molten resin is supplied into the cavities 26 of the upper and lower molds 23 and 24 to form the resin core 12 having the required shape, and then the upper and lower molds 23 and 24 are formed. When the skin 13 with the web-like hot melt sheet provided on the back surface is placed on the resin core 12 and then the upper and lower molds 23 and 24 are closed and pressed and cooled, the heat of the resin core 12 The hot melt sheet melts and the resin core 12 and the skin 13 are adhered. Thereafter, the attached state can be maintained by cooling.

  Therefore, in this molding method and molding apparatus, since the molten resin 12a is not directly injected onto the back surface of the skin 13, the gate mark is not formed on the skin 13 by injection molding, and the appearance is improved. Can be made. Further, since the press pressure applied to the skin 13 can be from a no-load to an ultra-low pressure required to make contact with the resin core material 12, the surface texture and soft feeling of the door trim 11 are improved by reducing hair fall. be able to. Further, since the resin core material 12 and the skin 13 can be adhered by melting the hot melt sheet with the heat of the resin core material 12, it is not necessary to use an adhesive or the like separately. Simplification, reduction of man-hours, improvement of work environment, etc. are possible.

  FIG. 4 shows a modification of the embodiment shown in FIG. The same components as those in the embodiment of FIG. 3 are denoted by the same reference numerals. In the modification shown in FIG. 4, the thickness T of the section a in the cavity 26 is changed to the thickness t of the section b. To the size obtained by adding the clearance α of the skin 13 to (t + α).

  In the core material forming step, the molten resin 12a is supplied in a short shot state so that a gap 27 is provided in the cavity 26 formed by the upper and lower molds 23 and 24. Then, during the processing in the pressing / cooling process, the molten resin that has become surplus by the thickness α of the skin 13 is caused to flow toward the gap 27 in the short shot state so that the gap 27 is eliminated.

  With such a method and apparatus configuration, when the pressing is performed in the pressing / cooling step, the molten resin 12a extruded by the press flows into the gap 27 where the short shot is made and escapes, so that the skin 13 is crushed. The force is reduced, and damage to the skin 13 caused by pressing can be reduced.

  FIG. 5 shows another modification of the embodiment shown in FIG. The same components as those in the embodiment of FIG. 3 are described with the same reference numerals. In the modification shown in FIG. 5, the thicknesses of the section a and the section b in the cavity 26 are set as follows. As in the case of, the thickness is t. 3 is different from the embodiment of FIG. 3 in that a part of the mold 23a of the upper mold 23 constituting the section b of the cavity 26 (hereinafter referred to as “movable mold part 23a”) can be moved outward. Is provided.

  Then, when pressing is performed in the pressing / cooling process, when the molten resin 12a that is surplus by the thickness of the skin 13 is generated, the movable mold portion 23a that is a part of the upper mold 23 is moved outward, and the surplus and Absorbs the volume of the molten resin 12a. Thereby, the force which crushes the skin 13 at the time of pressing by a press and cooling process is reduced, and the damage of the skin 13 by a press can be reduced. The movable part 23a returns to the original position when the resin core 12 and the skin 13 are removed from the cavity 26.

  6 to 8 show another embodiment of an automobile door trim manufactured by applying the method for forming a laminated molded product according to the present invention. FIG. 6 is a front view of the door trim, and FIG. BB sectional drawing, FIG. 8 is explanatory drawing which shows schematic structure and a shaping | molding process of the shaping | molding apparatus of the laminated molded product shown in FIG. 6, FIG.

  The automobile door trim 31 shown in FIGS. 6 and 7 is formed into a required shape, and has a skin 13 that imparts a surface texture and a soft feeling to the surface of the resin core 12 having shape retention and mounting rigidity to the door panel. The laminated molded product is affixed, and a two-color molded product 32 with an inscribed skin is provided in part.

  Next, a two-color molding method using this molding apparatus will be described with reference to FIGS. In the case of the molding apparatus and molding process for molding the door trim 31 provided with the two-color molded product 32 with the inscribed skin, the configuration and process of the molding apparatus are basically the same as those of the molding apparatus and molding process shown in FIG. First, the upper die 43 and the lower die 44 in the molding die 41 are closed (a), and then the resin core 12 is formed in the cavity 46 through the manifold and gate provided on the lower die 44 from the injection cylinder. A required amount of molten resin 12a is injected and supplied (b). This step becomes a core material forming step, and the resin core material 12 having a substantially required shape is formed. In the core material forming step, the injected molten resin 12a is not cooled. (There may be some cooling)

  Next, the process proceeds to the skin supply step, and the upper mold 43 is lifted to open the mold (c). When the mold is opened, the resin core material 12 is held on the lower mold 44. Moreover, this resin core material 12 is not solidified, and its surface temperature is 80 ° C. to 180 ° C. Subsequently, the skin 13 (not shown) and the two-color molded product 32 with the inscribed skin are laminated on the lower mold 44 from the top of the resin core 12 (d). Although not shown, the skin 13 and the two-color molded product 32 with the inscribed skin are temporarily provided with spider web-like hot melt sheets on the back surface (joining surface side).

  Next, the process proceeds to the pressing / cooling step, and the upper die 43 is again lowered and closed, and the outer skin 13 and the resin core material 12 and the two-color molded product 32 with the inscribed skin and the resin core material 12 are pressed against each other, And it cools and final shaping is performed (e). Also in this case, since the surface temperature of the resin core material 12 is higher than the melting point of the web-like hot melt sheet in the pressing / cooling step, the two-color molded product 32 with the inscribed skin was pressed against the resin core material 12. At this time, the web-like hot melt sheet is melted and adhesively bonded between the two-color molded product 32 with the inscribed skin and the resin core 12 and between the skin 13 and the resin core 12. Moreover, it adheres strongly by cooling after that. As a result, the two-color molded product 32 with the inscribed skin having the required shape and the door trim 31 with the skin 13 are formed.

  When the pressing / cooling process is completed, the upper mold 43 is raised again to open the mold, and the door trim 31, that is, the laminated molded product is taken out.

  It should be noted that the present invention can be modified in various ways without departing from the spirit of the present invention, and the present invention naturally extends to the modified ones.

11 Door trim (laminate molding)
12 Resin core material 12a Molten resin 13 Skin 21 Mold 21 Molding cylinder 23 Upper mold 23a Movable mold part 24 Lower mold 24a Manifold 24b Gate 26 Cavity 27 Gap 31 Door trim (Laminated molded product)
32 Two-color molded product 41 Molding die 43 Upper die 44 Lower die 46 Cavity

Claims (3)

In a molding method of a laminated molded article formed by pasting a skin on the surface of a resin core material molded into a required shape and the resin core material,
A core material molding step of supplying a thermally melted resin material into the upper and lower mold cavities in the molding die, and molding the resin core material into a required shape along the cavity shape;
Holding the resin core material before being cooled on the lower mold, opening the upper and lower molds, and supplying the skin provided with a web-like hot melt sheet on the back surface on the resin core material And the skin supply process to laminate,
A pressing / cooling step in which the outer skin is bonded to the outer surface of the resin core and cooled,
A method for forming a laminated molded product comprising:   The resin core material is formed in a short shot state in the core material molding step, and the resin material that has become surplus in the thickness of the skin in the pressing / cooling step is fluidly filled in the short shot gap, 2. The method for molding a laminated molded product according to claim 1, wherein a resin core material having a required shape is molded.   A part of the upper mold in the molding die is provided to be movable outward, and the thickness of the skin is absorbed by the movement of a part of the upper mold in the pressing and cooling step. The method for forming a laminated molded product according to claim 1.

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