JP2015016652A - Method of producing skin-provided resin molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of producing a skin-provided resin molding which enables efficient production of a skin-provided resin molding.SOLUTION: A method of producing a skin-provided resin molding in which a terminal part of a skin material is folded toward the back-surface side of a core material and includes a first press step of integrating the skin material 3 so as to be along the surface of the core material 2, in a state where the terminal part of the skin material 3 is left outside the mold, by means of freely opening upper and lower molds 11 and 12, a skin material push-in step of causing the upper mold alone to ascend and causing a slide die 13 to advance toward the center and pushing in the terminal part of the skin material 3 left outside the mold, a second press step of causing the slide die 13 to retreat and causing the upper mold 11 to descend again to fold the terminal part of the skin material 3 so as to be along the back surface of the core material and a step of fusing the folded terminal part of the skin material with the core material 3 with an ultrasonic horn 14.

Description

  The present invention relates to a method for producing a resin molded product with a skin material that can efficiently produce a resin molded product with a skin material in which a terminal portion of the skin material is bent toward the back surface side of the core material.

  For example, resin molded products with a skin material in which the surface of a core material made of a hard resin is coated with a skin material are widely used as automotive interior materials such as console boxes, dashboards, and door trims. Since such an automobile interior material is required to have high appearance quality, the end portion of the skin material is bent to the back surface side of the core material.

As a method for producing a resin-molded article with a skin material in which the terminal portion of the skin material is bent to the back side of the core material, a method in which an adhesive is previously applied to a predetermined portion of the terminal portion of the skin material, Prepare the one where the adhesive is applied to the back of the material in advance, and after the skin and core are integrated by pressing, the end of the skin is bent to the back of the core A method is known in which both are bonded and fixed with an adhesive.
However, the shape of the core material is complicated, and it is difficult to automate the operation of applying the adhesive to the core material and the skin material, which is performed manually. For this reason, work efficiency was bad and became a factor which reduces productivity. In addition, a dedicated worker is required for the operation of applying the adhesive to the core material and the skin material, resulting in an increase in cost.

On the other hand, as a method for adhering a core material and a skin material, a method of ultrasonic welding using an ultrasonic horn without using an adhesive is known (see, for example, Patent Documents 1 and 2). According to this method, no adhesive is required, and the cost can be reduced. However, these patent documents merely disclose an adhesion method in which an ultrasonic horn is pressed against a skin material and melted to be welded to a core material.
Thus, a manufacturing method that can efficiently and continuously produce a resin molded product with a skin material in which the end portion of the skin material is bent toward the back side of the core material is still effective at present. No method has been proposed.

JP-A-57-201621 Japanese Unexamined Patent Publication No. 58-19818

  The present invention solves the problems as described above, and makes it possible to efficiently produce a resin molded product with a skin material in which the end portion of the skin material is bent toward the back surface side of the core material without using an adhesive, and with high quality. The present invention has been completed for the purpose of providing a method for producing a resin molded product with a skin material that can be continuously produced.

  The method for producing a resin-molded article with a skin material of the present invention made to solve the above-mentioned problems is that the surface of the core material made of a hard resin is coated with the skin material, and the end portion of the skin material is the back surface of the core material. A method of manufacturing a resin molded product with a skin material that is bent to the side so that the skin material follows the surface of the core material with the upper and lower molds being openable and closable, leaving the end portion of the skin material outside the mold. The first pressing step integrated into the upper surface, and then the upper die alone is raised, the slide die is advanced toward the center, and the outer skin material is pushed inwardly to push the terminal portion of the outer skin material left outside the die. A second pressing step of retracting the slide mold and then lowering the upper mold again to fold the end portion of the skin material along the back surface of the core material; and Ultrasonic welds the terminal part to the core with an ultrasonic horn And it is characterized in that comprising the step.

  As the skin material, it is preferable to use a laminated skin material in which a cushion material layer is laminated on the back surface of the skin layer, and this is an invention according to claim 2.

  Moreover, it is preferable to perform ultrasonic welding with the ultrasonic horn arrange | positioned along the periphery of a core material, and let this be the invention which concerns on Claim 3.

  Further, it is preferable that the ultrasonic horn is lowered at the same time as the upper die and the ultrasonic welding is performed simultaneously with the second pressing step, which is the invention according to claim 4.

  In the invention according to claim 1, the first pressing step of integrating the skin material along the surface of the core material in a state in which the end portion of the skin material is left outside the mold by the openable and closable upper and lower molds, After raising only the upper mold, the slide mold was advanced toward the center, and the skin material pushing step of pushing the end portion of the skin material left outside the mold inward, and then the slide mold was retracted After that, the upper mold is lowered again, and the second pressing step of bending the end portion of the skin material along the back surface of the core material, and the ultrasonic wave horn is applied to the end portion of the folded skin material by the ultrasonic horn. Because it consists of a welding process, it is possible to continuously and efficiently produce a resin molded product with a skin material in which the end portion of the skin material is bent to the back side of the core material by a press machine consisting of upper and lower molds. It becomes. Furthermore, since the end portion of the skin material is automatically ultrasonically welded by an ultrasonic horn, it is possible to eliminate the manual work of applying the adhesive as in the prior art, and to achieve reduction in work man-hours and workers. Can do.

  In the invention according to claim 2, since the laminated skin material in which the cushion material layer is laminated on the back surface of the skin layer is used as the skin material, an automotive interior material excellent in cushioning and design properties can be obtained.

  In the invention which concerns on Claim 3, since ultrasonic welding is performed by the ultrasonic horn arrange | positioned along the periphery of a core material, a skin material can be firmly adhere | attached and fixed with respect to a core material.

  In the invention according to claim 4, since the ultrasonic horn is lowered simultaneously with the upper mold and the ultrasonic welding is performed simultaneously with the second pressing step, the ultrasonic welding can be performed efficiently and in a short time. .

It is a perspective view which shows the state which looked at the resin molded product with a skin material manufactured by this invention from the lower surface. It is an AA end view of FIG. It is an end view of the core material of the AA part. It is an expanded sectional view of a skin material. It is explanatory drawing which shows the state which set the skin material to the lower mold | type. It is explanatory drawing which shows a 1st press process. It is explanatory drawing which shows the state which raised only the upper mold | type. It is explanatory drawing which shows a skin material pushing process. It is explanatory drawing which shows a 2nd press process.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
FIG. 1 shows a case where a lid of a console box of an automobile is manufactured as an example. FIG. 1 is a perspective view showing a state in which a resin molded product with a skin material is viewed from the lower surface side, and FIG. A end view, FIG. 3 is an AA end view of only the core material, and FIG. 4 is an enlarged sectional view of the skin material.

In the figure, 1 is a resin molded product with a skin material, 2 is a core material made of a hard resin such as polypropylene resin, 3 is a skin material coated on the surface of the core material 2, and the resin molded product 1 of the present invention is a skin material. The end portion of the material 3 is bent to the back surface side of the core material 2.
More specifically, as shown in FIG. 2, the end portion of the skin material 3 is a bent portion 3a that is bent and adhered to the back side of the core material 2, and at the tip of the bent portion 3a, Further, several tongue pieces 3 b are extended, and the tongue pieces 3 b are ultrasonically welded to the protrusions 4 protruding from the top plate periphery on the back surface side of the core member 2. In FIG. 1, reference numeral 5 denotes a welded portion welded by an ultrasonic horn described later.

  As shown in FIG. 3, the skin material 3 is a laminated skin material in which a soft pad cushion material layer 32 made of an olefin resin is laminated on the back surface of a soft skin layer 31 such as a vinyl chloride resin. . When such a laminated skin material is used, a high-quality lid having cushioning properties can be obtained, which is optimal for an automobile interior material.

Below, it demonstrates per manufacturing method of the above resin-molded articles with a skin material.
As shown in FIG. 5, the resin molded product with a skin material is continuously molded by a pair of upper and lower molds. The lower mold 12 is a fixed mold. On the other hand, the upper mold 11 can move up and down and can be opened and closed with respect to the lower mold 12.
First, the upper mold | type 11 is moved to the raised position, and the core material 2 is set to the lower surface. On the other hand, the skin material 3 is set on the upper opening surface of the lower mold 12 by a clamper (not shown). These set operations can be easily performed manually.

Next, as shown in FIG. 6, the upper die 11 is lowered to perform the first pressing step. By pressing the core material 2 and the skin material 3 in a cavity formed between the upper and lower molds, the skin material 3 is integrated along the surface of the core material 2.
In the first pressing step, the end portion of the skin material 2 is in a state of being left out of the mold while standing vertically. This terminal portion is a portion that is bent to the back side in a subsequent process to become a bent portion.

  Next, as shown in FIG. 7, when the pressurization is completed, the skin material 2 is separated and only the upper mold 11 is raised. Thereby, the skin material 3 and the core material 2 are integrated inside the lower mold 12, and an intermediate molded product is left in a state where the end portion of the skin material 2 protrudes vertically out of the mold.

Next, as shown in FIG. 8, the skin material pushing process which pushes the terminal part of the skin material 3 inside is performed. In this skin material pushing step, the slide die 13 provided at the periphery of the lower die 12 is advanced toward the center, and the terminal portion of the skin material 3 left in the standing state outside the die is pushed inward. is there.
As a result, the end portion of the skin material 3 left outside the mold is bent by 90 ° along the bottom surface of the core material 2 toward the center.

Next, as shown in FIG. 9, after the slide mold 13 is retracted to the initial position, the upper mold 11 is lowered again, and the terminal portion of the skin material 3 is bent along the back surface of the core material 2. Step 2 is performed.
Thereby, the terminal part of the skin material 3 becomes the bending part 3a closely_contact | adhered to the back surface side of the peripheral wall part of the core material 2. FIG. Further, the tongue piece 3b at the tip of the bent portion 3a has a shape along the upper surface of the protruding portion 4 that is bent 90 ° toward the center and protrudes from the periphery of the top plate on the back side of the core material.

Next, the tongue piece 3 b of the terminal portion of the folded skin material 3 is ultrasonically welded to the core material 2 by the ultrasonic horn 14.
A plurality of ultrasonic horns 14 are arranged corresponding to the protrusions 4 and are configured to pass through guide holes 11 a formed in the peripheral edge of the upper mold 11 and descend. The descending ultrasonic horn 14 abuts on the tongue piece 3b on the upper surface of the protrusion 4 and ultrasonically welds them together. Since this ultrasonic welding can be performed in a short time (within 1 second), the welding process can be performed efficiently.
By performing ultrasonic welding with the ultrasonic horn 14, it is possible to omit the manual application of the adhesive, which is a conventional essential process, and to reduce the number of man-hours and workers.

The ultrasonic horn 14 is attached to an elevating bracket (not shown) that can be moved up and down, and is configured to descend at a predetermined timing and perform ultrasonic welding. In addition, it can also be set as the structure attached directly to the periphery of the upper mold | type 11 without using a bracket.
In addition, although the welding process by the ultrasonic horn 14 can also be performed immediately after the 2nd press process is complete | finished, the ultrasonic horn 14 is lowered | hung simultaneously with the upper mold | type 11, and ultrasonic welding is carried out in the 2nd press process. It is more preferable to carry out at the same time from the viewpoint of shortening the molding time.

As described above, after finishing the second pressing step and the ultrasonic welding step, the upper mold 11 and the ultrasonic horn 14 are raised to the initial position, and the resin molded product is taken out from the lower mold 12 to perform one cycle. finish.
The obtained resin molded product 1 with a skin material is one in which the end portion of the skin material 3 is bent toward the back side of the core material 2 and exhibits excellent appearance quality. Further, as shown in FIG. 1, the core material 2 and the skin material 3 are firmly fixed by the welded portion 5 by the ultrasonic horn 14, and since no adhesive is used as in the prior art, it is peculiar. There is no odor.

DESCRIPTION OF SYMBOLS 1 Plastic molded product with skin material 2 Core material 3 Skin material 3a Bending part 3b Tongue piece part 4 Projection part 5 Welding part 11 Upper mold | type
11a Guide hole 12 Lower mold 13 Slide mold 14 Ultrasonic horn 31 Skin layer 32 Cushion material layer

Claims (4)

The surface of the core material made of a hard resin is coated with a skin material, and the terminal portion of the skin material is further bent to the back side of the core material, and is a method for producing a resin molded product with a skin material,
A first pressing step of integrating the skin material along the surface of the core material in a state in which the end portion of the skin material is left out of the mold by an openable / closable upper and lower mold;
Then, after raising only the upper mold, the slide mold is advanced toward the center, and the skin material pushing process of pushing the terminal portion of the skin material left outside the mold inside,
Next, after retracting the slide mold, the upper mold is lowered again, a second pressing step of bending the end portion of the skin material along the back surface of the core material,
A method for producing a resin-molded article with a skin material, comprising the step of ultrasonically welding a terminal portion of the folded skin material to a core material with an ultrasonic horn.   The manufacturing method of the resin molded product with a skin material of Claim 1 which uses the laminated skin material by which the cushioning material layer was laminated on the back surface of the skin layer as a skin material.   The manufacturing method of the resin molded product with a skin material of Claim 1 or 2 which performs ultrasonic welding with the ultrasonic horn arrange | positioned along the periphery of a core material. The method for producing a resin-molded article with a skin material according to claim 1, wherein the ultrasonic horn is lowered simultaneously with the upper die, and ultrasonic welding is performed simultaneously with the second pressing step.