JP2017080973A - Production method of lamination molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production method of a lamination molded product in which a planar outer peripheral part of a preform molded product is sandwiched and fixed with mating surfaces of a female mold and a male mold, and in-mold molding is performed, capable of suppressing occurrence of a wrinkle on the laminated preform molded product.SOLUTION: A production method of a lamination molded product is configured to: close a female mold and a male mold to sandwich an outer peripheral part on mating surfaces in a state in which, a body part of a preform molded product is stored in a cavity part, then fill a molten resin in the cavity, for integrating the preform molded product with one surface of the molded injection molded product. The female mold has a corner where the cavity part and the mating surface cross. The preform molded product has a corner where a side surface and the outer peripheral part cross. When the corner of the preform molded product is brought close to the corners of molds, a distance between the corner on the preform molded product side and the corners on the molds, is 0.2 mm or lower.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for producing a laminated molded body by in-mold molding using a preform molded body obtained by molding a sheet material.

  In-mold molding is known in which a preform molded body obtained by molding a sheet material having design properties is placed in a cavity of a mold and injection molding is performed. According to in-mold molding, a laminated molded body in which a sheet material having design properties is integrated on the surface of an injection molded body can be manufactured. As a sheet material having design properties, a film protected by a gloss layer or a hard coat layer and provided with a pattern by painting, transfer, gravure printing or the like is widely used.

  A general method for producing a laminated molded body by in-mold molding using a preform molded body will be described with reference to FIG. In FIG. 12, 31 is a preform molded body, 12a is a female mold, 12b is a male mold, 3 is an injection body of an injection molding machine, 3a is a nozzle, 3b is a cylinder, 3c is an in-line screw, 4 is a gate, 5 is An injection molded body, 5a is a molten resin, and 40 is a laminated molded body.

  In in-mold molding using a preform molded body, first, as shown in FIG. 12 (a), an injection mold having a female die 12a having a cavity portion 12c and a male die 12b having a core portion 12d. 12, the preform molded body 31 is disposed in the cavity portion 12c of the female die 12a. Then, as shown in FIG. 12B, the female mold 12a and the male mold 12b are clamped. And as shown in FIG.12 (c), the cavity c formed by clamping the female type | mold 12a and the male type | mold 12b is filled with the molten resin 5a of a thermoplastic resin.

  And after completion | finish of the cooling process which cools the molten resin 5a in the cavity c, as shown in FIG.12 (d), the female type | mold 12a is retracted, and the female type | mold 12a and the male type | mold 12b are mold-opened. Thus, a laminated molded body 40 in which the preform molded body 31 is integrated with the injection molded body 5 is obtained.

  In in-mold molding of a film having design properties, the molten resin is injected at a temperature higher than the deflection temperature under load of the film, so that the film is softened and stretched by the heat and flow of the molten resin, and an injection molded body It has been known that wrinkles occur in the film integrated with the film. As a method for suppressing the occurrence of such wrinkles, for example, the following Patent Document 1 is molded so as to be curved without contacting a mold at a portion corresponding to a corner of a molded product in a closed state, By using a preform molded body whose end surface is punched so as to contact the mold at a position corresponding to the edge of the inner surface of the rising portion of the molded product, wrinkles are generated in the film integrated with the injection molded body. It is disclosed that this is suppressed.

  In addition, for example, in Patent Document 2 below, a number of trimming processes are performed on the end of a preform molded body sandwiched between a convex mold and a concave mold of an injection mold so as to communicate with a cavity provided inside the injection mold. A method of manufacturing an insert molded product by fixing a preform molded body in an injection mold by drawing an air flow through the air vents and filling a molten resin therein is disclosed.

  By the way, in recent years, a laminated molded body using a fiber structure thicker than a film has been proposed as a sheet material for in-mold molding that gives a soft touch in addition to design properties (for example, Patent Document 3 below).

JP 2005-104114 A JP 2011-148290 A JP-A-6-328498

  By forming a three-dimensional shape on the sheet material using a sheet forming method such as vacuum forming, vacuum pressure forming, hot press forming, etc. A preform molded body having a planar outer peripheral portion continuous to the periphery is manufactured. Since the planar outer periphery connected to the periphery of the main body is an unnecessary part, the preform molded body with only the main body removed from the flat outer periphery by punching or the like is usually accommodated in the cavity. In-mold molding is performed.

  There was a problem that the preform molded body accommodated in the cavity of the mold was displaced in the cavity. In order to avoid such misalignment, a method is used in which the preform is attached to the cavity of the mold with a double-sided tape, vacuum-adsorbed, or fitted into the protrusion of the core and fixed. Yes.

  As a method of fixing the preform molded body to the cavity portion of the mold, the present inventors refer to FIG. 1 and a three-dimensionally formed main body portion 1a and a plane formed around the main body portion 1a. The preform molded body 1 having the outer peripheral part 1b is used as it is, the main body part 1a is accommodated in the cavity, and the flat outer peripheral part 1b is sandwiched and fixed between the mating surfaces of the female mold and the male mold, We studied to suppress the displacement of the preform in the cavity.

  However, when injection molding is performed with the flat outer periphery sandwiched between the mating surfaces of the female mold and the male mold, wrinkles occur near the mating surface of the preform molded body integrated with the laminated molded body. There was a tendency to become easy.

  The present invention relates to a method for producing a laminated molded body in which a planar outer peripheral portion of such a preform molded body is fixed by sandwiching a mating surface of a female mold and a male mold and in-mold molding is performed. It aims at suppressing the generation | occurrence | production of the wrinkle in the vicinity of the mating surface of a molded object.

  The present inventors use a preform molded body that leaves a planar outer peripheral portion around the main body portion, accommodates the main body portion in a cavity, and makes the planar outer peripheral portion a mating surface of a female mold and a male mold. In the manufacturing method of the laminated molded body in which the in-mold molding is performed by being sandwiched and fixed, the cause of the tendency for wrinkles to occur near the mating surfaces was examined. And I thought that wrinkles occurred by the following mechanism.

  FIG. 13 is an explanatory diagram for explaining a mechanism in which wrinkles W are generated near the mating surface PL of the mold in the in-mold molding as described above. FIG. 13A shows that a main body 41a of a preform molded body 41 having a main body portion 41a shaped in a three-dimensional shape and a planar outer peripheral portion 41b formed around the main body portion 41a is accommodated in a cavity c. Shows the situation at times. When performing in-mold molding, the rising portion of the preform molded body 41 that transitions from the planar outer peripheral portion 41b to the main body portion 41a is shaped so as to coincide with the shape of the die-side corner c1 of the female die 2a with high accuracy. If not, in the vicinity of the mating surface PL surrounded by the broken-line circle in FIG. 13A, a part of the side surface 41c of the preform molded body 41 may not fit in the cavity c and may protrude outside the cavity c. Then, as shown in FIG. 13B, in order to accommodate the preform molded body 41 in the cavity c, the outer peripheral portion 41b is fixed by being sandwiched between the mating surfaces of the female mold 2a and the male mold 2b. When tightened, wrinkles occur as follows. Referring to FIG. 14, as shown in FIG. 14A, a part of the side surface 41 c that has come out of the cavity c becomes a mold-side corner c <b> 1 as the mold clamping progresses as shown in FIG. 14B. By being caught, an extra portion is generated in the planar outer peripheral portion 41b, and a waved portion N is generated in the planar outer peripheral portion 41b. Then, when the female mold 2a and the male mold 2b are clamped in a state where the undulating portion N is maintained, excess generated in the planar outer peripheral portion 41b is concentrated on the corners and the like. And as shown in FIG.14 (c), wrinkles W generate | occur | produce near the mating surface PL of the metal mold | die of a preform molded object. Then, in this state, as shown in FIG. 13 (c), the cavity is filled with molten resin and cooled, so that the preform is formed on the surface of the injection molded body 45 as shown in FIG. 13 (d). A laminated molded body 50 in which the bodies 41 are integrated is obtained. The present inventors have found that the wrinkles generated around the mating surface PL of the preform molded body 41 integrated with the obtained laminated molded body 50 are those caused by buckling as described above that occurred during mold clamping. I realized that it was due to being maintained as it was. In particular, when a preform molded body including a fiber structure is used, the fiber structure has a low rigidity and thus is easily deformed, and such wrinkles are easily generated.

  Based on such knowledge, the present inventors have used a preform molded body in which a rising portion that transitions from a planar outer peripheral portion to a main body portion is shaped with high accuracy, thereby forming a laminated preform molding. The inventors have found that wrinkles are suppressed in the vicinity of the mating surfaces of the bodies, and have arrived at the present invention.

  That is, one aspect of the present invention is a preform molded body having a main body portion shaped into a three-dimensional shape having a side surface rising in an angle range of 45 to 90 degrees and a planar outer peripheral portion connected to the periphery of the main body portion. An injection mold comprising: a male mold having a core part; and a female mold having a cavity part that accommodates the core part and forms a cavity when the mold is clamped. Forming the preform molded body so as to accommodate the main body, and clamping the female mold and the male mold so that the outer peripheral portion is sandwiched between the mating surfaces while the main body is accommodated in the cavity And filling the preformed cavity with a molten resin to integrate the preform molded body on one surface of the injection molded body to be molded, and the female mold is a region where the cavity portion and the mating surface intersect Mold side coating The preform molded body has a preform molded body side corner, which is a region where the side surface and the outer peripheral portion intersect, on the surface facing the female mold, the surface around the preform molded body side corner and the mold side Laminate molding in which the distance between the preform molded body side corner and the mold side corner is 0.2 mm or less when the surface around the corner is overlapped so that the preform molded body side corner and the mold side corner are close to each other It is a manufacturing method of a body.

  Moreover, it is preferable that a preform molded object contains a fiber structure.

  Another aspect of the present invention is a method of manufacturing a preform molded body having a main body portion shaped into a three-dimensional shape and a planar outer peripheral portion connected to the periphery of the main body portion. Forming a preform molding die having a main body forming surface for forming the outer peripheral portion and an outer peripheral portion forming surface for forming the outer peripheral portion; and a preform molding die using the preform molding die. A step of applying a pressure difference to the outer peripheral portion forming surface and forming the main body portion forming surface in this order.

  The preform molding die preferably has a body portion forming surface on a concave inner wall surface.

  According to the present invention, a preform molded body having a main body portion shaped in a three-dimensional shape and a planar outer peripheral portion continuous to the periphery of the main body portion is used, and the main body portion is accommodated in the cavity portion, and the planar shape is obtained. When the outer peripheral portion is sandwiched between the mating surfaces of the female mold and the male mold and fixed in-mold, a laminated molded body in which the generation of wrinkles near the mating surface is suppressed is obtained.

FIG. 1 is a schematic perspective view of a preform molded body 1 used in the embodiment, where (a) is a top view and (b) is a bottom view. FIG. 2 is a process schematic diagram illustrating a process of forming the preform molded body 1 using a concave mold. FIG. 3 is a process schematic diagram illustrating a process of forming the preform molded body 11 using a convex mold. Drawing 4 is an explanatory view explaining each process of a manufacturing method of a lamination fabrication object of an embodiment. FIG. 5 (a) is a schematic perspective view from the top when the preform 1 is fitted to the cavity of the female mold 2a of the injection mold, and FIG. 5 (b) is a perspective view of FIG. 5 (a). FIG. 5C is an enlarged schematic view in which a broken-line circle portion in FIG. 5B is enlarged. FIG. 6 is an enlarged schematic view in which the preform molded body side corner c2 and its vicinity are enlarged when the preform molded body 11 is combined with the cavity portion of the female mold 2a of the injection mold. FIG. 7 is an explanatory view for explaining in-mold molding using the preform molded body 1. FIG. 8 shows a case where the shape around the preform molded body side corner c2 and the shape around the female mold side corner c1 of the preform molded body obtained in Example 1 measured with the profile measuring device are overlapped. It is a figure which shows the relationship. FIG. 9 shows the shape of the preform molded body-side corner c2 and the shape of the female mold-side corner c1 of the preform molded body obtained in Comparative Example 1 measured with the profile measuring instrument when overlapped. It is a figure which shows the relationship. FIG. 10 shows dimensions of design values of the preform molded bodies molded in Example 1 and Comparative Example 1. FIG. 11 shows the dimensions of the design values of the preform molded bodies molded in Example 2 and Comparative Example 2. FIG. 12 is an explanatory diagram for explaining each step of a method for manufacturing a laminated molded body by in-mold molding using a conventional preform molded body. FIG. 13 is an explanatory view for explaining a mechanism of generation of wrinkles in the vicinity of a mating surface in conventional in-mold molding. FIG. 14 is an explanatory diagram for explaining a mechanism of generation of wrinkles near a mating surface in conventional in-mold molding.

  The manufacturing method of the laminated molded body of this embodiment is demonstrated with reference to drawings. First, the preform molded body used for the manufacturing method of a laminated molded body is demonstrated.

  FIG. 1 is a schematic perspective view of a preform molded body 1 which is an example of a preform molded body used for manufacturing a laminated molded body. FIG. 1A is a top view, and FIG. 1B is a bottom view. Indicates. The preform molded body 1 includes a main body portion 1a formed into a three-dimensional shape that forms a product main body portion, and a planar outer peripheral portion 1b that is an unnecessary portion that is trimmed and removed later. The main body portion 1a has, as a part thereof, a side surface 1c rising from a planar outer peripheral portion 1b at an angle θ in the range of 45 to 90 degrees, and an upper surface 1d. And when accommodated in the female mold in the in-mold molding, a preform molded body side corner c2 which is a corner where the planar outer peripheral portion 1b and the side surface 1c intersect with the surface facing the surface of the female mold, and the side surface 1c. And a corner c3 that is a corner where the upper surface 1d intersects.

  In FIG. 1, the main body 1a has a rectangular basin shape obtained by transversely cutting a box. However, the shape of the main body part is not limited to such a rectangular basin shape. There is no particular limitation as long as it is three-dimensional. The width of the planar outer peripheral portion is not particularly limited as long as it is a width that can be sandwiched and fixed between the mating surfaces of the female mold and the male mold.

  Preform molded products used in the production of laminated molded products are made by vacuuming leather-like materials such as artificial leather and synthetic leather, fiber structure sheets such as nonwoven fabrics, woven fabrics, woven fabrics and knitted fabrics, and sheet materials such as resin sheets. It can be obtained by preform molding which is shaped by molding means such as molding, pressure molding, vacuum pressure molding, hot press molding or the like. The mold used for preform molding is designed so that the outer surface of the resulting preform molded body exactly matches the surface of the cavity of the female mold of the injection mold.

  Although the thickness of the sheet material for shape | molding a preform molded object is not specifically limited, It is 0.1-2 mm, Furthermore, it is preferable that it is about 0.2-1 mm. When the sheet material is too thin, when the flat outer periphery of the formed preform is sandwiched and fixed between the mating surfaces of the female mold and the male mold, sufficient force is applied to the flat outer periphery. There is a tendency that it is difficult to fix sufficiently without being transmitted.

  Next, as an example of a preferable manufacturing method of the preform molded body 1 used in the present embodiment, referring to FIG. 2, a method of preforming the sheet material 8 by vacuum molding using a concave molding die M1. explain.

As shown in FIG. 2A, first, the sheet material 8 is heated and softened by the heater H. The heating temperature is not particularly limited as long as it is a temperature at which the sheet material 8 can be deformed into a shape along the mold of the vacuum forming machine and does not completely melt. For example, with respect to the glass transition temperature (T _g ) of the resin forming the sheet material, (T _g −10) ° C. or higher and (T _g +50) ° C. or lower, and further (T _g −10) ° C. or higher (T _g A temperature of +30) ° C. or lower, particularly (Tg) ° C. or higher and (T _g +20) ° C. or lower is preferably selected.

  Then, the softened sheet material 8 heated by the heater H is sent to the next step of vacuum forming, and is arranged so as to cover the concave forming mold M1 of the vacuum forming machine as shown in FIG. 2 (b). Is done. The concave mold M1 is a concave mold for molding a preform molded body 1 having a three-dimensional main body 1a as shown in FIG. Then, as shown in FIG. 2C, the softened sheet material 8 is discharged while the air between the softened sheet material 8 and the concave mold M1 is exhausted from the suction / exhaust hole h by a vacuum pump (not shown). Is brought into close contact with the concave mold M1. At this time, the sheet material 8 contacts the outer peripheral surface f surrounding the concave portion of the concave mold M1, and then contacts the inner wall surface i forming the concave shape. As a result, the preform molded body side corner c2 interposed between the planar outer peripheral portion 1b and the side surface 1c of the preform molded body 1 is first shaped. And as shown in FIG.2 (d), by further shaping along the inner wall surface i of the concave mold M1, a corner c3 interposed between the side surface 1c and the upper surface 1d of the preform molded body 1 is formed. Shaped.

  Then, the preformed body 1 is formed by cooling and solidifying the shaped sheet material 8. Then, as shown in FIG. 2 (e), the preform molded body 1 is released from the concave mold M1 by supplying air from the intake and exhaust holes h. In this way, as shown in FIG. 2 (f), a main body portion 1a shaped into a three-dimensional shape having a rising side surface 1c and an upper surface 1d, and a planar outer peripheral portion 1b connected to the periphery of the main body portion 1a, Is obtained.

  In the case of forming the sheet material 8 using such a concave mold M1, the sheet material 8 comes into close contact with the outer peripheral surface f surrounding the concave portion of the concave mold M1 and then forms an inner wall surface i that forms a concave shape. As a result, the preform molded body side corner c2 interposed between the planar outer peripheral portion 1b and the rising side surface 1c of the preform molded body 1 is first shaped. Then, by further shaping along the inner wall surface i of the concave mold M1, a corner c3 interposed between the side surface 1c and the upper surface 1d of the preform molded body 1 is shaped. When the shaping of the sheet material 8 proceeds in such an order, the preform molded body-side corner c2 that is shaped first is accurately shaped without causing shaping return or the like.

  Next, a main body part 11a shaped into a three-dimensional shape having a side surface 11c that rises by vacuum forming using a general convex mold M2, and a planar outer peripheral part 11b continuous around the main body part 11a, With reference to FIG. 3, the process when shape | molding the preform molded object 11 which has this is demonstrated.

  As shown in FIG. 3A, in the preform molding step, the sheet material 8 is first heated and softened by the heater H.

  Then, the sheet material 8 heated and softened by the heater H is sent to the next step of vacuum forming so as to cover the convex mold M2 of the vacuum forming machine as shown in FIG. 3 (b). Be placed. The convex mold M2 is a convex mold for molding a preform molded body 11 having a three-dimensional body portion 11a as shown in FIG. Then, as shown in FIG. 3 (c), the sheet material softened while exhausting the air between the sheet material 8 softened by a vacuum pump (not shown) and the convex mold M2 from the intake / exhaust hole h. 8 is brought into close contact with the convex mold M2. At this time, after the sheet material 8 comes into contact with the upper surface of the convex mold M2 for forming the upper surface 11d of the preform molded body 11, a corner c3 connected to the upper surface 11d is first shaped. Then, as shown in FIG. 3D, after contacting the side surface of the convex mold M2 for forming the side surface 11c of the preform molded body 11, the preform molded body side corner c2 connected to the side surface 11c is added. Shaped. Thus, the main body part 11a having the rising side surface 11c is formed by shaping along the convex mold M2.

  Then, the preformed body 11 is formed by cooling and solidifying the shaped sheet material 8. Then, as shown in FIG. 3 (e), the preform molded body 11 is released from the convex mold M2 by supplying air from the intake and exhaust holes h. In this way, as shown in FIG. 3 (f), a main body part 11a shaped into a three-dimensional shape having a rising side surface 11c and an upper surface 11d, and a planar outer peripheral part 11b connected to the periphery of the main body part 11a, Is obtained.

  When the sheet material 8 is shaped using the convex mold M2 as described above, the sheet material 8 comes into contact with the convex mold M2 and the corner c3 interposed between the upper surface 11d and the rising side surface 11c. Is molded, the preform molded body side corner c2 interposed between the side surface 11c and the planar outer peripheral portion 11b is shaped. When the shaping of the sheet material 8 progresses in such an order, the corner c3 that is shaped first is shaped accurately, whereas the preform molded body side corner c2 that is shaped later is shaped return, etc. As a result, the accuracy of shaping tends to be low.

  As described above, when the sheet material 8 is shaped using the concave molding die M1, the preform molded body side corner c2 interposed between the side surface 1c and the planar outer peripheral portion 1b is accurately shaped. The When the preform molded body 1 in which the preform molded body-side corner c2 interposed between the side surface 1c and the planar outer peripheral portion 1b is accurately shaped as described above is used, the main body having the rising side surface 1c. Laminated molded body that suppresses generation of wrinkles near the mating surface when in-mold molding is performed by accommodating 1a in the cavity and fixing the planar outer peripheral portion 1b between the mating surfaces of the female mold and the male mold. Is obtained.

  The method for improving the accuracy of the formability of the preform molded body side corner c2 is not limited to the method using a concave mold, and a jig that heats a preform molded body formed using a convex mold, You may correct | amend using press molding, or you may correct | amend the preform molded object side corner c2 using the cavity part of the female mold of an injection mold, after accommodating in an injection mold.

  Next, the manufacturing method of the laminated molded body of this embodiment is demonstrated. FIG. 4 is an explanatory view illustrating each process of in-mold molding using the preform molded body 1 of the present embodiment.

  In FIG. 4, 1 has a main body portion 1a shaped in a three-dimensional shape having a side surface rising at an angle θ degree in a range of 45 to 90 degrees, and a planar outer peripheral portion 1b connected to the periphery of the main body portion 1a. Preform molded body, 2a is a female mold having a concave cavity portion 2c, 2b is a male mold having a core portion 2d, 3 is an injection body of an injection molding machine, 3a is a nozzle, 3b is a cylinder, 3c is an inline screw, 4 is a gate, 5 is an injection molded body, 5a is a molten resin, and 9 is an in-mold molded body (laminated molded body). Reference numeral 10 denotes a final product obtained by cutting the planar outer peripheral portion 1 b of the preform molded body 1 and the sprue runner 9 b of the injection molded body 5 from the in-mold molded body 9. The female mold 2a and the male mold 2b are paired to form an injection mold 2 that forms a cavity c. In the present embodiment, the female mold 2a is the movable side of the injection mold, and the male mold 2b is the fixed side of the injection mold.

  In the manufacturing method of the laminated molded body of this embodiment, first, as shown to Fig.4 (a), the preform molded body 1 is fitted to the core part 2d of the male type | mold 2b. In addition, you may make it accommodate in a cavity part instead of making it fit in the core part 2d. When accommodated in the cavity part, the preform molded body is attached to the surface of the cavity part with a double-sided tape, vacuum-adsorbed, or attached using the surface adhesiveness of the preform molded body so that the position of the preform molded body is not displaced. Alternatively, the protrusion may be provided in the cavity, and may be fixed by being fitted into the protrusion.

  5A and 5B are schematic views when the preform molded body 1 is put together with the cavity portion 2c of the female mold 2a of the injection mold. FIG. 5A is a perspective view, and FIG. Sectional drawing of a B 'cross section, (c) is an enlarged view of the part enclosed with the broken-line circle of (b). As shown in FIG. 5 (c), the preform 1 includes a surface L1 of a planar outer peripheral portion 1b facing the female mold 2a, and a surface L2 of the side surface 1c facing the female mold 2a. Has a preform molded body side corner c2 which is an angle at which. On the other hand, the female mold 2a has a mold-side corner c1 that is an angle at which the cavity portion 2c and the mating surface PL intersect.

  In this embodiment, when the preform molded body side corner c2 of the preform molded body 1 accommodated in the cavity portion 2c and the mold side corner c1 of the female mold 2a are overlapped, c2 and c1 have high accuracy. Specifically, the preform molded body 1 is formed such that the distance D between the preform molded body side corner c2 and the mold side corner c1 is 0.2 mm or less, preferably 0.1 mm or less. It is shaped. In the method for manufacturing a laminated molded body according to the present embodiment, when the distance between the preform molded body side corner c2 and the mold side corner c1 is 0.2 mm or less, no gap is formed or an extremely narrow gap is formed. By using a preform molded body in which the rising portion is accurately shaped such that a wrinkle is formed, wrinkles generated in the vicinity of the mating surface in in-mold molding can be suppressed.

  FIG. 6 shows a preform molded body-side corner c2 when the preform molded body-side corner c2 has a slightly lower accuracy in shaping the cavity portion 2c of the injection mold female mold 2a. It is an expansion schematic diagram of the vicinity.

  As shown in FIG. 6, when a preform molded body 11 having a slightly low accuracy in shaping the preform molded body side corner c2 is used, the preform molded body 11 side of the preform molded body 11 accommodated in the cavity portion 2c is used. When the corner c2 and the mold side corner c1 of the female mold 2a are overlapped, the preform molded body side corner c2 and the mold side corner c1 move away from each other. In the case of the preform molded body 11 formed with corners that do not have clear corners, the surface L1 of the planar outer peripheral part 11b on the side facing the female mold 2a and the main body part 11a on the side facing the female mold 2a From the point where the surface L2 of the side surface 11c intersects, the intersection with the perpendicular line dropped on the outer surface of the preform molded body 11 is defined as a preform molded body side corner c2.

  As shown in FIG. 6, the surface around the preform molded body side corner c2 and the surface around the mold side corner c1 are overlapped so that the preform molded body side corner c2 and the mold side corner c1 are close to each other. At this time, a gap is formed between the outer surface of the main body 1a and the surface of the recess of the female mold 2a. And in the manufacturing method of the lamination molded object of this embodiment, the distance D of the preform molded object side corner c2 and the type | mold side corner c1 is 0.2 mm or less, Preferably it is 0.1 mm or less.

  FIG. 8 is a diagram showing the relationship when the shape around the preform molded body side corner c2 and the shape around the female mold side corner c1 of the preform molded body obtained in Example 1 described later are overlapped. is there. Moreover, FIG. 9 shows the relationship when the shape of the periphery of the preform molded body side corner c2 of the preform molded body obtained in Comparative Example 1 described later and the shape of the periphery of the female mold side corner c1 are overlapped. FIG. Further, (a) is a shape around the preform molded body side corner c2, (b) is a shape around the mold side corner c1, and (c) is a shape around the preform molded body side corner c2 and a mold side corner. The case where the shape around c1 is overlapped is shown.

  Referring to FIG. 8, a preform molded body preformed using a concave mold whose surface shape is matched with the surface shape of a female mold of an injection mold used for in-mold molding is shown in FIG. ), The shape around the preform molded body side corner c2 approximates the shape around the mold side corner c1, and the distance D between the preform molded body side corner c2 and the mold side corner c1 is 0.2 mm or less. Become. On the other hand, referring to FIG. 9, the surface shape was designed with a dimension obtained by subtracting the thickness of the preform molded body so as to match the surface shape of the female mold of the injection mold used for in-mold molding. As shown in FIG. 9C, the preform molded body preform-formed using the convex mold does not match the shape around the preform molded body-side corner c2 with the shape around the mold-side corner c1. The distance D between the preform molded body side corner c2 and the mold side corner c1 is large and becomes 1.0 mm or more. When a preform molded body having a large distance between the preform molded body side corner c2 and the mold side corner c1 as shown in FIG. 9 is accommodated in the cavity in the in-mold molding, the mold around the mold side corner c1 is placed. Since a part of the side surface of the reformed molded body goes out of the cavity, a part of the side surface is sandwiched between the mating surfaces of the female mold and the male mold and is accommodated so as to be folded. For this reason, the portion of the side surface of the preform molded body that has come out of the cavity buckles and causes wrinkles. In addition, the cross-sectional shape of the preform molded body and the cross-sectional shape of the female mold can be measured by using a two-dimensional shape measurement sensor such as a profile measuring device using a light beam such as laser light.

  In addition, the preform molded body used in the present embodiment has a main body portion having a side surface rising at an angle θ degree in the range of 45 to 90 degrees, and a planar outer peripheral portion continuous to the periphery of the main body portion. In such a shape, the distance D between the preform molded body side corner c2 and the mold side corner c1 is 0.2 mm or less. When the value of θ is small, the distance D between the preform molded body side corner c2 and the mold side corner c1 is likely to be 0.2 mm or less, and it is difficult to cause shaping return. This is because buckling or the like is difficult to occur.

  In the preform molded body used in the present embodiment, the distance D between all the preform molded body side corners c2 and the mold side corners c1 is 0.2 mm or less as an average value. Specifically, it means that the distance D between the preform molded body side corner c2 and the mold side corner c1 of the preform molded body is uniformly measured at three points, and the average value is 0.2 mm or less.

  Next, as shown in FIG. 4B, the female mold 2a and the male mold 2b are clamped in a state where the main body 1a of the preform molded body 1 is accommodated in the cavity 2c. At this time, the planar outer peripheral portion 1b is sandwiched and fixed by a mating surface PL formed by clamping the female mold 2a and the male mold 2b as surrounded by a broken line in the drawing. Thus, by fixing the planar outer peripheral portion 1b to the mating surface PL of the female mold 2a and the male mold 2b, the preform molded body 1 is less likely to be displaced. A cavity c is formed by clamping the female mold 2a and the male mold 2b.

  And as shown in FIG.4 (c), the cavity c is filled with the molten resin 5a. Specifically, the injection body 3 of the injection molding machine is moved forward, the nozzle 3a is brought into contact with the sprue bush s formed on the male mold 2b, and the molten resin 5a melted in the cylinder 3b is injected by the in-line screw 3c. Thus, the molten resin 5a is completely filled into the cavity c at a predetermined injection speed.

  FIG. 7 shows that by performing in-mold molding using the preform molded body 1 in which the distance D between the preform molded body side corner c2 and the mold side corner c1 is 0.2 mm or less, the mold is brought into the vicinity of the mating surface PL of the mold. It is explanatory drawing for demonstrating the mechanism which can suppress the wrinkles which generate | occur | produce. FIG. 7A shows a state when the main body 1a of the preform molded body 1 is accommodated in the cavity c. In the case where the distance D between the preform molded body side corner c2 and the mold side corner c1 is shaped with high accuracy so as to be 0.2 mm or less, in the vicinity of the mating surface PL surrounded by a broken line circle in FIG. The dimensions of the mold and the preform molded body 1 are close to high accuracy. Then, as shown in FIG. 7B, in a state where the preform molded body 1 is accommodated in the cavity portion 2c, the planar outer peripheral portion 1b is sandwiched and fixed between the mating surfaces of the female die 2a and the male die 2b. When the mold is clamped as described above, the size of the cavity portion 2c and the size of the preform molded body 1 are close to high precision around the mold side corner c1, so that there is a slack that causes wrinkles due to buckling. Absent. In such a state, as shown in FIG. 7 (c), the cavity is filled with molten resin and cooled, so that the preform molded body 1 is injection-molded on the surface as shown in FIG. 7 (d). A laminated molded body 10 integrated with the body 5 is obtained. At this time, since the preform 1 does not generate wrinkles due to buckling when the mold is clamped, generation of wrinkles in the obtained laminated molded body 10 is suppressed. The distance D between the preform molded body side corner c2 and the mold side corner c1 is 0.2 mm or less, and more preferably 0.1 mm or less.

  Specific examples of the thermoplastic resin to be injected include ABS resins, acrylic resins such as PMMA resins, polystyrene resins, polycarbonate resins, polyolefin resins such as polypropylene, polyethylene terephthalate (PET), and polybutylene. Examples thereof include polyester resins such as terephthalate (PBT), various polyamide resins, and COP resins. Moreover, these may be a compound product in which a filler or the like is blended, or a mixed product in which a plurality of types of resins are alloyed or blended. These are appropriately selected according to the application. For example, as a resin used for a casing of a mobile phone, a mobile device, a home appliance, etc., a resin having excellent impact resistance such as an ABS resin, a polycarbonate resin, and a polyolefin resin such as polypropylene is preferably used.

  The injection molding conditions are conditions that allow complete filling according to the thermal characteristics and melt viscosity of the thermoplastic resin, the shape of the molded body, and the resin thickness (resin temperature, mold temperature, injection pressure, injection speed, holding pressure after injection) , Cooling time) is appropriately set.

  The thickness of the injection-molded article to be molded is not particularly limited, and is appropriately selected according to the application and moldability. For example, when used for a casing of a mobile phone, a mobile device, a home appliance, etc., 0.3 to 2 mm, further 0.5 to 1.5 mm is selected as a preferable range.

  In the cooling step, after the molten resin 5a is cooled for a predetermined time in the cavity c formed with the female mold 2a and the male mold 2b clamped, as shown in FIG. 4 (d), the female mold 2a and the male mold 2b are opened, and an in-mold molded body 9 in which the molded injection molded body 5 and the preform molded body 1 laminated on the injection molded body 5 are integrated is taken out. Then, as shown in FIG. 4 (e), by trimming the planar outer peripheral portion 1 b of the preform molded body 1 from the in-mold molded body 9 and cutting and removing the sprue runner 9 b of the injection molded body 5. Thus, the laminated molded body 10 having the final product shape is obtained.

  The laminated molded body obtained by the manufacturing method of the present embodiment is preferably used for, for example, a mobile phone cover, a smartphone cover, a notebook personal computer decoration material, an automobile interior material, a camera or piano exterior material, a mouse surface decoration material, and the like. Used.

  Hereinafter, the present invention will be described more specifically with reference to examples. The scope of the present invention is not limited by the examples.

[Example 1]
Artificial leather having a grain tone surface thickness 0.5 mm ((manufactured by Kuraray Co., Ltd.) of TIRRENINA, ZK-5012: contains ultrafine fibers of the nonwoven fabric of glass transition temperature T _g 100 ° C. in modified PET with a fineness 0.9dtex ) Of 300 mm in length and 450 mm in width was prepared.

  Then, the sheet is heated to 140 ° C. using a vacuum / pneumatic molding machine (manufactured by Fuse Vacuum Co., Ltd., NGF-0406-T), and the main body part accommodated in the cavity of the injection mold and the periphery of the main body part A preform mold was obtained by shaping with a preform mold having a concave mold having a flat outer periphery. As shown in FIG. 10, the concave inner diameter has a rectangular basin-shaped main body portion having a vertical length of 150 mm, a horizontal width of 300 mm, a height of 10.0 mm, and a rising angle of 90 degrees, and a curvature at the boundary between the main body portion and the outer peripheral portion. It was the shape which shape | molds the preform molded object of the shape chamfered so that a radius might be set to 5.0 mm. G1 and G2 are gate positions. After molding, the cross-sectional shape between the side surface of the preform molded body and the planar outer peripheral portion was measured using a profile measuring instrument (manufactured by Keyence Corporation, LJ-V7000). Similarly, the cross-sectional shape of the female mold of the injection mold was also measured. In addition, the cross-sectional shape of the preform molded body measured three points selected uniformly. In addition, the cross-sectional shape of the female mold was measured at three points corresponding to the positions at which the cross-sectional shape of the preform molded body was measured. And the average of the distance measured about each point was made into the distance D. FIG. A typical measurement result is shown in FIG.

  As shown in FIG. 8 (a), the cross-sectional shape of the preform molding around the preform molding-side corner c2 is as shown in FIG. 8 (b). The cross-sectional shape around the corner c1 was approximated. Then, as shown in FIG. 8 (c), the preform molded body-side corner c2 and the mold-side corner c1 are close to each other so that the surface around the preform molded body-side corner c2 and the surface around the mold-side corner c1 are close to each other. When superposed, the distance D between the preform molded body side corner c2 and the mold side corner c1 was 0.1 mm.

  And in-mold shaping | molding was performed using the obtained preform molded object. Specifically, with the female mold and male mold of the injection mold mounted on the injection molding machine (NADEM5000-DM manufactured by Meiki Seisakusho Co., Ltd.) opened, the cavity of the female mold The preform molded body was placed in Then, the female mold and the male mold were clamped with the outer peripheral portions sandwiched between the mating surfaces. Note that the inner shape of the cavity portion of the injection mold was designed to match the inner shape of the preform mold. In the injection mold, two pin gates G1 and G2 were provided at the positions shown in FIG.

Then, ABS resin (T _g 87 ° C.) was injected and filled into the cavity under the conditions of a cylinder temperature of 235 ° C., a mold temperature of 50 ° C., and an injection peak pressure of 160 MPa. Then, after complete filling, the mold was opened after holding a cooling time of 40 seconds while applying a holding pressure of 20 MPa. And the laminated molded object with which the preform molded object was integrated with the surface of the ABS resin molded object whose average thickness T is 1 mm was obtained.

  Ten laminated molded bodies were prepared, and the wrinkle generation rate was calculated from the number of laminated molded bodies in which the generation of wrinkles was visually recognized. As a result, the soot generation rate was 20%.

[Comparative Example 1]
In Example 1, in order to form a preform molded body shaped as shown in FIG. 10, a rectangular basin shape having a length of 149.5 mm, a width of 299.5 mm, a height of 9.5 mm, and a rising angle of 60 degrees was used. Example 1 except that a preform molded body obtained by using a convex mold having a main body portion and chamfered so as to have a curvature radius of 5.0 mm at the boundary between the main body portion and the outer peripheral portion was used. In-mold molding was performed in the same manner as above.

  In addition, the cross-sectional shape between the side surface of the preform molded body and the planar outer peripheral portion was measured in the same manner as in Example 1. The results are shown in FIG.

  As shown in FIG. 9 (a), the cross-sectional shape of the preform molding around the preform molding-side corner c2 is as shown in FIG. 9 (b). The accuracy of shaping was low compared to the cross-sectional shape around the corner c1. Then, as shown in FIG. 9C, the surface around the preform molded body side corner c2 and the surface around the mold side corner c1 are overlapped so that the preform molded body side corner and the mold side corner are close to each other. The distance D between the preform molded body side corner c2 and the mold side corner c1 was 1.0 mm.

  Moreover, when the wrinkle generation rate of the obtained laminated molded body was evaluated in the same manner as in Example 1, the wrinkle generation rate was 90%.

[Example 2]
A sheet similar to that in Example 1 was prepared. Then, using a vacuum / pneumatic forming machine (manufactured by Fuse Vacuum Co., Ltd., NGF-0406-T), the sheet is heated to 140 ° C. and shaped with a preform mold having a concave mold as shown in FIG. A preform molded body having a main body portion having a curved surface having a diameter of a circle of 140 mm on the upper surface, an outer diameter of 150 mm on the bottom surface, a height of 10.0 mm, and an angle of 60 degrees on the rising portion, and an outer peripheral portion around the main body portion. Molded. 11A is a top view and a schematic cross-sectional view of a preform molded body, and FIG. 11B is a top view and a schematic cross-sectional view of an in-mold molded body to be described later.

  And in-mold shaping | molding was performed using the obtained preform molded object. Specifically, with the female mold and male mold of the injection mold mounted on the injection molding machine (NADEM5000-DM manufactured by Meiki Seisakusho Co., Ltd.) opened, the cavity of the female mold The preform molded body was placed in Then, the female mold and the male mold were clamped with the outer peripheral portions sandwiched between the mating surfaces. Note that the inner shape of the cavity portion of the injection mold was designed to match the inner shape of the preform mold. Further, the injection molding die was provided with a side gate at the position G3 shown in FIG.

Then, ABS resin (T _g 87 ° C.) was injected and filled into the cavity under the conditions of a cylinder temperature of 235 ° C., a mold temperature of 50 ° C., and an injection peak pressure of 160 MPa. After filling, the mold was opened after holding a cooling time of 40 seconds while applying a holding pressure of 20 MPa. And the laminated molded object with which the preform molded object was integrated with the surface of the ABS resin molded object whose average thickness T is 1 mm was obtained.

  The distance D between the preform molded body side corner c2 and the mold side corner c1 was 0.2 mm. Moreover, when the wrinkle generation rate of the obtained laminated molded body was evaluated in the same manner as in Example 1, the wrinkle generation rate was 10%.

[Comparative Example 2]
In Example 2, in order to form a preform molded body shaped as shown in FIG. 11, the diameter of the upper circle 139.5 mm and the outer diameter 149. In-mold molding was performed in the same manner as in Example 2 except that a preform molded body having a curved surface with a 5 mm height, a height of 9.5 mm, and a rising portion angle of 60 degrees was used.

  The distance D between the preform molded body side corner c2 and the mold side corner c1 was 1.2 mm. Moreover, when the wrinkle generation rate of the obtained laminated molded body was evaluated in the same manner as in Example 1, the wrinkle generation rate was 70%.

  ADVANTAGE OF THE INVENTION According to this invention, the lamination molded object which integrated the preform molded object with few generation | occurrence | production of wrinkles can be manufactured.

1, 11, 31, 41 Preform molded body 1a, 11a, 41a Body portion 1b, 11b, 41b Planar outer peripheral portion 1c, 11c, 41c Side surface 1d, 11d Upper surface c2 Preform molded body side corner c1 Mold side corner 2, 12 Injection mold 2a, 12a Female mold 2b, 12b Male mold 2c, 12c Cavity part 2d, 12d Core part 3 Injection body of injection molding machine 3a Nozzle 3b Cylinder 3c Inline screw 4 Gate 5, 45 Injection molded body 5a Molten resin 8 Sheet material 9, 10, 40, 50 In-mold molded body (laminated molded body)
PL Matching surface c Cavity M1 Concave mold M2 Convex mold L1 Surface of outer peripheral portion 1b L2 Surface of side surface 1c D Distance between preform molded body side corner c2 and mold side corner c1 N Wavy portion W

Claims (4)

A step of preparing a preform molded body having a body portion shaped into a three-dimensional shape having a side surface rising in the range of an angle of 45 to 90 degrees and a planar outer peripheral portion connected to the periphery of the body portion;
An injection mold having a male mold having a core part and a female mold having a cavity part that accommodates the core part to form a cavity when the mold is clamped, and the main body part is accommodated in the cavity part Placing the preform molded body so as to
By clamping the female mold and the male mold so that the outer peripheral part is sandwiched between the mating surfaces in a state where the body part is accommodated in the cavity part, and filling the formed cavity with molten resin A step of integrating the preform molded body on one surface of the injection molded body to be molded,
The female mold has a mold-side corner that is an area where the cavity portion and the mating surface intersect,
The preform molded body has a preform molded body side corner which is a region where the side surface and the outer peripheral portion intersect on a surface facing the female mold,
When the surface around the preform molded body corner and the surface around the mold side corner are overlapped so that the preform molded body side corner and the mold side corner are close to each other, the preform molded body side A method for producing a laminated molded body, wherein a distance between the corner and the mold side corner is 0.2 mm or less.   The method for producing a laminated molded body according to claim 1, wherein the preform molded body includes a fiber structure. A method of manufacturing a preform molded body having a main body shaped in a three-dimensional shape and a planar outer peripheral portion connected to the periphery of the main body,
Preparing a preform molding die having a main body part forming surface for forming the main body part and an outer peripheral part forming surface for forming the outer peripheral part;
Using the preform molding die, applying a pressure difference to the preform molding sheet, and shaping the body portion forming surface in order from the outer peripheral portion forming surface;
A method for producing a preform molded body comprising:   The manufacturing method according to claim 3, wherein the preform molding die has the main body portion forming surface on a concave inner wall surface.

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