JP2662933B2 - Skin integral molding method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the production of a multilayer molded product in which various skin materials are bonded to the surface of a base layer made of a thermoplastic resin.
Relates to a method relates to integral skin molding method can be suitably applied to an automobile interior material having a particularly undercut.

[0002]

2. Description of the Related Art In general, automotive interior parts are often constituted by multilayer molded articles in which various skin materials are bonded to the surface of a base material layer made of a thermoplastic resin. In particular, since the appearance is important, it is natural to attach a skin material to the undercut portion even for an interior component having an undercut portion such as a door trim. Conventionally, as shown in FIGS. 6 and 7, the peripheral portion 52 of the skin material H is cut to a predetermined size, and then the skin material peripheral portion 52 is folded back to the undercut portion 53 of the core material 51 and adhered by an adhesive or the like. , Staples and the like to maintain the appearance as a product.

[0003]

However, in the prior art, a cutting process or an adhesive bonding process is required, which requires a lot of man-hours. Therefore, an organic solvent is not used from the viewpoint of manufacturing efficiency and working environment (that is, the adhesive is not used). Therefore, it is desired to efficiently treat the skin material at the same time as molding.

SUMMARY OF THE INVENTION It is an object of the present invention to improve the working environment by giving a good appearance to the terminal portion of a molded article having a skin, to eliminate the use of an adhesive, and to improve the working efficiency by eliminating post-processing after molding. It is another object of the present invention to provide a method for integrally forming a skin, which can increase the height of the skin material without causing a risk of the skin material being torn, and can select a material of the skin material regardless of its elongation, tensile stress and the like.

[0005]

SUMMARY OF THE INVENTION According to the present invention, there is provided a method for integrally forming a skin, comprising: forming a cavity in a second mold facing a first mold and a movable block core having an overhang portion provided in the second mold; And forming a skin material between the first mold and the second mold, supplying a synthetic resin as a base material between the skin material and the second mold, pressurizing and cooling. In a method for integrally forming a skin having a multi-layered product having an undercut portion in which a skin material is integrally joined to a surface of a base material, after a skin material is disposed between the first mold and the second mold. Moving the movable block core away from the second mold and bringing the movable block core into contact with the skin material to draw the skin material into the cavity; The edge of the mold and the edge of the second mold are engaged, and the skin end is cut with both molds. And characterized in that it comprises a step of pushing the 1 member pushing from the mold edge was inserted between the overhang portion and the edge portion of the second mold movable block core skin material, the

[0006]

According to the present invention, after the skin material is disposed between the first mold and the second mold, the movable block core on the second mold is moved away from the second mold. The skin material is brought into contact with the skin material, the skin material is drawn into the cavity, and the edge of the first mold and the edge of the second mold are engaged with the movable block core away from the second mold. Both molds are cut. Thereafter, the pushing member is inserted between the overhang portion of the movable block core and the edge of the second mold from the edge of the first mold, so that the skin material is pushed in.

[0007] For this reason, the skin material is drawn into the cavity by a predetermined amount without being subjected to excessive tensile stress, and cut at the edge of the mold in this state. Automatically cuts exactly to the dimensions). Further, since the cut end portion of the skin material is pushed into a portion to be an undercut of the product by the pushing member, the skin can be integrally formed even in the undercut portion.

[0008]

An embodiment of the present invention will be described below with reference to the drawings. The members, arrangements, and the like described below do not limit the present invention, and can be variously modified within the scope of the present invention.

FIGS. 1 to 5 show an embodiment of a molding apparatus used in the present invention. FIG. 1 is a sectional view of an essential part of the apparatus when a skin material is arranged, and FIG. Sectional view,
FIG. 3 is a cross-sectional view of a main part of the apparatus when the pushing member is inserted and held, FIG. 4 is a cross-sectional view of the main part of the apparatus when a synthetic resin is supplied, and FIG.

As shown in FIG. 1, the molding apparatus S of this embodiment comprises a generally concave upper die 10 and a generally convex lower die 20 opposed thereto. Is provided with a slidable movable block core 30. In this example, the lower mold 20 is fixed and the upper mold 10 is movable. The upper mold 10 is moved up and down by a driving device (not shown) to open and close the mold. The setting may be reversed.

The upper mold 10 is provided with a slidable pushing plate 40 and a driving means 41 for the plate 40.
The pushing plate 40 is moved by the driving means 41 to the upper mold 1.
Thus, it is configured to be able to protrude from the cavity edge portion 11 in the cavity inward direction.

The movable block core 30 is configured to slide vertically by a push-up pin 31 connected to a driving device (not shown), and its overhang portion 32, the cavity edge portion 11 of the upper mold 10, and the lower mold The edge 21 forms a cavity space for forming an undercut of the molded product.

In the present embodiment, an extruder or an injection molding machine (not shown) is attached to the lower mold 20, and a synthetic resin in a molten state is supplied from the extruder or the injection molding machine to the lower mold 2.
The gate 22 provided in the cavity No. 0 is supplied through the cavity.

The material of the skin material used in the present invention includes thermoplastic resin such as woven fabric, nonwoven fabric, polyolefin, vinyl chloride and nylon, and thermoplastic elastomer such as polyolefin, polyester, urethane and vinyl chloride. Sheets and films. In addition, the above materials may be used alone or two or more layers may be used as a skin material.

In order to provide a softer feel, a foam material such as polypropylene, polyethylene, or urethane is bonded to the back surface of the skin material to protect it from the heat of the molten resin at the time of molding, or to form a layer between the skin material and the core material layer. It is also possible to use a laminate in which a cloth, a sheet, or the like is bonded to the back surface for the purpose of enhancing the adhesive force. In using these skin materials, preheating may be performed prior to supply in order to adjust the tensile stress and elongation of the skin material.

The resin used as the substrate in the present invention is, for example, polypropylene, polyethylene, polystyrene,
Acrylonitrile-styrene-butadiene copolymer, thermoplastic resin such as nylon, thermoplastic elastomer such as ethylene-propylene block copolymer, styrene-butadiene block copolymer, etc. are usually used for compression molding, injection molding and extrusion molding. Any of them can be used. In addition, those containing additives such as inorganic fillers, fillers such as glass fibers, pigments, lubricants, and antistatic agents can also be appropriately used.

Next, the operation of the molding apparatus S having the above configuration will be described. First, the skin material H is set between the upper mold 10 and the lower mold 20 with both molds open (not shown) as described above, and the mold is clamped to a predetermined position as shown in FIG.
The skin material H may be held by any holding frame,
Alternatively, it may be adsorbed to the upper mold 10 by means such as vacuum. At this time, the movable block core 30 is housed in the lower mold 20 in the initial position, and the cavity edge portions 11 and
1 is open.

The skin material H is held and the cavity edges 11,
In a state in which the block core 30 is opened, the drive means (not shown) is operated to raise the push-up pin 31 and
Is moved away from the lower mold 20, that is, upward, the skin material H comes into contact with the block core 30 and the block core 30.
And is drawn into the cavity by the amount of the rise. Therefore, if the holding force of the skin material H is kept constant,
The amount of the skin material H drawn into the cavity is constant and stable. In addition, since the fork is not forcibly pressed by the edge of the mold, an unreasonable force is not applied to the skin material H, and the skin tear can be prevented.

Next, when the upper mold 10 is lowered until the state shown in FIG. 2 is reached, the cavity edge 11 of the upper mold 10 and the cavity edge 21 of the lower mold 20 come to a position where they mesh with each other.
At this position, the skin material H is cut by the shearing force. In this example, the lowering of the upper mold 10 is stopped when the cutting of the skin material is completed.

After cutting the skin material H, as shown in FIG. 3, the plate driving means 41 is actuated to cause the pushing plate 40 to protrude from the cavity edge portion 11, and the cut skin material H is transferred to the block core 30 at the tip of the plate. Overhang part 3
2 into the space between the lower mold cavity edge 21. After the pushing is completed, the driving means 41 is operated in reverse to push the pushing plate 4.
0 is stored in the original position, and the push-up pin 31 is lowered to lower the block core 30.

In this embodiment, the upper mold 10 is still stopped at this time, and the supply of the molten synthetic resin J between the skin material H and the lower mold 20 is started from the synthetic resin supply gate (FIG. 4). . After the supply of the predetermined amount of the synthetic resin is completed, or during the supply of the predetermined amount of the synthetic resin, the upper mold 10 is lowered again, and the pressure is applied to the resin J through the skin material H, thereby closing the mold. And filling of the resin is achieved (FIG. 5).

After the mold clamping and the filling of the resin are completed as shown in FIG. 5, the resin J is left to stand for a while, cooled, the resin J is cured, the mold is opened again, and the molded product is taken out to complete a series of steps. I do.

In this embodiment, after the supply of the predetermined amount of the synthetic resin is completed in a state where the mold clamping of the upper mold 10 is stopped halfway, or simultaneously while the predetermined amount of the synthetic resin is supplied, the upper mold 10 is removed. Although the mold is clamped to the final position and the resin is filled using the pressure from the mold, the so-called stamping method is used.
The same effect can be obtained by applying the resin to the so-called injection molding method in which the resin is supplied in a state where the upper mold 10 and the lower mold 20 are clamped to the final positions and the resin J is filled by using the supply pressure. .

In this embodiment, after the skin material is cut, the pushing plate 30 is protruded to push the skin material, and then the pushing plate 30 is retracted into the edge portion 11 of the upper mold 10 and stored.
The lowering operation of the block core 30 and the lowering operation of the upper mold 10 are performed independently, but may be performed simultaneously by linking, or when the mold is clamped, the pressing plate 30 is If it is set so as to fit between the cavity edges 21 of the lower mold 20, the mold clamping and molding may be performed with the pushing plate 30 protruding. Further, in this example, a plate material is used as the pushing member, but this may be used as a pushing pin as a pin material.

[0025]

According to the present invention, after the skin material is disposed between the first mold and the second mold, the movable block core on the second mold is separated from the second mold. It moves and comes into contact with the skin material, draws the skin material into the cavity, and engages the edges of the first mold and the second mold in a state where the block core is separated from the second mold. Is cut by both molds. Thereafter, the pushing member is inserted between the overhang portion of the movable block core and the edge of the second mold from the edge of the first mold, so that the skin material is pushed in.

For this reason, the skin material is drawn into the cavity by a predetermined amount without being subjected to excessive tensile stress, and is cut at the edge of the mold in this state. Automatically cuts to exact dimensions. Further, since the cut end portion of the skin material is pushed into a portion to be an undercut of the product by the pushing member, the skin can be integrally formed even in the undercut portion.

As described above, according to the present invention, a good appearance is given to the terminal portion of a molded article having a skin, the use of an adhesive is not required, and the working environment is improved. Work efficiency can be improved, and there is no fear of the skin material being torn, and the material of the skin material can be selected irrespective of its elongation and tensile stress.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a main part of a device when a skin material used in the present invention is arranged.

FIG. 2 is a cross-sectional view of a main part of the device when the skin is cut.

FIG. 3 is a sectional view of a main part of the device when a pushing member is inserted and held.

FIG. 4 is a sectional view of a main part of the apparatus when a synthetic resin is supplied.

FIG. 5 is a cross-sectional view of a main part of the device at the end of molding.

FIG. 6 is an explanatory sectional view of a terminal portion processing showing a conventional example.

FIG. 7 is a cross-sectional view of a product terminal showing a conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Upper die 11 Upper die cavity edge surface 20 Lower die 21 Lower die cavity edge surface 22 Resin supply gate 30 Block core 31 Push-up pin 32 Overhang part 40 Push plate 41 Plate driving means S Molding device H Skin material J synthetic resin

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B29L 31:58

Claims (1)

(57) [Claims] A cavity is formed by a second mold facing the first mold and a movable block core having an overhang portion provided on the second mold, and the first mold and the second mold are formed. An undercut in which a skin material is disposed between the skin material and a synthetic resin serving as a base material is supplied between the skin material and the second mold, pressurized and cooled, and the skin material is integrally joined to the surface of the base material In the method for integrally forming a skin having a multi-layered product having a portion, the movable block core is moved away from the second mold after disposing a skin material between the first mold and the second mold. A step of bringing the skin material into contact with the skin material and drawing the skin material into the cavity; and engaging the edges of the first mold and the second mold with the movable block core separated from the second mold. The skin end is cut by both molds, and then the pushing member is moved from the edge of the first mold to the movable block core. A step of inserting between the overhang portion and the edge of the second mold and pushing in the skin material.