JP2809293B2 - Manufacturing method and manufacturing apparatus for insulator - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing an insulator.

[0002]

2. Description of the Related Art Generally, an insulator dash having a soundproofing property is installed on the indoor surface side of a dash panel located in front of a front seat, and the insulator dash is provided between a sound insulating material layer such as a rubber sheet and a felt. ,
It is composed of a laminate with a sound absorbing material layer such as a polyurethane foam.

Since the dash panel is attached to a dash panel having a complicated surface shape, the dash panel is formed into a required shape by a press forming apparatus shown in FIG. 6, and the outer periphery is trimmed and a piercing hole is formed at a predetermined position. Have been.

A method of manufacturing the insulator dash will be described with reference to FIG. 6. First, preheated and softened materials 2a and 2b are placed on a press-forming lower mold 1 having a mold surface shape along the surface shape of a dash panel. With the lower mold 1
The pad mold 3 having a mold surface shape substantially equal to the mold surface shape is lowered, and the cold press molding of the blanks 2a and 2b into the required shape is performed between the press molding lower mold 1 and the pad mold 3.

Further, the pad mold 3 is installed on the lower surface of the press molding upper mold 4 via a spring 5, and the press molding upper mold 4 has a cutting blade 6 for trimming the outer periphery and a piercing process. The piercing punch 7 for performing the above is mounted and fixed.

That is, in the pressing step of the insulator 2, the first press pressure is applied to the upper die 4 for press molding by the lowering of the press ram, and a part of the pressure is relieved by the spring 5 and applied to the pad die 3. Then, the raw materials 2a and 2b are cold-pressed between the pad die 3 and the lower die 1 for press molding, and the insulator 2 is formed into a required shape.

Thereafter, when a press pressure is further applied to the upper die for press molding 4 by lowering the press ram, the spring 5
Is compressed, the pad mold 3 is stopped, and only the press-molding upper mold 4 descends, and the cutting blade 6 and the piercing punch 7 descend to trim the outer periphery of the molded insulator 2. And piercing is performed.

[0008]

As described above, conventionally, as a method of forming, trim-cutting and piercing the insulator 2, a single press-forming apparatus is used, and the upper die 4 and the pad die 3 for press-forming are used. A spring 5 for adjusting the press pressure is provided between them, and cold press molding is performed in the first stage, and then trimming and piercing are performed in the second stage.

However, in the method of adjusting the press pressure by the spring pressure of the spring 5, it is not possible to adjust an appropriate press pressure at the time of press forming and trim and piercing, and at the time of press forming of the raw materials 2a and 2b, The cutting blade 6 and the piercing punch 7 are lowered while the material is still soft, and the finished state is poor due to the generation of burrs and the like, and the finishing work is required again. Have been.

[0010] The present invention has been made in view of such circumstances, and an object of the present invention is to efficiently perform insulator molding and piercing and cutting with the same press molding apparatus in a good finished state. It is an object of the present invention to provide an insulator manufacturing method and a manufacturing apparatus which enable the above.

[0011]

In order to achieve the above object, a method of manufacturing an insulator according to the present invention comprises: By engaging the spacer means between the mold and the pad mold, the press pressure of the upper mold for press molding is directly applied to the pad mold, and the material is formed between the lower mold for press molding and the pad mold in the required shape. Insulator forming process for cold press forming, disengagement of the spacer means between the press forming upper die and the pad die, and lower the cutting blade and piercing punch provided on the press forming upper die. ,
Piercing a predetermined portion of the cold-pressed insulator, and piercing and cutting the insulator to perform trim cutting along the outer periphery;
It is characterized by consisting of.

Further, an apparatus for manufacturing an insulator according to the present invention comprises a press-forming lower mold having a desired mold surface, and a press-forming upper mold located above the press-forming lower mold and capable of moving up and down. A die, a pad die suspended from the lower surface of the upper die for press molding, and having a die surface substantially the same as the lower die, a cutting blade attached and fixed to the upper die for press molding, and a piercing punch. In a manufacturing apparatus of an insulator, a material is cold-pressed into a required shape between a press-forming lower die and a pad die, an outer periphery is cut by a cutting blade, and piercing is performed at a predetermined location by a piercing punch. A fixed-side spacer and a movable-side spacer are installed between the upper mold and the pad mold. In the cold press molding process of the insulator, a driving cylinder is formed. The movable side spacer is engaged with the fixed side spacer by operation to apply the pressing pressure of the upper die for press molding directly to the pad mold, and in the piercing and cutting steps of the insulator, the movable side spacer is retracted and fixed. The piercing of the insulator and the cutting of the outer periphery are performed by press pressure applied from the upper die for press molding to the pad die, exceeding the spring force of the spring inserted in the side spacer.

[0013]

As is apparent from the above configuration, according to the method of the present invention, in the press step of the insulator, the fixed spacer and the movable spacer are engaged between the upper die for press molding and the pad die. Thereby, the press pressure applied to the upper mold for press molding is directly applied to the pad mold, and the press pressure applied to the pad mold can be adjusted to the optimal press pressure for molding the insulator.

Further, after the pressing pressure is applied for a predetermined time, the engagement between the fixed-side spacer and the movable-side spacer is released, so that the spring installed between the upper die for press molding and the pad die is opened. When compressed, only the cutting blade and the piercing punch descend while the pad mold is stopped, so that trim cut processing and piercing processing can be performed on the formed insulator without a burr or the like and a good finish state.

In addition, in the press forming apparatus used in the method of the present invention, a fixed side spacer is provided between the press forming upper die and the pad die, and the press forming upper die is slid by a driving cylinder. This is a simple configuration in which a movable spacer is arranged.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of a method and an apparatus for manufacturing an insulator according to the present invention will be described below in detail with reference to the accompanying drawings.

FIG. 1 is a cross-sectional view showing the configuration of an automobile insulator dash manufactured by the method of the present invention, FIG. 2 is a cross-sectional view showing the configuration of an insulator manufacturing apparatus used for carrying out the method of the present invention, and FIGS. FIG. 5 is a sectional view showing each step of the method of the present invention.

First, an insulator dash 10 for an automobile manufactured by the method of the present invention comprises a sound insulating material layer 11 made of a flexible material having a relatively high surface density such as a rubber sheet, a PVC sheet filled with an inorganic filler, and this sound insulating material. It is made of a laminated body of a sound absorbing material layer 12 such as polyurethane foam or felt having a desired sound absorbing function and integrated on the back surface of the layer 11, and is attached along the interior surface of the dash panel 13. It is formed into a shape that conforms to the shape.

Since the insulator 10 is formed by cold press molding as described later, the sound absorbing material layer 1
As the second material, thermoformable felt or polyurethane is used.

The insulator dash 10 has an opening 14 for piercing a harness or pipes from the engine room side to the room side by piercing, and is trimmed along a predetermined outer shape. It has been processed.

Next, the structure of the manufacturing apparatus for the insulator dash 10 will be described with reference to FIG.

A manufacturing apparatus 20 for manufacturing the insulator dash 10 has a press-forming lower mold 30 having a piercing hole 31 at a predetermined position, and is located above the press-forming lower mold 30 and can be moved up and down by a press ram (not shown). And the upper die 40 for press molding. In particular, the upper die 40 for press molding has an upper table 41 located on the upper surface thereof connected to a press ram (not shown) and a press ram. A pad mold 42 for pressing the insulator dash 10 is suspended from a lower surface of the molding upper mold 40 by a suspension device 43.

Further, the upper die 40 for press molding and the pad die 4
2, a return spring 44 is provided at a predetermined location.

Further, a cutting blade 45 for trimming the outer periphery of the insulator dash 10 is provided on the upper table 41.
A piercing punch 46 for performing piercing is fixed to the upper table 41 and installed so as to penetrate the press-forming upper mold 40 and the pad mold 42 while being fixed to the lower surface of the press-forming upper mold 40. I have. A stopper 47 is provided on the lower surface of the upper die 40 for press molding.

The feature of the present invention resides in that a means for appropriately adjusting the press pressure between the upper die 40 for press molding and the pad die 42 is provided.

That is, the fixed spacer 50 having a cylindrical shape is provided on the upper surface of the pad mold 42, and the flange portion 51 of the fixed spacer 50 is in contact with the upper surface of the pad mold 42.

Further, a space 52 for accommodating the fixed side spacer 50 is provided in the upper die 40 for press molding, and a spring 53 and a bolt 54 are interposed in the space 52. Are biased downward by a spring 53.

A slidable movable spacer 60 is provided on the lower surface of the press molding upper mold 40. The movable spacer 60 is fixed to a piston rod 62 of a driving cylinder 61 such as an air cylinder. I have.

In the pressing step, the movable-side spacer 60 is provided with the flange 5 of the fixed-side spacer 50.
(1) The cutting blade 45 and the piercing punch 46 are lowered by utilizing the spring force of the spring 53 installed on the fixed side spacer 50 by moving forward so as to overlap with the upper surface and retracting in the piercing step. I have.

Next, a manufacturing process of the insulator dash 10 using the above-described insulator manufacturing apparatus 20 will be described.

First, as shown in FIG. 3, raw materials 11a and 12a which are preheated to a predetermined temperature and are in a softened state are set on the upper surface of the lower die 30 for press molding.

At this time, the movable-side spacer 60 is at the retracted position, and the dimensional relationship between the fixed-side spacer 50, the movable-side spacer 60, and the stopper piece 47 of the pad mold 42 is as follows.

Here, when the thickness a of the movable side spacer 60, the thickness b of the flange portion 51 of the fixed side spacer 50, and the projection size c of the stopper piece 47 are set as follows, a + b> c a ≦ c, b ≦ c. ing.

Next, as shown in FIG. 4, the movable-side spacer 60 moves forward by the operation of the driving cylinder 61, hits the fixed-side spacer 50, and operates by the press ram.
Although the upper table 41 and the upper die 40 for press molding descend, the spring 53 installed on the fixed spacer 50 slightly expands and contracts because the flange portion 51 of the fixed spacer 50 and the movable spacer 60 are engaged. However, most of the press pressure of the upper mold 40 for press molding is transmitted to the pad mold 42, and the lower mold 30 and the pad mold 42 are engaged and clamped with an appropriate press pressure, whereby the material 1 is pressed.
1a and 12a are cold-pressed with an appropriate pressing pressure.

At this time, the stopper piece 47 of the pad mold 42
A clearance e of a + bc is secured between the pad mold 42 and the pad mold 42. This e is a cutting blade 45 or a piercing punch 46
Is larger than the sum of the stroke f and the thickness g of the insulator. That is, e = a + bc−f + g.

Therefore, in this pressing step,
The cutting blade 45 and the piercing punch 46 are used as the molding materials 11a, 1
The desired cold press molding is performed at an appropriate press pressure for a predetermined time without touching 2a.

Thereafter, after the cold press molding is completed, the press molding upper die 40 slightly rises upward, and after the movable side spacer 60 retreats, as shown in FIG. The press mold upper die 40 moves downward until the stopper piece 47 of the press mold upper mold 40 abuts against the pad mold 42, and the cutting blade 45 and the piercing punch 46 descend.

At this time, according to the relationship of e> f + g, the outer periphery of the press-formed insulator dash 10 is trimmed by the cutting blade 45, and piercing by a piercing punch (not shown) is simultaneously performed.

Thereafter, the cutting blade 45 and the piercing punch 46 are simultaneously raised as the upper table 41 is raised, and the return spring 4 is moved until the cutting blade 45 and the piercing punch 46 come off from the insulator dash 10.
4 is a state in which the pad mold 42 holds the product 10;
When the spring pressure of the return spring 44 becomes zero, the pad mold 42 also rises at the same time, and if the pad mold 42 rises to the position shown in FIG. 3, the product may be released.

[0040]

As described above, the present invention has the following special effects.

(1) According to the method of the present invention, in the two steps of the insulator forming step and the piercing cut step, the pad mold 42 is formed in both steps by the spacer provided between the press-molding upper mold and the pad mold. Since the applied press pressure can be adjusted appropriately, the cutting blade and piercing punch do not drop during the pressing process, and good piercing and cutting can be performed, and almost no rework is required. Has the effect that the production efficiency can be significantly improved.

(2) The press-forming apparatus used in the method of the present invention is a simple one in which a fixed-side spacer and a movable-side spacer that moves forward and backward by a driving cylinder are disposed between an upper die for press-forming and a pad die. With this configuration, the production efficiency of the insulator can be greatly improved, so that a simple and inexpensive configuration can provide a great effect, and has high practical value.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a configuration of an automobile insulator dash manufactured by applying the method of the present invention.

FIG. 2 is a cross-sectional view illustrating a configuration of an apparatus for manufacturing an insulator dash used in the method of the present invention.

FIG. 3 is a cross-sectional view showing one embodiment of the method of the present invention and showing a step of setting a material.

FIG. 4 is a cross-sectional view showing one step of the method of the present invention and showing a cold press forming step.

FIG. 5 is a cross-sectional view showing one step of the method of the present invention and showing a piercing and cutting step.

FIG. 6 is a sectional view showing a manufacturing process of a conventional insulator dash.

DESCRIPTION OF SYMBOLS 10 Insulator dash for automobile 11 Sound insulation material layer 12 Sound absorption material layer 11a, 12a Material 13 Dash panel 20 Manufacturing device 30 Press forming upper die 31 Pierce hole 40 Press forming upper die 41 Upper table 42 Pad type 43 Suspension device 44 Return spring 45 Cutting blade 46 Piercing punch 47 Stopper piece 50 Fixed spacer 51 Flange 52 Space 53 Spring 54 Bolt 60 Movable spacer 61 Driving cylinder

Continuation of the front page (58) Field surveyed (Int.Cl. ⁶ , DB name) B29C 51 / 06,51 / 08 B29C 51/14-51/26 B29C 51/30-51/40 B29C 33/20-33 / 28 B60R 13/08 B29L 31:58

Claims (2)

(57) [Claims] 1. A heat-softened material (11a, 12a) set on a press-forming lower mold (30) is:
By engaging spacer means (50, 60) between the upper mold for press molding (40) and the pad mold (42),
The pressing pressure of the upper mold for press molding (40) is directly applied to the pad mold (42), and the material (11a, 12a) is formed into a required shape between the lower mold for press molding (30) and the pad mold (42). A step of forming an insulator for cold press forming, and disengaging the spacer means (50, 60) between the press forming upper mold (40) and the pad mold (42) to form the press forming upper mold ( Lowering the cutting blade (45) and the piercing punch (46) provided at 40), the piercing process is performed on a predetermined portion of the cold-pressed insulator, and the piercing of the insulator that performs trim cutting along the outer periphery. A method for manufacturing an insulator, comprising: a cutting step. 2. A press molding lower mold (30) having a desired mold surface, and a press molding upper mold (40) located above the press molding lower mold (30) and capable of moving up and down. , Which is suspended from the lower surface of the upper die (40) for press molding,
Pad mold (4) having substantially the same mold surface as lower mold (30)
2) a cutting blade (45) attached and fixed to the upper die (40) for press molding, and a piercing punch (46),
The material (11a, 12a) is cold-pressed into a required shape between the press-molding lower mold (30) and the pad mold (42), and the outer periphery is cut by a cutting blade (45). 46) In the insulator manufacturing apparatus (20) for performing piercing according to (46), a fixed-side spacer (50) and a movable-side spacer (60) are provided between the press-molding upper mold (40) and the pad mold (42).
In the cold press forming step of the insulator, the movable side spacer (60) is engaged with the fixed side spacer (50) by the operation of the drive cylinder (61), and the upper die for press forming ( The press pressure of 40) is directly applied to the pad mold (42), and the movable side spacer (60)
Is retracted, the spring force of the spring (53) inserted into the fixed spacer (50) is exceeded, and the press force applied from the press molding upper mold (40) to the pad mold (42) causes the insulator to move. An insulator manufacturing apparatus for performing piercing and trim cutting of an outer periphery.