JP2846193B2 - Molding method and molding apparatus for laminated molded articles - 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 for forming a laminated molded product suitable for an automobile interior part such as a door trim for an automobile and a molding apparatus used for the molding.

[0002]

2. Description of the Related Art Conventionally, the structure of an automobile interior trim such as an automobile door trim, a rear corner trim, etc., which is installed in a vehicle body panel will be described with reference to an automobile door trim shown in FIG. Is
Resin core material 2 molded to have a desired curved shape
And a laminated molded body of a skin material 3 having a cushioning property, which is laminated and integrated on the surface side of the resin core material 2.

[0003] As a method of molding the resin core material 2,
In recent years, since a complicated three-dimensional shape is required in molding, a mold press molding method excellent in moldability tends to be frequently used.

In this case, the skin material 3 is integrated with the resin core material 2 at the time of mold press molding of the resin core material 2 in order to shorten the process.

That is, as shown in FIG. 15, first, the skin material 3 is attached to the set pins 4a of the upper mold 4 for mold press molding.
Is set in advance, and the upper mold 4 for mold press molding is lowered, and while maintaining a predetermined clearance between the upper and lower molds 4 and 5, on the mold surface of the lower mold 5 for mold press molding,
The resin material 7 distributed and supplied from the injection molding machine 6 through the hot runner 5a and a plurality of gates 5b branched from the hot runner 5a is press-molded into a required shape by engaging and pressing the upper and lower dies 4,5. To form a resin core material 2 and a surface material 3 on the surface side of the resin core material 2.
And the door trim 1 for an automobile shown in FIG. 14 is formed into a product shape.

[0006]

However, in the conventional method of integrally molding the resin core material 2 and the skin material 3 by mold press molding to form a laminated molded product as described above, in the case of the mold press molding, It has been pointed out that the No. 3 cannot follow the highly developed shape, the skin is cut, the resin exudes from the cut portion, and molding failure frequently occurs.

When the molded article is released from the mold, the upper mold 4 is lifted to open the mold. At this time, the space between the molded article and the upper mold 4 is in a vacuum state, May not easily come off from the set pin 4a, and the releasability of the upper mold 4 and the molded product is poor. The molded product is lifted upward with the rise of the upper die 4, and in particular, a clip seat or the like is attached to the resin core material 2. When the undercut portion is set, there are problems such as breakage of the undercut portion.

The present invention has been made in view of such circumstances, and an object of the present invention is to form a laminated molded product in which a resin core material and a skin material are integrated by a mold press molding method. In the method and the molding apparatus, it is possible to enhance the moldability of the skin material, to reliably prevent resin leakage due to the cut of the skin material during mold press molding, and to reliably perform the demolding operation between the molded product and the upper mold. It is an object of the present invention to provide a method and an apparatus for forming a laminated molded product.

[0009]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention provides a resin core formed by molding a molten resin into a required shape in a mold press mold, and a mold press for the resin core. At the time of molding, in the method of molding a laminated molded body composed of the resin core material and a skin material integrated with the resin core material, the surface material set in the mold press molding upper mold is provided on the upper mold. After hot air is blown from the air blow holes to preheat and soften the skin material, mold press molding is performed.

Further, hot air is blown from a blow / vacuum hole provided on the upper mold to the skin material set in the mold press molding upper mold to preheat and soften the skin material, and then the blow / vacuum hole is formed. Through the upper mold surface, vacuum forming the skin material, and then performing mold press molding.

After the mold press molding, air is blown to the molded body through an air blow hole or a blow / vacuum hole provided in the upper mold to perform a demolding operation between the upper mold and the molded body. The mold may be opened.

A molding apparatus according to the present invention comprises a lower mold for press molding having a desired mold surface to which a molten resin is distributed and supplied, and a mold press molding having a skin material set thereon and having a desired mold surface shape. An upper mold is provided, and the upper mold is connected to a blower having a hot air generator at least in part, and is provided with an air blow hole serving as a hot air passage for preheating the skin material. .

Further, the molding device includes a lower mold for mold press molding having a desired mold surface to which the molten resin is distributed and supplied;
A skin material is set, and an upper die for mold press molding having a desired mold surface shape is provided.The upper die has at least a blower provided with a hot air generator and a blower which is selectively connected to a vacuum pump. It is characterized by having a vacuum hole.

[0014]

As is clear from the above configuration, when the hot air is blown onto the skin material set on the upper mold through the air blow holes provided in the upper mold, the skin material is preheated and softened. The skin material easily follows the complicated curved shape of the mold.

Further, if hot air is blown on the skin material set on the upper mold through the blow / vacuum hole provided in the upper mold, the skin material is softened, and the vacuum is continuously applied to the upper mold through the blow / vacuum hole. By suction, the skin material can be faithfully formed along the upper mold surface.

Further, after the mold press molding, air can be blown from the air blow hole or the blow and vacuum hole to improve the releasability between the upper mold and the molded product.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for forming a laminated molded article and a molding apparatus according to the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is an external view showing an automobile door trim manufactured by the method of the present invention, FIG. 2 is a sectional view showing the structure of the automobile door trim, and FIG. 3 is a first embodiment of a molding apparatus according to the present invention. 4 to 6 are cross-sectional views showing each step of the method of the present invention using the forming apparatus shown in FIG. 3, and FIG. 7 is a view showing the structure of a second embodiment of the forming apparatus according to the present invention. 8 and 9 are sectional views showing each step of the method of the present invention using the molding apparatus shown in FIG. 7, and FIGS.
1 is an explanatory view showing a modified example of an air blow mechanism and a vacuum mechanism used in the method of the present invention. FIGS. 12 and 13 show air blow holes 43 and blow / vacuum holes 44 provided in the upper mold of the molding apparatus according to the present invention. It is each sectional view which shows a modification.

In FIG. 1 and FIG. 2, a door trim 10 for an automobile manufactured by the method of the present invention comprises a resin core material 11 formed into a required shape, and a skin laminated and integrated on the surface side of the resin core material 11. And the material 12.

More specifically, the resin core material 11 is made of polypropylene resin mixed with talc, distributed and supplied in a molten state into a mold press molding die having a required curved surface shape, and then subjected to mold press molding. It is formed into a shape with a complicated curved shape.

The skin material 12 may be of various specifications depending on the intended use. For example, if a thermoplastic elastomer such as styrene-based TPE or olefin-based TPE is used, the skin material 12 is heated to 40 to 50 ° C. In the state, the elongation rate is 2.2 times, and excellent moldability is obtained.

Next, a description will be given of the structure of a molding apparatus for molding and pressing the above-described door trim 10 for an automobile.

As shown in FIG. 3, this molding apparatus 20
A lower mold 30 for mold press molding having a desired mold surface;
An upper mold 40 for mold press molding, which is located above the lower mold 30 and has substantially the same mold surface, is connected to the lower mold 30, and is formed on the mold surface of the lower mold 30. It is roughly composed of a material supply mechanism for supplying resin and an air blow mechanism 60 installed on the upper mold 40.

More specifically, the material supply mechanism includes:
An injection molding machine 50 is connected to the lower mold 30 and is connected to a nozzle of the injection molding machine 50 through a hot runner 31 drilled in the lower mold 30 and a plurality of gates 32 branching from the hot runner 31. Is distributed and supplied to a predetermined location on the mold surface of the lower mold 30.

Next, the upper mold 4 located above the lower mold 30
Numeral 0 is configured to be able to move up and down by an elevating device 41, has a set pin 42 for setting the skin material 12, and has an air blow hole 43.

The air blow hole 43 is connected to the air blow mechanism 60.

That is, the air blow mechanism 60 includes a hot air generator 61 and a blower 62 juxtaposed, and is configured to be switchably connected to the air blow hole 43 by a switching valve 63.

A molding press molding step of the door trim 10 for an automobile using the molding apparatus 20 will be described.

First, as shown in FIG. 4, the skin material 12 is set on the set pins 42 of the upper die 40 with the back side thereof facing downward.

When the setting operation of the skin material 12 is completed, hot air of 80 ° C. is blown from the hot air generator 61 to the skin material 12 through the air blow holes 43 for 30 seconds, and the skin material 12 is heated and softened.

Next, the upper die 40 is lowered by the operation of the elevating device 41, and the lowering operation of the upper die 40 is stopped when the clearance between the upper and lower dies 30, 40 is about 30 mm. Then, the molten resin M is distributed and supplied to a predetermined location through the hot runner 31 and the gate 32 through the nozzle 51 of the injection molding machine 50. Then, as shown in FIG. 5, the resin core material 11 is formed by the engagement and pressing of the upper and lower molds 30, 40 for mold press molding, and the skin material 12 is integrated with the surface side of the resin core material 11. You.

At this time, since the skin material 12 is pre-heated and has excellent extensibility, it can easily follow a complicated mold surface shape, and does not have a cut or the like. Therefore, molding defects such as resin leakage can be reliably prevented.

Then, after the mold press molding and before the mold opening step, the switching valve 63 is switched, and air at room temperature which is not heated is supplied from the blower 62 to the air blow hole 43, and the skin material of the molded body is supplied from the upper mold 40. The door trim 10 sprayed and formed on the surface of the mold 12 repels the upper mold 40 by air blow pressure, is securely held on the lower mold 30, and can quickly raise the upper mold 40. The mold opening speed can be increased as compared with the conventional one.

Further, the releasability of the automobile door trim 10 formed by the air blow pressure is enhanced, and even if the undercut portion is formed in the resin core material 11, the undercut portion is broken or deformed. Or not.

As described above, according to the method of the present invention, the skin material 12 before the mold press molding is performed by the air blow mechanism 60.
Is preheated and softened to enhance the formability of the skin material 12 and prevent molding defects as much as possible. After mold press molding, air is blown from the air blow holes 43 through a blower 62 to form a molded automobile door trim. The mold removal operation can be performed easily and reliably, and the molding cycle can be shortened by increasing the mold opening speed, and the molded article can be reliably protected by preventing breakage of the undercut part of the molded article. There is an effect that it becomes possible.

Further, the present invention has a simple structure in which an air blow hole 43 is opened in the upper die 40 and connected to a hot air generator 61 and a blower 62 constituting an air blow mechanism 60. It can be used to enhance the moldability of mold 12 and the mold releasability of the molded product, and can greatly improve the function of molding device 20.

FIG. 7 shows a molding apparatus 20 according to the present invention.
In the second embodiment, the same parts as those in the first embodiment are denoted by the same reference numerals, and a detailed description thereof will be omitted.

In FIG. 7, a blow / vacuum hole 44 is provided over the entire surface of the upper mold 40. The blow / vacuum hole 44 is connected to a hot air generator 61 and a blower 62 through a switching valve 63. , A vacuum pump 64. The switching valve 63 is a three-way switching valve.

Therefore, as shown in FIG.
After the skin material 12 is set on the set pins 42, hot air is blown from the hot air generator 61 to the skin material 12 through the blower / vacuum hole 44, and the skin material 12 is in a softened state.

Next, as shown in FIG.
3, the blower / vacuum hole 44 and the vacuum pump 64 are connected, and the skin material 12 is vacuum formed through the blower / vacuum hole 44.

Thereafter, as in the first embodiment, the upper and lower dies 30,
The mold 40 is clamped, and the molten resin M is subjected to mold press molding to form the resin core material 11 and be integrated with the skin material 12.

As described above, according to the present embodiment, the upper mold 40
Through the blow / vacuum hole 44 provided in the skin material 1
2 is preheated and softened, and female elongation is performed along the mold surface of the upper mold 40. Therefore, extensibility of the skin material 12 can be expected, and a large clearance between the skin material 12 and the lower mold 30 is secured. In addition, since the influence of heat from the molten resin M is not so much affected as the skin material 12,
The fluidity of the molten resin M can be increased, the moldability can be significantly improved, and the skin material 12 does not have poor appearance or the like.

In addition, after molding, the blow and vacuum holes 4
By blowing air from the blower 62 to the molded product through 4, the releasability of the molded product can be improved and the molding cycle can be shortened.

Further, as the air blow mechanism 60, FIG.
As shown in FIG. 11 and FIG. 11, only the hot air generator 61 is used to blow the hot air from the hot air generator 61 onto the skin material 12.
May be used in the preheating step, and may also be used in the release step after the mold press molding of the molded product. In this case, there is an advantage that the configuration of the air blow mechanism 60 is further simplified.

In addition, the air blow holes 43 provided in the upper die 40 may be provided only at locations corresponding to the high expansion rate portion of the molded product as shown in FIG. 12, or as shown in FIG. As described above, the air blow hole 43 or the blow / vacuum hole 44 can be set at many positions over the entire surface of the upper die 40, and various variations are provided depending on the shape of the molded product and the material of the skin material 12. be able to.

[0046]

As described above, according to the present invention, the following special effects can be obtained.

(1) According to the method of the present invention, an air blow mechanism is installed on the upper die and hot air is blown onto the skin material through the air blow holes in the method of mold-pressing a laminate formed of the resin core material and the skin material. In order to improve the moldability of the skin material, the mold material can easily follow the upper mold surface during mold press molding. Since cutting or resin leakage does not occur, the degree of freedom in molding the product is greatly improved,
In addition, there is an effect that the defective rate can be significantly reduced.

(2) According to the method of the present invention, a blow / vacuum hole is provided in the upper die in the method of mold-pressing a laminated molded product of a resin core material and a skin material, and the blow mechanism and the vacuum mechanism can be switched. Then, hot air is blown to the skin material through the blow and vacuum holes to give the skin material extensibility. Further, after the skin material is vacuum formed through the blow and vacuum holes, mold press molding is performed. Therefore, the moldability of the skin material can be significantly improved, and the fluidity of the molten resin can be increased, so that the effect of contributing to thinning and weighing of the product can be obtained.

(3) According to the method of the present invention, after the air blow mechanism or the vacuum mechanism installed on the upper mold is used in the preheating step and the vacuum step of the skin material, after the mold press molding, the upper mold and the molded article are separated. Air is blown from the air blow hole or blow / vacuum hole to give the mold release property at the time of molding, so the mold releasing property between the upper mold and the molded product is improved, and molding can be performed even if the mold opening speed of the upper mold is increased. Since the product is not lifted and the undercut portion is not damaged, the molding cycle can be greatly shortened, and the molded product can be prevented from being damaged. Having.

(3) According to the apparatus for molding a laminated molded product according to the present invention, an air blow hole or a blow / vacuum hole is opened in the upper mold, and an air blow mechanism or a vacuum mechanism provided with a hot air generator at least in part. With the simple structure of connection, the moldability of the skin material can be significantly improved, and the molded product can be more reliably removed when the mold is opened. It has the effect that it can be improved.

[Brief description of the drawings]

FIG. 1 is an external view showing an automobile door trim manufactured by the method of the present invention.

FIG. 2 is a sectional view showing a configuration of the vehicle door trim shown in FIG. 1;

FIG. 3 is an overall view showing a configuration of an embodiment of a molding apparatus according to the present invention.

FIG. 4 is a cross-sectional view showing one step of the method for forming a laminated molded article according to the present invention and showing a step of preheating the skin material.

FIG. 5 is a cross-sectional view showing one step of a method for forming a laminated molded article according to the present invention and showing a mold press molding step.

FIG. 6 is a cross-sectional view showing one step of the method of forming a laminated molded article according to the present invention and showing a step of releasing the upper mold and the molded article.

FIG. 7 is a cross-sectional view showing the configuration of another embodiment of the molding apparatus according to the present invention.

FIG. 8 is a cross-sectional view showing another embodiment of the method of the present invention and showing a preheating step of the skin material.

FIG. 9 shows another embodiment of the method of the present invention, and is a cross-sectional view showing a vacuum forming step of a skin material.

FIG. 10 is a configuration diagram showing another embodiment of the air blow mechanism used in the molding apparatus according to the present invention.

FIG. 11 is a configuration diagram showing another embodiment of the air blow mechanism used in the molding apparatus according to the present invention.

FIG. 12 is a sectional view showing a modified example of the air blow holes provided in the upper mold of the molding apparatus according to the present invention.

FIG. 13 is a cross-sectional view showing a modified example of the air blow holes provided in the upper mold of the molding apparatus according to the present invention.

FIG. 14 is a sectional view showing a general configuration of an automobile door trim.

FIG. 15 is a sectional view showing a conventional mold press molding method.

[Explanation of symbols]

 REFERENCE SIGNS LIST 10 Door trim for automobile 11 Resin core material 12 Skin material 20 Molding device 30 Lower die for mold press molding 31 Hot runner 32 Gate 40 Upper die for mold press molding 41 Lifting device 42 Set pin 43 Air blow hole 44 Blow and vacuum hole 50 Injection molding Machine 51 Nozzle 60 Air blow mechanism 61 Hot air generator 62 Blower 63 Switching valve 64 Vacuum pump M Molten resin

Continued on the front page (58) Fields surveyed (Int. Cl. ⁶ , DB name) B29C 43/18-43/20, 43/34-43/4 2,43 / 52,33 / 02-33/04, 33/12-33/1 8

Claims (10)

(57) [Claims] 1. A mold for mold press molding (30, 40).
A resin core material (11) formed by molding a molten resin (M) into a required shape in the inside, and a skin material integrated with the resin core material (11) during mold press molding of the resin core material (11) (1
2) The method of forming a laminated molded body, comprising: the skin material (12) set in the mold press molding upper mold (40); and an air blow hole ( 43) hot air was blown from the skin material (1).
2. A method for forming a laminated molded article, comprising: performing prepress softening of 2) and then performing mold press molding. 2. A mold for mold press molding (30, 40).
A resin core material (11) formed by molding a molten resin (M) into a required shape in the inside, and a skin material integrated with the resin core material (11) during mold press molding of the resin core material (11) (1
2) The method of forming a laminated molded body, comprising: the surface material (12) set in the upper mold press molding die (40); and the blow and vacuum provided in the upper die (40). Hot air is blown from the hole (44) to preheat and soften the skin material (12), and then the skin material (12) is vacuum-suctioned along the mold surface of the upper mold (40) through the blow / vacuum hole (44). A method for forming a laminated body, comprising vacuum forming the material (12) and then performing mold press molding. 3. After the mold press molding, air is blown to the molded body through an air blow hole (43) or a blow / vacuum hole (44) provided in the upper mold (40) to separate the upper mold (40) from the molded body. 3. The method according to claim 1, wherein after performing the mold operation, the upper mold (40) is raised to open the mold. 4. The method for forming a laminate according to claim 1, wherein the skin material is a thermoplastic elastomer. 5. A resin core material (11) is molded by press-molding the molten resin (M) into a required shape, and the resin core material (11) is formed by molding and pressing the resin core material (11). In a molding apparatus for a laminated molded body formed integrally with a skin material (12), the molding apparatus (20) is a lower mold for mold press molding having a desired mold surface to which a molten resin (M) is distributed and supplied. (3
0) and an upper mold (40) on which a skin material (12) is set, and which has a desired mold surface shape.
At least a part of the hot air generator (6) is provided in the upper mold (40).
An apparatus for forming a laminated molded article, characterized in that an air blow hole (43) which is connected to a blower provided with (1) and is a passage for hot air for preheating of a skin material (12) is opened. 6. A resin core material (11) is molded by press-molding the molten resin (M) into a required shape, and when the resin core material (11) is subjected to mold press molding, the resin core material (11) is formed. In a molding apparatus for a laminated molded body formed integrally with a skin material (12), the molding apparatus (20) is a lower mold for mold press molding having a desired mold surface to which a molten resin (M) is distributed and supplied. (3
0) and an upper mold (40) on which a skin material (12) is set, and which has a desired mold surface shape.
At least a part of the hot air generator (6) is provided in the upper mold (40).
An apparatus for molding a laminated molded article, characterized in that a blower provided with 1) and a blow / vacuum hole (44) which is connected to and connected to a vacuum pump (64) are opened. 7. The blower is constituted by a hot air generator (61), and is supplied through an air blow hole (43) or a blow / vacuum hole (44) at the time of preheating the skin material (12) and at a stage before opening the mold. 7. The apparatus for molding a laminated molded product according to claim 5, wherein the is sprayed on the molded product side. 8. A blower has a hot air generator (61) and a blower (62) juxtaposed, and a switching valve (63) for preheating and softening the skin material (12) from the hot air generator (661) to the air blow holes (43). ) Or hot air is blown onto the skin material (12) through the blow / vacuum hole (44), and at the time of demolding after mold press molding, the blower (62) forms an air blow hole (43) or a blow / vacuum hole (44). 7. The apparatus for forming a laminate according to claim 5, wherein air is blown onto the laminate. 9. The laminated body according to claim 5, wherein the air blow holes (43) are set only in a complicated curved surface portion of the upper die (40) or a portion having a large expansion rate. Molding equipment. 10. The air blow hole (43) or the blow / vacuum hole (44) is provided over the entire mold surface of the upper mold (40).
9. The apparatus for forming a laminate according to 6, 7, or 8.