JP2907411B2 - 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 and an apparatus for forming a laminated molded product suitable for an automobile interior part such as an automobile door trim.

[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 an automobile 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 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 having excellent moldability tends to be frequently used.

In this case, in order to shorten the process, when molding the resin core material 2, the skin material 3, which is set in a mold press forming die in advance, is integrated with the resin core material 2 by press integration.

That is, as shown in FIG. 11, when the upper and lower molds 4 and 5 for mold press molding are in an open state, the skin material 3 is set on the set pins 4a of the upper mold 4 and
The lower mold 5 includes a hot runner 5a and the hot runner 5a.
A plurality of gates 5b branching from a are drilled, and molten resin from an injection molding machine 6 connected to the lower die 5 is passed through a hot runner 5a and a gate 5b to a predetermined location on the die surface of the lower die 5. Distribute and supply.

Then, upper and lower molds 4 for mold press molding are used.
By the engagement and tightening of 5, the molten resin is molded and press-molded into a required shape to form the resin core material 2 and to integrate the resin core material 2 and the skin material 3.

When the upper mold 4 is lifted after the mold press molding, a vacuum is formed between the upper mold 4 and the molded product, so that the molded product cannot be lifted integrally with the upper mold 4.
As shown in FIG. 12, a vacuum suction hole 7 is opened in the lower mold 5, and a countermeasure has been taken to hold the molded product in the lower mold 5 by a vacuum suction force when the mold is opened.

As a method of holding the molded body in the lower mold 5 when the mold is opened, as shown in FIG. 13, an undercut portion 2a is provided on the resin core material 2 and the undercut portion 2a of the resin core material 2 is used. The molded product is held by the lower mold 5 by locking the molded article after the mold press molding to the lower mold 5.

[0009]

As described above, in the method for press-molding a molded article, the laminated molded article 1 is prevented from being lifted together with the upper mold 4 when the mold is opened after the mold press molding. As shown in FIGS. 12 and 13, a method of installing a vacuum suction mechanism in the lower mold 5 or setting an undercut portion 2a in the resin core material 2 has been adopted. For example, the vacuum suction mechanism shown in FIG. In the method employing the mechanism, the hot runner 5a, the gate 5b, and the like for supplying the molten resin from the injection molding machine 6 are piped to the lower mold 5, so that the degree of freedom of the layout of the vacuum suction holes 7 is low. It has been pointed out that the piping work is troublesome.

[0010] In addition, large-scale auxiliary equipment such as a vacuum pump is required, which leads to an increase in cost and a problem that the material of the molding material is restricted.

[0013] Next, as shown in FIG.
In the method of setting the undercut portion 2a to the mold, when the molded product is released from the lower die 5, the undercut portion 2a becomes an obstacle, and it is difficult to remove the molded product from the lower die 5, resulting in deformation or breakage of the product. Easy and undercut 2a
In addition, the weight of the resin core material 2 is increased due to the addition of the resin core 2, and there is a drawback that it is not suitable for reducing the weight of the product.

Further, in both methods, since the holding force for holding the molded product in the lower mold 5 is weak, the speed of opening the mold must be set low, and the molding cycle is prolonged. It is pointed out.

The present invention has been made in view of such circumstances, and an object of the present invention is to form a laminate by integrally molding a resin core material and a skin material into a required shape by a mold press molding method. Provided are a molding method and a molding apparatus for a laminated molded article, in which a mold structure and a layout of a molding material can be freely set, a facility can be simplified, and a molding cycle can be shortened. It is in.

[0014]

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 an upper mold and a lower mold for mold press molding. In a molding method of a laminated molded body composed of a resin core material and a skin material integrated with the resin core material , a plurality of small-diameter air holes in an air blow mechanism installed in an upper mold are formed after mold press molding by the mold press molding die. Through
Then , air is applied to the surface of the skin material, and the upper mold is raised while the laminated molded body is held on the mold surface of the lower mold to open the mold.

Further, the molding apparatus according to the present invention is characterized in that
Mold press molding of fat into required shape to form resin core material
The resin core material and the skin material during mold press molding
In a molding apparatus for a laminated molded body integrating
The forming device has a desired mold surface shape, and molten resin is placed on the mold surface.
Lower mold for mold press molding distributed and supplied, and lower mold
Equipped with almost the same mold surface as the surface shape
Mold press that can be moved up and down as much as possible
Air is displayed from the upper mold after molding press molding and the upper mold.
An air blow mechanism for applying to the skin material surface side,
The above air blow mechanism is an air blow
Fittings into the recesses formed at predetermined locations on the mold surface of the upper mold
Blow with multiple vents that are fixed and communicate with the piping
Plug and a blower connected to the air blow pipe
Air from the blower for air blow
Skin material surface after mold press molding through pipes and vents
It is characterized by spraying . Also requires molten resin
Mold press molding to form a resin core material
In addition, at the time of mold press molding, the resin core material and
In a molding apparatus for forming a laminated molded body,
Has a desired mold surface shape, and the molten resin is distributed on the mold surface.
The supplied lower mold for press molding and the mold surface shape of the lower mold
With almost the same mold surface as the one above, it can be engaged and pressed against the lower mold
The upper and lower parts for mold press molding
After the mold and mold press molding, air is applied from the upper mold to the skin material surface.
And an air blow mechanism for applying pressure to the surface side.
The air blow mechanism is for air blow machined in the upper mold.
Fits in a recess formed in the pipe and a predetermined location on the upper mold surface
A plurality of slits that are fixed and formed
Connection with blow plug with air blow and piping for air blow
Air from the blower.
Mold blow through piping for blow, multiple slits
Sprayed on the surface of the skin material after molding
You.

[0016]

As is apparent from the above configuration, after the mold press molding, the holding of the molded article in the lower mold is performed by forming air from the upper mold through a plurality of small-diameter air holes in the air blow mechanism set in the upper mold. The air blow pipe to the upper mold can be easily performed because there is no obstacle.

Furthermore, since the releasability between the upper mold and the molded product is improved, restrictions due to the material and thickness of the molded product are eliminated.

Further, since the molded body can be securely held in the lower mold, the mold opening speed can be increased and the eject speed of the molded article can be increased.

[0019]

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 configuration of the automobile door trim, and FIG. 3 is an embodiment of a molding apparatus according to the present invention. FIG. 4 is a sectional view of a main part of the molding apparatus, FIG. 5 is an external view showing a plug used in the molding apparatus,
FIG. 6 is a perspective view showing another embodiment of the plug used in the molding apparatus.

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

More specifically, the resin core material 11 is made of a polypropylene resin material mixed with talc, and the molten resin is distributed and supplied into a mold press molding die having a required curved shape. It is formed into a shape with a complicated curved shape by the construction method.

The skin material 12 may be of various specifications depending on the application. For example, a single sheet such as a PVC sheet or a foamed PVC sheet may be used. Alternatively, a polyolefin foam layer such as a polyethylene foam may be used. A backed PVC sheet, a PVC sheet backed with a polyurethane foam, or the like may be appropriately selected.

In this embodiment, as the structure of the skin material 12, a laminated sheet material in which a polyethylene foam is laminated on the back surface of a PVC sheet is used.

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

As shown in FIG. 3, this molding device 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.
Numeral 0 is connected to the elevating device 41, is movable up and down, maintains a predetermined clearance with respect to the lower mold 30, and is configured to be capable of engaging and pressing.

Then, the lower mold 3 for mold press molding is formed.
0, an injection molding machine 50 is connected, and through a nozzle 51 of the injection molding machine 50, the molten resin is passed through a hot runner 31 and a gate 32 formed in the lower mold 30, and the molten resin is applied to the mold surface of the lower mold 30. To supply.

Further, the feature of the molding apparatus 20 is shown in FIG.
As shown in (1), the air blow mechanism 60 is installed on the upper die 40.

That is, an air blow pipe 61 is provided in the upper mold 40, and a blow plug 62 shown in FIG.
Air blow pipe 6 through a plurality of ventilation holes 63 provided in
1 is a configuration in which air from 1 is blown toward the lower mold 30.

The air blow pipe 61 is connected to the blower 6.
4, and the blow plug 62 is fitted and fixed in a concave portion 42 provided at a predetermined position on the mold surface of the upper mold 40.

The molding apparatus 20 according to the present invention is configured as described above, and the method of the present invention will be described with reference to FIGS. 6 to 8 by taking a molding step of an automobile door trim 10 as an example.

First, as shown in FIG. 6, when the skin material 12 is set on the upper mold 40, the periphery of the skin material 12 is set on the set pins 43 installed on the upper mold 40.

When the step of setting the skin material 12 is completed, the upper mold 40 starts to descend by the operation of the elevating device 41. At this time, the upper mold 40 is placed on the mold surface of the lower mold 30 from the nozzle 51 of the injection molding machine 50. The molten resin M is distributed and supplied to a predetermined location through the hot runner 31 and the gate 32.

As shown in FIG. 7, the resin core 11 is formed into a required shape by press-fitting the upper and lower molds 30 and 40 for mold press molding, and the resin core 11 and the skin material are joined together. 12 are integrated. still,
The pressing pressure is set at 40 to 80 kg / cm ² .

Next, after mold press molding, the upper mold 40
Rises to open the mold. At this time, as shown in FIG. 8, air is sent from a blower 64 installed in the upper mold 40 to an air blow pipe 61, and this air is blown by a blow plug 62. The door trim 10 is sprayed between the mold surface of the upper mold 40 and the surface of the skin material 12 of the molded body through the plurality of ventilation holes 63, and the door trim 10 molded and pressed by the blow pressure is pressed onto the mold surface of the lower mold 30. become,
The upper mold 40 may be quickly lifted to open the mold.

The blow plug 6 used in the present invention
The material 2 is not limited to metal or ceramic as long as it has heat resistance enough to withstand a resin temperature of 150 to 300 ° C.

Further, it is necessary that the air hole 63 does not leave any trace on the outer surface of the skin material 12, so that it is preferable to set the air hole 63 to 0.3 mm or less.

As described above, the molding apparatus 20 according to the present invention
Compared with the conventional method of holding a molded product by a vacuum suction force, the configuration in which the air blow mechanism 60 is installed on the upper mold 40 allows the piping layout of the air blow pipe 61 to be set freely, and is compared with vacuum suction equipment. In addition, the air blow mechanism 60 is less expensive and can simplify the equipment.

Further, according to the method of the present invention, the air blow effect is high, and the molded automobile door trim 10 can be firmly pressed and held on the mold surface of the lower mold 30.
The mold opening speed of the lower mold 30 can be increased.
The molding cycle can be greatly shortened, for example, the ejection speed of ejecting the door trim 10 can be increased, and restrictions due to the material and thickness of the product are eliminated, and there is no need to set an undercut portion. There is an advantage that it can contribute to simplification of processing and weight reduction of products.

FIG. 9 shows a modification of the air blow mechanism 60. In this embodiment, the blow plug 70 has a large number of slits 71 formed along the vertical direction on a cylindrical outer peripheral surface. If it is fitted and fixed in the concave portion 42 of the upper mold 40, air is blown to the molded product through the slit 71 provided on the outer periphery of the blow plug 70.

According to this embodiment, similarly to the above-described embodiment, the releasability between the molded product and the upper mold 40 can be improved, and the processing of the blow plug 70 is performed by forming the ventilation holes 63. In comparison with the above, there is an advantage that the formation of the slit 71 can be performed easily and inexpensively, and the processing cost of the blow plug 70 can be reduced.

[0042]

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

(1) According to the method of the present invention, after the mold press molding through a plurality of small-diameter air holes in the air blow mechanism installed in the upper mold, air is blown from the upper mold to form the upper mold and the molded body. The mold release speed of the upper mold and the rising speed of the eject pin installed on the lower mold can be set faster, and the molding cycle can be significantly shortened. This has the effect that productivity can be significantly improved.

(2) According to the method of the present invention, air is blown from the upper mold to the molded body through a plurality of small-diameter air holes in the air blow mechanism installed in the upper mold to separate the upper mold from the molded body. Since it is intended to enhance the moldability, it is not necessary to set an undercut portion in the resin core material, and it is possible to prevent damage or deformation of the undercut portion beforehand, and it has the effect of helping to reduce the weight of the product .

(3) According to the method of the present invention, air is blown from the upper mold through a plurality of small-diameter air holes in the air blow mechanism installed in the upper mold to release the mold between the upper mold and the molded product. Therefore, the restriction on the material and thickness of the molded product is eliminated, any material can be freely selected, and the degree of freedom in molding can be greatly improved.

[0046] (4) According to the molding apparatus according to the present invention, established the air blow pipe to the upper mold, and communicating therewith, a plurality of
This is a simple configuration that installs a blow plug with a ventilation hole or a plurality of slits.This is a simple and inexpensive configuration compared to the conventional configuration in which vacuum suction equipment is installed in a mold. Since there is no obstacle to the piping work in the mold, there is an effect that the degree of freedom in piping is significantly improved as compared with the conventional vacuum suction type.

[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 a sectional view showing one embodiment of a molding apparatus according to the present invention.

FIG. 4 is a sectional view showing a main part of the molding apparatus shown in FIG. 3;

FIG. 5 is an external view showing a blow plug used in the molding apparatus shown in FIG. 3;

FIG. 6 is a sectional view showing a state where a material is set in the molding apparatus shown in FIG. 3;

FIG. 7 is a sectional view showing a mold press molding step in the molding apparatus shown in FIG. 3;

FIG. 8 is a sectional view showing a demolding step in the molding apparatus shown in FIG. 3;

FIG. 9 is a perspective view showing a modification of the blow plug used in the method of the present invention.

FIG. 10 is a sectional view showing a general configuration of an automobile door trim.

FIG. 11 is a sectional view showing a mold structure used in a mold press molding method.

FIG. 12 is a sectional view showing a conventional mold press molding apparatus.

FIG. 13 is a sectional view showing a conventional mold press molding apparatus.

[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 Depression 43 Set pin 50 Injection molding machine 60 Air blow mechanism 61 Air blow Piping 62 Blow plug 63 Vent hole 64 Blower 70 Blow plug 71 Slit

──────────────────────────────────────────────────の Continued on the front page (58) Field surveyed (Int. Cl. ⁶ , DB name) B29C 43/18-43/20 B29C 43/36-43/42 B29C 43/50 B29C 33/44-33 / 46 B29C 45/43

Claims (3)

(57) [Claims] An upper and lower mold (30, 4) for mold press molding.
A resin core material (11) formed by molding a molten resin (M) into a required shape in the above (0), and a skin material (12) integrated with the resin core material (11) during mold press molding. In the method for forming a laminated molded article , a plurality of small-diameter air holes (63) in an air blow mechanism (60) installed in the upper mold (40) after the mold press molding by the mold press molding molds (30, 40 ). Through
Then , air is applied to the surface side of the skin material (12) to form the lower mold (3).
A method for forming a laminated molded article, wherein the upper mold (40) is lifted while the laminated molded article (10) is held on the mold surface of (0), and the mold is opened. As well as mold press molding a resin core member (11) to 2. A required shape molten resin (M), during press-molding, resin core member (11) and skin material (1
The molding device (20) is provided with a desired mold surface shape, and is provided with a lower surface for mold press molding in which the molten resin (M) is distributed and supplied onto the mold surface. A mold (30) having a mold surface substantially identical to the mold surface shape of the lower mold (30), and configured to be capable of ascending and descending so as to be capable of engaging and pressing against the lower mold (30). upper die (40), after the press molding, is constituted from an upper die (40) skin material and air (12) air blow mechanism to be applied to the surface side (60), the air blowing mechanism (6
0) is an air blow pipe drilled in the upper mold (40).
(61) and formed at predetermined locations on the mold surface of the upper mold (40).
It is fitted and fixed in the concave portion (42) and communicates with the pipe (61).
Blow plug (62) provided with a plurality of ventilation holes (63)
And a blower connected to the air blow pipe (61)
(64), and air from the blower (64).
Through the air blow pipe (61) and the vent hole (63)
Spraying on the surface of the skin material (12) after mold press molding
An apparatus for forming a laminated molded article, comprising: 3. Molding the molten resin (M) into a required shape.
While molding the resin core material (11) by
At the time of mold press molding, resin core material (11) and skin material (1)
2) In a molding device of a laminated molded body integrating The molding device (20) has a desired mold surface shape,
Molten resin (M) on top Mold press components distributed and supplied
The shape of the lower mold (30) is almost the same as that of the lower mold (30).
Equipped with a single mold surface, capable of engaging and clamping to the lower mold (30)
The upper and lower parts for mold press molding
After the mold (40) and mold press molding, the upper mold (40)
Blower that applies air to the surface of the skin material (12)
And the air blow mechanism (6).
0) is for air blow drilled in the upper mold (40)
The pipe (61) and the upper mold (40) are formed at predetermined locations on the mold surface.
Fits into the recessed part (42),
For blow having a plurality of slits (71) formed in
Connect with plug (70) and air blow pipe (61)
And a blower (64).
Air from the air blow pipe (61),
(71), the skin material (1
2) A laminated molded article characterized by spraying on the surface side
Molding equipment.