JP2907413B2 - Molding equipment for laminated moldings - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding apparatus used for molding 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 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. 11, 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. 10 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.

[0007] As a countermeasure, when the end of the skin material 3 is removed from the set pin 4a during molding so that the skin material 3 follows the highly developed shape, unevenness of the tension applied to the skin material 3 causes the set pin 4a. There is a problem that wrinkles are generated in the skin material 3 around the portion removed from the surface.

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. An object of the present invention is to provide a molding apparatus capable of improving the formability of a skin material, and reliably preventing wrinkles, irregularities, and the like from occurring in the skin material after molding, and forming a laminated molded article having a good design. is there.

[0009]

Means for Solving the Problems In order to achieve the above-mentioned object, the present invention provides a method of mold-pressing a molten resin into a required shape to form a resin core material, and further comprises the steps of: In a molding device for a laminated molded body obtained by integrating a resin core material and a skin material, 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; an upper mold for mold press molding having a desired mold surface shape and engageable with the lower mold; and a mold surface of the upper mold. And a support pin installed on the periphery of the upper mold so as to hold the skin material, and the support pins on at least one side of the periphery of the upper mold are attached to a support frame formed of a long body having a substantially L-shaped cross section.
And the support frame is supported by the upper mold, and comes into contact with and separates from the upper mold.
The support frame is movable in a direction in which the support frame can move in accordance with the tension from the skin material.

[0010]

As is clear from the above configuration, at least a part of the support pin for holding the end of the skin material is attached.
Since the support frame is configured to be movable, at the time of mold press molding, the skin material easily follows the complicated curved surface shape of the mold.

Furthermore, at the time of mold press molding, since the support frame is movable in accordance with the tension applied to the skin material,
The tension applied to the skin material is substantially uniform.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an apparatus for forming a laminated molded article 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 using the apparatus according to the present invention, FIG. 2 is a sectional view showing the structure of the automobile door trim, and FIG. 3 is a first view of a molding apparatus according to the present invention. 4 to 8 are sectional views showing respective steps of manufacturing a door trim using the molding apparatus shown in FIG. 3, and FIG. 9 is a second embodiment of the molding apparatus according to the present invention. FIG. 2 is a sectional view of a main part showing the configuration of FIG.

In FIG. 1 and FIG. 2, an automobile door trim 10 is roughly composed of a resin core material 11 formed in a required shape and a skin material 12 laminated and integrated on the surface side of the resin core material 11. ing.

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 mold having a required curved shape, and then subjected to mold press molding. It is formed into a shape with a complicated curved shape.

The top layer 1 is used as the skin material 12.
A laminated sheet composed of 2a, a foam layer 12b and a base fabric 12c is used. A PVC sheet is used as the top layer 12a, a polyethylene foam is used as the foam layer 12b, and a polyester fiber non-woven fabric is used as the base fabric 12c. And the top layer 12a has a better surface appearance,
The foam layer 12b provides good cushioning performance, and the base cloth 12c has a function of preventing the molten resin from seeping into the foam layer 12b during mold press molding of the resin core material 11.

Next, a description will be given of the construction 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 a material that is a material of the resin core material 11 on the mold surface of the lower mold 30. It is roughly composed of a material supply mechanism 50 for supplying a resin, and a skin material support mechanism 60 for holding the skin material 12 installed on the upper mold 40 with uniform tension.

More specifically, as the material supply mechanism 50, an injection molding machine 51 is connected to the lower mold 30 and installed.
The molten resin is distributed and supplied from the nozzle of the injection molding machine 51 to a predetermined location on the mold surface of the lower mold 30 through the hot runner 31 formed in the lower mold 30 and the plurality of gates 32.

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 cylinder 41, and a support mechanism 60 for the skin material 12 is installed along the peripheral edge of the upper die 40.

A movable support mechanism is employed on at least one side of the support mechanism 60.

That is, a support frame 61 having an L-shaped cross section
And a support pin 62 piercing the skin material 12 installed at predetermined intervals along an end of the support frame 61, and a through hole 63 a provided in a flange 63 of the support frame 61, and fixed to the side surface of the upper die 40. The support frame 64 is configured to be able to move in the direction of the arrow in FIG. 3 by inserting the support rod 64 and winding a spring 65 around the support rod 64.

In this embodiment, the movable support pins 62 are employed on one side, and the remaining three sides of the upper mold 40 are provided with fixed support pins 66 on the mold surface of the upper mold 40. ing.

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 upper die 40 with the base cloth 12c facing downward.

Next, the upper mold 40 is lowered by the operation of the elevating cylinder 41, the clearance between the upper and lower dies 30, 40 is about 30 mm, and the lowering operation of the upper mold 40 is stopped.
As shown in the figure, the molten resin M passes through the nozzle of the injection molding machine 51 and the lower mold 30 passes through the hot runner 31 and the gate 32.
Is distributed and supplied to a predetermined location on the mold surface.

Thereafter, the upper mold 40 is lowered again, and as shown in FIG. 6, the resin core material 11 is formed by the engagement press-tightening of the upper and lower molds 30, 40 for mold press molding.
The skin material 12 is integrated with the surface of the resin core material 11.

At this time, the skin material 12 is made of the upper and lower dies 30, 4
The tension is applied to conform to the mold surface shape of 0, but the support frame 61 is moved leftward in the figure by the movable support mechanism 60 as shown in FIG. Can be used without any damage, and the epidermis side 1
No excessive tension is applied to 2.

When the mold press molding step is completed, the upper mold 40 is raised, and the lower side of the door trim 10 is ejected in the direction of arrow A by an eject mechanism (not shown) installed on the lower mold 30, and thereafter, the arrow B is moved. After the door trim 10 is removed from the lower mold 30 in the direction, the peripheral portion of the skin material 12 is wound around the back side of the resin core material 11,
The manufacture of the automobile door trim 10 shown in FIGS. 1 and 2 is completed.

As described above, when the molding apparatus 20 according to the present invention is used, at the time of mold press molding, the support frame 6 of the support mechanism 60 according to the tension applied to the skin material 12.
1 can move in response to the spring pressure of the spring 65, and even if the mold shape of the upper and lower molds 30, 40 for mold press molding has a complicated curved shape, the skin material 12 easily follows the mold shape, There are no problems such as cuts,
Since uniform tension is applied to the skin material 12, appearance defects such as wrinkles and irregularities after molding are eliminated.

Therefore, the molding apparatus 20 according to the present invention has the advantage that molding defects can be prevented beforehand and that the door trim 10 having a good surface appearance can be molded. There is also an advantage that the degree of freedom in selecting the material of the skin material 12 can be greatly improved.

In the above-described embodiment, the support frame 61 can be moved by utilizing the spring pressure of the spring 65. In addition, as shown in FIG. The air cylinder 67 may be attached to the air cylinder 67, and the flange 63 of the support frame 61 may be fixed to the piston rod 67a of the air cylinder 67. The stroke amount of the air cylinder 67 is determined by the shape of the mold and the material of the skin material 12. If it is set in advance, the skin material 12 can surely follow the shape of the mold at the time of mold press molding, and a substantially uniform tension is applied to the skin material. An effect can be obtained.

[0033]

As described above, the molding apparatus according to the present invention has the following special effects.

(1) Since at least a part of the periphery of the skin material is held via a movable support frame , tension is applied to the skin material during mold press molding of the resin core material and the skin material. If added, the support pin will move and the skin material will easily follow the complicated mold surface shape, so even if the product shape is set to a complicated three-dimensional shape, the skin material will not be cut or resin leakage will occur, This has the effect of greatly improving the degree of freedom in shaping the product and significantly reducing the defect rate.

(2) Since at least one side of the peripheral edge of the skin material is held via a movable support frame, the tension applied to the skin material by the movement of the support pin is substantially uniform. Thus, there is no effect of appearance defects such as wrinkles, sagging, and grain defects on the skin material after the mold press molding, and an effect is obtained that a laminated molded body having good design properties can be obtained.

(3) Since at least a part of the periphery of the skin material is held through the movable support frame, a material having relatively low elongation characteristics can be used as the skin material. The degree of freedom in material selection can be greatly improved, which has the effect of reducing costs.

[Brief description of the drawings]

FIG. 1 is an external view showing an automobile door trim manufactured using the apparatus according to 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 sectional view showing a setting state of a skin material in the molding apparatus shown in FIG. 3;

FIG. 5 is a sectional view showing a supply step of a molten resin in the molding apparatus shown in FIG. 3;

FIG. 6 is a sectional view showing a mold press molding step in the molding apparatus shown in FIG. 3;

FIG. 7 is a sectional view showing the operation of a support pin in the molding device shown in FIG. 3;

8 is a cross-sectional view showing a step of removing a molded article after mold press molding in the molding apparatus shown in FIG. 3;

FIG. 9 is a sectional view of a main part showing a configuration of a second embodiment of a molding apparatus according to the present invention.

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

FIG. 11 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 mold for mold press molding 40 Upper mold for mold press molding 50 Material supply mechanism 60 Support mechanism 61 Support frame 62, 66 Support pin 65 Spring 67 Air cylinder

Continuation of the front page (58) Field surveyed (Int.Cl. ⁶ , DB name) B29C 43/18-43/20 B29C 43/32-43/42 B29C 33/14

Claims (1)

(57) [Claims] 1. A resin core material (11) is molded by press-molding a 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), an upper mold (40) having a desired mold surface shape and capable of engaging with the lower mold (30), and an upper mold (4).
In order to hold the skin material (12) on the mold surface of (0), the upper mold (4)
A support pin (62, 66) installed on the periphery of the upper mold (40) , wherein the support pin (62) on at least one side of the periphery of the upper mold (40 ) is formed of a long body having a substantially L-shaped cross section.
The support frame (61) is attached to the frame (61).
Direction supported by upper mold (40) and coming and going with upper mold (40)
A support frame (61) movable in accordance with the tension from the skin material (12).