JP2931236B2 - Resin molding and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin molded product such as an instrument panel, a door trim, and a console box, and a method of manufacturing the same. More specifically, a skin material is partially adhered to a resin core to be integrally formed. The present invention relates to a molded resin article and a method for producing the same.

[0002]

2. Description of the Related Art As a method of manufacturing a resin molded body such as an instrument panel, a door trim, a console box, etc., which is an interior part of an automobile, a resin blend of vinyl chloride and ABS resin is extruded into a sheet shape, and then etched by a drawing roll. A pattern is formed, and a skin material formed by vacuum forming and a core material (base material) formed by injection molding or stamping are placed in a urethane foam mold, and then urethane foam is injected and integrally molded. The method was mainstream.

[0003] The problems of this method include design problems such as insufficient squeezing feeling due to the etching squeezing, and the drawing being enlarged and shallow due to stretching of the sheet by vacuum forming. In addition, when considering recycling of parts, there is a problem that the three-layer structure cannot be easily separated, and the cost of waste disposal increases. Furthermore, since the above-mentioned method comprises three steps of skin molding, core material molding, and foam molding, it has been evaluated that foam molding, especially for obtaining a soft feeling of the product, is too costly.

[0004] Therefore, as a urethane removal method, a method of obtaining a molded article with less distortion and less deformation due to low pressure is performed by an injection press molding method or an SP mold (Low).
What is called Strain Molding Process) is adopted. This involves forming a composite sheet lined with EPP on a calender or extruded sheet by vacuum forming, setting it in a female mold of an injection mold, and supplying molten resin into the mold during the mold clamping operation. The skin material and the core material are integrally formed by pressing pressure.

On the other hand, as a method for reproducing the feeling of squeezing the skin, there has been a slash-molded skin using an electroforming mold, and a vinyl chloride skin, a vinyl chloride foam using this method,
And the integral foam of the core body has been adopted as a product having an excellent squeezing feeling.

[0006]

However, one of the disadvantages of the SP molding method among the above molding methods is that the exposed portion of the resin is large in the partial bonding portion of the skin material, or the product shape is complicated and the shape is difficult. When there is a part where the molten resin is difficult to rotate, it is necessary to set a gate at an appropriate position, but at that time, usually a ring mark around the gate,
Poor appearance such as uneven gloss occurs.

Further, in the mold structure, the resin is supplied before the mold is clamped. Therefore, in order to set a through hole (opening) in the product at the time of molding, the resin flowing into the through hole before the mold clamp is sealed. It is necessary to install a special nest as much as possible, and this is necessary for all openings including mounting holes and the like. Further, even in the exposed resin portion where the skin is not bonded, a cut-out shape is required on the outer periphery similarly to the skin bonded portion, and the mold cost is increased.

The present invention has been made to solve such a problem. By changing the structure of the core body depending on the presence or absence of the skin material, the appearance quality of the product can be improved, the mold cost can be reduced, and the skin material can be reduced. An object of the present invention is to provide a resin molded body capable of giving a soft feeling firmly adhered to a core material and a method for producing the same.

[0009]

That is, a feature of the present invention resides in a resin molded product obtained by integrally forming a skin material on a surface of a resin core body and bonding the core material to the surface thereof. bound in the core of the high-pressure compression molding is not stuck to the core material and the skin material of the low-pressure compression molding by bonding the wood, further
The end of the skin material is a concave portion of a core body of low pressure compression molding,
It is housed in the recess facing the core of high pressure injection molding.
It is a characteristic resin molded article.

Further, the present invention relates to a method of manufacturing a resin molded article in which a skin material is integrally formed on a surface of a resin core body and bonded together, wherein the skin material is partially disposed in one of the molds. ,
The molten resin is supplied between the unclosed female mold and the male mold, the female mold and the male mold are closed, the molten resin is pushed into the cavity, expanded and pressed, and the molten resin is formed by the protrusions provided on the female mold. flow
To prevent intrusion between the mold surface and the skin material.
After integrally molding the skin material and the core material, the molten resin is injection-molded at a high pressure into the cavity between the female mold and the male mold closed from the side gate other than the product equivalent part to form the core body, The present invention also includes a method for producing a resin molded product, which is characterized by being combined with a compression molded core.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a resin molded product of the present invention and a method for producing the same will be described in detail with reference to the accompanying drawings. FIG.
FIG. 1 is a perspective view for explaining a basic concept of a resin molded body according to the present invention. Reference numeral 1 denotes an example of a resin molded body, and the resin molded body has a skin material partially adhered to the surface of the core body (the right half in FIG. 1), and the remaining portion has no skin material adhered. It has a structure having a core exposed portion 3.

The materials of the cores 4 and 5 of the resin molded body 1 are the same, but the molding method is different, that is, the core 4 on the side where the skin material is bonded is a low pressure compression molding method. The core 5 on the exposed side of the core without bonding is formed by a high-pressure injection molding method, and a through hole 6 serving as an opening of a product is provided at the center.

Here, the skin material 2 is a skin material obtained by slush-molding a pulverized thermoplastic elastomer, a skin material obtained by powder slush-molding a vinyl chloride resin, or a vinyl chloride resin and an ABS resin. Any of the skin materials obtained by vacuum forming the mixed sheet material. The materials of the cores 4 and 5 are polypropylene, ABS,
It is made of a polystyrene resin or the like.

Next, a method for manufacturing a resin molded article according to the present invention will be described with reference to FIGS. In the following description, the male type and the female type are set horizontally, but the present invention is not limited to this. The male type and the female type may be set vertically. Figure 2
As shown in FIG. 5, the skin material 2 is bonded to the surface of the resin core and integrally formed. First, the skin material 2 separately formed by powder slush molding or vacuum molding is mounted on a female mold 7 as shown in FIG. In this case, a passage 8 penetrating into the mold surface is provided in the female mold 7, and the skin material 2 is mounted on the female mold 7 by operating the suction device 9 and performing vacuum suction.

At approximately the center of the female mold 7, a projection 10 protruding from the mold surface is provided, and is in close contact with the end 11 of the skin material. This projection 10 forms a recess 21 in the product,
A boundary is formed between the side where the skin material is bonded and the exposed side of the resin where the skin material is not bonded. On the other hand, at the center of the female mold 7 corresponding to the resin exposed portion side 3 where the skin material is not bonded, a projection 12 projecting more than the projection 10 from the mold surface is provided. At the left end of the mold 7, a cut groove 22 is provided on the surface of the mold.

On the other hand, the male mold 13 has a concave portion 14 for accommodating the female protrusion 10 on the surface of the mold at a substantially central portion thereof, and gates 15 and 16 for injecting molten resin to the left and right sides thereof.
Is provided. Of these, the gate 15 is located at a position corresponding to the product equivalent portion to which the skin material is attached, and the side gate 16 is provided at a position not corresponding to the product equivalent portion on the resin exposed portion side. Female 7 and Male 13 in this case
Is 30 to 40 ° C.

Next, as shown in FIG.
The resin 3 having a relatively high viscosity is supplied to the mold surface of the male mold 13 from the gate 15 of the male mold 13 in a half-closed, unclosed state. Further, as shown in FIG.
And the molten resin 17 is pushed out into the cavity 18 on the side where the skin material is bonded, and the mold clamping surface pressure is 30 to 150 kg.
/ Cm ² for shaping. In this case, the molten resin 17
Is prevented from flowing by the projections 10 provided on the female mold 7 and does not enter between the mold surface and the skin material 2.

Then, as shown in FIG. 5, a molten resin 19 is injection-molded from the other side gate 16 at a high pressure and filled into the cavity 20 on the side where the skin material is not bonded. This injection molding is desirably performed as soon as possible after the completion of the low-pressure compression molding.

Thereafter, the female mold 7 and the male mold 13 are opened, and the resin molded body is released. As shown in FIG. 1, the obtained resin molded body 1 has a panel shape, and a high-pressure injection molding in which a skin material 2 is bonded to a resin core 4 and a low-pressure compression molded core 4 and a skin material are not bonded. And the core body 5 of the above. The end portion 11 of the skin material is accommodated in the concave portion 21 of the core body 4 and has a good appearance.

[0020]

As described above, in the resin molded article and the method of manufacturing the same according to the present invention, the core body on which the skin material is bonded is integrally formed by the low-pressure compression molding method, and the core body on which the skin material is not bonded is formed. The following effects can be expected by high-pressure injection molding. The exposed portion of the core body can be made to have a structure that does not adversely affect the product surface of the side gate by high-pressure injection molding, and a skin-integrated molded product having good appearance quality can be obtained. Through-holes on the side where the skin material is not bonded can be obtained at the time of molding by injection molding after mold clamping, so that post-finishing costs can be reduced and hole precision can be improved. The exposed portion of the resin does not require a biting structure in a mold, and a normal injection molding structure can be adopted, so that the cost of the mold can be reduced.

Also, the female skin material is projected to the side to be bonded.
By providing the raised portion, the flow of the molten resin is
It stops and molten resin enters between the mold surface and the skin material.
There is no nagging and a skin-integrated molded product with good appearance quality is obtained
You.

[Brief description of the drawings]

FIG. 1 is a perspective view of a resin molded body according to the present invention.

FIG. 2 shows a step of attaching a skin material to a female mold.

FIG. 3 shows a step of supplying molten resin from the male gate to the male mold surface in a state where the female mold and the male mold are not closed.

FIG. 4 shows a step of closing the female mold and the male mold and forcing the molten resin into the cavity.

FIG. 5 shows a step of injection-molding a molten resin into the remaining cavity with the female mold and the male mold closed.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Resin molded body 2 Skin material 3 Core exposed part 4 Low pressure compression molded core 5 High pressure injection molded core 7 Female die 8 Passage 10 Projection 12 Projection 13 Male 15 Gate 16 Side gate 17 Molten resin 18 Cavity 19 molten resin 20 cavity 21 concave portion 22 cut groove

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification symbol FI // B29L 31:58 Examiner Yasuhide Nomura (56) References JP-A-6-143337 (JP, A) JP-A-6-184316 (JP, A) JP-A-8-47941 (JP, A) (58) Fields investigated (Int. Cl. ⁶ , DB name) B29C 43/00-43/58 B29C 45/00-45/84 B29C 69 / 00-69/02

Claims (2)

(57) [Claims] 1. A resin molded article in which a skin material is integrally formed on a surface of a resin core body and bonded to each other, wherein the core material is a low-pressure compression-molded core material in which a skin material is bonded and a skin material. bound in the core of the high pressure compression molding not over Zhang, further said surface
The end of the skin material is the concave part of the core of low pressure compression molding
It is housed in a recess facing the core of injection molding
Resin molded body. 2. A method of manufacturing a resin molded article in which a skin material is integrally formed on a surface of a resin core and partially adhered thereto, wherein the skin material is partially disposed on one of the molds, and an unclosed mold is provided. the molten resin was supplied between the female mold and the male mold, the molten resin closes the female and male by applying press spread pressure in the cavity shaping further female
The protrusion on the mold prevents the molten resin from flowing,
After integrally molding the skin material and the core material so that they do not enter between the surface and the skin material , high-pressure molten resin is injected into the cavity between the female mold and the male mold closed from the side gate other than the product equivalent part. A method for producing a resin molded article, wherein the core is molded by injection molding in step (a), and the core is combined with the core of the low-pressure compression molding.