JP2951698B2 - Method for producing composite molded article and press mold thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial applications]

The present invention relates to a method for producing a composite molded article such as an interior part of various trims of an automobile and a press die used for producing the same.

[Prior art]

For example, various trims and the like of automobiles are composite molded articles in which a base material is pressed against a skin layer, and a cold press method is often used as a method for manufacturing these. As the cold press method, for example, JP-A-62-18
This is proposed in Japanese Patent Publication No. 111 and Japanese Patent Laid-Open No. 62-18114, which will be described with reference to FIG. Reference numeral 1 denotes an upper die, which is moved up and down by a pressing device (not shown) and presses a pair of pressed articles on the lower die 2. The skin layer 4 is positioned between the molding surfaces 5 and 6 of the upper mold 1 and the lower mold 2 before pressing, and the molding surface 6
Is placed on the substrate material 3 in a molten state. A side land portion (hereinafter referred to as a land) 7 having a draft with respect to a pressing direction is provided on an extension of the outer peripheral end of the molding region of the base material 3 on the upper mold 1, the lower mold 2, and the molding surfaces 5 and 6. ,
The lands 7 and 8 are formed so that the gap at the time of molding and pressing is substantially the same as the thickness of the skin layer 4 at the time of pressing and molding. The operation of the known device having the above configuration will be described. Before pressurization, thickness between the molding surfaces 5 and 6 of the upper mold 1 and the lower mold 2
A sheet-like skin layer 4 of 0.3 to 4 mm woven fabric, carpet or other raised fiber products or soft vinyl chloride resin is held by a clamp device (not shown). Then, on the forming surface 6 of the lower mold 2 adjusted to about 30 to 50 ° C., through a nozzle of an extruder (not shown), heated to 150 to 250 ° C. to be in a semi-molten state, for example, polypropylene, A base material 3 of a thermoplastic resin such as polyethylene is placed, and the upper die 1 is pressed downward by a pressing device (not shown), and the skin layer 4 and the base material 3 are compressed between the lower die 2 and the upper die 1. It is joined to produce a composite molded body. At this time, only the gap between the land portions 7 and 8 of the upper mold 1 and the lower mold 2 is substantially the same as the thickness of the skin layer 4 at the time of pressing and molding. Even in the state, it does not flow out of the dies from the lands 7 and 8 and the burrs are not generated. When the door trim portion 20 with an armrest of an automobile shown in FIG. 1 is press-formed by the press die, a convex surface for the armrest portion 20a must be formed on the forming surface. However, since the armrest portion 20a protrudes at a steep angle from the molding surface, in a press die such as the upper and lower dies, both ends of the skin layer 4 are held by a clamp device. In this case, only the skin layer 4 in contact with the armrest portion 20a, which is raised substantially vertically, is greatly extended, and tends to be extremely thin as compared with other portions. Since the armrest portion 20a is required to have a particularly good cushioning property, the quality of the cushion layer is particularly reduced when the cushion layer is thinned. For this reason, recently, as shown in FIG.
The base material 3 is provided on the lower mold 12 having a convex portion 16a protrudingly provided on the molding surface 16 of the lower mold 12 while the skin layer 4 is suction-adsorbed and vacuum-formed on the upper mold 11 in advance. Has been developed by pressing the upper mold 11 and press-molding it.

[Problems to be solved by the invention]

However, even in the door trim manufactured by the above-described method, since the skin layer is sucked on the entire molding surface, a portion other than the armrest portion is sucked first, and the armrest portion that is suddenly depressed is sucked slowly and this portion is delayed. As a result, the tendency of the armrest part to become thinner is hardly improved. In view of such circumstances, in the press molding method of the composite molded body, the thickness of the cushion layer such as the armrest portion having a high elevation at a steep angle does not become thin, and the press molding method and the press mold that do not reduce the cushion performance are provided. Early development was a challenge. SUMMARY OF THE INVENTION The present invention solves the above-mentioned problems, and maintains a normal thickness of a skin layer of a protruding portion such as an armrest portion without particularly changing a conventional press molding method, and has a uniform cushion thickness and a good cushioning property as a whole. It is an object of the present invention to provide a press method and a press die that enable molding of a body.

[Means for Solving the Problems]

In order to achieve the above-mentioned object, the present invention provides a method for forming a base layer and a skin layer using a set of press dies in which a concave portion and a convex portion corresponding to a molded product are formed, and a cavity is formed between the concave and convex portions during mold clamping. In the method of manufacturing a composite molded body composed of a material layer and having a protruding portion in a part, the convex portion of the skin layer is formed by fitting a convex portion to the concave portion in advance at the time of pressing, and then the skin layer is formed on a molding surface. In the positioned state, a method of manufacturing a composite molded body in which a molten base material is placed on the back side of the skin layer and press-molded, and the method includes a skin layer and a base material layer, and partially includes a protrusion. A press mold for producing a composite molded article having a convex portion formed on a part of one press mold forming surface and projecting from the other press mold forming surface so as to enter the concave portion. Are provided independently and slidably with respect to the molding surfaces. It was composed of a press mold.

[Operation]

Since the present invention is configured as described above, when press-forming a composite molded product, for example, a door trim described later, first, a skin material and a cushion material are laminated between the molding surfaces of the upper die and the lower die of the press. The layers are loaded by known clamping devices, while keeping the tension relatively low. Next, the well-known hydraulic cylinder is actuated to slowly push up the convex portion, and the head is fitted into the concave portion to form the convex portion of the skin layer. After the skin layer in this state is held in close contact with, for example, the upper mold layer, the hydraulic cylinder is loosened to return the convex portion to the molding of the lower mold. During this time, the back side of the skin layer, for example, on the molding surface on both sides of the concave portion located at the approximate center on the molding surface described below adjusted to 30 to 50 ° C., heated to 150 to 250 ° C. to a semi-molten state The resulting substrate material is positioned by a well-known nozzle. Then, when the upper die is pressed down by a pressing device, the convex portions and the concave portions are fitted again and pressed and formed, and the skin layer 24 and the entire base material 23 are compressed and formed. At this time, since the projections have already been formed so that the skin layer is hardly stretched by the recesses and the projections on the molding surface of the upper mold, it is possible to form a composite molded body having a substantially uniform thickness as a whole. it can.

【Example】

An example in which the present invention is applied to a door trim of an automobile shown in FIG. 1 will be described in detail with reference to FIGS. FIG. 2 is a cross-sectional view of the press die of the present invention, which corresponds to the conventional example shown in FIG. Reference numeral 21 denotes a lower die 22 and a pair of upper dies for press molding.
Similarly to the press die shown in the figure, the upper die 21 has a molding surface 25 formed with a concave portion 25a for forming an armrest portion, and a skin layer is attracted from the molding surface 25 toward the back surface of the upper die 21. Air intake hole 11a and an intake groove 11b are provided. On the other hand, on the molding surface 26 of the lower mold 22, a convex portion that fits with the concave portion 25a, that is, a head 27a of an assist plug 27 having the same shape is provided so as to protrude from the molding surface 26. The cylinder is loosely fitted to the lower mold 22 so as to be movable up and down. The convex portion, that is, the assist plug 27 and the concave portion 25a correspond to a thickness obtained by adding the thickness of the base material layer 23 to the thickness of a skin layer 24 to be described later after molding when the two are fitted together. The size is determined so that a space (cavity) exists. At the time of press molding of the door trim, firstly, between the molding surfaces 25 and 26 of the upper mold 21 and the lower mold 22 configured as described above, a skin material 17 made of a PVC sheet and a polypropylene cushion material 18 are provided. The laminated skin layer 24 is loaded by a clamping device (not shown), but the tension is kept relatively low. Next, a hydraulic cylinder (not shown) is operated, and the assist plug 27 is slowly pushed up, so that the head 27a
Is fitted in the concave portion 25a. Here, a vacuum device (not shown) is operated to suction air from the suction hole 11a connected to the suction groove 11b, and as shown in FIG.
After being sucked and held at 25, the hydraulic cylinder is loosened and the assist plug 27 is lowered to the molding surface 26 of the lower mold 22. During this, the molding surface 26 of the lower mold 22 adjusted to 30 to 50 ° C.
The base material 23 which has been heated to 150 to 250 ° C. and is in a semi-molten state is placed on a molding surface 26 on both sides of the assist plug 27 which is located substantially at the center by a nozzle (not shown). Then, when the upper die 21 is pressed down by a pressing device (not shown), the assist plug 27 and the recess 25a are fitted again and pressed together as shown in FIG. Then, the entire base material 23 is compressed and molded. At this time, since the projection is formed so as to hardly extend the skin layer by the concave portion 25a of the molding surface 25 of the upper die and the assist plug 27, the whole is a composite molded body having a substantially uniform thickness. A door trim can be formed. In the above embodiment, the base material 23 is directly placed on the lower mold 22. However, the skin layer 24 is placed on the lower mold 22, and the base material 23 is placed on the back surface of the skin layer. May be placed. In this case, it becomes the reverse of the above embodiment,
The upper die is provided with an assist plug slidably upward and downward. Also, an actuator such as an air cylinder or a motor can be used instead of the hydraulic cylinder. Furthermore, it is also possible to press-mold the assist plug pushed up at the time of molding the skin layer of the armrest portion without lowering it to the molding surface of the lower die.

【The invention's effect】

As described above, according to the present invention, the concave and convex portions corresponding to the molded product are respectively formed, and at the time of mold clamping, the concave and convex portions are formed by a set of press dies. In the method of manufacturing a composite molded article having a projection partly consisting of, after pressing the convex part of the skin layer by fitting the convex part in advance to the concave part at the time of pressing, the skin layer was positioned on the molding surface. In a state, a method of manufacturing a composite molded body that is formed by pressing and molding a base material in a molten state on the back surface side of the skin layer,
A press die for producing a composite molded body composed of a skin layer and a base material layer, and having a protruding part in a part, wherein a convex part is formed in a part of one press mold forming surface, and the concave part is formed. Since the assist plug protruding from the other press mold forming surface so as to enter into is formed of a press die slidably provided independently of the two press surfaces, a composite having a projecting portion such as an armrest portion is provided. In the molded article, the skin layer of the protruding portion can be easily press-molded without causing any defects or defects such as an excessively thinned skin layer and a deteriorated cushioning property.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an example of a composite molded article according to the present invention,
FIGS. 2, 3 and 4 are sectional views of the lower mold used in the method of manufacturing the composite molded article of the present invention, and also show the molding process.
FIG. 3 is a diagram showing a molded state of the skin layer, FIG. 3 is a diagram showing a completed state of the molding of the skin layer and the state of being held in the mold, FIG. 4 is a diagram showing a completed state of the cushion layer, and FIG. Sectional view,
FIG. 6 is a view showing one process of manufacturing using a conventional press die. 1, 11, 21 ... upper mold, 2, 12, 22 ... lower mold, 3, 23 ... base material, 4, 24 ... skin layer, 5, 6, 15, 16, 25, 26 ... Molding surface, 25a recess, 7, 8, 17, 18 land, 16a, 27 projection (assist plug).

──────────────────────────────────────────────────の Continuing on the front page (72) Inventor ▲ Shoes ▼ Ki Terumichi 2100 Endo, Fujisawa-shi, Kanagawa Prefecture Press Industry Co., Ltd.Fujisawa Plant (72) Inventor Akira Suzuki 2100 Endo, Fujisawa-shi, Kanagawa Prefecture Press Industry Stock (72) Inventor Sadayoshi Mase 2100 Endo, Fujisawa-shi, Kanagawa Prefecture Press Industry Co., Ltd.Fujisawa Plant (72) Inventor Eiji Takeuchi 2100 Endo, Fujisawa-shi, Kanagawa Prefecture Press Industry Co., Ltd.Fujisawa Plant ( 56) References JP-A-63-132026 (JP, A) JP-A-64-185715 (JP, A) (58) Fields investigated (Int. Cl. ⁶ , DB name) B29C 33/00-33/76 B29C 43/00-43/58

Claims (3)

(57) [Claims] 1. A set of press dies in which a concave and a convex corresponding to a molded article are formed, and a cavity is formed between the concave and the convex when the mold is clamped, comprising a skin layer and a base material layer. In a method of manufacturing a composite molded body having a protrusion in part,
At the time of pressing, after the convex portion of the skin layer is formed by fitting the convex portion to the concave portion in advance, the base material in a molten state is placed on the back side of the skin layer with the skin layer positioned on the forming surface. And subjecting the mixture to press molding. 2. A mold comprising a skin layer and a base material layer formed by a set of press dies in which a concave portion and a convex portion corresponding to a molded article are formed, and a cavity is formed between the concave and convex portions at the time of mold clamping. In a method of manufacturing a composite molded body having a protrusion in part,
At the time of pressing, the convex portion of the skin layer is formed by fitting the convex portion to the concave portion in advance, and then the base material in the molten state is coated with the skin layer in a state where the skin layer is positioned on the molding surface by the intake hole opened in the molding surface. A method for producing a composite molded body, wherein the composite molded body is press-formed while being positioned on the back side of a layer. 3. A press die for producing a composite molded article comprising a skin layer and a base material layer and having a projection in a part thereof,
A convex part is formed on a part of one press mold forming surface,
A press die, wherein an assist plug protruding from the other press die molding surface so as to enter the concave portion is slidably provided independently of the two molding surfaces.