JP2983136B2 - Laminated molded article and method for molding 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 laminated molded product such as an automobile door trim and a method for molding the same.

[0002]

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

[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 surface of the resin core material 2 at the time of mold press molding of the resin core material 2 in order to shorten the process.

[0005] That is, as shown in FIG. 7, first, the skin material 3 is set in advance on the set pins 4 a of the upper mold 4 for mold press molding. When the upper mold 4 is lowered and the upper and lower molds 4 and 5 reach a predetermined clearance, as shown in FIG. 8, the gate is placed on the mold surface of the mold press molding lower mold 5 through the hot runner 5a and the gate 5b. The molten resin 6 as the material of the resin core material 2 is distributed and supplied from the hole 5c.

Thereafter, the upper mold 4 is further lowered, and as shown in FIG. 9, the upper and lower molds 4, 5 are engaged and pressed to form the resin core material 2 into a required shape. The skin material 3 is integrated with the surface side of the material 2, and the automobile door trim 1 shown in FIG. 6 is formed into a product shape.

[0007]

However, in the conventional method in which the resin core material 2 and the skin material 3 are integrally press-formed by mold press molding to form a laminated molded product, the material of the resin core material 2 is used. It has been pointed out that the skin material 3 is damaged by the resin heat of a certain molten resin 6 and the external appearance performance of the product is impaired.

Various countermeasures have been proposed as a countermeasure. The first countermeasure is to reduce the resin temperature of the molten resin 6 so as to eliminate the adverse effect of resin heat. When the temperature is lowered, the fluidity of the molten resin is reduced, and there is a problem that a short shot occurs.

Further, in order to shorten the contact time between the skin material 3 and the molten resin 6, when supplying the molten resin 6 onto the mold surface of the lower mold 5, the clearance between the upper and lower molds 4, 5 is set to be large. However, also in this case, similarly to the above, there is a problem that the cooling of the molten resin is accelerated at the time of mold press molding, which causes a short shot.

In addition, it is conceivable that the use of a material having a small foaming ratio or a material having a large thickness as the skin material 3 can eliminate the adverse effect of the heat of the molten resin 6. In addition to this, there is a problem that the cost is increased and a good soft feeling cannot be obtained.

Then, as shown in FIG. 10, the present inventors distribute and supply the molten resin 6 from three gate holes 5c opened in the lower mold 5, and measure the temperature of each part of the lower mold 5. did.

For example, when the resin temperature of the molten resin 6 near the gate hole 5c when supplied is set to 190 ° C., the molten resin 6 flows on the mold surface of the lower mold 5 and is separated from the gate hole 5c by 500 mm. 14 when you reach point A
Since the resin temperature of the molten resin 6 decreases to 0 ° C., it has been found that the influence of the resin heat of the molten resin 6 is sufficient if only the vicinity of the gate hole 5c is dealt with.

SUMMARY OF THE INVENTION The present invention has been made in view of such circumstances, and in a laminated molded body in which a resin core material and a skin material are integrated by a mold press molding method, and in a molding method therefor, a molded article such as a short shot is formed. A laminated molded article that protects a skin material during mold press molding without causing defects, and enables the use of a skin material having a high foaming ratio, a thin plate thickness, and a good cushioning performance as a skin material, and molding thereof. It is intended to provide a way.

[0014]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention provides a resin core obtained by mold-pressing a molten resin into a desired shape, and a resin core formed by molding and pressing the resin core. In a laminated molded body obtained by integrating a material and a skin material, the molten resin is formed between the resin core material and the skin material .
A barrier sheet made of a high-melting cloth sheet having air permeability is inserted in the injection portion .

Further, the present invention provides a resin core obtained by molding a molten resin into a required shape in a mold press mold,
In this method of molding a resin core material, in a method of molding a laminated molded article composed of a resin material and a skin material integrated with the resin core material, the method comprises setting a skin material on a mold surface of the upper mold for mold press molding. A step of setting a material for placing a barrier sheet having heat resistance and heat insulation and air permeability so as to cover the gate hole of the lower mold for mold press molding, and onto the lower mold surface through the gate hole of the gate. After distributing and supplying the molten resin, the upper and lower molds are pressed together to form the resin core into the required shape, and the resin core and the skin are partially integrated via a barrier sheet. And a mold press forming step.

Further, the conditions of the barrier sheet include resin heat of the molten resin, for example, 160 to 200 ° C. for polypropylene resin, and 24 to 240 ° C. for ABS resin.
It is necessary not to melt at 0 to 300 ° C.

Further, since it is necessary to join the skin material and the resin core material during mold press molding, the molten resin penetrates into the barrier sheet by the pressing pressure, and in order to join the skin material, Ventilation is required.

As the barrier sheet, a non-woven fabric or a knitted fabric made of a high-melting fiber, a felt or a glass fiber mat, or the like may be used. In the case of a blended non-woven fabric of polyester and polyamide, the basis weight is 30 to 100 g / g.
m ² , in the case of a knitted fabric made of polyester and polyamide fibers, the basis weight is 50 to 120 g / m ² , in the case of felt, the basis weight is 50 to 150 g / m ² , and in the case of a glass fiber mat, the basis weight is 100. ~ 200g
/ M ² is preferred.

If the basis weight is less than the lower limit, the desired heat insulating effect cannot be obtained, and the skin material is damaged. If the basis weight exceeds the upper limit, the permeability of the resin is poor, and the skin material and the resin core are poor. Good bonding with the material cannot be obtained.

[0020]

As is apparent from the above constitution , a high-melting cloth sheet having air permeability so as to cover the upper gate hole is used.
Made if the barrier sheet is placed, during press-molding, for high-temperature molten resin through the gate holes be injected, the resin heat of the molten resin by the barrier sheet not transmitted directly to the skin material, the skin material The skin material can be protected in the vicinity of the gate which is easily damaged, and good appearance quality of the skin material can be maintained.

Further, since the barrier sheet has air permeability, the resin permeates into the back surface of the skin material by the mold press pressure, and there is no problem in joining the skin material and the resin core material.

[0022]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a sectional view showing a laminated molded article according to the present invention;

FIG. 1 is a front view showing a door trim for an automobile to which the laminated molding according to the present invention is applied, FIG. 2 is a sectional view showing the structure of the door trim for the automobile, and FIGS. 3 to 5 are laminated moldings by the method of the present invention. It is sectional drawing which shows each process of the shaping | molding method of a body.

First, referring to FIGS. 1 and 2, an automobile door trim 10 according to the present invention comprises a resin core material 11 formed in a required shape, and a skin material laminated and integrated on the surface side of the resin core material 11. 12 and a barrier sheet 13 partially interposed between them.

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 desired curved surface shape, and then subjected to mold press molding. It is formed into a complicated curved shape.

The skin material 12 may be of various specifications depending on the intended use, but a laminated sheet having a polyolefin resin foam lined on the back surface of a PVC sheet is suitable. For example, polypropylene foam, polypropylene and polyethylene Preferred is a blended foam with
In the present embodiment, a blend of polypropylene and polyethylene having a good cushioning property with an expansion ratio adjusted to 20 times is used.

Conventionally, when a skin material in which a polypropylene foam is lined on the back of a PVC sheet is used,
The expansion ratio is limited to 15 times due to the adverse effect of resin heat,
There was a problem with cushioning performance.

Further, when a PVC foam sheet is used as the skin material 12, 2- to 2.5-fold foaming (non-crosslinked type) is expanded to 5 times, and 3 to 5 times expanded (crosslinked type) to 8 to 10 times. For foaming, increase the foaming ratio in the skin material 12 respectively,
An automobile door trim 10 having good cushion performance can be provided.

The reason why a material having good cushioning properties can be used as the skin material 12 is as follows.
This is because the barrier sheet 13 is partially inserted between the cover material 1 and the skin material 12.

As a material of the barrier sheet 13, in this embodiment, a polyester / polyamide blended nonwoven fabric having a basis weight of 30 to 100 g / m ² is used. ~ 120 g / m ² may be used,
Felt and basis weight 50 to 150 g / m ^2, may be used glass fiber mat having a basis weight 100 to 200 g / m ^2, the molten resin which is a material of the resin core member 11,
In addition to using a high melting point fiber that does not easily melt, it is only necessary to have air permeability so that the molten resin penetrates and joins with the skin material 12 during mold press molding.

Further, the shape of the barrier sheet 13 is as follows:
The dimensions are not particularly limited, such as a rectangular shape and a circular shape, and the dimensions may be any dimensions provided that they have an outer dimension that covers the block-shaped molten resin material supplied onto the lower mold at the time of mold press molding described later. In the embodiment, a rectangular sheet material of 150 × 150 mm is used.

The barrier sheet 13 is partially set only in a portion where the skin material is likely to be adversely affected by the resin heat of the molten resin when the resin core material 11 is subjected to mold press molding.

Next, with reference to FIGS. 3 to 5, a process of forming the door trim 10 for an automobile as a laminated body according to the present invention will be described.

First, to carry out the method of the present invention, a mold press molding die shown in FIG. 3 is used. This mold press molding die is a mold press molding lower die 20.
And an upper mold 30 for mold press molding located above the lower mold 20. The lower mold 20 is supplied with a molten resin as a material of the resin core material 11 from an injection molding machine (not shown). In addition, a hot runner 21 is opened, and gates 22 are opened at three places through the hot runner 21.
The molten resin M is distributed and supplied from above a onto the mold surface of the lower mold 20.

On the other hand, the upper die 30 located above the lower die 20
Is configured to be able to move up and down by a predetermined stroke by a lifting cylinder 31, and is provided with a set pin 32 for positioning and setting the skin material 12 along the periphery of the mold surface.

Accordingly, first, the skin material 12 is set on the set pins 32 of the upper die 30 and the barrier sheet 13 is placed so as to hide the gate holes 22a formed in the lower die 20.

Thereafter, the upper die 30 is lowered by a predetermined stroke by the operation of the driving cylinder 31, and the upper and lower dies 20, 30 are moved downward.
When a predetermined clearance is reached, as shown in FIG. 4, molten resin M is distributed and supplied from the injection molding machine (not shown) through the hot runner 21 and the gate 22 to the mold surface of the lower mold 20 through the gate hole 22a.

Thereafter, as shown in FIG. 5, the upper mold 30 is lowered to the maximum descending point, and the upper and lower dies 20, 30 are engaged and pressed for a predetermined time, and the molten resin M is transferred to the upper and lower dies 20, 3, as shown in FIG.
0, and the resin core material 11 is formed into a desired curved shape.
The surface material 12 is press-integrated on the surface side of FIG.
The automotive door trim 10 shown in FIG.

At this time, the lower mold 2 is passed through the gate hole 22a.
As described above, the temperature of the molten resin M supplied to the gate hole 22 is high near the gate 22 and the temperature tends to decrease as it reaches the periphery of the lower mold 20. With regard to the above, since the back surface of the skin material 12 is protected by the barrier sheet 13, the skin material 12 is not adversely affected by the resin heat of the molten resin M, and the appearance performance of the skin material 12 can be favorably maintained.

Since the barrier sheet 13 has air permeability, the molten resin M
Exudation can be ensured, and a favorable joint state with the skin material 12 can be ensured.

As described above, according to the method of the present invention, the lower mold 20
By simply placing the barrier sheet 13 so as to cover the gate hole 22a, the same molding method as that of the conventional method can be used to perform molding with high precision without molding defects. Since a foaming ratio is high and a thin plate can be used, it is possible to use the skin material 12 which is inexpensive and has good cushioning performance.

[0042]

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

(1) According to the present invention, if the barrier sheet is placed so as to cover the gate hole of the lower mold for mold press molding and the mold press molding is performed, the adverse effect of resin heat on the molten resin can be eliminated. This has the effect that the skin material can be reliably protected, molding defects of the skin material near the gate, which have conventionally occurred, can be prevented as much as possible, and the appearance performance of the laminated molded article can be significantly improved.

(2) According to the method of the present invention, the barrier sheet eliminates the adverse effect of the resin heat of the molten resin. Therefore, as the skin material, a material having a high expansion ratio and a small thickness is used. Therefore, it has various effects such as saving of the molten resin material, weight reduction of the molded body, cost reduction, and good feel.

[Brief description of the drawings]

FIG. 1 is a front view showing an automobile door trim to which the present invention is applied.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a cross-sectional view showing a material setting step in the method of the present invention.

FIG. 4 is a sectional view showing a step of supplying a molten resin in the method of the present invention.

FIG. 5 is a sectional view showing a mold press molding step in the method of the present invention.

FIG. 6 is a sectional view showing a configuration of a conventional automobile door trim.

FIG. 7 is a cross-sectional view showing a step of setting a skin material in a conventional mold press molding method.

FIG. 8 is a cross-sectional view showing a molten resin supply step in a conventional mold press molding method.

FIG. 9 is a sectional view showing a mold press molding step in a conventional mold press molding method.

FIG. 10 is an explanatory view showing a resin temperature distribution of a molten resin distributed and supplied to a lower mold for mold press molding.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Automobile door trim 11 Resin core material 12 Skin material 13 Molding apparatus 20 Lower mold for mold press molding 22 Gate 22a Gate hole 30 Upper mold for mold press molding 31 Cylinder for raising and lowering 32 Set pin M Molten resin

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ identification code FI B29L 31:58 (58) Investigated field (Int.Cl. ⁶ , DB name) B29C 43/18 B29C 45/14 B29C 45/56

Claims (2)

(57) [Claims] 1. A resin core material (11) obtained by mold-pressing a molten resin (M) into a required shape, and a resin core material (11) and a skin material at the time of mold-press molding of the resin core material (11). (12) in a laminated molded body, wherein a molten resin is formed between the resin core material (11) and the skin material (12).
High melting point fabric sheet having air permeability in the injection part of fat (M)
Molded laminate, characterized in that the barrier sheet (13) is inserted consisting of. 2. A mold for mold press molding (20, 30).
A resin core material (11) formed by molding the molten resin (M) into a required shape in the inside thereof, and a skin material integrated with the resin core material (11) during mold press molding of the resin core material (11). 12)
In the method for forming a laminated molded body, a skin material (12) is set on a surface of the upper mold (30) for mold press molding, and a gate hole (20) of the lower mold (20) for mold press molding is formed. A step of setting a material on which a barrier sheet (13) having heat resistance and heat insulation and having air permeability is placed so as to cover the lower mold (2) through the gate hole (22a) of the gate (22);
After the molten resin (M) is distributed and supplied onto the mold surface of (0), the upper and lower molds (20, 30) are engaged and pressed to form the resin core material (1).
1) into a required shape and resin core material (11)
And a barrier sheet (1)
(3) a mold press molding step of integrating the two via (1) and (2).