JP3058816B2 - Molding method of laminated molded body - 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 of forming a laminated molded product suitable for an automobile interior part such as an automobile door trim, and more particularly, to a method of integrally coating a part of the surface of a resin core material with a skin material. The present invention relates to a method for molding a laminated molded article, which enables a two-color molded article to be easily molded without impairing the surface appearance.

[0002]

2. Description of the Related Art FIG. 9 is a cross-sectional view showing a typical automobile door trim as an interior part for a vehicle. The automobile door trim 1 includes an upper part 1a and a lower part 1b in order to enhance the appearance design. The upper member and the lower member are usually manufactured separately, and both are joined by screws or the like.

Recently, a two-color molded article having a structure in which the core material is shared to reduce the cost has also been proposed. As a basic structure, the molded article is formed into a curved surface, and has a suitable shape retaining property and Resin core material 2 having rigidity for attachment to vehicle body panel
And a skin material 3 covering a part of the surface side of the resin core material 2. The upper portion 1 a covers the surface side of the resin core material 2 with the skin material 3, while the lower portion 1 b covers the surface material. 3, the resin core material 2 is exposed to provide an accent effect on the appearance.

[0004] Then, an automobile door trim 1 shown in FIG.
As a method for forming such a laminated molded article, the applicant has previously filed Japanese Patent Application No. 6-181500.

As shown in FIG. 10, when the upper and lower molds 4 and 5 for mold press molding are in an open state, as shown in FIG.
The skin material 3 previously formed into a required shape was set on a part of the mold surface of the upper mold 5, and the skin material 3 was suction-held on the mold surface of the upper mold 5 by vacuum suction means provided on the upper mold 5. In the state, upper die 5
When the clearance between the upper and lower dies 4 and 5 reaches a predetermined size by performing a predetermined stroke lowering operation, the semi-molten resin M which is the material of the resin core material 2 through the injection molding machine 6 connected to the lower die 4. Is distributed to a predetermined location on the mold surface of the lower mold 4 through a gate 4 a formed in the lower mold 4. Then, upper mold 5
Descends to the bottom dead center,
The resin core material 2 is subjected to mold press molding into a required shape, and a skin material 3 is adhered and integrated on a part of the surface of the resin core material 2 to complete the molding of the automobile door trim 1.

[0006]

However, in the conventional molding method, although the skin material 3 is held on a part of the mold surface of the upper mold 5 by vacuum suction means, the material is inferior in shape retention. Is used as the skin material 3, it is difficult to adsorb the entire surface of the upper mold 5 in a fit shape, and
When the entire surface of the skin material 3 does not fit, it has been pointed out that a defect such as wrinkling occurs in the skin material 3 during mold press molding.

Further, in order to secure the vacuum holding force of the skin material 3, it is necessary to open a large number of vacuum holes in the upper mold 5, and the molding process is very troublesome. When set to 5, there is also a problem that the equipment cost increases, such as the necessity of a machine for charging the skin material 3.

Further, it is pointed out that it is difficult to perform accurate molding, for example, misalignment of the skin material 3 by the input machine or misalignment or peeling of the skin material 3 during mold press molding tends to cause molding defects. I was

The present invention has been made in view of the above circumstances, and a part of the surface side of a resin core material is covered with a skin material so as to obtain a good appearance and design due to a contrast effect between the skin surface and the resin surface. In the molding method of the laminated molded body to obtain the laminated molded body provided with, the wrinkles and the like do not occur even if a skin material of a material having poor shape retention is used, and there is no set displacement, and a resin core with high accuracy It is an object of the present invention to provide a method for forming a laminated molded article that enables integral molding of a material and a skin material.

[0010]

In order to achieve the above object, the present invention provides a resin core formed by molding a semi-molten resin into a required shape in a mold press molding die, In the molding press molding, in a method of forming a laminated molded body composed of a skin material covering a part of the surface of the resin core material, the skin material is preformed into a required shape, and the upper and lower molds are opened. Occasionally, on a part of the outer periphery of the lower mold for press molding, the skin material is placed on the preceding pad arranged at a position protruding above the mold surface of the lower mold, and the upper mold is moved down to The outer periphery of the skin material is sealed by the mold and the preceding pad, and after the skin material is sucked and held on the upper mold surface by the vacuum suction means provided on the upper mold, the semi-molten resin is poured into the cavity between the upper and lower molds. Distribute and supply, resin core material by upper and lower mold clamping As well as press molding to the required shape, and wherein the coated integrated skin material on a part of the surface of the resin core member.

Here, the configuration of the upper and lower molds for mold press molding is as follows. First, the lower mold for mold press molding has a desired mold surface, a gate is bored therein, and the half mold is supplied from an injection molding machine. The molten resin is distributed and supplied to a predetermined location on the mold surface through the gate.

On the other hand, the upper mold for mold press molding is capable of moving up and down by a predetermined stroke, and is provided with vacuum suction means for adsorbing a skin material on a part of the mold surface.

Further, the leading pad installed on a part of the outer periphery of the lower mold (installed only in the area where the skin material is installed) is always urged upward by a spring, and the upper pad is moved upward by the downward movement of the upper mold. It is configured to be able to move up and down while the outer periphery of the skin material is sealed by the mold surface of the mold and the preceding pad.

Further, locate pins are provided on the upper surface of the preceding pad at predetermined pitch intervals.

As is apparent from the above configuration, according to the method of the present invention, the outer periphery of the skin material is placed on the preceding pad located above the die surface of the lower die and arranged on a part of the outer periphery of the lower die. If it is placed, the skin material can be easily positioned at a position slightly floating from the lower mold surface, and then the outer periphery of the skin material is sandwiched between the upper mold surface and the preceding pad as the upper mold descends. Inset
At the same time as sealing the outer periphery of the skin material, drive the vacuum suction means of the upper mold to attach the skin material faithfully to the upper mold surface by the sealing function and vacuum suction function of the upper mold and the preceding pad. The upper mold and the preceding pad are lowered to the bottom dead center, and the semi-molten resin is press-molded to form the resin core into the required shape. It can be attached and integrated on a part of the surface of the core material.

As described above, according to the method of the present invention, since the sealing property of the outer peripheral portion of the skin material is improved, there is no displacement of the skin material due to the resin pressure at the time of mold press molding, and the dipping phenomenon of the resin material. Can also be prevented.

Further, since the skin material is in close contact with the mold surface of the upper mold, adverse effects due to resin pressure and resin heat during mold press molding can be eliminated.

Further, since tension can be applied to the skin material during mold press molding, wrinkles and the like do not occur on the skin material.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, an embodiment of a method for forming a laminated molded product according to the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is a front view showing a vehicle door trim manufactured by using the method of the present invention, FIG. 2 is a cross-sectional view showing the structure of the vehicle door trim, and FIG. 3 is used to carry out the method of the present invention. FIG. 4 is a cross-sectional view showing the entire configuration of the molding apparatus, FIG. 4 is a plan view of a lower mold showing the arrangement of preceding pads in the molding apparatus, and FIG. 5 is a time chart of an upper mold in the molding apparatus used in the method of the present invention. 6 to 8 are sectional views showing each step of the method of the present invention.

First, the structure of a door trim 10 for an automobile manufactured by the method of the present invention will be briefly described with reference to FIGS.

The door trim 10 for an automobile is generally constituted by a resin core material 20 formed into a desired curved shape and a skin material 30 adhered and integrated on a part of the surface of the resin core material 20. The resin core material 20 is formed into a complicated curved shape by mold press molding described below using a polypropylene resin mixed with a filler such as talc as a material, and when the resin core material 20 is subjected to mold press molding, the skin material 30 The resin core material 20 is integrally attached to a part of the surface side.

Further, as the skin material 30, in this embodiment, a vinyl chloride resin sheet is used as the top layer 31 and polyethylene foam is used as the foamed layer 32 lined on the back surface, and the resin core material 20 has a depth. A wood grain groove 21 of about 5 to 10 mm is formed along the lower edge end of the skin material 30, and a good parting line of the skin material 30 is formed by graining the end of the skin material 30 in the wood grain groove 21. Is formed.

As described above, the door trim 10 for an automobile manufactured by the method of the present invention has a skin material 30 only in the upper portion A in order to exhibit an appearance contrast effect between the upper portion A and the lower portion B. To cover the surface of the resin core material 20, and the lower portion B is composed of the resin core material 20 alone.

Therefore, as compared with the conventional door trim consisting of a two-color molded body, since the resin core 20 is used alone, the number of steps can be reduced, and the upper member and the lower member are joined and fixed by screws or the like. It is possible to greatly reduce the processing cost, for example, by eliminating the man-hours for performing the processing.

Further, the resin core material 2 constituting the upper portion A
The laminate of the rubber material 0 and the skin material 30 has a uniform cushioning property over the entire surface of the upper portion A, has no wrinkles or the like at the peripheral edge portion, and is extremely excellent in cushioning properties and appearance. A beautiful parting line is formed for the boundary line between A and the lower part B,
Automotive door trim 10 with excellent cushioning and decorativeness
Is a feature of the present invention in that it is devised so as to be easily and inexpensively manufactured.

First, the configuration of a molding apparatus used in the method of the present invention will be described with reference to FIGS.

A molding die apparatus used in the method of the present invention comprises a lower mold press molding die 40 having a desired mold surface, and an upper mold press molding die positioned above and configured to be vertically movable by a predetermined stroke. An injection molding machine 60 connected to the mold 50 and the lower mold press molding die 40 to supply the semi-molten resin M which is a material of the resin core material 20, and a part of the outer periphery of the lower mold press molding die 40 (skin And a leading pad 70 that seals the outer periphery of the skin material 30 satisfactorily during mold press molding.

More specifically, a manifold 41 connected to the nozzle of the injection molding machine 60 is provided in the lower mold 40 for mold press molding, and a plurality of gates 42 are provided at appropriate locations so as to communicate with the manifold 41. Has been drilled.

On the other hand, the upper mold 50 for mold press molding located above it can be moved up and down by a predetermined stroke by an elevating cylinder 51, and the product shape, that is, FIG.
It has a mold surface that matches the surface shape of the automobile door trim 10 shown in FIG. 2, and is provided with vacuum suction means so that a part of the skin material 30 can be sucked.

That is, vacuum suction holes 52 having a hole diameter of 6 mm are formed at predetermined pitch intervals in a part of the outer periphery of the cavity C of the upper die 50, and a 0.3 mm vacuum is provided in a pull handle portion, an air vent portion, and the like. Suction holes 53 are respectively set, and these vacuum suction holes 52 and 53 are connected to a vacuum suction pipe 54. The vacuum suction pipe 54 is connected to a vacuum pump 55, and an opening / closing valve 56 is provided on the vacuum suction pipe 54. is set up.

Further, the leading pad 70 installed on a part of the outer periphery of the lower mold 40 is arranged at a position protruding above the mold surface of the lower mold 40, and is always spring-up by a coil spring 71. The leading pad 70 can be lowered by a stroke of 30 mm against the spring force of the coil spring 71, and locate pins 72 are arranged on the upper surface of the leading pad 70 at appropriate pitch intervals.

Next, a two-color molding method of the automobile door trim 10 shown in FIGS. 1 and 2 will be described with reference to FIGS.

FIG. 5 is a press chart of the upper die 50. The upper die 50 moves down from the uppermost position (a) to (b). At this time, the vacuum suction means provided on the upper die 50 is driven. The skin material 30 is held by the upper mold 50.

Then, the semi-molten resin M is distributed and supplied to a predetermined portion of the lower mold 40 during 6 to 8 seconds from (b) to (c).
Thereafter, the upper mold 50 descends to the bottom dead center (d) and press-molding is performed for 40 seconds until (e), and thereafter the upper mold 50 rises and returns to the original position.

More specifically, the steps will be described in detail. In the step of setting the skin material 30 shown in FIG.
Reference numeral 0 denotes a mold opening state, and the preformed skin material 30
Is placed on the lower mold 40.

Actually, it is placed on the preceding pad 70 located above the lower die 40 and set in a state that it is slightly lifted from the die surface of the lower die 40. At this time, the locate pin 72 provided on the preceding pad 70 is set. If the locating hole of the skin material 30 is inserted into the device, the skin material 30 can be easily and accurately set, and it is not necessary to set the upper material using an input device as in the related art, so that the equipment can be simplified.

When the setting of the skin material 30 is completed, the upper mold 5
When the clearance between the upper and lower dies 40 and 50 reaches 30 mm, the upper die 50 and the leading pad 70 move as shown in FIG.
As a result, the outer periphery of the skin material 30 is sealed and held,
The skin material 30 is sucked through the vacuum suction holes 52 and 53 provided in the upper mold 50 so as to faithfully follow the mold surface of the upper mold 50.

At this time, the lower mold 4 is passed through the injection molding machine 60.
The semi-molten resin M is distributed and supplied to a predetermined location on the mold surface of the lower mold 40 via the zero gate 41.

Thereafter, as shown in FIG. 8, the upper die 50 descends to the bottom dead center to mold-press the resin core 20 into a required shape, and at the same time, a part of the surface of the resin core 20 The leading pad 70 moves down by a predetermined stroke against the spring force of the coil spring 71.

As described above, according to the method of the present invention, the outer periphery of the skin material 30 is sandwiched between the upper die 50 and the preceding pad 70 to perform sealing, and the vacuum suction means is used in an auxiliary manner. The pitch interval between the vacuum suction holes 52 and 53 can be made large, and the mold processing can be simplified.
The simple setting work that only requires placing on the top of the machine is enough, and the conventional expensive skin loading machine is not required. Since the skin material 30 can be accurately and reliably held on the mold surface of the mold 50, the skin material 30 is free from wrinkles and other defects.
There are various advantages that the door trim 10 excellent in appearance design can be mass-produced.

[0042]

As described above, the method of the present invention has the following special effects.

(1) According to the method of the present invention, the outer periphery of the skin material is sealed by the leading pad and the upper mold provided on a part of the outer periphery of the lower mold. Can be firmly adhered to the surface, and during mold press molding, there is no displacement or wrinkling of the skin material due to resin pressure etc., and the skin material is accurately adhered to part of the surface of the resin core material This has the effect of improving molding accuracy.

(2) According to the method of the present invention, the outer periphery of the skin material is reliably sealed between the preceding pad provided on a part of the outer periphery of the lower die and the upper die. There is no defect such as resin leakage at the time or a waving of a parting line of a skin material terminal, and an effect that a beautiful product appearance can be guaranteed.

(3) In the method of the present invention, the positioning of the skin material is completed by installing the preceding pad on a part of the outer periphery of the lower mold and placing the skin material on the preceding pad. The skin feeding machine can be eliminated, and the pitch interval between the vacuum suction holes formed in the upper mold can be made large, so that the mold equipment can be simplified and the mold processing can be easily performed.

(4) According to the method of the second aspect of the present invention, the leading pad is disposed on a part of the outer periphery of the lower die, and the locate pin is placed on the upper surface of the leading pad. If the locating hole of the skin material is inserted into the locating pin provided on the preceding pad, the positioning of the skin material can be performed easily and accurately, and the workability in the positioning work is improved. Tension will be added,
In particular, the terminal flange part of the product can be stuck without wrinkles, the failure rate due to wrinkles can be greatly reduced, productivity can be increased, and a complicated curved surface shape can be set as the shape of the terminal part. This has the effect that it can be improved.

[Brief description of the drawings]

FIG. 1 is a front view showing an automobile door trim manufactured by applying the method of the present invention.

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

FIG. 3 is a cross-sectional view showing an embodiment of a mold apparatus for mold press molding used in the method of the present invention.

FIG. 4 is a plan view of a lower die showing the arrangement of the leading pads shown in FIG. 3;

FIG. 5 is a time chart of an upper mold for mold press molding used in the method of the present invention.

FIG. 6 is a sectional view showing a step of setting a skin material in the method of the present invention.

FIG. 7 is a cross-sectional view showing a state in which a skin material is held by suction on an upper mold in the method of the present invention.

FIG. 8 is a sectional view showing a mold press molding step in the method of the present invention.

FIG. 9 is a sectional view showing a configuration of a conventional automobile door trim.

FIG. 10 is a sectional view showing a conventional mold press molding step.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Automobile door trim 20 Resin core material 30 Skin material 40 Lower mold for mold press molding 50 Upper mold for mold press molding 52, 53 Vacuum suction hole 60 Injection molding machine 70 Leading pad 71 Spring 72 Locating pin

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-6-15671 (JP, A) JP-A-6-312435 (JP, A) JP-A-3-27910 (JP, A) 41740 (JP, U) (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 43/18-43/20 B29C 43/32-43/40 B29C 33/12-33/18 B29C 45/14

Claims (2)

(57) [Claims] 1. A mold for mold press molding (40, 50).
Inside, a resin core (20) formed by molding a semi-molten resin (M) into a required shape, and a part of the surface of the resin core (20) during mold press molding of the resin core (20). In a method of forming a laminated molded body comprising a covering material (30) to be coated, the covering material (30) is preformed into a required shape, and a mold is formed when the upper and lower dies (40, 50) are opened. A part of the outer periphery of the lower mold for press molding (40) is
The above-mentioned skin material (30) is placed on the preceding pad (70) arranged at a position protruding above the mold surface of (0), and the upper mold (50) is moved down to advance the upper mold (50). Pad (7
0), the outer periphery of the skin material (30) is sealed, and the skin material (30) is sucked and held on the mold surface of the upper mold (50) by vacuum suction means provided on the upper mold (50). The semi-molten resin (M) is distributed and supplied into the cavity (C) between the molds (40, 50), and the upper and lower molds (40, 50) are clamp-molded to mold the resin core material (20) into a required shape. A method of forming a laminated molded body, wherein a part of the surface of a resin core material (20) is covered and integrated with a skin material (30). The leading pad (70) is provided with a spring (7) so as to be able to move up and down in accordance with the up and down movement of the upper mold (50).
1) Spring material and skin material (30)
2. The method according to claim 1, wherein locating pins (72) for locating the pin at an appropriate position are provided at predetermined pitch intervals.