JP3523372B2 - Manufacturing method of partial skin molded product - 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 for producing a so-called partial skin molded article in which only a predetermined surface area is covered with a skin material.

[0002]

2. Description of the Related Art Conventionally, in a resin molded article such as an automobile interior trim, the interior side surface of a synthetic resin trim base material is covered with a skin material such as a so-called fabric to form an interior material. It is generally well-known that it is designed to give a high-class feeling. When manufacturing such a resin molded product whose surface is covered with a skin material, it is considered that the skin material is integrally laminated in a molding die at the time of molding the base material. For example, JP-A-63-116815. The publication discloses a method of injection-molding a so-called full-skin composite material product in which a fibrous material is bonded to the entire surface on one side of a support member (for example, a seat unit) made of synthetic resin. Incidentally, in Japanese Utility Model Laid-Open No. 6-27249, in press-molding such a full-face skin-molded article, a mesh body of high-melting-point fibers is inserted between the base material and the skin material in a portion where the expansion rate of the base material is high. It is disclosed that it is reinforced by.

Also known is a so-called partial skin type resin-molded product whose interior side surface is covered with a skin material, in which only a specific region of the interior side surface is covered with the skin material. There is. As a method of molding such a partial skin-molded article, another member corresponding to the specific region is manufactured by coating with a skin material and attached to a separately molded body substrate (for example, Japanese Utility Model Laid-Open No. 4-76516 or JP-A-6-9
9735), or a separate member having the above-mentioned entire surface skin is loaded into the mold at the time of molding the main body base material to perform integral molding (see, for example, JP-A-5-318613).
Alternatively, a skin material is adhered and fixed to a specific region of the molded main body substrate by using a mold for skin pressure bonding (for example, JP-A-2-3).
No. 05627) is known.

In addition, for example, in Japanese Unexamined Patent Publication No. 64-26414, a skin material having a shape corresponding to the above-mentioned specific area is separately prepared and attached to a portion corresponding to the specific area in a molding die. A method is disclosed in which a molten resin is supplied to the back surface side of the attached skin material and the skin material and the main body base material are integrally molded by compression molding. Furthermore, JP-A-64-
In Japanese Patent No. 85715, a decorative sheet for decorating only a specific area is attached to the back surface side of a surface layer material set on the entire surface of one mold surface, and a molten resin is supplied to the other mold surface to form a main body base material. A method of integrally compression-molding the decorative sheet and the entire surface layer material is disclosed.

[0005]

However, each of the above-mentioned conventional methods has the following drawbacks.
That is, when a separate member is manufactured and attached to the main body base material, an additional man-hour is required to manufacture the separate member covered with the entire surface skin, and a molding die for this is additionally required. It also takes time to attach (or integrally mold) to the main body substrate. In other words, the number of parts increases, the equipment cost increases, and it is difficult to expect improvement in productivity. Further, even when the skin material is bonded and fixed to the molded main body substrate, a separate mold for skin pressure bonding is required, and the bonding and fixing work performed separately from the molding is troublesome. Furthermore, even when the skin material is integrally laminated at the time of molding the main body material, prepare a skin material having a shape corresponding to a specific area to be covered with the skin material, and accurately position and set it in the molding die. It takes a lot of work to do.

The present invention has been made in view of the above problems, and in a series of steps within one molding cycle, a portion in which a skin material is laminated only on a predetermined surface region of a molded product and integrally molded. It is an object of the present invention to provide a method for manufacturing a skin-molded article.

[0007]

Therefore, the invention according to claim 1 of the present application (hereinafter referred to as the first invention) is to manufacture a partial skin-formed product in which only a predetermined surface region is covered with a skin material. In the method, a skin material setting step of stretching a skin material between a pair of molding dies that are in a separated state, and closing the both molding dies, and projecting a sealing tool into the molding cavity to correspond to the predetermined surface area. A step of forming a partial cavity to be formed, a primary molding step of filling a material resin into the partial cavity, and with the molding die closed, cut the skin material with a cutting tool along the peripheral edge of the partial cavity, The step of removing the excess skin material from the molding cavity, the step of retracting the sealing tool and cutting tool from the molding cavity, and filling the molding cavity portion other than the partial cavity with the material resin. A secondary molding step that is obtained by comprising the.

The invention according to claim 2 of the present application (hereinafter,
2nd invention), in the above-mentioned 1st invention, in the mold surface of the molding die corresponding to the surface side of the molded product of the above-mentioned molding die, the portion corresponding to the peripheral edge of the partial cavity is moved to the molding cavity side. A protruding portion is formed so that the skin material is pressed against the protruding portion by the sealing member, and then the outside of the pressing portion by the sealing member is cut on the protruding portion. It is a thing.

The invention according to claim 3 of the present application (hereinafter,
In the first invention, a cutting blade for cutting a skin material is formed at the tip of the sealing tool, and the tip of the sealing tool is cut off when the partial cavity is formed. When the molding tool is brought into contact with the material to partition the molding cavity and the skin material is cut, the sealing tool is advanced by the thickness of the skin material to perform cutting along the peripheral edge of the partial cavity. It is what

[0010]

According to the first invention of the present application, after the skin material is stretched and set between the molding dies, both molding dies are closed and the sealing member is projected to correspond to the predetermined surface area. After forming a partial cavity and filling the material resin into the partial cavity and performing primary molding, the skin material is cut with a cutting tool along the peripheral edge of the partial cavity with the molding die closed, Since the skin material is removed from the molding cavity, the sealing tool and the cutting tool are retracted from the inside of the molding cavity, and then the secondary molding is performed in which the molding cavity portion other than the partial cavity is filled with the material resin. In a series of steps in the molding cycle, the skin material can be laminated only on a predetermined surface region of the molded product and integrally molded. Therefore, it is not necessary to prepare and attach a separate member, and it is not necessary to prepare a skin material having a shape corresponding to a predetermined surface area and position and set the skin material in the mold to perform a troublesome work. That is, the partial skin-molded article can be formed by a series of a small number of steps without increasing the number of parts and the equipment cost, and without the need for performing another operation that requires time and labor.

According to the second invention of the present application, basically, the same effect as that of the first invention can be obtained. Moreover, since the above-mentioned protrusion is formed on the mold surface of the molding die on the surface side of the molded product, it corresponds to the peripheral edge of the partial cavity on the surface side of the molded product (thus corresponding to the peripheral edge of the predetermined surface region). It is possible to form a so-called wood grain portion with respect to the peripheral edge portion of the skin material. Further, since the skin material is pressed against the protruding portion by the sealing member, and the outside of the pressing portion by the sealing member is cut on the protruding portion, it corresponds to the partial cavity of the skin material. The peripheral portion of the portion (that is, the predetermined surface area) can be left on the molding cavity side other than the partial cavity on the protrusion. Therefore, by performing the secondary molding after the primary molding, the peripheral edge portion of the skin material can be held behind the wood grain portion formed on the surface side of the molded product. In other words, it is possible to carry out the graining work at the same time as the secondary molding without providing a special process. And
As a result, with respect to the skin material having a predetermined surface area, the wood grain of the peripheral portion becomes good, and the appearance can be enhanced.

Further, according to the third invention of the present application, basically, the same effect as that of the first invention can be obtained. Moreover, the cutting blade is formed at the tip of the sealing tool, and when forming the partial cavity, the tip of the sealing tool is brought into contact with the skin material to partition the molding cavity and cut the skin material. At this time, the sealing tool is advanced by the thickness of the skin material to cut along the peripheral edge of the partial cavity, so that the sealing tool can be used also as the cutting tool, and the drive mechanism can also be used. It will be all right. As a result, the number of parts can be reduced and the structure and operation of the mold can be simplified.

[0013]

Embodiments of the present invention will now be described in detail with reference to the accompanying drawings, in the case where the embodiment of the present invention is applied to a method of manufacturing a partial skin type automobile door trim. 1 and 2 are a front explanatory view and a vertical cross-sectional explanatory view of a vehicle door trim according to this embodiment. As shown in these drawings, the door trim 1 is formed of, for example, polypropylene (PP) resin. Further, only the armrest portion 3 on the interior surface of the trim base material 2 is covered with the skin material 5 (for example, so-called fabric). In the door trim 1 as the partial skin-molded product, the skin material 5 is integrally laminated and molded when the trim base material 2 is molded.

FIG. 3 shows a mold clamping state of a pair of molds 10 and 15 for injection molding the door trim 1. Of the two molds 10 and 15, a mold 15 having a mold surface 15f corresponding to the back surface side (anti-interior surface side) of the door trim 1.
On the back side of (the right mold in the figure), both molds 10,
In the molding cavity 8 formed by closing 15 together,
An injection cylinder 21 for injecting a material resin (polypropylene resin) in a molten state by injection is connected. In the mold 15, a cylindrical sealing tool 22 whose vertical cross-sectional contour corresponds to the peripheral shape of the fabric (skin material) covering region of the door trim 1 (that is, the armrest portion 3) appears in and out of the molding cavity 8. The seal member 22 is provided so as to be possible.
Is connected to a drive cylinder 23 for its reciprocation.

The sealing member 22 is projected into the molding cavity 8 when the molds 10 and 15 are clamped, so that the skin material covering region 3 is formed in the molding cavity 8.
The partial cavity 8A corresponding to is formed. Further, in the mold 15, on the outer peripheral side of the sealing member 22, in order to cut the fabric 5 (skin material) along the peripheral edge of the covering region 3 in the mold clamped state, a cutting blade 24a is provided at the tip. A cylindrical cutting tool 24 provided with is provided so as to be retractable in the molding cavity 8, and the cutting tool 24 is connected to a drive cylinder 25 for advancing and retracting the cutting tool 24. The inner part of the sealing tool 22 of the mold 15 is a peripheral part (main mold 1
6) is formed with a so-called slide core 17 which is slidable in the opening / closing direction of the molds 10 and 15, and the slide core 17 is moved back and forth by a drive cylinder (not shown), so that as will be described later, Main mold 1 at predetermined timing
The slide operation is performed with respect to 6.

Further, a resin passage 26 for guiding the molten material resin from the injection cylinder 21 into the molding cavity 8 is provided in the mold 15, and the resin passage 26 is provided with the injection nozzle 21a of the injection cylinder 21. Is connected to the primary passage 26A and the secondary passages 26B and 26B. The primary passage 26A is
In the protruding state of the sealing tool 22, the material resin is guided into the partial cavity 8A partitioned by the sealing tool 22, while
The outlet position of each secondary passage 26B is set so as to guide the material resin to the molding cavity portion 8B side other than the partial cavity 8A. As shown in detail in FIG. 16, the primary passage 26A includes a passage hole 16h formed in the main mold 16 and a passage hole 17h formed in the slide core 17. The slide core 17 is integrally provided with a cylindrical sleeve 17a protruding to the back side.
7a is slidably inserted in the passage hole 16h of the main mold 16 in the longitudinal direction. A seal member 18 that seals the molten resin in a liquid-tight manner is interposed between the outer peripheral portion of the cylindrical sleeve 17a and the inner peripheral portion of the main mold passage hole 16h. The insertion length of the cylindrical sleeve 17a into the main mold passage hole 16h is set to be sufficiently longer than the maximum slide amount of the slide core 17, and even if the slide core 17 performs the maximum slide movement, The passage 26A is designed to be maintained without any trouble (that is, without interruption in the middle).

The primary passage 26A and the secondary passages 26B, 2
A rotary switching valve 27, for example, is provided at a branch portion of the valve 6B to switch the communication state between the passages 26A and 26B and the inlet passage 26I. This switching valve 2
The drive mechanism 7 and the drive cylinders 23 and 25 for advancing and retracting the sealing tool 22 and the cutting tool 24, respectively, are electrically connected to a control panel (not shown) of the molding apparatus, and are mainly composed of, for example, a microcomputer. The operation is controlled on the basis of a control signal from the device control unit (not shown).

Door trim 1 which is carried out by using the above apparatus
Manufacturing process will be described mainly with reference to a series of process explanatory diagrams of FIGS. 4 to 9 and partially enlarged sectional views of FIGS. 10 to 13. In addition, in order to facilitate understanding of the drawings, these mold explanatory drawings
Regarding the structure of 15 or its attached members, parts that are not particularly necessary for explaining the process are omitted for the sake of convenience, but the mold used throughout each process shown in these figures is the same. is there. First, as the first step (skin material setting step), as shown in FIG. 4, a fabric 5 as a skin material is stretched between the two molds 10 and 15 in the separated state. At this time, fabric 5 (skin material)
Is stretched between the molds 10 and 15 with both ends pulled and held by the holders 7 and 7 so that slack, waviness, and wrinkles do not occur.

Next, as shown in FIG. 5, both molds 10, 1 are
5, the sealing member 22 is projected into the molding cavity 8 formed by the mold surfaces 10f and 15f, and the skin material covering region 3 (armrest portion) is formed in the molding cavity 8.
The partial cavity 8A corresponding to is formed. At this time,
After the molds 10 and 15 are clamped, the drive cylinder 23 may be operated to project the sealing member 22 into the molding cavity 8 by a predetermined amount to form the partial cavity 8A. A predetermined amount may be made to protrude from the mold surface 15f so that the partial cavity 8A is formed at the same time when the mold is clamped. In any case, the tip of the sealing tool 22 is pressed against the mold surface 10f of the mold 10 through the skin material 5 with a predetermined pressing force, so that the partial cavity 8A is separated from the other molding cavity portion 8B.
It is set so as to seal liquid-tightly.

In this embodiment, as shown in detail in FIG. 10, the mold 1 corresponding to the surface side (interior side) of the door trim 1
Mold surface 10 of 0 (the mold on the left side in the figure, that is, the mold on the side opposite to where the seal tool 22 and the cut tool 24 are provided)
In f, a projecting portion 11 projecting toward the molding cavity 8 side is formed at a portion corresponding to the peripheral edge of the partial cavity 8A. By providing the projecting portion 11, the peripheral edge of the partial cavity 8A on the surface side of the molded product is formed. Corresponding (hence,
A so-called wood grain portion 1a with respect to the peripheral edge of the skin material 5 can be formed in a portion (corresponding to the peripheral edge of the predetermined surface region). The tip of the sealing member 22 is located on the relatively inner side of the protrusion 11 with the skin material 5 interposed therebetween.
It is set to be pressed to the 0f side.

Next, as shown in FIG. 6, after the switching state of the switching valve 27 is set so that the inlet passage 26I of the resin passage 26 and the primary passage 26A communicate with each other, as a primary molding step, as described above. The material resin is injected and injected into the partial cavity 8A thus formed. This allows the door trim 1
The skin material covering region 3 (armrest portion) is molded. In this primary molding process, the slide core 17 of the mold 15 has a curved surface in which the mold surface 15f of the mold 15 is continuous from the main mold 16 to the slide core 17 as shown by the broken line curve in FIG. From the initial state, which corresponds to the thickness of the skin material 5 after compression by mold clamping (hereinafter, referred to as compression thickness), in advance in the molding cavity 8 (that is, in the partial cavity 8A). ) It is slid so that it sticks out. The sliding operation of the slide core 17 may be performed at any stage before the material resin is injected and injected in the primary molding process.

After that, as shown in FIG.
Operate the drive cylinder 25 while keeping 5 closed,
A cutting tool 24 arranged along the outer periphery of the sealing tool 22 is advanced into the molding cavity 8 to cut the skin material 5 along the peripheral edge of the partial cavity 8A. At this time, as shown in detail in FIG. 11, the skin material 5 is pressed against the above-mentioned protruding portion 11 by the seal member 22, and then the outside of the portion pressed by the seal member 22 is cut off on this protruding portion 11. . As a result, the skin material 5 covering the armrest portion 3 of the door trim 1 remains on the side of the molding cavity 8B other than the primary-molded armrest portion 3 as shown in FIG. ,
It is located on the above-mentioned protruding portion 11 which forms the wood grain portion of the door trim 1 by the secondary molding described later. After the cutting process is completed, the molds 10 and 15 are opened by a slight amount, and the excess skin material 5 is removed from the molding cavity 8 by pulling the holders 7 and 7 outside the mold. After that, the molds 10 and 15 are closed again and the mold is clamped. At this time, prior to this mold clamping, the slide core 17 is retracted by an amount corresponding to the compressed thickness of the skin material 5, whereby the mold surface 15f of the mold 15 extends from the main mold 16 to the slide core 17. Are returned to the initial state of forming a continuous curved surface.
That is, by performing mold clamping in this state, after removing the extra skin material 5, the molding cavity 8B other than the primary-molded armrest portion 3 is sealed.

Next, as shown in FIG. 8, both drive cylinders 23 and 25 are operated to retract the sealing tool 22 and the cutting tool 24 from the inside of the molding cavity 8 (see FIG. 12), and also shown in FIG. As described above, after switching the switching valve 27 so that the inlet passage 26I of the resin passage 26 and the secondary passages 26B, 26B communicate with each other, the forming cavity 8 other than the primary-formed armrest portion 3 is subjected to the secondary forming step.
Material resin is injected and injected into the B side. As a result, the portion of the door trim 1 other than the skin material covering region 3 (armrest portion) is molded.

Then, after the material resin injected and injected is cooled and solidified to some extent, the molds 10 and 15 are opened, the molded product (door trim 1) is taken out from between the molds 10 and 15, and one molding cycle is completed. finish. At this time, as clearly shown in FIG. 13, the protrusion 1 of the mold 10 of the door trim 1
The portion corresponding to 1 forms the wood grain portion 1a of the trim 1, and the peripheral edge portion of the skin material 5 is located on the projecting portion 11 as described above, so that the wood grain portion 1a is formed by the secondary molding.
Will be held deep inside. In other words, it is possible to carry out the graining work at the same time as the secondary molding without providing a special process. As a result, the grain of the peripheral portion of the skin material 5 becomes good, and the appearance can be improved.

As described above, according to this embodiment, the skin material 5 is laminated only on the predetermined surface area (armrest portion 3) of the molded product (door trim 1) in a series of steps in one molding cycle. Can be integrally molded. Therefore, it is not necessary to prepare and attach a separate member, and it is not necessary to prepare a skin material having a shape corresponding to the predetermined surface area 3 and to position and set the skin material in the mold. That is, the partial skin-molded product 1 can be molded in a series of a small number of steps without increasing the number of parts or equipment cost, and without the need for a separate work requiring labor and man-hours.

In the above embodiment, the sealing tool 22 and the cutting tool 24 are formed separately, but they can be formed integrally. Next, another embodiment of the present invention will be described. In the following description, the same parts as those in the above-described embodiment are designated by the same reference numerals, and further description will be omitted. In this embodiment, as shown in FIG. 14, a cutting blade 42a for cutting the skin material 5 (fabric) is formed at the tip of the sealing tool 42, and when the partial cavity 8A is formed, the cutting tool 42a The tip (that is, the cutting blade 42a) is brought into contact with the fabric 5, and the molding cavity 8 is partitioned by the sealing tool 42, as shown in FIG.
As shown in FIG. 6, when the fabric 5 is cut, the seal tool 42 is advanced by the thickness of the fabric 5 and cut along the peripheral edge of the partial cavity 8A.

As described above, in this embodiment, the sealing member 42
Cut blade 42a is formed at the tip of the
When forming the sheet, the tip of the seal member 42 is brought into contact with the skin material 5 to partition the molding cavity 8 and when the skin member 5 is cut, the seal member 42 is cut to the thickness of the skin member 5. Since the cutting is performed along the peripheral edge of the partial cavity 8A by advancing by the amount, the sealing tool 42 can be used also as the cutting tool, and only one drive mechanism is required. As a result, it is possible to reduce the number of parts and simplify the structure and operation of the mold 15.

The present invention is not limited to the above-described embodiment, and for example, the sealing tool and the cutting tool are attached to different molds to be driven, and the scope thereof is not deviated from. Needless to say, various improvements and design changes are possible.

[Brief description of drawings]

FIG. 1 is a front explanatory view of a partial skin door trim according to an embodiment of the present invention.

FIG. 2 is a vertical cross-sectional explanatory view taken along the line YY of FIG.

FIG. 3 is a vertical cross-sectional explanatory view of a mold for molding the door trim.

FIG. 4 is a process explanatory view showing a skin material setting process.

FIG. 5 is a process explanatory view showing a mold clamping and partial cavity forming process.

FIG. 6 is a process explanatory view showing a primary molding process.

FIG. 7 is a process explanatory diagram illustrating a skin material cutting process.

FIG. 8 is a process explanatory view showing a retracting process of the sealing tool and the cutting tool.

FIG. 9 is a process explanatory view showing a secondary molding process.

FIG. 10 is an enlarged cross-sectional explanatory view showing the tip portion of the sealing tool in the partial cavity forming step.

FIG. 11 is a cross-sectional explanatory view showing enlarged tip portions of a sealing tool and a cutting tool in a skin material cutting step.

FIG. 12 is a cross-sectional explanatory view showing an enlarged peripheral edge portion of the skin material in the retracting step of the sealing tool and the cutting tool.

FIG. 13 is an explanatory cross-sectional view showing an enlarged wood grain portion of the skin material.

FIG. 14 is a process explanatory view showing a partial cavity forming process using a sealing tool according to another embodiment of the present invention.

FIG. 15 is a process explanatory diagram illustrating a skin material cutting process using a sealing tool according to another embodiment.

FIG. 16 is an enlarged cross-sectional explanatory view showing a slide core and a primary passage of a mold according to an embodiment of the present invention.

[Explanation of symbols]

1 ... door trim 3 ... Armrest part 5 ... Fabric (skin material) 8 ... Molding cavity 8A ... Partial cavity 8B: Mold cavity portion other than partial cavity 10, 15 ... Mold 10f ... Mold surface 11 ... Projection 22, 42 ... Sealing tool 24 ... Cut tool 42a ... cutting blade

Continuation of front page (56) Reference JP-A-4-325216 (JP, A) JP-A-63-116815 (JP, A) JP-A-6-99735 (JP, A) JP-A-5-318613 (JP , A) JP-A-2-305627 (JP, A) JP-A-63-26414 (JP, A) JP-A-64-85715 (JP, A) Actually flat 6-27249 (JP, U) Actually flat 4-76517 (JP, U) (58) Fields investigated (Int.Cl. ⁷ , DB name) B60J 5/00 B29C 45/14 B60R 13/02

Claims (3)

(57) [Claims] 1. A method of manufacturing a partial skin-molded article in which only a predetermined surface region is covered with a skin material, and a skin material setting step of stretching the skin material between a pair of molds in a separated state, A step of forming a partial cavity corresponding to the predetermined surface area by projecting a sealing tool into the molding cavity by closing the two molding dies; a primary molding step of filling a material resin into the partial cavity; While the above is closed, a step of cutting the skin material with a cutting tool along the peripheral edge of the partial cavity and removing excess skin material from the molding cavity; and retracting the sealing tool and the cutting tool from the molding cavity. A method of manufacturing a partial skin-molded article, comprising: a step of secondary molding in which a material resin is filled in a molding cavity portion other than the partial cavity. 2. The molding surface of the molding die corresponding to the surface side of the molded product of the molding die is provided with a projecting portion projecting to the molding cavity side at a portion corresponding to the peripheral edge of the partial cavity. The partial skin-molded article according to claim 1, wherein the skin material is pressed against the protruding portion by the sealing tool, and the outside of a portion pressed by the sealing tool is cut on the protruding portion. Production method. 3. A cutting blade for cutting a skin material is formed at a tip of the sealing tool, and when the partial cavity is formed, the tip of the sealing tool is brought into contact with the skin material and the sealing tool is used. The partial skin forming according to claim 1, wherein when the molding cavity is partitioned and the skin material is cut, the sealing tool is advanced by the thickness of the skin material to cut along the peripheral edge of the partial cavity. Method of manufacturing goods.