JP3574195B2 - Molding method of laminated molded article and its mold - Google Patents

Molding method of laminated molded article and its mold Download PDF

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Publication number
JP3574195B2
JP3574195B2 JP30592694A JP30592694A JP3574195B2 JP 3574195 B2 JP3574195 B2 JP 3574195B2 JP 30592694 A JP30592694 A JP 30592694A JP 30592694 A JP30592694 A JP 30592694A JP 3574195 B2 JP3574195 B2 JP 3574195B2
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Prior art keywords
mold
skin surface
surface material
skin
molding
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JPH08156023A (en
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知和 阿部
悟士 松本
義昭 齋藤
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Idemitsu Petrochemical Co Ltd
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Idemitsu Petrochemical Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C45/14262Clamping or tensioning means for the insert
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C45/14262Clamping or tensioning means for the insert
    • B29C2045/1427Clamping or tensioning means for the insert controlling the slip of the insert
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/30Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005Body finishings
    • B29L2031/3041Trim panels

Description

【0001】
【産業上の利用分野】
本発明は、両面が表皮面材で被覆された積層成形品の製造方法に関し、シートバック、サイドピラー、および、ドアの内装パネル等の自動車部品や、椅子の背もたれ等の家具部品等を製造する際に利用できる。
【0002】
【背景技術】
従来より、自動車内装品等、例えば、ドアの内装パネル、シートバック、および、サイドピラーには、合成樹脂製の本体の表面を、塩化ビニールおよび発泡ポリプロピレン等からなる多層面材や、柔軟性を有する布等の表皮面材で被覆した積層成形品が利用されている。
このような積層成形品によれば、表面が柔軟な表皮面材で覆われていることから、手で触れた際等に良好な感触を与えることができるうえ、織物等を表皮面材として用いれば、装飾性を付与することができる。
また、表皮面材の厚みを増すことにより良好なクッション性が得られるため、コンソールボックスの蓋等に積層成形品を用いれば、開閉の際の衝撃音、走行時の振動等を抑制できる。
さらに、クッション性を有する表皮面材は、隙間を密閉することが可能となるので、良好な遮音性やシール性等を付与することができる。
【0003】
このような積層成形品を製造するには、芯となる本体を成形した後、この本体の表面に表皮面材を接着することにより行うのが一般的であるが、表皮面材を接着する作業が煩雑であるため、製造コストを高騰させるという問題がある。
この問題は、予め表皮面材を装着しておいた金型に溶融樹脂を充填することで、成形と同時に表皮面材と本体とを一体化し、接着作業を省略する製造方法により解消できる。
このような製造方法では、表皮面材を金型に装着するのに、次のA〜Dのような構造の装着手段を採用している。
A.雄型および雌型等の二つの型部に金型を分割し、金型を閉鎖する際に、型部の合わせ面の間に表皮面材の端縁を挟み込んで当該表皮面材を完全に固定してしまう装着手段。
B.金型を二つの型部に分割するとともに、型部の分割面の間に表皮面材の厚さとほぼ同一寸法の隙間を設け、この隙間に表皮面材の端縁を配置し、表皮面材を両側から押さえ付けず、金型内部へ表皮面材が自由に滑り込めるように装着する装着手段。
C.金型からはみ出た表皮面材の端縁を引っ張るスプリング等の引張装置を金型の周囲に設け、この引張装置の張力に抗する力が表皮面材に与えられると、表皮面材の端縁が金型の内部へ滑り込むことを可能とする表皮面材を装着する装着手段(特開平2−229014号)。
D.雄型および雌型等の二つの型部に金型を分割し、これら二つの型部の一方との間に表皮面材を挟み込む固定枠と、固定枠を前記一方の型部に向かって押圧する複数の流体シリンダ装置等とを設け、固定枠および型枠の間に表皮面材を挟持するとともに、流体シリンダ装置等の押圧力の調節により、固定枠および型枠の挟持力を調節可能にした装着手段(特公平4−76291 号)。
【0004】
【発明が解決しようとする課題】
以上のA〜Dの製造方法には、それぞれ次のイ〜ニに示す問題がある。
イ.型部の間に挟み込んで表皮面材の端縁を移動不可能に固定することから、凹凸のある立体的な成形品を成形しようとすると、成形時に表皮面材に過大な張力が加わる。このため、布等の伸びない表皮面材は破れやすく、発泡ポリプロピレン等のクッション性を有する表皮面材は、引き伸ばされて厚みを失い、クッション性が損なわれるという問題がある。
ロ.金型内へ表皮面材が自由に滑り込めることから、表皮面材に張力が全く与えられない。このため、凹凸のある立体的な成形品を成形しようとすると、金型に充填される溶融樹脂の流動により、表皮面材が自由に変形し、立ち上がり部分の付け根部分等にシワを発生させるという問題がある。
ニ.引張装置を設けることにより、金型の構造が複雑になるとともに、引張装置は金型の周囲に設けられるので、金型の全体の寸法が大型化する。
そのうえ、引張装置で表皮面材を引っ張るには、引張装置と表皮面材とをある程度強固に接続する必要があるので、成形毎に行われる表皮面材の装着作業が面倒となり、サイクルタイムを長引かせ、積層成形品の生産性を向上できないという問題がある。
また、表皮面材を金型の外部にはみ出させることから、表皮面材全体のうち有効利用できない割合が大きくなり、表皮面材の無駄が多いという問題がある。
ホ.金型の型締め動作とは別個に固定枠を移動可能に設ける必要があるので、金型の構造が複雑となり、金型毎に固定枠を作成しなければならないので、金型の作成費用を高騰させるという問題がある。
また、固定枠を複数に分割し、分割された各部毎に流体シリンダ装置を設け、各シリンダ装置の押圧力を調節して挟持力を設定すれば、表皮面材の各部毎に対する摩擦力や滑り込み量を調節できるようになる。しかし、摩擦力や滑り込み量が不連続となる境界線が生じるので、この境界線の両側で滑り込み量が大きく相違すると、シワや破れが発生する原因となるので、複雑な形状の積層成形品の成形は難しいという問題がある。
【0005】
本発明の目的は、凹凸のある複雑な形状の成形品でも、その表面にシワや破れ等の欠陥が生じないうえ、生産性の向上が図れる積層成形品の成形方法およびその金型を提供することにある。
【0006】
【課題を解決するための手段】
本発明の積層成形品の成形方法は、柔軟性を有する表皮面材が表面に貼り付けられた成形品を成形する積層成形品の成形方法であって、予め前記成形品を成形する金型に前記表皮面材を滑動可能に挟持する固定手段を複数離間させて設けておき、これらの固定手段の位置と数とを前記成形品の形状に応じて予め設定された表皮面材の各部の滑り量に応じて設定しておき、前記固定手段は、前記表皮面材と当接する部分に前記表皮面材との摩擦抵抗を小さくする滑り手段を備え、かつ、前記金型を構成する固定金型および移動金型に固定され、前記固定手段により前記金型に前記表皮面材を取付けた後、溶融樹脂を充填するとともに、前記固定手段で挟持した前記表皮面材を滑らせながら、前記金型の内部の溶融樹脂を展延させることを特徴とする。
以上において、成形方式としては、金型内に充填した溶融樹脂を金型の型締めにより圧縮して金型内部に展延する成形方式が採用できる。
【0007】
本発明の積層成形品の金型は、柔軟性を有する表皮面材が表面に貼り付けられた成形品を成形するための積層成形品の金型であって、前記金型はインロー構造とされるとともに、この金型に前記表皮面材を滑動可能に挟持する固定手段を複数離間させて設け、前記固定手段は、前記金型を構成する固定金型および移動金型に固定され、かつ、前記表皮面材と当接する部分に前記表皮面材との摩擦抵抗を小さくする滑り手段を備え、この滑り手段は、前記固定手段の前記表皮面材と当接する部分に回転自在に取付けられた転がり装置であることを特徴とする。
また、本発明の積層成形品の金型は、柔軟性を有する表皮面材が表面に貼り付けられた成形品を成形するための積層成形品の金型であって、前記金型はインロー構造とされるとともに、この金型に前記表皮面材を滑動可能に挟持する固定手段を複数離間させて設け、前記固定手段は、前記金型を構成する固定金型および移動金型に固定され、かつ、前記表皮面材と当接する部分に前記表皮面材との摩擦抵抗を小さくする滑り手段と、この滑り手段を前記表皮面材に向かって押圧するコイルスプリングと、このコイルスプリングの変位方向の任意の位置に固定可能にされて当該コイルスプリングの押圧力を調節する押圧力調節手段と、を備えていることを特徴とする。
【0008】
以上の成形方法では、次のような材料、成形装置、および、成形手順を採用することができる。
(1)材 料
成形品を形成する合成樹脂としては、ポリエチレン、ポリプロピレン、ポリスチレン、ABS、ポリカーボネート、ポリアミド等の熱可塑性樹脂、および、これらの熱可塑性樹脂にタルク、炭酸カルシウム、マイカ、ガラス繊維等の充填材を添加したものが採用できる。
また、表皮面材としては、織布、不織布、編布等の布、熱可塑性樹脂面材、熱可塑性エラストマ製面材、熱可塑性樹脂の発泡面材、および、模様等が印刷されたフィルム等の単層面材、ならびに、これらの単層面材を適宜貼り合わせた多層面材が採用できる。
【0009】
(2)成形装置
成形装置としては、射出成形機、プレス成形機、射出圧縮成形機、もしくは、射出プレス成形機が採用できる。
(3)成形手順
以上のような成形装置等で成形を行う場合には、次のような成形手順が採用できる。
▲1▼金型を開いた状態で、当該金型の移動側金型に表皮面材を仮止めする。
▲2▼金型を閉じるにあたり、完全に閉鎖する位置よりも所定寸法、例えば、5〜50mm程度手前の位置に移動側の金型を停止させ、この位置から移動側の金型が後退して型開きしないように、同金型の後方をブロックしておく。
ここで、表皮面材は、金型の固定手段に挟持され、金型の内部からある程度以上の力で引っ張られると、金型の内部へ滑る込めようになっている。
▲3▼射出装置を駆動して溶融樹脂を金型内に充填する。
▲4▼充填の完了の直前もしくは直後に金型内に圧縮力を加えて圧縮工程を開始し、圧縮力により内部の樹脂を展延して金型内に充満させる。
この際、表皮面材は、金型内部を流動する溶融樹脂により引っ張られ、適度な張力を保ちつつ、金型の中心方向へ引き寄せられる。
▲5▼必要により圧縮力を低下させる。
▲6▼樹脂が冷却固化した後、金型を開いて成形品を取り出す。
【0010】
【作用】
このような本発明では、表皮面材が成形時に必要とする滑り込み量に応じて固定手段を金型に設ける。
具体的には、表皮面材の滑り込み量を多く必要とする部分には、固定手段を少なく配置し、表皮面材の滑り込み量を小さくすべき部分には、固定手段を多く配置する。そして、表皮面材の滑り込み量を連続的に異ならせる場合には、固定手段の配置数を徐々に増減する。
これにより、金型内を展延する溶融樹脂が表皮面材を引っ張ると、表皮面材は、固定手段に挟持されていても、破れる前に設定された滑り込み量だけ金型内へ滑り込み、表皮面材の各部に適度な張力が加わるようになり、成形品が凹凸を有する複雑な形状であっても、その表面にシワや破れ等が生じなくなる。
また、固定手段は、単に表皮面材を挟持する簡単な構造で済むので、金型の構造を複雑にしないうえ、表皮面材の取付作業を容易にし、成形サイクルを長引かせることがなく、これらにより、前記目的が達成される。
さらに、固定手段として、表皮面材と当接する部分に当該表皮面材との摩擦抵抗が小さい滑り手段を有するものを採用すれば、紙のように破れやすい表皮面材でも、表皮面材が滑り出すのに必要な張力が小さくなり、破れを生じさせない。
また、滑り手段を前記表皮面材に向かって押圧するコイルスプリングと、前記コイルスプリングの押圧力を調節する押圧力調節手段とを固定手段に設ければ、表皮面材が滑り出のに大きな張力が必要となり、硬めの表皮面材でも成形できるようになる。
従って、表皮面材の種類によらず、シワや破れ等の欠陥のない良好な積層成形品の成形が可能となる。
【0011】
【実施例】
以下、本発明の一実施例を図面に基づいて説明する。
図1および図2には、本実施例の金型10が示されている。この金型10は、自動車のドアに取付けられる内装パネルを成形するものであり、図中右側の固定金型部10A と左側の可動金型部10B とに分割されている。
金型10の固定金型部10A および可動金型部10B の間には、溶融樹脂が充填されるキャビティ10C が設けられている。このキャビティ10C の周囲には、積層成形品の表面部分を形成する表皮面材を挟持する固定手段として、複数の固定装置20が離間して設けられている。
【0012】
固定金型部10A は、前述の射出圧縮成形機に移動不可能に固定された雄型である。この固定金型部10A には、キャビティ10C に充填される溶融樹脂の通路であるスプル11が設けられている。固定金型部10A に設けられた成形面12には、自動車のドアに設けられる肘掛けおよびポケットを成形するために、凸部13および凹部14が形成されている。
可動金型部10B は、前述の射出圧縮成形機に移動可能に設けられた雌型である。この可動金型部10B の成形面15には、固定金型部10A の凸部13および凹部14の各々に対応する凹部16および凸部17が設けられている。
なお、固定金型部10A および可動金型部10B の各々の四隅には、図示しない型締装置のガイドピンを挿通させるための挿通孔18が設けられている。
【0013】
固定装置20は、図3に示されるように、表皮面材1を挟持するものであり、表皮面材1と当接する部分に表皮面材1との摩擦抵抗を小さくする滑り手段としての滑り部材21, 22が設けられたものとなっている。滑り部材21, 22は、摩擦係数の小さいテフロン樹脂等からなる部材である。
滑り部材21, 22のうち、可動金型部10B 側の滑り部材22は、可動金型部10B に接着され、可動金型部10B と一体化している。
一方、固定金型部10A 側の滑り部材21は、可動金型部10B に対して進退自在に設けられた押圧ブロック23に接着されている。
【0014】
押圧ブロック23は、固定金型部10A と螺合するボルト24を挿通させる貫通孔25を有し、ボルト24の軸方向に沿ってスライドするようになっている。ボルト24には、ダブルナット26が螺合されている。このダブルナット26と押圧ブロック23との間にコイルスプリング27が介装されている。コイルスプリング27は、押圧ブロック23に接着された滑り部材21を可動金型部10B 側の滑り部材22に向かって押圧するようになっている。
この際、コイルスプリング27の押圧力は、ダブルナット26の螺合位置を変えることで調節可能となっている。ここにおいて、ボルト24およびダブルナット26は、コイルスプリング27の押圧力を調節する押圧力調節手段となっている。
なお、ダブルナット26は、二つのナットから構成されるものである。このダブルナット26を、コイルスプリング27の押圧力の調節後、互いに逆方向に回転操作することにより、ダブルナット26の螺合位置が固定され、金型10に加わる振動等により、調節済みの押圧力が変動しないようになっている。
【0015】
このような本実施例では、次のような手順により射出圧縮成形を行う。
なお、金型10を製作するにあたり、予め、成形品の形状に応じて表皮面材1の各部の滑り量を設定し、この滑り量に応じて固定装置20の数と位置とを設定しておく。例えば、滑り量を多くしたい部分には、固定装置20を設けない、あるいは、その数を少なく設定する。一方、滑り量を少なくしたい部分には、固定装置20の数を多く設定する。そして、設定した数の固定装置20をそれぞれ金型10の設定した位置に設ける。
本実施例では、図2に示したように、金型10のキャビティ10C の図中上辺に4個、左辺に3個、下辺に3個、右辺に2個、下辺および右辺の間の円弧状の切欠部に1個の計13個の固定装置20がほぼ等間隔に配置される。
また、射出圧縮成形を行う前に、表皮面材1の引っ張り強さ等に応じてコイルスプリング27の押圧力を調節しておく。これにより、表皮面材1が強く引っ張られた時に、表皮面材1が固定装置20の滑り部材21, 22の間を滑って移動するので、表皮面材1が破れやすい柔らかなものでも、表皮面材1の破れが防止されるとともに、表皮面材1に適度な張力が与えられる。
【0016】
射出圧縮成形を行うにあたり、まず、金型10を開き、固定金型部10A に表皮面材1を仮止めした後、金型10を閉じる。
この際、可動金型部10B は、図4(A)に示されるように、完全に閉鎖する位置イよりも所定寸法aだけ手前の位置ロに停止させ、この位置ロから後退して型開きしないように、その後方をブロックしておく。
なお、寸法aは、5〜50mmの範囲内で設定できる。
そして、この可動金型部10B の閉鎖が不完全な状態で、射出装置を駆動して充填工程を開始し、金型10のキャビティ10C の内部に溶融樹脂2を充填する。
次に、充填工程の完了直前もしくは完了直後に、型締装置を駆動して圧縮工程を開始し、可動金型部10B を前進させ、キャビティ10C 内部の溶融樹脂2に圧縮力を加える。
この際、圧縮された溶融樹脂2は、キャビティ10C の隅々に向かって流動し、表皮面材1をキャビティ10C の内部側に引っ張る。引っ張られた表皮面材1は、図4(B)に示されるように、その端縁部が固定装置20の滑り部材21, 22の間を滑って金型10の内部へ移動する。このため、表皮面材1には、適度な張力が与えられた状態となり、表皮面材1の破れやシワの発生が防止される。
次いで、溶融樹脂2を冷却固化し、溶融樹脂2が充分冷却固化したら、金型10を開いて成形品を取り出す。なお、射出が完了したら次の射出成形のために樹脂2を可塑化する可塑化工程を開始する。
【0017】
前述のような本実施例によれば、次のような効果がある。
すなわち、表皮面材1が必要とする滑り込み量に応じた複数の固定装置20を金型10に離間して設け、金型内を展延する溶融樹脂2が表皮面材1を引っ張ると、表皮面材1は、固定装置20に挟持されていても、破れる前に設定された滑り込み量だけ金型内へ滑り込むようにしたので、表皮面材1の各部に適度な張力が加わるようになり、成形品が凹凸を有する複雑な形状であっても、その表面にシワが発生せず、成形品の外観を向上できる。
【0018】
また、固定装置20の、表皮面材1と当接する部分に摩擦抵抗が小さい滑り部材21, 22を設けたので、表皮面材1が滑り出のに必要な張力が小さく制限され、紙のように強度がなく破れやすい表皮面材1でも、表皮面材1の破れを未然に防止でき、この点からも成形品の外観を向上できる。
【0019】
さらに、表皮面材1を挟持する滑り部材21, 22、および、滑り部材21を表皮面材1に向かって押圧するコイルスプリング27等の押圧手段等から固定装置20を構成したので、金型10全体の構造を簡単なものにできるうえ、表皮面材1の取付けは、金型10を閉鎖する際に、仮止めした表皮面材1を固定金型部10A および可動金型部10B で挟むといった簡単な作業で行えるようになる。
このため、表皮面材1の取付作業に時間がかからず、成形サイクルを長引かせることもなく、生産性を向上させることができる。
【0020】
また、摩擦係数の小さい滑り部材21, 22で表皮面材1を挟持するとともに、滑り部材21を表皮面材1に向かって押圧するコイルスプリング27の押圧力を調節するダブルナット26を設けたので、滑り部材21, 22と表皮面材1との摩擦力を微妙に調節することができるうえ、成形の際に大きな張力が必要となる場合には、摩擦力を大きくすることができるので、破れやすい柔らかな表皮面材から硬めの表皮面材までも成形でき、表皮面材の種類によらず、破れやシワ等の欠陥のない良好な積層成形品を成形できる。
【0021】
続いて、本発明の効果を具体的な実験例に基づいて説明する。
〔実験例1〕
本実験例1は、前記実施例に基づいて積層成形品を成形する実験である。
〔比較例1〕
本比較例1は、前記実施例における固定装置20を省略した金型を用い、前記実験例1と同様の成形品を成形しようとする実験である。
〔比較例2〕
本比較例2は、前記実施例における固定装置20の滑り部材21, 22を摩擦係数が大きい金属板に代えるとともに、コイルスプリング27の押圧力を著しく大きくすることにより、表皮面材1に滑りが全く生じない状態の金型で、前記実験例1と同様の成形品を成形しようとする実験である。
なお、以上において、金型にはバルブ開閉式のゲートを2点設け、これらのゲートから溶融樹脂を金型内に充填する。
【0022】
〔成形品〕
実験例1および比較例1,2で成形しようとする成形品は、自動車のドアの内装パネルとしてのドアトリム30である。このドアトリム30には、図5に示されるように、表面に肘掛け部31および小物入れ用のポケット32が設けられている。
ドアトリム30の各寸法は、幅寸法Wが800mm、高さ寸法Hが700mm、厚さ寸法tが2.5mmとなっている。
なお、表皮面材1のポケット32となる部分は、裏面に塩化ビニル製の内張シートが仮貼着され、成形後に、樹脂部分と一体化した表皮面材1を打ち抜くことにより、小物を入れる空間の開口部が形成されるようになっている。
〔共通射出条件〕
実験例1および比較例1,2では、以下のような同一の材料、装置、および、成形条件等により成形を行う。
(1)材 料
成形品を構成する合成樹脂としては、メルトインデックスMIが 55g/10分(230℃、2.16kgf)のポリプロピレン(出光石油化学(株)製 商品名:出光ポリプロJ−5050H )を用いる。
また、表皮面材としては、厚さ0.5mmの塩化ビニル樹脂製の表皮層と、厚さ3.0mmのポリプロピレンの発泡体とを一体化した厚さ3.5mmの積層シート材を採用する。この表皮面材の表面(塩化ビニル樹脂製の表皮層)には、牛皮等の表面を模した皮シボ模様が設けられている。
(2)成形装置
成形装置としては、汎用の横型射出成形機(スクリュー径:85mm,最大型締力:850ton 、三菱重工業(株)製)に射出圧縮成形機構を組み込んだものを用いる。
(3)成形条件
成形条件としては、以下のような値を採用する。
▲1▼成形温度 : 190℃
▲2▼金型温度 : 30℃
▲3▼樹脂の射出圧力 : 90kg/cm(ゲージ圧)
▲4▼射出時間 : 3秒間
▲5▼圧縮開始タイミング :射出開始から2.8秒後
▲6▼金型の圧縮量(寸法a): 30mm
▲7▼可動金型部の圧縮速度 : 10mm/秒
▲8▼圧縮力 : 400t
▲9▼冷却時間 : 50秒間
【0023】
〔実験結果〕
(1)実験例1により得られたドアトリム30の表皮面材1には、シワや破れ等の欠陥が発生しないうえ、表皮面材1の発泡体の厚みは、ドアトリム30の平坦部分において2.5mm以上確保でき、良好なクッション性を保持することができた。このことから、実験例1では、外観品質の良好な成形品が得られることが判る。
(2)比較例1により得られたドアトリム30は、肘掛け部31の付け根に、表皮面材1のたわみによるシワが発生するという欠陥が生じ、比較例1では成形品の外観が損なわれることが判る。
(3)比較例2により得られたドアトリム30は、肘掛け部31の頂部の表皮面材1が引き伸ばされ、表皮面材1の表面の皮シボ模様が薄くなって消えかかっていた。このため、本比較例2のドアトリム30は、商品としては使用できないものとなり、比較例2では外観品質が著しく損なわれることが判る。
また、当該肘掛け部31の頂部の表皮面材1の発泡体は、潰れてしまって消失しており、肘掛け部31の頂部はクッション性を喪失していた。
【0024】
以上、本発明について好適な実施例や実験例を挙げて説明したが、本発明は、これらの実施例や実験例に限られるものでなく、本発明の要旨を逸脱しない範囲において種々の改良並びに設計の変更が可能である。
例えば、成形品を構成する合成樹脂としては、ポリプロピレンに限らず、ポリエチレン、ポリスチレン、ABS、および、ポリカーボネート、等の他の熱可塑性樹脂や、これらの熱可塑性樹脂にタルク、炭酸カルシウム、マイカ、ガラス繊維等の充填剤を添加したものでもよい。
【0025】
また、表皮面材としては、塩化ビニル樹脂製の表皮層とポリプロピレンの発泡体とからなる積層シート材に限らず、織布、不織布、編布等の布、他の熱可塑性樹脂の発泡体、熱可塑性樹脂面材、および、模様等が印刷されたフィルム等の単層面材でもよく、あるいは、塩化ビニル樹脂や熱可塑性エラストマ等の表皮材に、熱可塑性樹脂の発泡体等からなる裏地材を裏打ちしたものであって前記表皮面材とは異なる多層面材でもよい。
【0026】
さらに、成形品としては、ドアの内装パネルに限らず、シートバックや、サイドピラー等の他の自動車部品や、椅子の背もたれ等の家具部品等でもよい。
【0027】
また、滑り手段を表皮面材に向かって押圧する押圧手段としては、コイルスプリングに限らず、他の形式のスプリング、空気式シリンダ装置、および、油圧式シリンダ装置でもよい。
さらに、コイルスプリングの押圧力を調節する押圧力調節手段としては、ボルトにダブルナットを螺合させたものに限らず、コイルスプリングの圧縮量を変えるサーボモータや油圧シリンダ装置でもよい。
【0028】
また、コイルスプリングの押圧力を調節する押圧力調節手段は省略できる。この際、ばね係数が異なるばねを数種用意し、この中から、滑り量に応じたばね係数を有するものを選択して設置すれば、表皮面材に対して所望の滑り量を付与することができる。
さらに、滑り手段としては、表皮面材と当接する部分に固定された摩擦係数の小さい部材に限らず、図6に示されるように、表皮面材1と当接する部分に回転自在に取付けられたローラ28等の転がり装置でもよい。
【0029】
【発明の効果】
前述のように本発明によれば、凹凸がある複雑な形状の成形品であっても、その表面にシワや破れ等の欠陥を生じさせず、生産性を向上できる。
【図面の簡単な説明】
【図1】本発明の一実施例に係る金型を示す断面図である。
【図2】図1の金型の可動金型部の平面図である。
【図3】前記実施例の要部を示す拡大断面図である。
【図4】前記実施例の成形手順を説明するための図である。
【図5】前記実験例の成形品であるドアトリムを示す二面図である。
【図6】本発明の変形例を示す図3と同様の図である。
【符号の説明】
1 表皮面材
2 溶融樹脂
10 金型
20 固定手段としての固定装置
21, 22 滑り手段としての滑り部材
23 コイルスプリング
24 押圧力調節手段を構成するボルト
26 押圧力調節手段を構成するダブルナット
28 滑り手段としての転がり装置であるローラ
30 積層成形品としてのドアトリム
[0001]
[Industrial applications]
The present invention relates to a method for producing a laminated molded product having both surfaces covered with a skin facing material, and produces automobile parts such as seat backs, side pillars, and door interior panels, and furniture parts such as chair backrests. Available when
[0002]
[Background Art]
Conventionally, for interior parts of automobiles, for example, interior panels of doors, seat backs, and side pillars, the surface of a synthetic resin main body is made of a multi-layer face material made of vinyl chloride, foamed polypropylene, or the like. Laminated molded articles covered with skin facing materials such as cloths have been used.
According to such a laminated molded product, since the surface is covered with a soft surface material, a good feel can be given when touched by hand, and a woven fabric or the like is used as the surface material. If it is, decorativeness can be imparted.
In addition, since a good cushioning property can be obtained by increasing the thickness of the skin surface material, the use of a laminated molded product for a console box lid or the like can suppress the impact sound at the time of opening and closing, vibration during running, and the like.
Furthermore, since the skin surface material having cushioning properties can seal the gap, good sound insulation and sealing properties can be provided.
[0003]
In order to manufacture such a laminated molded product, it is common to form a core body and then bond a skin surface material to the surface of the body. However, there is a problem that the manufacturing cost is increased because of the complicated operation.
This problem can be solved by a manufacturing method in which the skin material and the main body are integrated at the same time as molding by filling the mold in which the skin material is mounted in advance with the molten resin, and the bonding operation is omitted.
In such a manufacturing method, mounting means having the following structures A to D is used to mount the skin facing material to the mold.
A. The mold is divided into two mold parts such as a male mold and a female mold, and when closing the mold, the edge of the skin material is sandwiched between the mating surfaces of the mold parts to completely cover the skin material. Mounting means that will be fixed.
B. The mold is divided into two mold portions, and a gap having substantially the same dimension as the thickness of the skin surface material is provided between the divided surfaces of the mold portions. A mounting means that allows the skin surface material to slide freely into the mold without pressing down from both sides.
C. A tension device, such as a spring, that pulls the edge of the skin material protruding from the mold is provided around the mold, and when a force against the tension of the tension device is applied to the skin material, the edge of the skin material is removed. Mounting means (Japanese Patent Laid-Open No. 229014/1990) for mounting a skin surface material that allows the skin to slide into the mold.
D. A mold is divided into two mold parts such as a male mold and a female mold, and a fixed frame for sandwiching a skin facing material with one of the two mold parts, and the fixed frame is pressed toward the one mold part. Provide a plurality of fluid cylinder devices, etc. to clamp the skin surface material between the fixed frame and the mold, and adjust the clamping force of the fixed frame and the mold by adjusting the pressing force of the fluid cylinder device, etc. Mounting means (Japanese Patent Publication No. 4-76291).
[0004]
[Problems to be solved by the invention]
The above methods A to D have the following problems a to d.
I. Since the edge of the skin surface material is fixed so as not to move by being sandwiched between the mold portions, when molding a three-dimensional molded article having irregularities, excessive tension is applied to the skin surface material at the time of molding. For this reason, there is a problem that a skin surface material that does not stretch, such as cloth, is easily torn, and a skin surface material having cushioning properties, such as foamed polypropylene, is stretched to lose its thickness and the cushioning properties are impaired.
B. Since the skin material can slide freely into the mold, no tension is applied to the skin material. For this reason, when trying to mold a three-dimensional molded product with irregularities, the surface of the skin surface material is freely deformed due to the flow of the molten resin filled in the mold, and wrinkles are generated at the base part of the rising part. There's a problem.
D. The provision of the tension device complicates the structure of the mold, and the tension device is provided around the mold, so that the overall size of the mold is increased.
In addition, in order to pull the skin surface material with the tension device, it is necessary to connect the tension device and the skin surface material firmly to some extent, so the mounting work of the skin surface material performed for each molding becomes troublesome, and the cycle time is prolonged. However, there is a problem that the productivity of the laminated molded product cannot be improved.
In addition, since the skin material protrudes outside the mold, the ratio of the skin material that cannot be effectively used increases, and there is a problem that the skin material is wasted.
E. Since it is necessary to provide a fixed frame movably separately from the mold clamping operation of the mold, the structure of the mold becomes complicated, and a fixed frame must be created for each mold. There is a problem of soaring.
Also, if the fixed frame is divided into a plurality of parts, a fluid cylinder device is provided for each of the divided parts, and the pressing force of each cylinder device is adjusted to set the clamping force, the frictional force and the slip-in of each part of the skin surface material are set. You can adjust the amount. However, there is a boundary line where the frictional force and the amount of slip are discontinuous. If the amount of slip on both sides of this boundary greatly differs, wrinkles and tears may occur. There is a problem that molding is difficult.
[0005]
An object of the present invention is to provide a method for molding a laminated molded product that does not cause defects such as wrinkles and tears on its surface even if the molded product has a complicated shape with irregularities, and that can improve productivity, and a mold thereof. It is in.
[0006]
[Means for Solving the Problems]
The method for molding a laminated molded product of the present invention is a method for molding a laminated molded product in which a molded product having a flexible skin material adhered to the surface thereof is formed, and a mold for molding the molded product in advance is used. A plurality of fixing means for slidably holding the skin surface material are provided at a distance, and the position and number of these fixing means are set in advance according to the shape of the molded product by sliding each part of the skin surface material. The fixing means is provided in accordance with the amount, and the fixing means includes a sliding means for reducing a frictional resistance with the skin surface material at a portion in contact with the skin surface material, and a fixed mold constituting the mold And fixed to a movable mold, and after attaching the skin surface material to the mold by the fixing means, filling the molten resin and sliding the skin surface material sandwiched by the fixing means, Characterized by spreading the molten resin inside That.
In the above, the formed shape method, molding method a molten resin filled in the mold is compressed by the mold clamping of the mold to spread inside the mold can be employed.
[0007]
The mold of the laminated molded article of the present invention is a mold of a laminated molded article for molding a molded article having a skin surface material having flexibility attached to the surface, and the mold has an inlay structure. In addition, a plurality of fixing means for slidably holding the skin surface material are provided in the mold at a distance from each other, and the fixing means is fixed to a fixed mold and a movable mold constituting the mold , and A sliding means for reducing frictional resistance with the skin surface material is provided at a portion in contact with the skin surface material, and the sliding means is rotatably mounted on a portion of the fixing means abutting on the skin surface material. The device is characterized in that:
Further, the mold of the laminated molded article of the present invention is a mold of a laminated molded article for molding a molded article having a flexible skin material adhered to the surface thereof, wherein the mold has an inlay structure. And a plurality of fixing means for slidably sandwiching the skin surface material is provided in the mold, and the fixing means is fixed to a fixed mold and a moving mold constituting the mold, A sliding means for reducing the frictional resistance with the skin surface material at a portion in contact with the skin surface material, a coil spring for pressing the sliding means toward the skin surface material, and a displacement direction of the coil spring. And a pressing force adjusting means which can be fixed to an arbitrary position and adjusts the pressing force of the coil spring.
[0008]
In the above molding method, the following materials, molding apparatus, and molding procedure can be adopted.
(1) Material The synthetic resin forming the molded article includes thermoplastic resins such as polyethylene, polypropylene, polystyrene, ABS, polycarbonate, and polyamide, and talc, calcium carbonate, mica, glass fiber, and the like. Can be employed.
Examples of the skin surface material include woven fabric, nonwoven fabric, knitted fabric, and the like, thermoplastic resin surface material, thermoplastic elastomer surface material, thermoplastic resin foam surface material, and film on which a pattern or the like is printed. And a multi-layer face material obtained by appropriately bonding these single-layer face materials.
[0009]
(2) Molding device As the molding device, an injection molding machine, a press molding machine, an injection compression molding machine, or an injection press molding machine can be employed.
(3) Molding Procedure When molding is performed by the molding apparatus described above, the following molding procedure can be adopted.
{Circle around (1)} In a state where the mold is opened, the skin surface material is temporarily fixed to the movable side mold of the mold.
{Circle around (2)} When closing the mold, the movable mold is stopped at a position of a predetermined dimension, for example, about 5 to 50 mm before the completely closed position, and the movable mold is retracted from this position. Block the back of the mold so that the mold does not open.
Here, the skin surface material is sandwiched by the fixing means of the mold, and is slid into the inside of the mold when it is pulled from the inside of the mold by a certain force or more.
(3) The injection device is driven to fill the mold with the molten resin.
{Circle around (4)} Immediately before or immediately after the completion of filling, a compression force is applied to the inside of the mold to start the compression step, and the resin inside is spread by the compression force to fill the inside of the mold.
At this time, the skin surface material is pulled by the molten resin flowing inside the mold, and is drawn toward the center of the mold while maintaining an appropriate tension.
(5) If necessary, reduce the compressive force.
(6) After the resin has cooled and solidified, the mold is opened and the molded product is taken out.
[0010]
[Action]
In the present invention as described above, the fixing means is provided in the mold in accordance with the amount of slip required by the skin surface material during molding.
Specifically, a small number of fixing means are arranged in a portion where a large amount of sliding of the skin surface material is required, and a large number of fixing means are arranged in a portion where a small amount of sliding of the skin surface material is required. When the sliding amount of the skin surface material is continuously changed, the number of the fixing means is gradually increased or decreased.
Thereby, when the molten resin spreading in the mold pulls the skin surface material, the skin surface material slides into the mold by a set amount of slip before breaking even if it is sandwiched by fixing means, Appropriate tension is applied to each part of the face material, and even if the molded article has a complicated shape having irregularities, wrinkles and tears do not occur on the surface.
In addition, since the fixing means only needs to have a simple structure for sandwiching the skin surface material, the structure of the mold is not complicated, the mounting work of the skin surface material is easy, and the molding cycle is not prolonged. Thereby, the above object is achieved.
Furthermore, if a fixing means having a sliding means having a small frictional resistance with the skin surface material in a portion in contact with the skin surface material is adopted, the skin surface material starts to slip even on a skin surface material that is easily broken like paper. The required tension is reduced and does not cause tearing.
Further, if the coil spring for pressing the sliding means toward the skin surface material and the pressing force adjusting means for adjusting the pressing force of the coil spring are provided in the fixing means, the skin surface material has a large tension for sliding out. Is required, and it becomes possible to mold even a hard skin material.
Therefore, regardless of the type of the skin surface material, it is possible to form a good laminated molded product without defects such as wrinkles and tears.
[0011]
【Example】
Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
1 and 2 show a mold 10 of the present embodiment. The mold 10 is for molding an interior panel to be attached to a door of an automobile, and is divided into a fixed mold portion 10A on the right side and a movable mold portion 10B on the left side in the drawing.
A cavity 10C filled with a molten resin is provided between the fixed mold portion 10A and the movable mold portion 10B of the mold 10. Around the cavity 10C, a plurality of fixing devices 20 are separately provided as fixing means for holding the skin material forming the surface portion of the laminated molded product.
[0012]
The fixed mold section 10A is a male mold immovably fixed to the above-mentioned injection compression molding machine. The fixed mold part 10A is provided with a sprue 11 which is a passage for the molten resin to be filled in the cavity 10C. A convex portion 13 and a concave portion 14 are formed on a molding surface 12 provided on the fixed mold portion 10A to form an armrest and a pocket provided on an automobile door.
The movable mold part 10B is a female mold movably provided in the above-mentioned injection compression molding machine. A concave surface 16 and a convex portion 17 corresponding to the convex portion 13 and the concave portion 14 of the fixed mold portion 10A are provided on the molding surface 15 of the movable mold portion 10B.
At four corners of each of the fixed mold part 10A and the movable mold part 10B, insertion holes 18 for inserting guide pins of a mold clamping device (not shown) are provided.
[0013]
As shown in FIG. 3, the fixing device 20 sandwiches the skin facing material 1, and a sliding member as a sliding means for reducing frictional resistance with the skin facing material 1 at a portion in contact with the skin facing material 1. 21 and 22 are provided. The sliding members 21 and 22 are members made of Teflon resin or the like having a small friction coefficient.
Among the sliding members 21 and 22, the sliding member 22 on the movable mold portion 10B side is bonded to the movable mold portion 10B and is integrated with the movable mold portion 10B.
On the other hand, the sliding member 21 on the fixed mold part 10A side is adhered to a pressing block 23 provided to be able to advance and retreat with respect to the movable mold part 10B.
[0014]
The pressing block 23 has a through hole 25 through which a bolt 24 screwed with the fixed mold part 10A is inserted, and slides along the axial direction of the bolt 24. A double nut 26 is screwed into the bolt 24. A coil spring 27 is interposed between the double nut 26 and the pressing block 23. The coil spring 27 presses the sliding member 21 bonded to the pressing block 23 toward the sliding member 22 on the movable mold part 10B side.
At this time, the pressing force of the coil spring 27 can be adjusted by changing the screwing position of the double nut 26. Here, the bolt 24 and the double nut 26 serve as pressing force adjusting means for adjusting the pressing force of the coil spring 27.
Note that the double nut 26 is composed of two nuts. After adjusting the pressing force of the coil spring 27, the double nut 26 is rotated in opposite directions to fix the screwing position of the double nut 26, and the adjusted pressing force is generated by vibration applied to the mold 10. The pressure does not fluctuate.
[0015]
In this embodiment, injection compression molding is performed according to the following procedure.
In manufacturing the mold 10, the slip amount of each part of the skin facing material 1 is set in advance according to the shape of the molded product, and the number and the position of the fixing device 20 are set according to the slip amount. deep. For example, the fixing device 20 is not provided in a portion where the amount of slip is desired to be increased, or the number thereof is set to be small. On the other hand, the number of the fixing devices 20 is set to be large in a portion where the amount of slip is to be reduced. Then, the set number of fixing devices 20 are provided at the set positions of the mold 10 respectively.
In this embodiment, as shown in FIG. 2, the cavity 10C of the mold 10 has four cavities on the upper side, three on the left side, three on the lower side, two on the right side, and an arc between the lower and right sides. , A total of thirteen fixing devices 20 are arranged at substantially equal intervals.
Further, before performing the injection compression molding, the pressing force of the coil spring 27 is adjusted according to the tensile strength of the skin surface material 1 and the like. Thereby, when the skin surface material 1 is strongly pulled, the skin surface material 1 slides and moves between the sliding members 21 and 22 of the fixing device 20, so that even if the skin surface material 1 is soft and easy to be broken, The surface material 1 is prevented from being torn, and an appropriate tension is applied to the skin material 1.
[0016]
In performing the injection compression molding, first, the mold 10 is opened, and after the skin surface material 1 is temporarily fixed to the fixed mold portion 10A, the mold 10 is closed.
At this time, as shown in FIG. 4 (A), the movable mold part 10B is stopped at a position B which is a predetermined distance a before the completely closed position A, and is retracted from this position B to open the mold. Block behind it so that you don't.
In addition, the dimension a can be set within a range of 5 to 50 mm.
Then, in a state where the movable mold portion 10B is not completely closed, the injection device is driven to start the filling process, and the inside of the cavity 10C of the mold 10 is filled with the molten resin 2.
Next, immediately before or immediately after the completion of the filling step, the mold clamping device is driven to start the compression step, the movable mold part 10B is advanced, and a compression force is applied to the molten resin 2 inside the cavity 10C.
At this time, the compressed molten resin 2 flows toward the corners of the cavity 10C and pulls the skin facing material 1 toward the inside of the cavity 10C. As shown in FIG. 4 (B), the edge portion of the pulled skin surface material 1 slides between the sliding members 21 and 22 of the fixing device 20 and moves into the mold 10. For this reason, the skin facing material 1 is in a state where an appropriate tension is applied, so that the skin facing material 1 is prevented from being torn or wrinkled.
Next, the molten resin 2 is cooled and solidified. When the molten resin 2 is sufficiently cooled and solidified, the mold 10 is opened and the molded product is taken out. When the injection is completed, a plasticizing step for plasticizing the resin 2 for the next injection molding is started.
[0017]
According to the present embodiment as described above, the following effects are obtained.
That is, a plurality of fixing devices 20 corresponding to the amount of sliding required by the skin facing material 1 are provided separately from the mold 10, and when the molten resin 2 spreading in the mold pulls the skin facing material 1, Since the face material 1 is slid into the mold by the set slip amount before the face material 1 is pinched by the fixing device 20, an appropriate tension is applied to each part of the skin surface material 1, Even if the molded article has a complicated shape with irregularities, no wrinkles are generated on the surface, and the appearance of the molded article can be improved.
[0018]
Further, since the sliding members 21 and 22 having a small frictional resistance are provided in a portion of the fixing device 20 that comes into contact with the skin surface material 1, the tension required for the skin surface material 1 to slide out is limited to a small amount, and the paper surface is made of paper. Even if the skin surface material 1 has no strength and is easily broken, the skin surface material 1 can be prevented from being broken, and the appearance of the molded product can be improved from this point as well.
[0019]
Further, since the fixing device 20 is constituted by the sliding members 21 and 22 for sandwiching the skin facing material 1 and the pressing means such as the coil spring 27 for pushing the sliding member 21 toward the skin facing material 1, the mold 10 is formed. In addition to simplifying the entire structure, the mounting of the skin facing material 1 is such that when the mold 10 is closed, the temporarily fixed skin facing material 1 is sandwiched between the fixed mold portion 10A and the movable mold portion 10B. You can do it with simple tasks.
For this reason, the mounting work of the skin facing material 1 does not take much time, and the productivity can be improved without prolonging the molding cycle.
[0020]
Further, since the skin member 1 is sandwiched between the sliding members 21 and 22 having a small coefficient of friction, the double nut 26 for adjusting the pressing force of the coil spring 27 for pressing the sliding member 21 toward the skin member 1 is provided. The frictional force between the sliding members 21 and 22 and the skin surface material 1 can be finely adjusted, and when a large tension is required during molding, the frictional force can be increased. It is possible to mold from an easy soft skin material to a hard skin material, and it is possible to mold a good laminated molded article free from defects such as tears and wrinkles regardless of the type of skin material.
[0021]
Subsequently, effects of the present invention will be described based on specific experimental examples.
[Experimental example 1]
The first experimental example is an experiment in which a laminated molded product is formed based on the above-described example.
[Comparative Example 1]
Comparative Example 1 is an experiment in which a molded product similar to that of Experimental Example 1 was molded using a mold in which the fixing device 20 in the above-described example was omitted.
[Comparative Example 2]
In Comparative Example 2, the sliding members 21 and 22 of the fixing device 20 in the above-described embodiment were replaced with metal plates having a large friction coefficient, and the pressing force of the coil spring 27 was significantly increased. This is an experiment in which a molded product similar to that of Experimental Example 1 is to be molded using a mold in a state where no mold is generated.
In the above description, the mold is provided with two valve opening / closing gates, and the molten resin is filled into the mold from these gates.
[0022]
〔Molding〕
The molded product to be molded in Experimental Example 1 and Comparative Examples 1 and 2 is a door trim 30 as an interior panel of an automobile door. As shown in FIG. 5, the door trim 30 is provided with an armrest portion 31 and a pocket 32 for storing small items on its surface.
As for the dimensions of the door trim 30, the width W is 800 mm, the height H is 700 mm, and the thickness t is 2.5 mm.
In addition, in the part which becomes the pocket 32 of the skin facing material 1, a vinyl chloride lining sheet is temporarily attached to the back surface, and after molding, the small surface material 1 integrated with the resin portion is punched, so that small items are put therein. An opening of the space is formed.
[Common injection conditions]
In Experimental Example 1 and Comparative Examples 1 and 2, molding is performed using the same materials, equipment, and molding conditions as described below.
(1) Material As the synthetic resin constituting the molded article, polypropylene having a melt index MI of 55 g / 10 min (230 ° C., 2.16 kgf) (trade name: Idemitsu Polypro J-5050H, manufactured by Idemitsu Petrochemical Co., Ltd.) Is used.
As the skin surface material, a laminated sheet material having a thickness of 3.5 mm in which a skin layer made of a vinyl chloride resin having a thickness of 0.5 mm and a foamed material of polypropylene having a thickness of 3.0 mm are integrated. . On the surface of this skin facing material (a skin layer made of a vinyl chloride resin), a grain pattern imitating the surface of a cow skin or the like is provided.
(2) Molding device As the molding device, a general-purpose horizontal injection molding machine (screw diameter: 85 mm, maximum clamping force: 850 ton, manufactured by Mitsubishi Heavy Industries, Ltd.) with an injection compression molding mechanism is used.
(3) Molding conditions The following values are adopted as molding conditions.
(1) Molding temperature: 190 ° C
(2) Mold temperature: 30 ° C
(3) Injection pressure of resin: 90 kg / cm 2 (gauge pressure)
(4) Injection time: 3 seconds (5) Compression start timing: 2.8 seconds after the start of injection (6) Die compression amount (dimension a): 30 mm
(7) Compression speed of movable mold part: 10 mm / sec (8) Compression force: 400 t
(9) Cooling time: 50 seconds
〔Experimental result〕
(1) The skin trim 1 of the door trim 30 obtained in Experimental Example 1 has no defects such as wrinkles and tears, and the foam of the skin trim 1 has a thickness of 2. in the flat portion of the door trim 30. 5 mm or more could be secured, and good cushioning properties could be maintained. From this, it can be seen that in Experimental Example 1, a molded article having good appearance quality was obtained.
(2) The door trim 30 obtained in Comparative Example 1 has a defect that wrinkles are generated at the base of the armrest portion 31 due to the bending of the skin facing material 1, and in Comparative Example 1, the appearance of the molded product is impaired. I understand.
(3) In the door trim 30 obtained in Comparative Example 2, the skin surface material 1 on the top of the armrest 31 was stretched, and the grain pattern on the surface of the skin surface material 1 was thinned and disappeared. Therefore, the door trim 30 of Comparative Example 2 cannot be used as a commercial product, and it can be seen that the appearance quality of Comparative Example 2 is significantly impaired.
Further, the foam of the skin facing material 1 on the top of the armrest 31 was crushed and disappeared, and the top of the armrest 31 lost the cushioning property.
[0024]
As described above, the present invention has been described with reference to the preferred embodiments and experimental examples, but the present invention is not limited to these examples and experimental examples, and various improvements and modifications can be made without departing from the gist of the present invention. Design changes are possible.
For example, the synthetic resin constituting the molded article is not limited to polypropylene, but may be other thermoplastic resins such as polyethylene, polystyrene, ABS, and polycarbonate, and talc, calcium carbonate, mica, and glass. What added a filler, such as a fiber, may be used.
[0025]
Further, the skin surface material is not limited to a laminated sheet material composed of a skin layer made of a vinyl chloride resin and a foam of polypropylene, and a cloth such as a woven fabric, a nonwoven fabric, and a knitted fabric, a foam of another thermoplastic resin, A thermoplastic resin face material, and a single-layer face material such as a film on which a pattern or the like is printed may be used, or a lining material made of a thermoplastic resin foam or the like may be used as a skin material such as a vinyl chloride resin or a thermoplastic elastomer. It may be a multi-layer surface material that is lined and different from the skin surface material.
[0026]
Further, the molded article is not limited to the interior panel of the door, but may be other automobile parts such as a seat back and a side pillar, and furniture parts such as a chair back.
[0027]
The pressing means for pressing the sliding means toward the skin material is not limited to a coil spring, but may be another type of spring, a pneumatic cylinder device, or a hydraulic cylinder device.
Further, the pressing force adjusting means for adjusting the pressing force of the coil spring is not limited to one in which a double nut is screwed into a bolt, but may be a servomotor or a hydraulic cylinder device for changing the compression amount of the coil spring.
[0028]
Further, the pressing force adjusting means for adjusting the pressing force of the coil spring can be omitted. At this time, several kinds of springs having different spring coefficients are prepared, and if a spring having a spring coefficient corresponding to the slip amount is selected and installed, a desired slip amount can be given to the skin surface material. it can.
Further, the sliding means is not limited to a member having a small coefficient of friction fixed to a portion in contact with the skin surface material, and is rotatably attached to a portion in contact with the skin surface material 1 as shown in FIG. A rolling device such as a roller 28 may be used.
[0029]
【The invention's effect】
As described above, according to the present invention, even in the case of a molded article having a complicated shape having irregularities, it is possible to improve productivity without causing defects such as wrinkles and tears on the surface.
[Brief description of the drawings]
FIG. 1 is a sectional view showing a mold according to one embodiment of the present invention.
FIG. 2 is a plan view of a movable mold part of the mold of FIG.
FIG. 3 is an enlarged sectional view showing a main part of the embodiment.
FIG. 4 is a diagram for explaining a molding procedure of the embodiment.
FIG. 5 is a two-sided view showing a door trim which is a molded product of the experimental example.
FIG. 6 is a view similar to FIG. 3, showing a modification of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Skin surface material 2 Molten resin 10 Die 20 Fixing device 21 and 22 as fixing means Sliding member 23 as sliding means Coil spring 24 Bolt 26 which constitutes pressing force adjusting means Double nut 28 which constitutes pressing force adjusting means Sliding Roller 30 as a rolling device as a means Door trim as a laminated molded product

Claims (5)

柔軟性を有する表皮面材が表面に貼り付けられた成形品を成形する積層成形品の成形方法であって、
予め前記成形品を成形する金型に前記表皮面材を滑動可能に挟持する固定手段を複数離間させて設けておき、これらの固定手段の位置と数とを前記成形品の形状に応じて予め設定された表皮面材の各部の滑り量に応じて設定しておき、
前記固定手段は、前記表皮面材と当接する部分に前記表皮面材との摩擦抵抗を小さくする滑り手段を備え、かつ、前記金型を構成する固定金型および移動金型に固定され、
前記固定手段により前記金型に前記表皮面材を取付けた後、溶融樹脂を充填するとともに、前記固定手段で挟持した前記表皮面材を滑らせながら、前記金型の内部の溶融樹脂を展延させることを特徴とする積層成形品の成形方法。
A method for molding a laminated molded article, which is a method of molding a molded article in which a skin material having flexibility is attached to the surface,
A plurality of fixing means for slidably holding the skin surface material are provided in advance in a mold for molding the molded article, and the positions and numbers of these fixing means are determined in advance according to the shape of the molded article. Set according to the slip amount of each part of the set skin surface material,
The fixing means includes a sliding means for reducing frictional resistance with the skin surface material at a portion in contact with the skin surface material, and is fixed to a fixed mold and a moving mold which constitute the mold ,
After attaching the skin surface material to the mold by the fixing means, the molten resin is filled, and the molten resin inside the mold is spread while sliding the skin surface material held by the fixing means. A method for forming a laminated molded product.
請求項1に記載の積層成形品の成形方法において、前記固定手段は、成形前に予め前記表皮面材を挟持する挟持力が所定の大きさに調節されていることを特徴とする積層成形品の成形方法。2. The method according to claim 1, wherein the fixing unit adjusts a clamping force for clamping the surface material to a predetermined magnitude before molding. 3. Molding method. 請求項1に記載の積層成形品の成形方法において、前記溶融樹脂は、前記金型の型締めにより圧縮されて前記金型の内部に展延されることを特徴とする積層成形品の成形方法。2. The method according to claim 1, wherein the molten resin is compressed by mold clamping of the mold and spread inside the mold. . 柔軟性を有する表皮面材が表面に貼り付けられた成形品を成形するための積層成形品の金型であって、
前記金型はインロー構造とされるとともに、この金型に前記表皮面材を滑動可能に挟持する固定手段を複数離間させて設け、
前記固定手段は、前記金型を構成する固定金型および移動金型に固定され、かつ、前記表皮面材と当接する部分に前記表皮面材との摩擦抵抗を小さくする滑り手段を備え、この滑り手段は、前記固定手段の前記表皮面材と当接する部分に回転自在に取付けられた転がり装置であることを特徴とする積層成形品の金型。
A mold of a laminated molded product for molding a molded product having a skin surface material having flexibility attached to the surface,
The mold has a spigot structure, and a plurality of fixing means for slidably holding the skin surface material are provided in the mold at a distance from each other,
The fixing means is fixed to the fixed die and movable die for forming the mold, and comprising a sliding means for reducing the frictional resistance between the skin surface material to the skin surface member abutting portion, the The mold for a laminated molded product, wherein the sliding means is a rolling device rotatably attached to a portion of the fixing means which comes into contact with the skin material.
柔軟性を有する表皮面材が表面に貼り付けられた成形品を成形するための積層成形品の金型であって、
前記金型はインロー構造とされるとともに、この金型に前記表皮面材を滑動可能に挟持する固定手段を複数離間させて設け、
前記固定手段は、前記金型を構成する固定金型および移動金型に固定され、かつ、前記表皮面材と当接する部分に前記表皮面材との摩擦抵抗を小さくする滑り手段と、この滑り手段を前記表皮面材に向かって押圧するコイルスプリングと、このコイルスプリングの変位方向の任意の位置に固定可能にされて当該コイルスプリングの押圧力を調節する押圧力調節手段と、を備えていることを特徴とする積層成形品の金型。
A mold of a laminated molded product for molding a molded product having a flexible skin material adhered to the surface thereof,
The mold has a spigot structure, and a plurality of fixing means for slidably holding the skin surface material are provided in the mold at a distance from each other,
The fixing means is fixed to the fixed die and movable die for forming the mold, and a slide means for reducing the frictional resistance between the skin surface material to the skin surface member abutting portion, the slip A coil spring for pressing the means toward the skin material; and a pressing force adjusting means which can be fixed at an arbitrary position in the displacement direction of the coil spring and adjusts the pressing force of the coil spring. A mold for a laminated molded product, characterized in that:
JP30592694A 1994-12-09 1994-12-09 Molding method of laminated molded article and its mold Expired - Lifetime JP3574195B2 (en)

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