JP3642852B2 - Interior material molding method and molding apparatus - Google Patents

Interior material molding method and molding apparatus Download PDF

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Publication number
JP3642852B2
JP3642852B2 JP33165395A JP33165395A JP3642852B2 JP 3642852 B2 JP3642852 B2 JP 3642852B2 JP 33165395 A JP33165395 A JP 33165395A JP 33165395 A JP33165395 A JP 33165395A JP 3642852 B2 JP3642852 B2 JP 3642852B2
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Prior art keywords
molding
mold
interior material
molds
molten resin
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JPH09169038A (en
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敏和 谷村
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Nanjo Auto Interior Co Ltd
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Nanjo Auto Interior Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B29C43/183—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
    • B29C43/184—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould shaped by the compression of the material during moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/34—Feeding the material to the mould or the compression means
    • B29C2043/3444—Feeding the material to the mould or the compression means using pressurising feeding means located in the mould, e.g. plungers or pistons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/58—Measuring, controlling or regulating
    • B29C2043/5833—Measuring, controlling or regulating movement of moulds or mould parts, e.g. opening or closing, actuating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/58—Measuring, controlling or regulating
    • B29C2043/5833—Measuring, controlling or regulating movement of moulds or mould parts, e.g. opening or closing, actuating
    • B29C2043/5841—Measuring, controlling or regulating movement of moulds or mould parts, e.g. opening or closing, actuating for accommodating variation in mould spacing or cavity volume during moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C2045/2683—Plurality of independent mould cavities in a single mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3014—Door linings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3041—Trim panels

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、内装材の成形方法及び成形装置に関する技術分野に属する。
【０００２】
【従来の技術】
一般に、この種の内装材の一例として、自動車用ドアのインナパネルに取り付けられる樹脂製のドアトリムが知られており、このドアトリムに小物部品として、スピーカを覆った状態で取り付けるためのスピーカグリルを設けることがある。
【０００３】
このようなドアトリムを成形する場合、従来、▲１▼ドアトリム本体とスピーカグリル（小物部品）とを一体形状として成形型間でインジェクション成形する方法、▲２▼ドアトリム本体は成形型によるスタンピング成形により、またスピーカグリルは上記と同様にインジェクション成形によりそれぞれ成形し、成形後に両者を組み付ける方法、▲３▼ドアトリム本体とスピーカグリルとを一体形状として成形型間でスタンピング成形する方法が一般的に行われている。
【０００４】
【発明が解決しようとする課題】
しかし、上記従来の方法では以下に示す問題があった。すなわち、▲１▼の方法では、溶融樹脂を成形型内に射出するので、成形型締力を大きくする必要があり、そのための設備費が高くなる。
【０００５】
また、▲２▼の方法では、ドアトリム本体とスピーカグリルとを別工程で成形するので、各々の成形後の樹脂の収縮度に差が生じる。この収縮差を考慮すると、成形直後にスピーカグリルをドアトリム本体に組み付けることはできず、成形後、４〜２４時間放置して収縮が安定したときに組み付ける必要があり、工程の効率が悪い。しかも、別工程で成形されるドアトリム本体及びスピーカグリルの色が微妙に異なることがあり、そのための色合せが困難であった。
【０００６】
さらに、▲３▼の方法では、スピーカグリルにはスピーカからの音声を通過させるための多数の小さい孔が形成されているので、スタンピング成形時に、このスピーカグリル成形部分の樹脂が流れ難く、欠肉が発生する。この欠肉を防ぐためには、スピーカグリル成形部分に近付けて個別の樹脂供給用ゲートを新たに開口させればよいが、その場合、このゲートから供給される溶融樹脂と、本来のゲートから供給される溶融樹脂とが成形面間でぶつかり合って両樹脂の境界面がいわゆるウェルド不良となり、外観見映えが悪くなる。
【０００７】
本発明は斯かる諸点に鑑みてなされたものであり、その目的は、上記のように内装材をスタンピング成形する方法を改良することにより、成形された内装材の欠肉やウェルド不良等の品質低下を招くことなく、しかも内装材本体と小物部品との別成形による色合せ作業や収縮差による放置のための待ち時間を要することなく、小物部品を有する内装材をスタンピング成形を利用して安価に成形できるようにすることにある。
【０００８】
【課題を解決するための手段】
上記の目的の達成のため、この発明では、内装材の本体と小物部品とをそれぞれ専用にスタンピング成形する成形型を設けて、各成形型における溶融樹脂の供給のためのゲートは同じ樹脂供給源に接続し、両成形型でそれぞれ内装材本体及び小物部品を同時にスタンピング成形することとした。
【０００９】
具体的には、請求項１〜６の発明は内装材の成形方法の発明であり、請求項１の発明では、内装材本体と、その内装材本体に一体に設けられる小物部品とからなる内装材を成形する成形方法として、まず、互いに嵌合可能な成形面をそれぞれ有する固定型及び可動型からなり、樹脂供給手段に連通する溶融樹脂供給用ゲートが上記成形面に開口された内装材本体用成形型と、互いに嵌合可能な成形面をそれぞれ有しかつ上記内装材本体用成形型の固定型及び可動型の接離動作と同時に接離する固定型及び可動型からなり、上記樹脂供給手段に連通する溶融樹脂供給用ゲートが成形面に開口された小物部品用成形型とを備えた成形装置を用意する。
【００１０】
そして、上記両成形型の可動型をそれぞれ固定型に接近させて両成形型の成形面同士を嵌合させながら、樹脂供給手段により各成形型のゲートから溶融樹脂を供給することにより、内装材本体用成形型の成形面間で内装材本体を、また小物部品用成形型の成形面間で小物部品をそれぞれ同時に成形する。
【００１１】
上記の構成により、内装材の成形時、内装材本体用成形型及び小物部品用成形型の各可動型がそれぞれ固定型に同時に接近して、両成形型の成形面同士が嵌合される。この成形面同士の嵌合状態に至る途中で、樹脂供給手段により溶融樹脂が送られて各成形型のゲートから両成形型の成形面間に供給され、内装材本体用成形型の成形面間で内装材本体が、また小物部品用成形型の成形面間で小物部品がそれぞれ同時に成形される。
【００１２】
この場合、内装材を内装材本体と小物部品とに分けてそれぞれ専用の成形型により同時にスタンピング成形するので、樹脂供給手段により各成形型のゲートから供給する溶融樹脂の圧力によって型が開かないようにする成形型締力は低くて済み、インジェクション成形するときに比べて１／３〜１／１０の圧力でよく、成形装置の設備費を下げることができる。
【００１３】
また、内装材が内装材本体と小物部品とに分かれていても、両者を同時に成形するので、成形後の収縮度合いは互いに同じとなって寸法上の誤差が生じず、内装材本体及び小物部品を成形後に直ちに組み付けることができる。また、このように内装材本体及び小物部品を成形後の熱いうちに組み付けることができるので、加熱溶着方法により組み付ける場合には、そのための加熱容量を少なくすることができる。また、強嵌合等の機械的締結をも容易に行うことができる。
【００１４】
さらに、内装材本体と小物部品とをそれぞれ専用成形型により同時にスタンピング成形し、その各成形型に個別のゲートから溶融樹脂が供給されるので、両者を１つの成形型でスタンピング成形する従来例のように、異なるゲートから供給された溶融樹脂が成形面間でぶつかり合ってウェルド不良が生じることはない。しかも、小物部品がスピーカグリルのように多数の小孔があいたものであっても、その小物部品用成形型のゲートから溶融樹脂をスムーズに供給でき、欠肉の発生を防止することができる。よって、内装材の成形品質を向上させることができる。
【００１５】
また、同じ樹脂供給手段から両成形型に溶融樹脂を供給するので、両成形型で同じ色の樹脂が成形されることとなり、内装材本体及び小物部品の色合せをする必要がなくなる。
【００１６】
請求項２の発明では、上記内装材本体用成形型の固定型及び可動型が接近する前に、固定型及び可動型の成形面間に、内装材本体の少なくとも一部に設けられる表皮材をセットする。そして、固定型及び可動型の接近による成形面同士の嵌合により内装材本体を成形すると同時に上記表皮材を内装材本体に一体に貼り合わせる。こうすれば、表皮材を内装材本体にその成形と同時に自動的に容易に貼り合わせることができる。
【００１７】
その場合、請求項３の発明では、両成形型の固定型及び可動型が接近するとき、まず、内装材本体用成形型の成形面のうち表皮材が貼り合わされる範囲にゲートから溶融樹脂を供給し、次いで、この内装材本体用成形型の成形面のうちの表皮材を貼り合わせない範囲にゲートから溶融樹脂を供給し、最後に小物部品用成形型の成形面にゲートから溶融樹脂を供給する。
【００１８】
この発明では、内装材本体用成形型に最初に供給された溶融樹脂が成形されると、その成形された樹脂に表皮材が貼り合わされて表皮材部の成形が行われ、その後に内装材本体において表皮材を貼り合わせない部分が成形される。従って、表皮材の部分貼合成形を容易に行うことができる。
【００１９】
一方、請求項４の発明では、両成形型の固定型及び可動型が接近するとき、まず、内装材本体用成形型の成形面にゲートから溶融樹脂を供給し、次いで、小物部品用成形型の成形面に溶融樹脂を供給する。この方法は、表皮材があっても、内装材本体用成形型における成形面間の全体に溶融樹脂がスムーズに広がるときに採用することができる。
【００２０】
請求項５の発明では、以上の請求項１、２、３又は４の発明の内装材の成形方法において、固定型は下型とし、可動型は上型とする。
【００２１】
請求項６の発明では、上記請求項１、２、３、４又は５の発明の内装材の成形方法において、内装材本体は自動車のドアトリム本体とし、小物部品は、ドアトリム本体に設けられるスピーカグリルとする。従って、ドアトリム本体とスピーカグリルとからなるドアトリムを成形するときに、上記効果を果たすことができる。
【００２２】
請求項７の発明は内装材の成形装置の発明である。この発明では、内装材本体と、その内装材本体に一体に設けられる小物部品とからなる内装材を成形するようにした成形装置として、互いに嵌合可能な成形面をそれぞれ有する固定型及び可動型からなり、上記成形面に溶融樹脂供給用ゲートが開口された内装材本体用成形型を備えている。
【００２３】
また、互いに嵌合可能な成形面をそれぞれ有しかつ上記内装材本体用成形型の固定型及び可動型の接離動作と同時に接離する固定型及び可動型からなり、上記成形面に溶融樹脂供給用ゲートが開口された小物部品用成形型を備える。
【００２４】
さらに、上記両成形型のゲートに接続された１つの樹脂供給手段を備えてなり、上記両成形型の可動型をそれぞれ固定型に接近させて両成形型の成形面同士を嵌合させながら、樹脂供給手段により各成形型のゲートから溶融樹脂を供給することにより、内装材本体用成形型の成形面間で内装材本体を、また小物部品用成形型の成形面間で小物部品をそれぞれ同時に成形するように構成されているものとする。従って、この発明によると、上記請求項１の発明と同様の効果が得られる。
【００２５】
【発明の実施の形態】
（実施形態１）
図１は本発明の実施形態１に係る成形装置Ａを示し、この成形装置Ａは内装材としての自動車用ドアトリムを成形するものである。図２に示すように、上記ドアトリムＷは例えばポリプロピレン樹脂等の樹脂製のもので、ドアトリム本体Ｗ１（内装材本体）と、そのドアトリム本体Ｗ１の前側下部に一体に設けられ、取り付けられるスピーカ（図示せず）からの音声を通すための多数の小さい孔Ｗ５，Ｗ５，…が開口されたスピーカグリルＷ４（小物部品）とからなる。尚、図２中、Ｗ２はアームレストを兼ねたドア開閉用のプルハンドル、Ｗ３はドアロック用のインナハンドル（図示せず）を収容するための開口である。
【００２６】
成形装置Ａは上記ドアトリム本体Ｗ１及びスピーカグリルＷ４を同時に成形するようになっている。すなわち、図１において、１は上記ドアトリム本体Ｗ１を成形するためのドアトリム本体用成形型、２は上記スピーカグリルＷ４を成形するためのスピーカグリル用成形型であって、これら両成形型１，２は互いに左右に並設されている。
【００２７】
上記ドアトリム本体用成形型１は、下型連結板４上に設置された固定型としての下型５と、この下型５の上方に昇降可能につまり下型５に対して接離可能に配設され、上面が連結板９に取付固定された可動型としての上型７とからなる。上記下型５の上面には下型成形面６が、また上型７の下面には上記下型成形面６と嵌合可能な上型成形面８が形成されており、上型７が下降移動により下型５へ接近して下型成形面６と上型成形面８とが嵌合したときに、両成形面６，８間にドアトリム本体Ｗ１を加圧成形するための密閉空間からなる成形用キャビティ（図示せず）が形成されるようになっている。
【００２８】
一方、上記スピーカグリル用成形型２は、上記ドアトリム本体用成形型１の下型５と同じ下型連結板４上に取付固定された固定型としての下型１１と、この下型１１の上方に昇降可能につまり下型１１に対して接離可能に配設され、上面が上記ドアトリム本体用成形型１の上型７と同じ連結板９に取付固定された上型１３とからなる。下型１１の上面には下型成形面１２が、また上型１３の下面には該下型成形面１２と嵌合可能な上型成形面１４が形成されており、上型１３が下降移動により下型１１へ接近して下型成形面１２に上型成形面１４が嵌合したときに、両成形面１２，１４間にスピーカグリルＷ４を成形するための成形用キャビティ（図示せず）が形成される。
【００２９】
そして、上記両成形型１，２の上型７，１３が取付固定されている連結板９は、上下方向のシリンダ軸心を有する図外の昇降シリンダに駆動連結されており、この昇降シリンダの伸縮作動により両成形型１，２の上型７，１３を同時に昇降させて両成形型１，２での加圧成形を行うようになっている。
【００３０】
上記ドアトリム本体用成形型１における下型５上面の成形面６には溶融樹脂供給用のゲート１６が、またスピーカグリル用成形型２の下型１１上面の成形面１２には同様のゲート１７がそれぞれ開口されている。これらゲート１６，１７はそれぞれ樹脂供給用の分岐通路１８，１９の下流端に設けられ、両分岐通路１８，１９の上流端はドアトリム本体用成形型１の下型５内で集合通路２０に集合され、この集合通路２０は下型５の側面からその外側に延びた後、上流端が樹脂供給手段としての樹脂押出し装置２１に接続されている。そして、図示しないが、例えば分岐通路１８，１９には樹脂供給及び停止用の開閉弁が配置されており、樹脂押出し装置２１からの溶融樹脂（ポリプロピレン）を集合通路２０及び各分岐通路１８，１９を経て各成形型１，２のゲート１６，１７に圧送して、その各ゲート１６，１７から成形面６，８及び１２，１４間に成形型１，２で互いに独立して吐出させるようにしている。
【００３１】
そして、上記ドアトリム本体用成形型１及びスピーカグリル用成形型２の各上型７，１３を昇降シリンダの伸長作動によりそれぞれ下降移動させて対応する下型５，１１に接近させ、両成形型１，２の成形面６，８及び１２，１４同士が嵌合する直前に、つまり成形面６，８及び１２，１４同士が嵌合しないで両成形面６，８及び１２，１４間にキャビティが形成されていない状態で、樹脂供給手段としての樹脂押出し装置２１により各成形型１，２のゲート１６，１７から溶融樹脂を供給し、その後、両成形型１，２の成形面６，８及び１２，１４同士を嵌合させて型締めすることにより、ドアトリム本体用成形型１の成形面６，８間でドアトリム本体Ｗ１を、またスピーカグリル用成形型２の成形面１２，１４間でスピーカグリルＷ４をそれぞれ同時に成形するようにしている。
【００３２】
次に、上記構成の成形装置Ａを用いてドアトリム本体Ｗ１とスピーカグリルＷ４とからなるドアトリムＷを成形する方法について説明する。
作動開始時には、成形装置Ａにおける昇降シリンダが収縮作動していてドアトリム本体用成形型１及びスピーカグリル用成形型２の各上型７，１３が上昇しており、この状態から昇降シリンダの伸長作動により各上型７，１３をそれぞれ下降移動させて対応する下型５，１１に接近させる。そして、ドアトリム本体用成形型１の成形面６，８同士が嵌合する直前に、またスピーカグリル用成形型２にあってはその成形面１２，１４同士が嵌合した後に、それぞれ樹脂押出し装置２１により各成形型１，２のゲート１６，１７から溶融樹脂を供給する。各成形型１，２の上型７，１３がさらに下降移動して成形面６，８及び１２，１４同士が嵌合すると、これら両成形面６，８及び１２，１４間に形成されるキャビティ内に上記供給溶融樹脂が閉じ込められる。その後、両成形型１，２の上型７，１３のさらなる下降移動により、成形型１，２同士を型締めすることにより、ドアトリム本体用成形型１の成形面６，８間でドアトリム本体Ｗ１を、またスピーカグリル用成形型２の成形面１２，１４間でスピーカグリルＷ４をそれぞれ同時に成形する。
【００３３】
しかる後、上記型締め状態で所定時間冷却して溶融樹脂を硬化させた後、昇降シリンダの収縮作動により各上型７，１３をそれぞれ上昇移動させて成形型１，２を型開きし、上記成形されたドアトリム本体Ｗ１及びスピーカグリルＷ４をそれぞれ成形型１，２から取り出す。次いで、ドアトリム本体Ｗ１にスピーカグリルＷ４を熱溶着等により一体に組み付けてドアトリムＷを作製すればよい。以後、各ドアトリムＷにつき、上記と同様にしてドアトリム本体Ｗ１及びスピーカグリルＷ４を同時に成形する。
【００３４】
したがって、この実施形態では、ドアトリムＷをドアトリム本体Ｗ１とスピーカグリルＷ４とに分けて成形し、ドアトリム本体Ｗ１はドアトリム本体用成形型１により、またスピーカグリルＷ４にあってはスピーカグリル用成形型２によりそれぞれ同時に成形するので、成形時、これらをそれぞれ同時にインジェクション成形するときに比べ、樹脂押出し装置２１により各成形型１，２のゲート１６，１７から供給する溶融樹脂の成形型締力が１／３〜１／１０の圧力の低圧で済み、成形装置Ａ全体の設備費を低減してコストダウンを図ることができる。
【００３５】
また、上記ドアトリム本体Ｗ１とスピーカグリルＷ４とを同時に成形するので、これらが成形後に冷却により硬化しながら収縮する収縮度合いの経時変化特性は互いに同じとなって、両者間の寸法上の誤差が生じない。よって、ドアトリム本体Ｗ１及びスピーカグリルＷ４を成形後に直ちに組み付けることができ、工程の効率を高めることができる。
【００３６】
しかも、このようにドアトリム本体Ｗ１及びスピーカグリルＷ４を成形後に直ちに組み付けると、ドアトリム本体Ｗ１及びスピーカグリルＷ４は未だ完全に冷えきっていなくて熱いままの状態で組み付けられることとなり、加熱溶着により組み付ける際に溶融温度まで加熱するための加熱容量が少なくて済み、省エネルギー化を図ることができる。また、強嵌合等の機械的締結も容易にできる。
【００３７】
さらに、ドアトリム本体Ｗ１とスピーカグリルＷ４とをそれぞれ専用の成形型１，２により同時に成形し、その各成形型１，２にそれぞれ専用のゲート１６，１７から溶融樹脂が供給されるので、両者を１つの成形型で成形する場合のように、異なるゲートから供給された溶融樹脂がぶつかり合ってウェルド不良が生じることはない。しかも、スピーカグリルＷ４のように多数に小さい孔Ｗ５，Ｗ５，…があいたものであっても、そのスピーカグリル用成形型２のゲート１７から溶融樹脂をスムーズに供給でき、欠肉の発生を防止できる。よって、ドアトリムＷの成形品質を向上させることができる。
【００３８】
また、ドアトリム本体用成形型１及びスピーカグリル用成形型２の双方に同じ１つの樹脂押出し装置２１から溶融樹脂を供給するので、両成形型１，２に同じ色の樹脂が供給されて同色のドアトリム本体Ｗ１及びスピーカグリルＷ４が成形されることとなり、これらドアトリム本体Ｗ１及びスピーカグリルＷ４を成形後に色合せする必要はなく、作業効率を高めることができる。
【００３９】
（実施形態２）
図３は実施形態２を示し（尚、図１と同じ部分については同じ符号を付してその詳細な説明は省略する）、ドアトリム本体Ｗ１の上半部に表皮材を貼り付けるようにしたものである。
【００４０】
すなわち、この実施形態では、ドアトリム本体用成形型１の下型５（上型７）の回りにそれを取り囲むようにクランプ枠２４が配設され、図４にも示す如く、このクランプ枠２４の所定位置には上下方向に貫通する複数のピン挿通孔２５，２５，…が間隔をあけて開口されている。クランプ枠２４の周縁部には複数の支持部２６，２６，…が突設され、この各支持部２６にはロッド挿通孔２７が開口されている。
【００４１】
また、ドアトリム本体用成形型１の下型５周囲の下型連結板４上には下型５側方を上下方向に延びる複数本のロッド２８，２８，…が立設され、この各ロッド２８の上端部には上記クランプ枠２４の支持部２６のロッド挿通孔２７に摺動可能に挿通されている。そして、クランプ枠２４の各支持部２６下面と下型連結板４上面との間にはロッド２８回りに配置したコイルばね２９が縮装されており、クランプ枠２４をロッド２８，２８，…により昇降可能に支持し、かつコイルばね２９のばね力により成形型１の型開き状態で上下型７，５間の位置に相当する上昇端位置に付勢している。
【００４２】
上記クランプ枠２４の上面にはドアトリムＷの上半部（その範囲を図２に破線の斜線部分にて示す）に貼り付けられる表皮材Ｗ６が載置され、図５に示すように、その表皮材Ｗ６は周縁部をクランプ枠２４の各ピン挿通孔２５に挿通されるセットピン３０により位置決めされた状態で固定される。
【００４３】
また、詳しくは図示しないが、ドアトリム本体用成形型１の下型成形面６には、上記表皮材Ｗ６に含まれる範囲と、表皮材Ｗ６から外れた範囲とにそれぞれゲート１６，１６が開口されている。そして、これらドアトリム本体用成形型１の両ゲート１６，１６及びスピーカグリル用成形型２のゲート１７について、例えば分岐通路１８，１９の開閉制御等により溶融樹脂の供給及びその停止を独立して切換可能とされている。
【００４４】
このような成形装置ＡによりドアトリムＷを、そのドアトリム本体Ｗ１の上半部に表皮材Ｗ６を貼り付けながら一体的に成形する場合、まず、ドアトリム本体用成形型１及びスピーカグリル用成形型２を型開きした状態で、ドアトリム本体用成形型１の両成形面６，８間の上昇端位置にあるクランプ枠２４に表皮材Ｗ６を位置決めしてセットする。
【００４５】
次いで、上記実施形態１で説明した動作と同様に、両成形型１，２の上型７，１３を同時に下降移動させて、そのドアトリム本体用成形型１の上型７により上記表皮材Ｗ６をコイルばね２９を圧縮しながらクランプ枠２４と共に押し下げる。そして、ドアトリム本体用成形型１の成形面６，８同士が嵌合される前に、まず、上型７の下降状態（又は上型７の下降動作を一旦停止させた状態）で、成形型１における成形面６，８のうち表皮材Ｗ６が貼り合わされる範囲に、該範囲に対応する一方のゲート１６から溶融樹脂を供給する。このことで、供給された樹脂が表皮材Ｗ６に溶着する。
【００４６】
次いで、上型７がさらに下降移動（又は上型７が下降移動を再開）して、ドアトリム本体用成形型１の成形面６，８同士が嵌合する前に、またスピーカグリル用成形型２は成形面１２，１４同士が嵌合した後に、それぞれドアトリム本体用成形型１の成形面６，８のうちの表皮材Ｗ６を貼り合わせない範囲に、該範囲に対応する他方のゲート１６から、またスピーカグリル用成形型２の成形面１２のゲート１７からそれぞれ溶融樹脂を供給する。以後は上記実施形態１と同様に動作を行わせる。このことで、ドアトリム本体用成形型１の成形面６，８同士の嵌合によりドアトリム本体Ｗ１を成形し、それと同時に、そのドアトリム本体Ｗ１に表皮材Ｗ６を一体に貼り合わせる。
【００４７】
したがって、この実施形態の場合、表皮材Ｗ６をドアトリム本体Ｗ１の上半部にその成形と同時に自動的に容易に貼り合わせることができる。
また、上記ドアトリム本体用成形型１に最初に供給された溶融樹脂が成形された際、それと同時に表皮材Ｗ６が貼り合わされて表皮材Ｗ６の成形が行われ、その後にドアトリム本体Ｗ１において表皮材Ｗ６を貼り合わせない部分が成形されることとなり、表皮材Ｗ６の成形を容易に行うこともできる。
【００４８】
この実施形態２のように、溶融樹脂の供給方法として、まず、ドアトリム本体用成形型１の成形面６，８のうち表皮材Ｗ６が貼り合わされる範囲に、次いで表皮材Ｗ６を貼り合わせない範囲にそれぞれ溶融樹脂を供給する方法は、成形型１の成形面６，８全体への溶融樹脂の拡散が表皮材Ｗ６の存在によって遅れるときに、それを補うように、成形面６，８の範囲を２つに分けて各範囲のゲート１６，１６から溶融樹脂を供給するようにしたものである。しかし、表皮材Ｗ６があっても、ドアトリム本体用成形型１における成形面６，８間の全体に溶融樹脂がスムーズに広がる場合には、両成形型１，２の下型５，１１及び上型７，１３が接近して各成形型１，２の成形面６，８及び１２，１４同士が嵌合する前に、まず、ドアトリム本体用成形型１の成形面６，８にゲート１６（この場合は１つでよい）から溶融樹脂を供給し、次いで、スピーカグリル用成形型２の成形面１２，１４にゲート１７から溶融樹脂を供給する方法を採用することができる。
【００４９】
尚、上記実施形態２では、表皮材Ｗ６をドアトリムＷの上半部に貼り付けるようにしているが、ドアトリムＷの上半部以外の他の部分や全体に貼り付けるようにすることもできる。
【００５０】
また、上記各実施形態では、自動車用ドアトリムＷのトリム本体Ｗ１とそのスピーカグリルＷ４とを同時に成形する場合を説明しているが、本発明は、スピーカグリルＷ４以外の小物部品をドアトリム本体Ｗ１と共に成形する場合や、自動車用ドアトリムＷ以外の内装材をその小物部品と共に同時に成形する場合にも適用することができる。
【００５１】
【発明の効果】
以上説明のように、請求項１又は７の発明によると、内装材本体と小物部品とからなる内装材を成形する場合、内装材の本体と小物部品とをそれぞれ専用にスタンピング成形する成形型を設けて、各成形型における溶融樹脂の供給のためのゲートは同じ樹脂供給源に接続し、両成形型でそれぞれ内装材本体及び小物部品を同時にスタンピング成形するようにしたことにより、内装材の欠肉やウェルド不良等の品質低下を招くことなく、しかも内装材本体と小物部品との別成形による色合せ作業や収縮差を補償する養生のための待ち時間を要することなく、安価な設備によって内装材を成形することができる。
【００５２】
請求項２の発明によると、内装材本体用成形型の固定型及び可動型が接近する前に、両型の成形面間に内装材本体の少なくとも一部に設けられる表皮材をセットし、内装材本体の成形と同時に表皮材を内装材本体に一体に貼り合わせることにより、表皮材の内装材本体への貼合せを容易に行うことができる。
【００５３】
請求項３の発明によると、両成形型の固定型及び可動型が接近するとき、最初に、内装材本体用成形型の成形面のうち表皮材が貼り合わされる範囲に溶融樹脂を供給し、次いで、内装材本体用成形型の成形面の残りの範囲に、最後に小物部品用成形型にそれぞれ溶融樹脂を供給することにより、表皮材の部分貼合成形を容易に行うことができる。
【００５４】
請求項４の発明によると、両成形型の固定型及び可動型が接近するとき、まず、内装材本体用成形型に溶融樹脂を供給し、次いで、小物部品用成形型に溶融樹脂を供給することにより、表皮材があっても、内装材本体用成形型における成形面間の全体に溶融樹脂がスムーズに広がるときに有効な溶融樹脂の供給態様が得られる。
【００５５】
請求項６の発明によると、内装材本体は自動車のドアトリム本体とし、小物部品は、ドアトリム本体に設けられるスピーカグリルとしたことにより、ドアトリム本体とスピーカグリルとからなるドアトリムを成形するときに有効な効果を奏することができる。
【図面の簡単な説明】
【図１】本発明の実施形態１に係る成形装置の正面図である。
【図２】成形されるドアトリムの正面図である。
【図３】実施形態２を示す図１相当図である。
【図４】表皮材クランプ枠の平面図である。
【図５】表皮材をクランプ枠で位置決めして支持する状態を示す拡大断面図である。
【符号の説明】
Ａ 成形装置
１ ドアトリム本体用成形型（内装材本体用成形型）
２ スピーカグリル用成形型（小物部品用成形型）
５，１１ 下型（固定型）
６，１２ 下型成形面
７，１３ 上型（可動型）
８，１４ 上型成形面
１６，１７ ゲート
２１ 樹脂押出し装置（樹脂供給手段）
２４ クランプ枠
Ｗ ドアトリム（内装材）
Ｗ１ ドアトリム本体（内装材本体）
Ｗ４ スピーカグリル（小物部品）
Ｗ６ 表皮材[0001]
BACKGROUND OF THE INVENTION
The present invention belongs to a technical field related to a molding method and molding apparatus for interior materials.
[0002]
[Prior art]
In general, a resin door trim that is attached to an inner panel of an automobile door is known as an example of this type of interior material, and a speaker grill for attaching the speaker in a state of covering the speaker is provided on the door trim as a small part. Sometimes.
[0003]
In the case of molding such door trim, conventionally, (1) the door trim body and the speaker grill (small parts) are integrally formed and molded between the molds, and (2) the door trim body is stamped by the mold, In addition, the speaker grill is generally formed by injection molding in the same manner as described above, and both are assembled after molding, and (3) the stamping molding is performed between the molds by integrally forming the door trim body and the speaker grill. Yes.
[0004]
[Problems to be solved by the invention]
However, the conventional method has the following problems. That is, in the method (1), since the molten resin is injected into the mold, it is necessary to increase the mold clamping force, which increases the equipment cost.
[0005]
In the method (2), since the door trim main body and the speaker grill are formed in separate processes, a difference occurs in the degree of shrinkage of the resin after each molding. Considering this shrinkage difference, the speaker grille cannot be assembled to the door trim body immediately after molding, and it is necessary to leave it for 4 to 24 hours after molding and to assemble it when the shrinkage is stable, resulting in poor process efficiency. Moreover, the colors of the door trim main body and the speaker grill formed in a separate process may be slightly different, and color matching for this purpose is difficult.
[0006]
Further, in the method (3), since the speaker grill has a large number of small holes for allowing the sound from the speaker to pass therethrough, it is difficult for the resin in the molded portion of the speaker grill to flow during stamping molding. Will occur. In order to prevent this thinning, it is sufficient to open a separate resin supply gate close to the speaker grill molding part. In that case, the molten resin supplied from this gate and the original gate are supplied. The molten resin collides between the molding surfaces and the boundary surface between the two resins becomes a so-called weld defect, and the appearance looks worse.
[0007]
The present invention has been made in view of such various points, and its purpose is to improve the quality of the molded interior material such as lack of wall and weld defects by improving the method of stamping the interior material as described above. Low cost by using stamping molding for interior materials with small parts without incurring degradation and without waiting time for color matching work by separate molding of interior material body and small parts and neglect due to shrinkage difference It is to be able to be molded.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, according to the present invention, a molding die for exclusively stamping the interior material main body and small parts is provided, and the gate for supplying molten resin in each molding die is the same resin supply source. The interior material body and the small parts were simultaneously stamped with both molds.
[0009]
Specifically, the invention of claims 1 to 6 is an invention of a molding method of an interior material. In the invention of claim 1, an interior comprising an interior material body and small parts integrally provided on the interior material body. As a molding method for molding a material, first, an interior material body comprising a fixed mold and a movable mold each having a molding surface that can be fitted to each other, and a molten resin supply gate communicating with the resin supply means is opened in the molding surface The resin supply comprises a molding die for use, and a fixed die and a movable die that have molding surfaces that can be fitted to each other, and that come into and out of contact with the movable die at the same time. A molding apparatus including a molding die for small parts in which a molten resin supply gate communicating with the means is opened in the molding surface is prepared.
[0010]
Then, by moving the movable molds of both molds close to the fixed molds and fitting the molding surfaces of both molds to each other, the molten resin is supplied from the gates of the respective molds by the resin supply means, thereby providing an interior material. The interior material main body is molded between the molding surfaces of the molding die for the main body, and the small component is molded simultaneously between the molding surfaces of the molding die for the small component.
[0011]
With the above configuration, when molding the interior material, the movable molds of the interior material main body mold and the accessory part molding mold simultaneously approach the fixed mold, and the molding surfaces of both molds are fitted to each other. On the way to the fitting state between the molding surfaces, the molten resin is sent by the resin supply means and supplied between the molding surfaces of both molding dies from the gate of each molding die, and between the molding surfaces of the molding die for the interior material body Thus, the interior material body and the small parts are simultaneously formed between the molding surfaces of the small part molding die.
[0012]
In this case, the interior material is divided into an interior material body and small parts and stamped and molded by dedicated molding dies at the same time, so that the mold does not open due to the pressure of the molten resin supplied from the gate of each mold by the resin supply means. The molding die clamping force required is low, and a pressure of 1/3 to 1/10 is sufficient as compared with the injection molding, and the equipment cost of the molding apparatus can be reduced.
[0013]
Even if the interior material is divided into an interior material body and small parts, since both are molded at the same time, the degree of shrinkage after molding is the same and there is no dimensional error. Can be assembled immediately after molding. Moreover, since the interior material main body and the small parts can be assembled while they are hot after being molded in this way, when assembled by the heat welding method, the heating capacity for that can be reduced. Further, mechanical fastening such as strong fitting can be easily performed.
[0014]
Furthermore, the interior material main body and the small parts are simultaneously stamped and molded by dedicated molding dies, and molten resin is supplied to the respective molding dies from individual gates. As described above, the molten resin supplied from different gates does not collide between the molding surfaces to cause a weld defect. In addition, even if the small component has many small holes such as a speaker grille, the molten resin can be smoothly supplied from the gate of the small component molding die, and the occurrence of the lack of thickness can be prevented. Therefore, the molding quality of the interior material can be improved.
[0015]
In addition, since the molten resin is supplied from the same resin supply means to both molds, the same color resin is molded by both molds, and it is not necessary to match the colors of the interior material body and the small parts.
[0016]
In the invention of claim 2, the skin material provided on at least a part of the interior material main body between the fixed mold and the molding surface of the movable mold before the fixed mold and the movable mold of the interior material main body mold approach each other. set. Then, the interior material body is molded by fitting the molding surfaces by the approach of the fixed mold and the movable mold, and at the same time, the skin material is integrally bonded to the interior material body. In this way, the skin material can be easily and automatically bonded to the interior material body simultaneously with the molding.
[0017]
In that case, according to the invention of claim 3, when the fixed mold and the movable mold of both molds approach, first, the molten resin is first applied from the gate to the surface of the molding surface of the mold for interior material main body to which the skin material is bonded. Next, the molten resin is supplied from the gate to the extent that the skin material of the molding surface for the interior material main body is not bonded, and finally the molten resin is supplied from the gate to the molding surface of the small component molding die. Supply.
[0018]
In this invention, when the molten resin initially supplied to the interior material body molding die is molded, the skin material is bonded to the molded resin to form the skin material portion, and then the interior material body The part where the skin material is not bonded is formed. Therefore, the partial pasting composition of the skin material can be easily performed.
[0019]
On the other hand, in the invention of claim 4, when the fixed mold and the movable mold of both molds approach, first, molten resin is supplied from the gate to the molding surface of the mold for interior material body, and then the mold for small parts The molten resin is supplied to the molding surface. This method can be employed when the molten resin spreads smoothly over the entire molding surface of the interior material body molding die even if there is a skin material.
[0020]
According to the fifth aspect of the present invention, in the interior material molding method according to the first, second, third or fourth aspect of the present invention, the fixed mold is the lower mold and the movable mold is the upper mold.
[0021]
According to a sixth aspect of the present invention, in the interior material molding method according to the first, second, third, fourth, or fifth aspect of the present invention, the interior material body is a door trim body of an automobile, and the accessory part is a speaker grill provided on the door trim body. And Therefore, the above effect can be achieved when a door trim composed of the door trim body and the speaker grill is formed.
[0022]
The invention of claim 7 is an invention of an interior material molding apparatus. According to the present invention, as a molding apparatus configured to mold an interior material composed of an interior material main body and small parts integrally provided on the interior material main body, a fixed mold and a movable mold each having molding surfaces that can be fitted to each other. And a molding die for interior material body having a molten resin supply gate opened on the molding surface.
[0023]
Further, the mold includes a fixed mold and a movable mold each having a molding surface that can be fitted to each other, and simultaneously contacting and separating the fixed mold and the movable mold of the interior material body molding mold. A small component molding die having a supply gate opened is provided.
[0024]
Furthermore, it comprises a single resin supply means connected to the gates of both molds, while moving the movable molds of both molds close to the fixed mold and fitting the molding surfaces of both molds, By supplying the molten resin from the gate of each mold by the resin supply means, the interior material body is placed between the molding surfaces of the interior material body mold, and the accessory parts are simultaneously placed between the molding surfaces of the molding parts mold. It shall be comprised so that it may shape | mold. Therefore, according to the present invention, the same effect as that of the first aspect of the invention can be obtained.
[0025]
DETAILED DESCRIPTION OF THE INVENTION
(Embodiment 1)
FIG. 1 shows a molding apparatus A according to Embodiment 1 of the present invention, and this molding apparatus A is for molding an automobile door trim as an interior material. As shown in FIG. 2, the door trim W is made of a resin such as polypropylene resin, for example, and is a door trim main body W1 (interior material main body) and a speaker that is integrally provided and attached to the lower front side of the door trim main body W1 (see FIG. 2). A speaker grill W4 (small part) having a large number of small holes W5, W5,. In FIG. 2, W2 is a door opening / closing pull handle that also serves as an armrest, and W3 is an opening for accommodating an inner handle (not shown) for door locking.
[0026]
The molding apparatus A is configured to simultaneously mold the door trim body W1 and the speaker grill W4. That is, in FIG. 1, 1 is a door trim body mold for molding the door trim body W1, and 2 is a speaker grill mold for molding the speaker grill W4. Are juxtaposed side by side.
[0027]
The door trim body mold 1 is arranged such that the lower mold 5 is a fixed mold installed on the lower mold connecting plate 4 and can be moved up and down above the lower mold 5. And an upper die 7 as a movable die whose upper surface is fixedly attached to the connecting plate 9. A lower mold forming surface 6 is formed on the upper surface of the lower mold 5, and an upper mold forming surface 8 that can be fitted to the lower mold forming surface 6 is formed on the lower surface of the upper mold 7. When the lower mold forming surface 6 and the upper mold forming surface 8 are fitted to each other by moving to the lower mold 5, a sealed space for press-molding the door trim body W <b> 1 is formed between the both molding surfaces 6 and 8. A molding cavity (not shown) is formed.
[0028]
On the other hand, the speaker grill mold 2 includes a lower mold 11 as a fixed mold mounted and fixed on the same lower mold connecting plate 4 as the lower mold 5 of the door trim body mold 1, and an upper portion of the lower mold 11. The upper mold 13 is arranged to be movable up and down, that is, to be able to contact and separate from the lower mold 11, and whose upper surface is attached and fixed to the same connecting plate 9 as the upper mold 7 of the door trim body mold 1. A lower mold forming surface 12 is formed on the upper surface of the lower mold 11, and an upper mold forming surface 14 that can be fitted to the lower mold forming surface 12 is formed on the lower surface of the upper mold 13. The upper mold 13 moves downward. A molding cavity (not shown) for molding the speaker grill W4 between the molding surfaces 12 and 14 when the upper mold molding surface 14 is fitted to the lower mold molding surface 12 by approaching the lower mold 11 Is formed.
[0029]
The connecting plate 9 to which the upper molds 7 and 13 of both the molds 1 and 2 are attached and fixed is drivingly connected to a lifting cylinder (not shown) having a vertical cylinder axis. The upper molds 7 and 13 of both molds 1 and 2 are moved up and down simultaneously by expansion and contraction to perform pressure molding with both molds 1 and 2.
[0030]
In the door trim body mold 1, a molten resin supply gate 16 is provided on the molding surface 6 on the upper surface of the lower mold 5, and a similar gate 17 is provided on the molding surface 12 on the upper surface of the lower mold 11 of the speaker grill molding die 2. Each is open. These gates 16 and 17 are provided at the downstream ends of the branch passages 18 and 19 for supplying the resin, respectively, and the upstream ends of both the branch passages 18 and 19 gather in the collecting passage 20 in the lower mold 5 of the door trim body mold 1. The collecting passage 20 extends from the side surface of the lower mold 5 to the outside, and is connected to a resin extrusion device 21 serving as a resin supply means at the upstream end. Although not shown, for example, on-off valves for resin supply and stop are arranged in the branch passages 18 and 19, and molten resin (polypropylene) from the resin extrusion device 21 is collected into the collecting passage 20 and the branch passages 18 and 19. Through the gates 16 and 17 of the respective molds 1 and 2, and the respective molds 1 and 2 are allowed to discharge independently from the gates 16 and 17 between the molding surfaces 6, 8 and 12 and 14. ing.
[0031]
Then, the upper molds 7 and 13 of the door trim body mold 1 and the speaker grill mold 2 are moved downward by the elongating operation of the elevating cylinder so as to approach the corresponding lower molds 5 and 11, respectively. , 2 immediately before the molding surfaces 6, 8 and 12, 14 are fitted to each other, that is, the molding surfaces 6, 8 and 12, 14 are not fitted to each other, and a cavity is formed between the molding surfaces 6, 8, and 12, 14. In a state where it is not formed, molten resin is supplied from the gates 16 and 17 of the respective molds 1 and 2 by the resin extrusion device 21 as a resin supply means, and thereafter, the molding surfaces 6 and 8 of both molds 1 and 2 and The door trim body W1 is placed between the molding surfaces 6 and 8 of the door trim body molding die 1 and the speaker 12 is molded between the molding surfaces 12 and 14 of the speaker grill molding die 2 by clamping the molds 12 and 14 together. Grill W4 Respectively and so as to simultaneously molded.
[0032]
Next, a method for forming the door trim W including the door trim main body W1 and the speaker grill W4 using the forming apparatus A having the above-described configuration will be described.
At the start of the operation, the lifting cylinder in the molding apparatus A is contracted, and the upper molds 7 and 13 of the door trim main body molding die 1 and the speaker grill molding die 2 are raised. Thus, the upper molds 7 and 13 are moved downward to approach the corresponding lower molds 5 and 11, respectively. Then, immediately before the molding surfaces 6 and 8 of the door trim body molding die 1 are fitted to each other, and in the speaker grill molding die 2, the molding surfaces 12 and 14 are fitted to each other, and then a resin extrusion device, respectively. The molten resin is supplied from the gates 16 and 17 of the molds 1 and 2 by 21. When the upper molds 7 and 13 of the respective molding dies 1 and 2 are further moved downward and the molding surfaces 6, 8 and 12, 14 are fitted to each other, a cavity formed between the molding surfaces 6, 8 and 12, 14 The supplied molten resin is confined inside. Thereafter, by further lowering the upper molds 7 and 13 of the molding molds 1 and 2, the molds 1 and 2 are clamped to each other, so that the door trim body W1 is formed between the molding surfaces 6 and 8 of the door trim body molding mold 1. The speaker grill W4 is simultaneously formed between the molding surfaces 12 and 14 of the speaker grill mold 2 respectively.
[0033]
After that, after the molten resin is cured by cooling for a predetermined time in the above-mentioned mold-clamped state, the upper molds 7 and 13 are moved up by the contraction operation of the elevating cylinder to open the molds 1 and 2, respectively. The molded door trim main body W1 and speaker grill W4 are taken out from the molds 1 and 2, respectively. Next, the door trim W may be manufactured by assembling the speaker grill W4 integrally with the door trim body W1 by heat welding or the like. Thereafter, for each door trim W, the door trim body W1 and the speaker grill W4 are simultaneously formed in the same manner as described above.
[0034]
Therefore, in this embodiment, the door trim W is divided into the door trim main body W1 and the speaker grill W4, and the door trim main body W1 is formed by the door trim main body mold 1, and the speaker grill W4 is formed by the speaker grill mold 2. Therefore, the molding resin clamping force of the molten resin supplied from the gates 16 and 17 of the molding dies 1 and 2 by the resin extrusion device 21 is less than 1 / at the time of molding. A low pressure of 3 to 1/10 of the pressure is sufficient, and the equipment cost of the entire molding apparatus A can be reduced to reduce the cost.
[0035]
In addition, since the door trim body W1 and the speaker grill W4 are formed at the same time, the time-varying characteristics of the degree of shrinkage that shrinks while being cured by cooling after molding are the same, resulting in dimensional errors between the two. Absent. Therefore, the door trim main body W1 and the speaker grill W4 can be assembled immediately after molding, and the process efficiency can be improved.
[0036]
Moreover, if the door trim body W1 and the speaker grill W4 are assembled immediately after molding as described above, the door trim body W1 and the speaker grill W4 are not yet completely cooled and assembled in a hot state. In addition, the heating capacity for heating to the melting temperature is small, and energy saving can be achieved. Further, mechanical fastening such as strong fitting can be easily performed.
[0037]
Further, the door trim body W1 and the speaker grill W4 are simultaneously molded by the dedicated molding dies 1 and 2, respectively, and molten resin is supplied to the molding dies 1 and 2 from the dedicated gates 16 and 17, respectively. As in the case of molding with one mold, molten resin supplied from different gates do not collide with each other to cause a weld defect. Moreover, even if there are a large number of small holes W5, W5,... Like the speaker grill W4, the molten resin can be smoothly supplied from the gate 17 of the speaker grill mold 2 to prevent the occurrence of a lack of thickness. it can. Therefore, the molding quality of the door trim W can be improved.
[0038]
In addition, since the molten resin is supplied from the same resin extrusion device 21 to both the door trim body mold 1 and the speaker grill mold 2, the same color resin is supplied to both molds 1 and 2. The door trim main body W1 and the speaker grill W4 are molded, and it is not necessary to color match the door trim main body W1 and the speaker grill W4 after molding, so that the work efficiency can be improved.
[0039]
(Embodiment 2)
FIG. 3 shows the second embodiment (the same parts as those in FIG. 1 are denoted by the same reference numerals and detailed description thereof is omitted), and a skin material is attached to the upper half of the door trim body W1. It is.
[0040]
That is, in this embodiment, the clamp frame 24 is disposed around the lower mold 5 (upper mold 7) of the door trim body mold 1 so as to surround the mold 5 as shown in FIG. A plurality of pin insertion holes 25, 25,... Penetrating in the vertical direction are opened at predetermined positions at intervals. A plurality of support portions 26, 26,... Project from the periphery of the clamp frame 24, and rod insertion holes 27 are opened in the support portions 26.
[0041]
Further, a plurality of rods 28, 28,... Extending in the vertical direction on the side of the lower mold 5 are erected on the lower mold connecting plate 4 around the lower mold 5 of the door trim body mold 1. Is inserted into the rod insertion hole 27 of the support portion 26 of the clamp frame 24 so as to be slidable. A coil spring 29 disposed around the rod 28 is mounted between the lower surface of each support portion 26 of the clamp frame 24 and the upper surface of the lower die connecting plate 4, and the clamp frame 24 is moved by the rods 28, 28,. It is supported so as to be able to move up and down, and is biased to the rising end position corresponding to the position between the upper and lower molds 7 and 5 in the mold open state of the mold 1 by the spring force of the coil spring 29.
[0042]
On the upper surface of the clamp frame 24, a skin material W6 to be attached to the upper half of the door trim W (the range of which is shown by the hatched portion in FIG. 2) is placed. As shown in FIG. The material W6 is fixed in a state where the peripheral portion is positioned by the set pin 30 inserted into each pin insertion hole 25 of the clamp frame 24.
[0043]
Although not shown in detail, gates 16 and 16 are opened on the lower mold forming surface 6 of the door trim body mold 1 in a range included in the skin material W6 and a range outside the skin material W6, respectively. ing. Then, for both the gates 16 and 16 of the door trim body mold 1 and the gate 17 of the speaker grill mold 2, the supply and stop of the molten resin are switched independently by, for example, opening / closing control of the branch passages 18 and 19. It is possible.
[0044]
When the door trim W is molded integrally with the molding apparatus A by attaching the skin material W6 to the upper half of the door trim main body W1, first, the door trim main body mold 1 and the speaker grill molding mold 2 are formed. With the mold opened, the skin material W6 is positioned and set on the clamp frame 24 at the rising end position between the molding surfaces 6 and 8 of the door trim body mold 1.
[0045]
Next, similarly to the operation described in the first embodiment, the upper molds 7 and 13 of the molding dies 1 and 2 are simultaneously moved downward, and the skin material W6 is moved by the upper mold 7 of the door trim body molding mold 1. The coil spring 29 is pressed down together with the clamp frame 24 while being compressed. Then, before the molding surfaces 6 and 8 of the door trim body molding die 1 are fitted together, first, the molding die is in the lowered state of the upper die 7 (or the state where the lowering operation of the upper die 7 is temporarily stopped). In the molding surfaces 6 and 8 in 1, the molten resin is supplied from one gate 16 corresponding to the range to which the skin material W6 is bonded. Thus, the supplied resin is welded to the skin material W6.
[0046]
Next, before the upper mold 7 further moves downward (or the upper mold 7 resumes downward movement) and the molding surfaces 6 and 8 of the door trim body molding mold 1 are fitted together, the speaker grill molding mold 2 After the molding surfaces 12 and 14 are fitted to each other, in the range where the skin material W6 of the molding surfaces 6 and 8 of the door trim body molding die 1 is not pasted, from the other gate 16 corresponding to the range, In addition, molten resin is supplied from the gate 17 of the molding surface 12 of the speaker grill mold 2. Thereafter, the same operation as in the first embodiment is performed. Thus, the door trim main body W1 is formed by fitting the molding surfaces 6 and 8 of the door trim main body mold 1, and at the same time, the skin material W6 is integrally bonded to the door trim main body W1.
[0047]
Therefore, in the case of this embodiment, the skin material W6 can be easily and automatically bonded to the upper half of the door trim body W1 simultaneously with the molding.
Further, when the molten resin initially supplied to the door trim body mold 1 is molded, the skin material W6 is bonded at the same time to form the skin material W6, and then the skin material W6 is formed in the door trim body W1. Therefore, the portion where the material is not bonded is formed, and the skin material W6 can be easily formed.
[0048]
As in the second embodiment, as a method for supplying the molten resin, first, in the molding surfaces 6 and 8 of the door trim body molding die 1, the range in which the skin material W6 is pasted, and then the range in which the skin material W6 is not pasted The method of supplying the molten resin to each of the surfaces of the molding surfaces 6 and 8 is to compensate for the diffusion of the molten resin to the entire molding surfaces 6 and 8 of the mold 1 due to the presence of the skin material W6. Is divided into two, and the molten resin is supplied from the gates 16 and 16 in each range. However, even if the skin material W6 is present, if the molten resin spreads smoothly between the molding surfaces 6 and 8 of the door trim body molding die 1, the lower molds 5 and 11 and the upper molds 1 and 2 are formed. Before the molds 7 and 13 approach and the molding surfaces 6, 8 and 12, 14 of the molding dies 1 and 2 are fitted to each other, first, the gate 16 ( In this case, a method may be employed in which the molten resin is supplied from the gate 17 and then the molten resin is supplied from the gate 17 to the molding surfaces 12 and 14 of the speaker grill mold 2.
[0049]
In the second embodiment, the skin material W6 is attached to the upper half of the door trim W. However, the cover material W6 may be attached to other parts or the whole other than the upper half of the door trim W.
[0050]
Moreover, although each said embodiment demonstrated the case where the trim main body W1 of the door trim W for motor vehicles and its speaker grill W4 were shape | molded simultaneously, this invention is a small part other than the speaker grill W4 with the door trim main body W1. The present invention can also be applied to the case where molding is performed or an interior material other than the automobile door trim W is molded together with its small parts.
[0051]
【The invention's effect】
As described above, according to the invention of claim 1 or 7, when molding an interior material composed of an interior material main body and small parts, the molding die for stamping and molding the interior material main body and the small parts individually. The gate for supplying molten resin in each mold is connected to the same resin supply source, and the interior material body and small parts are stamped and molded simultaneously in both molds. Inner interiors with low-cost equipment without incurring quality degradation such as meat and weld defects, and without waiting time for color matching work and curing to compensate for shrinkage differences by separate molding of the interior material body and small parts The material can be molded.
[0052]
According to the invention of claim 2, before the fixed mold and the movable mold of the interior material body molding die approach, the skin material provided on at least a part of the interior material body is set between the molding surfaces of both molds. By simultaneously bonding the skin material to the interior material body simultaneously with the molding of the material body, the skin material can be easily pasted to the interior material body.
[0053]
According to the invention of claim 3, when the fixed mold and the movable mold of both molds approach, first, the molten resin is supplied to the range where the skin material is bonded on the molding surface of the mold for interior material body, Subsequently, the partial pasting composition of the skin material can be easily performed by supplying the molten resin to the small part molding die finally in the remaining range of the molding surface of the interior material body molding die.
[0054]
According to the invention of claim 4, when the fixed mold and the movable mold of both molds approach, first, the molten resin is supplied to the interior material body mold, and then the molten resin is supplied to the small component mold. Thus, even if there is a skin material, an effective supply mode of the molten resin can be obtained when the molten resin spreads smoothly between the molding surfaces of the interior material body molding die.
[0055]
According to the invention of claim 6, the interior material main body is a door trim main body of an automobile, and the accessory part is a speaker grill provided in the door trim main body, which is effective when molding a door trim composed of the door trim main body and the speaker grill. There is an effect.
[Brief description of the drawings]
FIG. 1 is a front view of a molding apparatus according to Embodiment 1 of the present invention.
FIG. 2 is a front view of a door trim to be molded.
FIG. 3 is a view corresponding to FIG.
FIG. 4 is a plan view of a skin material clamp frame.
FIG. 5 is an enlarged cross-sectional view showing a state in which a skin material is positioned and supported by a clamp frame.
[Explanation of symbols]
A molding equipment
1 Mold for door trim body (mold for interior material body)
2 Molds for speaker grills (molds for small parts)
5,11 Lower mold (fixed mold)
6,12 Lower mold surface
7,13 Upper mold (movable)
8,14 Upper mold forming surface
16, 17 gate
21 Resin extrusion equipment (resin supply means)
24 Clamp frame
W Door trim (interior material)
W1 Door trim body (interior material body)
W4 Speaker grill (small parts)
W6 skin material

Claims (7)

内装材本体と、その内装材本体に一体に設けられる小物部品とからなる内装材を成形する成形方法であって、
互いに嵌合可能な成形面をそれぞれ有する固定型及び可動型からなり、樹脂供給手段に連通する溶融樹脂供給用ゲートが上記成形面に開口された内装材本体用成形型と、互いに嵌合可能な成形面をそれぞれ有しかつ上記内装材本体用成形型の固定型及び可動型の接離動作と同時に接離する固定型及び可動型からなり、上記樹脂供給手段と連通する溶融樹脂供給用ゲートが成形面に開口された小物部品用成形型とを備えた成形装置を用意し、
上記両成形型の可動型をそれぞれ固定型に接近させて両成形型の成形面同士を嵌合させながら、樹脂供給手段により各成形型のゲートから溶融樹脂を供給することにより、内装材本体用成形型の成形面間で内装材本体を、また小物部品用成形型の成形面間で小物部品をそれぞれ同時に成形することを特徴とする内装材の成形方法。A molding method for molding an interior material comprising an interior material body and small parts integrally provided on the interior material body,
It is composed of a fixed mold and a movable mold each having a molding surface that can be fitted to each other, and a molten resin supply gate that communicates with the resin supply means can be fitted to a molding die for an interior material body that is open to the molding surface. A molten resin supply gate comprising a fixed mold and a movable mold each having a molding surface and contacting and separating simultaneously with the fixed mold and movable mold of the interior material body mold, and communicating with the resin supply means Prepare a molding device equipped with a molding tool for small parts opened on the molding surface,
For the interior material body by supplying the molten resin from the gate of each mold by the resin supply means while bringing the movable molds of both molds close to the fixed mold and fitting the molding surfaces of both molds. An interior material molding method comprising molding an interior material body between molding surfaces of a molding die and molding a small part between molding surfaces of a molding die for small parts. 請求項１記載の内装材の成形方法において、
内装材本体用成形型の固定型及び可動型が接近する前に、固定型及び可動型の成形面間に、内装材本体の少なくとも一部に設けられる表皮材をセットし、
上記固定型及び可動型の接近による成形面同士の嵌合により内装材本体を成形すると同時に上記表皮材を内装材本体に一体に貼り合わせることを特徴とする内装材の成形方法。In the interior material molding method according to claim 1,
Before the fixed mold and the movable mold of the interior material body forming mold approach, set the skin material provided on at least a part of the interior material main body between the molding surfaces of the fixed mold and the movable mold,
An interior material molding method comprising molding an interior material body by fitting molding surfaces by approaching the fixed mold and the movable mold, and simultaneously bonding the skin material to the interior material body. 請求項２記載の内装材の成形方法において、
両成形型の固定型及び可動型が接近するとき、まず、内装材本体用成形型の成形面のうち表皮材が貼り合わされる範囲にゲートから溶融樹脂を供給し、
次いで、内装材本体用成形型の成形面のうちの表皮材を貼り合わせない範囲に、また最後に小物部品用成形型の成形面にそれぞれゲートから溶融樹脂を供給することを特徴とする内装材の成形方法。In the molding method of the interior material according to claim 2,
When the fixed mold and the movable mold of both molds approach, first, the molten resin is supplied from the gate to the range where the skin material is bonded to the molding surface of the interior material mold.
Next, the interior material is characterized in that molten resin is supplied from the gate to the molding surface of the molding die for the interior material main body in a range where the skin material is not bonded, and finally to the molding surface of the molding die for small parts. Molding method. 請求項２記載の内装材の成形方法において、
両成形型の固定型及び可動型が接近するとき、まず、内装材本体用成形型の成形面にゲートから溶融樹脂を供給し、
次いで、小物部品用成形型の成形面に溶融樹脂を供給することを特徴とする内装材の成形方法。In the molding method of the interior material according to claim 2,
When the fixed mold and the movable mold of both molds approach, first, the molten resin is supplied from the gate to the molding surface of the interior material body mold,
Next, a method for molding an interior material, comprising supplying molten resin to a molding surface of a molding die for small parts. 請求項１、２、３又は４記載の内装材の成形方法において、
固定型は下型で、可動型は上型であることを特徴とする内装材の成形方法。In the molding method of the interior material according to claim 1, 2, 3, or 4,
A method for molding an interior material, wherein the fixed mold is a lower mold and the movable mold is an upper mold. 請求項１、２、３、４又は５記載の内装材の成形方法において、
内装材本体は自動車のドアトリム本体であり、
小物部品は、上記ドアトリム本体に設けられるスピーカグリルであることを特徴とする内装材の成形方法。In the molding method of the interior material according to claim 1, 2, 3, 4 or 5,
The interior material body is a car door trim body,
A method for molding an interior material, wherein the accessory part is a speaker grill provided in the door trim body. 内装材本体と、その内装材本体に一体に設けられる小物部品とからなる内装材を成形するようにした成形装置であって、
互いに嵌合可能な成形面をそれぞれ有する固定型及び可動型からなり、上記成形面に溶融樹脂供給用ゲートが開口された内装材本体用成形型と、
互いに嵌合可能な成形面をそれぞれ有しかつ上記内装材本体用成形型の固定型及び可動型の接離動作と同時に接離する固定型及び可動型からなり、上記成形面に溶融樹脂供給用ゲートが開口された小物部品用成形型と、
上記両成形型のゲートに接続された１つの樹脂供給手段とを備えてなり、
上記両成形型の可動型をそれぞれ固定型に接近させて両成形型の成形面同士を嵌合させながら、樹脂供給手段により各成形型のゲートから溶融樹脂を供給することにより、内装材本体用成形型の成形面間で内装材本体を、また小物部品用成形型の成形面間で小物部品をそれぞれ同時に成形するように構成されていることを特徴とする内装材の成形装置。A molding apparatus configured to mold an interior material composed of an interior material body and small parts provided integrally with the interior material body,
An interior material body molding die comprising a fixed mold and a movable mold each having a molding surface that can be fitted to each other, wherein a molten resin supply gate is opened on the molding surface;
The mold has a fixed surface and a movable die that have a molding surface that can be fitted to each other, and that comes in contact with and separates from the fixed mold and movable mold of the interior material body mold. Mold for small parts with an open gate,
One resin supply means connected to the gates of both the molds,
For the interior material body by supplying the molten resin from the gate of each mold by the resin supply means while bringing the movable molds of both molds close to the fixed mold and fitting the molding surfaces of both molds. An interior material molding apparatus configured to simultaneously mold an interior material body between molding surfaces of a molding die and a small part between molding surfaces of a molding die for small parts.
JP33165395A 1995-12-20 1995-12-20 Interior material molding method and molding apparatus Expired - Lifetime JP3642852B2 (en)

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