JP3670596B2

JP3670596B2 - Powder slush molding skin material and molding apparatus therefor

Info

Publication number: JP3670596B2
Application number: JP2001144609A
Authority: JP
Inventors: 秀泰吉岡; 秀春大▲崎▼
Original assignee: 西川化成株式会社
Priority date: 2001-05-15
Filing date: 2001-05-15
Publication date: 2005-07-13
Anticipated expiration: 2021-05-15
Also published as: JP2002337171A

Description

【０００１】
【発明の属する技術分野】
この発明は、パウダースラッシュ成形法により成形された表皮材とその成形に用いられる成形装置の改良に関するものである。
【０００２】
【従来の技術】
特開平９−３９００５号公報に開示されているパウダースラッシュ成形表皮材では、成形面が部分的に冷却され、他の部分が加熱されたスラッシュ成形型を原料収容ボックスに組み付けて原料収容ボックスを反転させ、上記スラッシュ成形型の冷却箇所を除く領域にパウダー樹脂原料を落下させて溶着させることにより、成形と同時に開口部を有する表皮材を成形するようにしている。
【０００３】
実登第２６０１６１０号公報に開示されているパウダースラッシュ成形表皮材では、カバー部材が設けられた第１原料収容ボックスにスラッシュ成形型を組み付けてスラッシュ成形型の成形面をカバー部材で部分的に覆い、上記第１原料収容ボックスを反転させて上記カバー部材を除く領域に第１パウダー樹脂原料を落下させて溶着させることにより開口部を有する表皮表面層を成形し、その後、この表皮表面層が成形されたスラッシュ成形型をカバー部材のない別の第２原料収容ボックスに組み付けて第２原料収容ボックスを反転させ、第２パウダー樹脂原料を上記表皮表面層及び開口形成予定部に対応するスラッシュ成形型の成形面に落下させて溶着させ、上記表皮表面層の裏面に表皮表面層の開口部を含む全領域に亘って表皮裏面層が成形された２層構造の表皮材を成形するようにしている。
【０００４】
【発明が解決しようとする課題】
ところで、上述の如き表皮材で成形体の意匠面を構成する場合、前者の公報例の表皮材では、既に開口部が形成されているため、成形体成形時に成形型にセットされた表皮材の開口部周りから溶融樹脂が漏れ、成形体の意匠面である表皮材表面が汚れて見栄えを損なうことがある。
【０００５】
一方、後者の公報例の表皮材では、表皮表面層の開口部は表皮裏面層で塞がれているため、成形体成形時に溶融樹脂は漏れない。しかし、表皮材はパウダースラッシュ成形品であるため、成形された表皮材には表皮表面層の開口部内周縁に表皮裏面層が密着していて、当該箇所の肉厚が表皮表面層の肉厚と表皮裏面層の肉厚とのトータル肉厚となって厚肉になっていることから、表皮材の成形後に当該箇所の表皮裏面層を表皮表面層の開口部内周縁に沿って綺麗に取り除くことが困難になる。
【０００６】
この発明はかかる点に鑑みてなされたものであり、その目的とするところは、上記の後者の公報例のように開口部を成形体成形後に形成する場合において、開口形成予定部の表皮裏面層を簡単にしかも綺麗に取り除こうとすることである。また、そのための成形装置を提供することである。
【０００７】
【課題を解決するための手段】
上記の目的を達成するため、この発明は、表皮材の開口形成予定部周りの肉厚を薄くしたこと、及びそのために成形装置の構造を改良したことを特徴とする。
【０００８】
具体的には、この発明は、少なくとも芯材と一体成形されて成形体の意匠面を構成し上記芯材の開口部に対応する開口形成予定部を有するパウダースラッシュ成形表皮材及びその成形装置を対象とし、次のような解決手段を講じた。
【０００９】
すなわち、請求項１に記載の発明は、前者のパウダースラッシュ成形表皮材に関するものであり、上記開口形成予定部を除く領域に設けられた表皮表面層と、この表皮表面層の裏面に上記開口形成予定部を含む全領域に亘るように設けられた表皮裏面層とからなり、上記開口部の内周縁に対応する表皮表面層の内周縁と上記表皮裏面層との間には、環状凹条溝が形成され、この環状凹条溝により表皮裏面層の肉厚に相当しかつ一般部である表皮表面層及び表皮裏面層のトータル肉厚よりも薄肉の環状薄肉部が形成され、上記環状凹条溝で囲まれる表皮裏面層は上記一般部の表皮表面層よりも表面側に突出していることを特徴とする。
【００１０】
上記の構成により、請求項１に記載の発明では、成形体成形時には開口形成予定部に対応する表皮表面層の開口部を表皮裏面層が塞いでいるため、当該箇所から溶融樹脂は漏れず、成形体の意匠面である表皮材表面が溶融樹脂で汚れず綺麗に仕上がる。
【００１１】
また、この発明の表皮材は、芯材の開口部の内周縁に対応する表皮表面層の内周縁と表皮裏面層との間に環状薄肉部が環状凹条溝により形成され、しかもこの環状凹条溝は深くなっているため、成形体成形後に上記表皮裏面層の開口形成予定部の表皮裏面層を取り除く際、表皮裏面層が表皮表面層の開口部内周縁に沿って簡単にしかも綺麗に取り除かれて表皮材に目的通りの開口部が形成される。
【００１２】
請求項２に記載の発明は、後者のパウダースラッシュ成形表皮材の成形装置に関するものであり、成形面に上記開口部の内周縁に対応するように環状突条部が内周縁側を外周縁側よりも多く突出させて環状突条部で囲まれる成形面を環状突条部外側の成形面よりも低所に位置付けて突設され、パウダー樹脂原料を上記成形面に溶着させるスラッシュ成形型と、耐熱性の弾性シール材を有するカバー部材が設けられ、上記スラッシュ成形型が組み付けられた状態で、上記カバー部材の弾性シール材外周縁が上記環状突条部内周縁に圧接してこの環状突条部によって包囲される部分を覆い、反転することで内部に収容されたパウダー樹脂原料を上記スラッシュ成形型の成形面に落下させて溶着させ、上記開口形成予定部を除く領域に表皮表面層を成形する第１原料収容ボックスと、カバー部材が設けられておらず、上記表皮表面層が成形されたスラッシュ成形型が組み付けられた状態で反転し、内部に収容されたパウダー樹脂原料を上記表皮表面層及び上記開口形成予定部に対応するスラッシュ成形型の成形面に落下させて溶着させ、上記表皮表面層の裏面に上記開口形成予定部を含む全領域に亘るように表皮裏面層を成形し、上記開口部の内周縁に対応する表皮表面層の内周縁と上記表皮裏面層との間に環状凹条溝が形成され、この環状凹条溝により表皮裏面層の肉厚に相当しかつ一般部である表皮表面層及び表皮裏面層のトータル肉厚よりも薄肉の環状薄肉部が形成されているとともに、上記環状凹条溝で囲まれる表皮裏面層は上記一般部の表皮表面層よりも表面側に突出したパウダースラッシュ成形表皮材を成形する第２原料収容ボックスとを備えたことを特徴とする。
【００１３】
上記の構成により、請求項２に記載の発明では、表皮材の開口形成予定部に対応するスラッシュ成形型の成形面がカバー部材で覆われ、この際、上記開口部の内周縁に対応して突設された環状突条部内周縁に上記カバー部材の弾性シール材外周縁が圧接していることから、請求項１の作用効果を奏する表皮材が得られ、さらには、上記環状突条部周りのシールが確実に行われるとともにカバー部材の周囲にパウダー樹脂原料の溶融樹脂が付着せず、該溶融樹脂物による糸引き現象が発生せず、よって、糸引き状態の樹脂屑が第１原料収容ボックス内の第１パウダー樹脂原料に混入してその後に成形される表皮表面層に付着する事態が回避されるため、表皮表面層ひいては２層構造である表皮材の品質が保証される。
【００１４】
【発明の実施の形態】
以下、この発明の実施の形態について図面に基づいて説明する。
【００１５】
図８はこの発明の一実施形態に係るパウダースラッシュ成形表皮材１を示す。図９及び図１０はこの表皮材１が適用された成形体としての自動車用ドアトリム１１を成形するドアトリム成形装置１２５を示す。ここでは、上記表皮材１及びドアトリム１１は共に一部分しか現していないが、後述する図６には表皮材１の全体断面形状が現れており、また、図１，図３，図４及び図６のスラッシュ成形型１１１の型形状からして成形体がドアトリム１１であることが判る。
【００１６】
上記ドアトリム１１は、図９及び図１０に示すように、上記表皮材１と芯材１３との間に発泡層１５が一体成形された３層構造であり、表皮材１はドアトリム１１の意匠面を構成している。上記表皮材１のほぼ中央には横方向に長い略矩形の開口部１ａが形成され（図１０参照）、上記芯材１３のほぼ中央にも、上記表皮材１の開口部１ａに対応するように横方向に長い略矩形の開口部１３ａが形成されている（図９及び図１０参照）。図１のスラッシュ成形型１１１でハッチングを付している領域が開口部１ａ，１３ａに対応する箇所である。これら開口部１ａ，１３ａは装飾材であるオーナメント（図示せず）を装着するためのものである。
【００１７】
完成品としてのドアトリム１１では、上述の如く表皮材１には開口部１ａが形成されているが、ドアトリム１１を成形する際に用いられる表皮材１は、図８及び図９に示すように、上記開口部１ａは形成されておらず塞がっており、この領域を上記芯材１３の開口部１３ａに対応する開口形成予定部Ａとしている。上記表皮材１は、表皮表面層３と表皮裏面層５とからなる２層構造であり、上記表皮表面層３は上記開口形成予定部Ａを除く領域に設けられ、この開口形成予定部Ａに対応して開口部３ａが形成されている。上記表皮裏面層５は、上記表皮表面層３の裏面に上記開口形成予定部Ａを含む全領域に亘るように一体に接合されている。また、上記芯材１３の開口部１３ａの内周縁に対応する表皮表面層３の内周縁（開口部３ａ）と上記表皮裏面層５との間には、断面Ｖ字形の環状凹条溝７が形成され、この環状凹条溝７により環状薄肉部９が形成されている。そして、この環状薄肉部９の肉厚は表皮裏面層５の肉厚に相当し、一般部である表皮表面層３及び表皮裏面層５のトータル肉厚よりも薄肉に形成されている。
【００１８】
上述のように構成された表皮材１は、図１〜６に示すような成形装置を用いてパウダースラッシュ成形される。
【００１９】
この成形装置は、第１原料収容ボックス１０１（図２〜４参照）と第２原料収容ボックス１０３（図６参照）とを備え、上記第１原料収容ボックス１０１には第１パウダー樹脂原料Ｒ１が収容され、上記第２原料収容ボックス１０３には、上記第１パウダー樹脂原料Ｒ１よりも安価な第２パウダー樹脂原料Ｒ２が収容されている。これら第１及び第２原料収容ボックス１０１，１０３は共に、上方が開口した直方体形状をしており、短辺側の互いに対向する側壁１０１ａ，１０３ａには回転軸１０５が１つずつ突設され、この２つの回転軸１０５を図示しない回転装置によって回転させることにより、上記第１及び第２原料収容ボックス１０１，１０３を鉛直面内で回転させるようになっている。また、上記第１及び第２原料収容ボックス１０１，１０３の長辺側の互いに対向する側壁１０１ｂ，１０３ｂには、クランプ治具１０７が３個ずつ合計６個取り付けられている。さらに、上記第１及び第２原料収容ボックス１０１，１０３の内部には略矩形環状の仕切板１０９が設置され、この仕切板１０９で囲まれた空間に上記第１及び第２パウダー樹脂原料Ｒ１，Ｒ２が実質的に収容される。そして、スラッシュ成形型１１１をその成形面１１３を下に向けた姿勢で、上記第１及び第２パウダー樹脂原料Ｒ１，Ｒ２が収容された第１及び第２原料収容ボックス１０１，１０３の開口端（仕切板１０９の上端）をスラッシュ成形型１１１の成形面１１３外周に当接させて上記第１及び第２原料収容ボックス１０１，１０３の開口を覆うようにセットし、上記クランプ治具１０７でスラッシュ成形型１１１の外周を挟持してスラッシュ成形型１１１を第１及び第２原料収容ボックス１０１，１０３に組み付けるようにしている。
【００２０】
ここで、上記スラッシュ成形型１１１の型構造について説明する。このスラッシュ成形型１１１は、図１に示すように、シェル状に形成された横長矩形の型本体１１５を備えてなり、該型本体１１５には成形すべき表皮材１（表皮表面層３，表皮裏面層５）の形状を呈する上記成形面１１３が形成されている。この成形面１１３には、表皮材１の表皮表面層３と表皮裏面層５との２層部分に対応する製品部１１３ａと、この製品部１１３ａで囲まれる開口形成予定部Ａに対応する非製品部１１３ｂ（図１に斜線を付して表わす領域）とが形成されている。また、上記成形面１１３には、上記非製品部１１３ｂの外周縁（芯材１３の開口部１３ａの内周縁）に対応するように断面三角形の環状突条部１１３ｃが突設され（図５参照）、上記製品部１１３ａの外周には、上記第１及び第２原料収容ボックス１０１，１０３の仕切板１０９が当接する見切りライン１１３ｄが形成されている。上記環状突条部１１３ｃの突出量は、環状突条部１１３ｃ内周縁側の成形面１１３である非製品部１１３ｂ（開口形成予定部Ａ）側の方が環状突条部１１３ｃ外周縁側の成形面１１３である製品部１１３ａ側の方よりも多く突出していて、つまり非製品部１１３ｂ（開口形成予定部Ａ）側の成形面１１３が製品部１１３ａ側の成形面１１３よりも低くなっていて、これにより、成形された表皮材１の環状凹条溝７を深く確保するようになっている。
【００２１】
上記第１原料収容ボックス１０１の仕切板１０９内には、板状のカバー部材１１７が４本のロッド状の橋脚部材１１９によって支持されて配置され、上記カバー部材１１７は、上記スラッシュ成形型１１１が第１原料収容ボックス１０１にクランプ保持されて第１原料収容ボックス１０１に組み付けられた状態で、上記環状突条部１１３ｃに当接してこの環状突条部１１３ｃによって包囲される部分、つまり成形面１１３の非製品部１１３ｂを覆うようになっている。
【００２２】
図５に拡大して示すように、上記カバー部材１１７はカバープレート１２１を備え、このカバープレート１２１には、上記環状突条部１１３ｃと当接するシリコーンゴム等の耐熱性の弾性シール材１２３が貼着されている。そして、スラッシュ成形型１１１を第１原料収容ボックス１０１に組み付けたボックス密閉状態で、上記弾性シール材１２３は上記スラッシュ成形型１１１の成形面１１３の非製品部１１３ｂ外周である環状突条部１１３ｃに当接して非製品部１１３ｂを取り囲むようになっている。この状態で、上記弾性シール材１２３は上記非製品部１１３ｂと接触せずに間隔をあけており、かつ弾性シール材１２３の外周縁が上記環状突条部１１３ｃの内側面に隙間が生じないように圧接している。
【００２３】
一方、上記第２原料収容ボックス１０３内には、図６に示すように、上記第１原料収容ボックス１０１内の如き橋脚部材１１９によって支持されたカバー部材１１７が設けられていないほかは、第１原料収容ボックス１０１と同一に構成されている。
【００２４】
上述の如く構成された成形装置では、図３に示すように、スラッシュ成形型１１１の成形面１１３外周（製品部１１３ａ外周）である見切りライン１１３ｄを第１原料収容ボックス１０１の開口端（仕切板１０９の上端）に当接させるとともに、カバー部材１１７の弾性シール材１２３を環状突条部１１３ｃに当接させて非製品部１１３ｂをカバー部材１１７で覆ってスラッシュ成形型１１１を第１原料収容ボックス１０１に組み付けたボックス密閉状態で、図４に示すように、第１原料収容ボックス１０１を反転させることで内部に収容された第１パウダー樹脂原料Ｒ１を上記スラッシュ成形型１１１の成形面１１３の製品部１１３ａに落下させて溶着させ、上記非製品部１１３ｂ（表皮材１の開口形成予定部Ａ）を除く領域に表皮表面層３を成形するようになっている。さらに、上記表皮表面層３が成形されたスラッシュ成形型１１１を第２原料収容ボックス１０３に上記第１原料収容ボックス１０１の場合と同様にして組み付けたボックス密閉状態で、第２原料収容ボックス１０３を反転させ、内部に収容された第２パウダー樹脂原料Ｒ２を上記表皮表面層３び上記開口形成予定部Ａに対応するスラッシュ成形型１１１の成形面１１３を構成する非製品部１１３ｂに落下させて溶着させ、図６及び図７に示すように、上記表皮表面層３の裏面に上記開口形成予定部Ａを含む全領域に亘るように表皮裏面層５を成形し、これにより、２層構造の表皮材１を成形するようになっている。
【００２５】
次に、表皮材１の成形要領を説明する。
【００２６】
まず、図３に示すように、予め所定温度に加熱されたスラッシュ成形型１１１をその成形面１１３を下に向けた姿勢で、第１パウダー樹脂原料Ｒ１が収容された第１原料収容ボックス１０１に組み付ける。この際、第１原料収容ボックス１０１の仕切板１０９上端をスラッシュ成形型１１１の成形面１１３の見切りライン１１３ｄに当接させて第１原料収容ボックス１０１の開口をスラッシュ成形型１１１で覆うようにし、クランプ治具１０７で上記スラッシュ成形型１１１の外周を挟持する。この状態で、カバー部材１１７の弾性シール材１２３がスラッシュ成形型１１１の成形面１１３の環状突条部１１３ｃに当接して非製品部１１３ｂを覆って非製品部１１３ｂ周りをシールする。
【００２７】
次いで、図４に示すように、上記第１原料収容ボックス１０１をその一対の回転軸１０５を回転装置によって回転させることにより鉛直面内で上下方向に１８０°反転させ、第１原料収容ボックス１０１内に収容された第１パウダー樹脂原料Ｒ１を上記スラッシュ成形型１１１の成形面１１３の製品部１１３ａに落下させる。これにより、成形面１１３の製品部１１３ａに付着した第１パウダー樹脂原料Ｒ１が型温により溶融して製品部１１３ａに溶着し、表皮表面層３が成形される。
【００２８】
この際、図５に拡大して示すように、カバー部材１１７の弾性シール材１２３外周縁をスラッシュ成形型１１１の成形面１１３の環状突条部１１３ｃ内周縁に圧接させていることから、開口形成予定部Ａに対応する非製品部１１３ｂ周りを確実にシールするとともに上記弾性シール材１２３の周囲に第１パウダー樹脂原料Ｒ１の溶融樹脂が付着せず、該溶融樹脂による糸引き現象を発生しないようにすることができる。これにより、糸引き状態の樹脂屑が第１原料収容ボックス１０１内の第１パウダー樹脂原料Ｒ１に混入してその後に成形される表皮表面層３に付着する事態を回避して、表皮表面層３ひいては２層構造である表皮材１の品質を保証することができる。
【００２９】
また、弾性シール材１２３が環状突条部１１３ｃに押圧されて弾性変形することでシールを一層確実に行うことができる。
【００３０】
その後、上記第１原料収容ボックス１０１を鉛直面内で１８０°反転させ、余剰の第１パウダー樹脂原料Ｒ１を第１原料収容ボックス１０１内に落下させた後、上記各クランプ治具１０７をアンクランプ作動させて表皮表面層３が成形されたスラッシュ成形型１１１を第１原料収容ボックス１０１から取り外し、今度は第２原料収容ボックス１０３に組み付ける。その組付け方は、カバー部材１１７がないほかは第１原料収容ボックス１０１の場合と同じである。
【００３１】
しかる後、上記第２原料収容ボックス１０３をその一対の回転軸１０５を回転装置によって回転させることにより鉛直面内で上下方向に１８０°反転させ、第２原料収容ボックス１０３内に収容された第２パウダー樹脂原料Ｒ２を上記表皮表面層３及び上記開口形成予定部Ａに対応するスラッシュ成形型１１１の成形面１１３の非製品部１１３ｂに落下させる。これにより、上記表皮表面層３及び成形面１１３の非製品部１１３ｂに付着した第２パウダー樹脂原料Ｒ２が型温により溶融して表皮表面層３及び非製品部１１３ｂに溶着し、上記表皮表面層３の裏面に上記開口形成予定部Ａを含む全領域に亘るように表皮裏面層５が成形され、２層構造の表皮材１が成形される（図６及び図７参照）。
【００３２】
次に、図６に示すように、第２原料収容ボックス１０３を鉛直面内で上下方向に１８０°反転させ、余剰の第２パウダー樹脂原料Ｒ２を第２原料収容ボックス１０３内に落下させた後、上記各クランプ治具１０７をアンクランプ作動させて表皮材１が成形されたスラッシュ成形型１１１を第２原料収容ボックス１０３から取り外す。
【００３３】
その後、上述の如くして表皮材１が成形されたスラッシュ成形型１１１を冷却ボックスにセットし、その成形面１１３裏面に冷却水を吹き付けて冷却した後、表皮材１をスラッシュ成形型１１１の成形面１１３から脱型する。
【００３４】
この脱型された表皮材１は、図９に示すようなドアトリム成形装置１２５の下型である第１成形型１２７の成形面１２７ａに開口形成予定部Ａが第１成形型１２７の貫通孔１２７ｂに対応するようにセットされてドアトリム１１の成形に供せられる。一方、上記ドアトリム成形装置１２５の上型である第２成形型１２９の成形面１２９ａに芯材１３がその開口部１３ａが第２成形型１２９の貫通孔１２９ｂに対応するようにセットされる。そして、上記第１成形型１２７と第２成形型１２９の型閉じ状態で芯材１３の開口部１３ａ周りに突設された突起１３ｂを表皮材１の表皮裏面層５に当接させて当該箇所をシールし、上記表皮材１（表皮裏面層５）と芯材１３との間に形成されたキャビティ１３１にポリウレタン等の発泡樹脂原料を注入して発泡層１５を一体成形し、３層構造のドアトリム１１を成形するようになっている。
【００３５】
この際、表皮材１には開口形成予定部Ａがあって未だ開口部１ａが形成されていないことから、キャビティ１３１内に注入された発泡樹脂原料が漏れる事態が回避され、ドアトリム１１の意匠面である表皮材１表面を発泡樹脂原料の漏出による汚染から守ることができる。
【００３６】
上記第１成形型１２７の貫通孔１２７ｂ内には、上方に延びるピストンロッド１３３を有する流体圧シリンダ（図示せず）が配置され、上記ピストンロッド１３３先端には、直角三角形の厚肉の金属板からなる２つのブロック状の押切具１３５がプレート１３７を介して取り付けられている。そして、上述の如くして成形されたドアトリム１１が型内にある状態で、つまり、型閉じした状態で、上記２つの押切具１３５を流体圧シリンダの伸長作動により第１成形型１２７側から上方に進出させて表皮材１の開口形成予定部Ａの外周縁部に押し当て、これにより、図１０に示すように、上記表皮材１の環状薄肉部９を押し切って表皮材１に開口部１ａを形成する。
【００３７】
このように、表皮材１の環状薄肉部９を押し切って表皮材１に開口部１ａを形成するようにしていることから、表皮裏面層５を表皮表面層３の開口部３ａ内周縁に沿って簡単にしかも綺麗に取り除くことができて目的通りの開口部１ａを表皮材１に形成することができる。
【００３８】
なお、上記の実施形態では、スラッシュ成形型１１１の成形面１１３の非製品部１１３ｂが成形面１１３のほぼ中央部分に位置して該非製品部１１３ｂを製品部１１３ａで取り囲んでいる場合を示したが、非製品部１１３ｂの一端側が成形面１１３の端部にまで延びている場合等であっても同様の作用効果を得ることができるものである。
【００３９】
また、上記の実施形態では、第１成形型１２７と第２成形型１２９とを型閉じした後、キャビティ１３１に発泡樹脂原料を注入するクローズド注入法であったが、第１成形型１２７と第２成形型１２９とを型開きした状態で発泡樹脂原料を注入した後に型閉じするオープン注入法でもよい。
【００４０】
さらに、成形体としてドアトリム１１を示したが、インストルメントパネルやその他の自動車用内装品、さらには自動車用内装品以外のものであってもよい。また、その構造も表皮材１と芯材１３との間に発泡層１５が一体成形された３層構造に限らず、発泡層がなくて表皮材と芯材との２層からなるものにも適用することができる。
【００４１】
【発明の効果】
以上説明したように、請求項１に係る発明によれば、開口形成予定部を除く領域に設けられた表皮表面層の裏面に上記開口形成予定部を含む全領域に亘るように表皮裏面層を設けたので、成形体成形時に開口形成予定部に対応する表皮表面層の開口部を表皮裏面層で塞いで溶融樹脂の漏出をなくし、表皮材表面を綺麗に仕上げることがきる。
【００４２】
また、芯材の開口部の内周縁に対応する表皮表面層の内周縁と表皮裏面層との間に環状薄肉部を環状凹条溝により形成し、しかもこの環状凹条溝を深くしているので、成形体成形後に上記開口形成予定部に対応する表皮裏面層を表皮表面層の開口部内周縁に沿って簡単にしかも綺麗に取り除いて表皮材に目的通りの開口部を形成することができる。
【００４３】
請求項２に係る発明によれば、芯材の開口部の内周縁に対応するようにスラッシュ成形型の成形面に突設された環状突条部内周縁にカバー部材の弾性シール材外周縁を圧接させているので、請求項１の作用効果に加えて、環状突条部周りのシールを確実にでき、樹脂漏れ及びカバー部材周囲への溶融樹脂の付着に起因する糸引き現象をなくして樹脂屑がその後に成形される表皮表面層に付着する事態を回避し、品質の高い表皮材を成形することができる。
【図面の簡単な説明】
【図１】スラッシュ成形型の正面図である。
【図２】第１原料収容ボックスの斜視図である。
【図３】第１原料収容ボックスにスラッシュ成形型をセットした状態を示す断面図である。
【図４】第１原料収容ボックスを反転させてスラッシュ成形型に第１パウダー樹脂原料を落下させて溶着させ、スラッシュ成形型に表皮表面層が成形された状態を示す断面図である。
【図５】図４のＢ部拡大図である。
【図６】スラッシュ成形型に成形された表皮表面層の裏面に表皮裏面層が成形されて表皮材が成形された状態を示す断面図である。
【図７】図６のＣ部において表皮材を上に向けた状態を示す拡大図である。
【図８】スラッシュ成形型から脱型した表皮材の図７相当図である。
【図９】成形直後のドアトリムの開口部に対応する表皮材の開口形成予定部に押切具が対応配置されている状態を示すドアトリム成形装置の断面図である。
【図１０】ドアトリムの開口部に対応する表皮材の開口形成予定部を押切具の上昇により押し切った状態を示すドアトリム成形装置の断面図である。
【符号の説明】
１表皮材
１ａ開口部
３表皮表面層
５表皮裏面層
７環状凹条溝
９環状薄肉部
１１ドアトリム（成形体）
１３芯材
１０１第１原料収容ボックス
１０３第２原料収容ボックス
１１１スラッシュ成形型
１１３成形面
１１３ｃ環状突条部
１１７カバー部材
１２３弾性シール材
Ａ開口形成予定部
Ｒ１第１パウダー樹脂原料
Ｒ２第２パウダー樹脂原料[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to an improvement in a skin material molded by a powder slush molding method and a molding apparatus used for the molding.
[0002]
[Prior art]
  In the powder slush molding skin material disclosed in Japanese Patent Application Laid-Open No. 9-39005, the slush molding mold in which the molding surface is partially cooled and the other part is heated is assembled to the raw material storage box and the raw material storage box is inverted. Then, by dropping and welding the powder resin raw material to the region excluding the cooling portion of the slush molding die, a skin material having an opening is molded at the same time as molding.
[0003]
  In the powder slush molding skin material disclosed in Japanese Utility Model No. 2601610, the slush molding die is assembled to the first raw material storage box provided with the cover member, and the molding surface of the slush molding die is partially covered with the cover member. Inverting the first raw material storage box to drop and weld the first powder resin raw material to the region excluding the cover member, thereby forming the skin surface layer having an opening, and then forming the skin surface layer The assembled slush mold is assembled to another second raw material storage box without a cover member, the second raw material storage box is inverted, and the second powder resin raw material is applied to the skin surface layer and the opening formation scheduled portion. It is dropped on the molding surface and welded, and the skin back layer is formed over the entire area including the opening of the skin surface layer on the back surface of the skin surface layer. So that molding the skin material in the form a two-layer structure.
[0004]
[Problems to be solved by the invention]
  By the way, when the design surface of the molded body is constituted by the skin material as described above, since the opening is already formed in the skin material of the former publication example, the skin material set in the molding die at the time of molding the molded body The molten resin may leak from around the opening, and the surface of the skin material, which is the design surface of the molded body, may become dirty and impair the appearance.
[0005]
  On the other hand, in the skin material of the latter publication example, the opening of the skin surface layer is closed by the skin back layer, so that the molten resin does not leak during molding. However, since the skin material is a powder slush molded product, the skin surface back layer is in close contact with the inner periphery of the opening of the skin surface layer on the molded skin material, and the thickness of the part is the thickness of the skin surface layer. Since the total thickness with the thickness of the skin back layer is increased, it is possible to cleanly remove the skin back layer at the relevant location along the inner periphery of the opening of the skin surface layer after molding the skin material. It becomes difficult.
[0006]
  The present invention has been made in view of such points, and the object of the invention is to form a skin back surface layer of an opening formation scheduled portion when the opening is formed after molding a molded body as in the above-mentioned latter publication example. Is to remove it easily and cleanly. Moreover, it is providing the shaping | molding apparatus for it.
[0007]
[Means for Solving the Problems]
  In order to achieve the above object, the present invention is characterized in that the thickness around the opening formation scheduled portion of the skin material is reduced and the structure of the molding apparatus is improved for that purpose.
[0008]
  Specifically, the present invention provides a powder slush molding skin material and a molding apparatus therefor, which are integrally molded with at least a core material to form a design surface of the molded body and have an opening formation scheduled portion corresponding to the opening of the core material. Targeted the following solutions.
[0009]
  That is, the invention according to claim 1 relates to the former powder slush-molded skin material, the skin surface layer provided in a region excluding the opening formation planned portion, and the opening formation on the back surface of the skin surface layer. An annular groove groove between the inner peripheral edge of the skin surface layer corresponding to the inner peripheral edge of the opening and the outer skin rear surface layer. Is formed by this annular grooveCorresponds to the thickness of the skin back layer and is thinner than the total thickness of the skin surface layer and skin back layer, which is a general part.An annular thin part is formedThe skin back surface layer surrounded by the annular groove groove protrudes to the surface side from the skin surface layer of the general part.It is characterized by.
[0010]
  With the above configuration, in the invention according to claim 1, since the skin back layer closes the opening of the skin surface layer corresponding to the opening formation scheduled portion during molding, the molten resin does not leak from the location, The surface of the skin material, which is the design surface of the molded product, is finished cleanly without being stained with molten resin.
[0011]
  Further, in the skin material of the present invention, an annular thin portion is formed by an annular groove between the inner peripheral edge of the skin surface layer corresponding to the inner peripheral edge of the opening of the core material and the skin back surface layer.And this annular groove is deeperTherefore, when removing the skin back layer in the opening formation portion of the skin back layer after molding the molded body, the skin back layer is easily and cleanly removed along the inner periphery of the skin surface layer opening.For skin materialA desired opening is formed.
[0012]
  Claim2The described invention relates to a molding apparatus for the latter powder slush molding skin material., MatureAn annular ridge is formed on the shape surface so as to correspond to the inner peripheral edge of the opening.Project the inner peripheral edge side more than the outer peripheral edge side and position the molding surface surrounded by the annular ridge part at a lower position than the molding surface outside the annular ridge part.A slush mold that protrudes and welds the powder resin raw material to the molding surface;Has heat-resistant elastic sealing materialThe cover member is provided with a cover member and the slash mold is assembled.Elastic seal material outer peripheryIs the above-mentioned annular ridgeInner peripheryInPressureCovering the portion surrounded by the annular ridge and contacting it, the powder resin raw material housed inside is dropped and welded to the molding surface of the slush molding die, and the region excluding the opening formation planned portion The first raw material storage box for forming the skin surface layer and the powder resin which is not provided with a cover member and is inverted in a state in which the slush mold in which the skin surface layer is molded is assembled and is stored inside The raw material is dropped on the molding surface of the slush mold corresponding to the skin surface layer and the opening formation planned portion and welded, and the skin back surface so as to cover the entire area including the opening formation planned portion on the back surface of the skin surface layer. Forming layerAnd an annular groove is formed between the inner peripheral edge of the skin surface layer corresponding to the inner peripheral edge of the opening and the skin back surface layer, and this annular groove corresponds to the thickness of the skin back layer and An annular thin-walled portion that is thinner than the total thickness of the skin surface layer and the skin back layer, which is a general part, is formed, and the skin back layer surrounded by the annular groove is more than the skin surface layer of the general part Molded powder slush molding skin material protruding to the front sideAnd a second raw material storage box.
[0013]
  With the above configuration, in the invention described in claim 2, the molding surface of the slash molding die corresponding to the opening formation scheduled portion of the skin material is covered with the cover member, and at this time, corresponding to the inner peripheral edge of the opening portion. Projected annular ridgeInner peripheryOn the cover memberElastic seal material outer peripheryButPressureAccordingly, the skin material having the function and effect of claim 1 is obtained, and further, the sealing around the annular ridge portion is surely performed and the molten resin of the powder resin material is attached around the cover member. The stringing phenomenon due to the molten resin material does not occur, so that the resin waste in the stringed state is mixed into the first powder resin raw material in the first raw material storage box and is formed on the skin surface layer formed thereafter Since the situation of adhesion is avoided, the quality of the skin surface layer and thus the skin material having a two-layer structure is guaranteed..
[0014]
DETAILED DESCRIPTION OF THE INVENTION
  Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0015]
  FIG. 8 shows a powder slush molding skin material 1 according to an embodiment of the present invention. 9 and 10 show a door trim molding device 125 for molding the automobile door trim 11 as a molded body to which the skin material 1 is applied. Here, both the skin material 1 and the door trim 11 are only partially shown, but the overall cross-sectional shape of the skin material 1 appears in FIG. 6 to be described later, and FIG. 1, FIG. 3, FIG. 4 and FIG. From the shape of the slush mold 111, it can be seen that the molded body is the door trim 11.
[0016]
  As shown in FIGS. 9 and 10, the door trim 11 has a three-layer structure in which a foam layer 15 is integrally formed between the skin material 1 and the core material 13, and the skin material 1 is a design surface of the door trim 11. Is configured. A substantially rectangular opening 1a that is long in the lateral direction is formed in the substantially center of the skin material 1 (see FIG. 10), and the center of the core material 13 also corresponds to the opening 1a of the skin material 1. A substantially rectangular opening 13a that is long in the lateral direction is formed in the top (see FIGS. 9 and 10). The hatched areas in the slash mold 111 of FIG. 1 are the locations corresponding to the openings 1a and 13a. These openings 1a and 13a are for mounting ornaments (not shown) which are decorative materials.
[0017]
  In the door trim 11 as a finished product, the opening 1a is formed in the skin material 1 as described above, but the skin material 1 used when molding the door trim 11 is as shown in FIGS. The opening 1a is not formed and is closed, and this region is defined as an opening formation scheduled portion A corresponding to the opening 13a of the core member 13. The skin material 1 has a two-layer structure composed of a skin surface layer 3 and a skin back surface layer 5, and the skin surface layer 3 is provided in a region excluding the opening formation scheduled portion A, and the opening formation scheduled portion A Correspondingly, an opening 3a is formed. The skin back surface layer 5 is integrally joined to the back surface of the skin surface layer 3 so as to cover the entire region including the opening formation scheduled portion A. An annular groove 7 having a V-shaped cross section is formed between the inner peripheral edge (opening 3a) of the skin surface layer 3 corresponding to the inner peripheral edge of the opening 13a of the core member 13 and the skin back surface layer 5. The annular thin groove portion 9 is formed by the annular groove 7 formed. The thickness of the annular thin portion 9 corresponds to the thickness of the skin back layer 5 and is thinner than the total thickness of the skin surface layer 3 and the skin back layer 5 which are general portions.
[0018]
  The skin material 1 configured as described above is powder slush molded using a molding apparatus as shown in FIGS.
[0019]
  The molding apparatus includes a first raw material storage box 101 (see FIGS. 2 to 4) and a second raw material storage box 103 (see FIG. 6), and a first powder resin raw material R1 is contained in the first raw material storage box 101. The second raw material storage box 103 stores the second powder resin raw material R2 which is cheaper than the first powder resin raw material R1. Both of these first and second raw material storage boxes 101, 103 have a rectangular parallelepiped shape with an opening on the upper side, and a rotating shaft 105 is projected one by one on the side walls 101a, 103a facing each other on the short side, By rotating these two rotating shafts 105 by a rotating device (not shown), the first and second raw material storage boxes 101 and 103 are rotated in a vertical plane. A total of six clamp jigs 107 are attached to the side walls 101b and 103b facing each other on the long sides of the first and second raw material storage boxes 101 and 103, respectively. Furthermore, a substantially rectangular annular partition plate 109 is installed inside the first and second raw material storage boxes 101 and 103, and the first and second powder resin raw materials R 1 and R 2 are placed in a space surrounded by the partition plate 109. R2 is substantially contained. Then, with the slush mold 111 placed in a posture in which the molding surface 113 faces downward, open ends of the first and second raw material storage boxes 101 and 103 in which the first and second powder resin raw materials R1 and R2 are stored ( The upper end of the partition plate 109 is brought into contact with the outer periphery of the molding surface 113 of the slush mold 111 so as to cover the openings of the first and second raw material storage boxes 101 and 103, and the slash molding is performed by the clamp jig 107. The slash molding die 111 is assembled to the first and second raw material storage boxes 101 and 103 while sandwiching the outer periphery of the die 111.
[0020]
  Here, the mold structure of the slash mold 111 will be described. As shown in FIG. 1, the slash mold 111 includes a horizontally long rectangular mold body 115 formed in a shell shape, and the mold body 115 has a skin material 1 (skin surface layer 3, skin) to be molded. The molding surface 113 having the shape of the back layer 5) is formed. The molding surface 113 includes a product portion 113a corresponding to the two-layer portion of the skin surface layer 3 and the skin back surface layer 5 of the skin material 1, and a non-product corresponding to the opening formation scheduled portion A surrounded by the product portion 113a. A portion 113b (a region represented by hatching in FIG. 1) is formed. Further, an annular protrusion 113c having a triangular cross-section is provided on the molding surface 113 so as to correspond to the outer peripheral edge of the non-product part 113b (the inner peripheral edge of the opening 13a of the core member 13) (see FIG. 5). ), A parting line 113d with which the partition plate 109 of the first and second raw material storage boxes 101 and 103 abuts is formed on the outer periphery of the product portion 113a. The amount of protrusion of the annular ridge 113c isThis is a molding surface 113 on the inner peripheral edge side of the annular ridge 113c.The non-product part 113b (opening formation scheduled part A) side isThis is the molding surface 113 on the outer peripheral edge side of the annular protrusion 113c.It protrudes more than the product part 113a side, that is, the molding surface 113 on the non-product part 113b (opening formation scheduled part A) side is lower than the molding surface 113 on the product part 113a side. The annular groove 7 of the formed skin material 1 is secured deeply.
[0021]
  In the partition plate 109 of the first raw material storage box 101, a plate-like cover member 117 is supported and arranged by four rod-shaped bridge pier members 119. The cover member 117 includes the slash molding die 111. In a state of being clamped and held in the first raw material storage box 101 and assembled to the first raw material storage box 101, a portion that comes into contact with the annular ridge 113c and is surrounded by the annular ridge 113c, that is, a molding surface 113. The non-product part 113b is covered.
[0022]
  As shown in an enlarged view in FIG. 5, the cover member 117 includes a cover plate 121, and a heat-resistant elastic sealing material 123 such as silicone rubber that abuts on the annular protrusion 113c is attached to the cover plate 121. It is worn. The elastic sealing material 123 is attached to the annular ridge 113c that is the outer periphery of the non-product portion 113b of the molding surface 113 of the slash molding die 111 in a sealed state where the slash molding die 111 is assembled to the first raw material storage box 101. It abuts and surrounds the non-product portion 113b. In this state, the elastic sealing material 123 is spaced apart from the non-product portion 113b and the outer peripheral edge of the elastic sealing material 123 does not cause a gap on the inner side surface of the annular protrusion 113c. Is in pressure contact.
[0023]
  On the other hand, in the second raw material storage box 103, as shown in FIG. 6, a cover member 117 supported by a pier member 119 as in the first raw material storage box 101 is not provided. It is configured in the same manner as the raw material storage box 101.
[0024]
  In the molding apparatus configured as described above, as shown in FIG. 3, the parting line 113 d that is the outer periphery of the molding surface 113 (outer periphery of the product portion 113 a) of the slush mold 111 is connected to the open end (partition plate) of the first raw material storage box 101. 109, and the elastic sealing material 123 of the cover member 117 is brought into contact with the annular protrusion 113c so that the non-product portion 113b is covered with the cover member 117 and the slash mold 111 is placed in the first raw material storage box. In the sealed state of the box assembled to 101, as shown in FIG. 4, the first powder resin raw material R1 housed inside is inverted by turning the first raw material housing box 101 into the product of the molding surface 113 of the slush molding die 111. It is dropped and welded to the portion 113a, and the skin surface layer is formed in a region excluding the non-product portion 113b (the opening formation scheduled portion A of the skin material 1). It is adapted to form the. Furthermore, the second raw material storage box 103 is assembled in a sealed state in which the slush mold 111 formed with the skin surface layer 3 is assembled to the second raw material storage box 103 in the same manner as the first raw material storage box 101. The second powder resin raw material R2 contained inside is dropped and welded to the non-product portion 113b constituting the molding surface 113 of the slush molding die 111 corresponding to the skin surface layer 3 and the opening formation scheduled portion A. 6 and 7, the skin back surface layer 5 is formed on the back surface of the skin surface layer 3 so as to cover the entire area including the opening formation scheduled portion A, whereby the skin having a two-layer structure is formed. The material 1 is formed.
[0025]
  Next, the molding procedure of the skin material 1 will be described.
[0026]
  First, as shown in FIG. 3, the slush mold 111 heated in advance to a predetermined temperature is placed in the first raw material storage box 101 in which the first powder resin raw material R1 is stored with the molding surface 113 facing downward. Assemble. At this time, the upper end of the partition plate 109 of the first raw material storage box 101 is brought into contact with the parting line 113d of the molding surface 113 of the slash molding die 111 so as to cover the opening of the first raw material storage box 101 with the slush molding die 111, The outer periphery of the slash mold 111 is clamped by the clamp jig 107. In this state, the elastic sealing material 123 of the cover member 117 abuts on the annular protrusion 113c of the molding surface 113 of the slash molding die 111 to cover the non-product portion 113b and seal around the non-product portion 113b.
[0027]
  Next, as shown in FIG. 4, the first raw material storage box 101 is inverted 180 ° in the vertical direction in the vertical plane by rotating the pair of rotating shafts 105 by a rotating device, and the first raw material storage box 101 The first powder resin raw material R1 accommodated in the slush mold 111 is dropped onto the product portion 113a of the molding surface 113 of the slush molding die 111. Thereby, the first powder resin raw material R1 adhering to the product part 113a of the molding surface 113 is melted by the mold temperature and welded to the product part 113a, and the skin surface layer 3 is molded.
[0028]
  At this time, as shown in an enlarged view in FIG. 5, the elastic sealing material 123 of the cover member 117.Outer peripheryThe annular ridge 113c of the molding surface 113 of the slash mold 111Inner peripheryInPressureTherefore, the periphery of the non-product portion 113b corresponding to the opening formation scheduled portion A is reliably sealed, and the molten resin of the first powder resin raw material R1 does not adhere to the periphery of the elastic sealing material 123, and the melt It is possible to prevent the stringing phenomenon due to the resin from occurring. Thereby, the situation where the resin waste in the stringing state is mixed into the first powder resin raw material R1 in the first raw material storage box 101 and adheres to the skin surface layer 3 to be molded thereafter, the skin surface layer 3 is avoided. As a result, the quality of the skin material 1 having a two-layer structure can be guaranteed.
[0029]
  Further, the elastic sealing material 123 is pressed against the annular protrusion 113c and elastically deformed, so that the sealing can be performed more reliably.
[0030]
  Thereafter, the first raw material storage box 101 is inverted 180 ° in the vertical plane, and the excess first powder resin raw material R1 is dropped into the first raw material storage box 101, and then the clamp jigs 107 are unclamped. The slush mold 111 in which the skin surface layer 3 is formed by operating is removed from the first raw material storage box 101 and this time is assembled to the second raw material storage box 103. The assembly method is the same as that of the first raw material storage box 101 except that the cover member 117 is not provided.
[0031]
  Thereafter, the second raw material storage box 103 is inverted 180 ° in the vertical direction in the vertical plane by rotating the pair of rotating shafts 105 by a rotating device, and the second raw material storage box 103 is stored in the second raw material storage box 103. The powder resin raw material R2 is dropped on the non-product part 113b of the molding surface 113 of the slush molding die 111 corresponding to the skin surface layer 3 and the opening formation scheduled part A. As a result, the second powder resin raw material R2 adhering to the skin surface layer 3 and the non-product portion 113b of the molding surface 113 is melted by the mold temperature and welded to the skin surface layer 3 and the non-product portion 113b. The skin back surface layer 5 is formed on the back surface of 3 so as to cover the entire region including the opening formation scheduled portion A, and the skin material 1 having a two-layer structure is formed (see FIGS. 6 and 7).
[0032]
  Next, as shown in FIG. 6, after the second raw material storage box 103 is inverted 180 ° in the vertical direction in the vertical plane, and the excess second powder resin raw material R2 is dropped into the second raw material storage box 103. The slush mold 111 on which the skin material 1 is molded is removed from the second raw material storage box 103 by unclamping each of the clamp jigs 107.
[0033]
  Thereafter, the slush mold 111 on which the skin material 1 is molded as described above is set in a cooling box and cooled by spraying cooling water on the back surface of the molding surface 113, and then the skin material 1 is molded into the slush mold 111. Demold from surface 113.
[0034]
  The removed skin material 1 has an opening formation scheduled portion A on a molding surface 127a of a first molding die 127 which is a lower die of a door trim molding device 125 as shown in FIG. 9 and a through hole 127b of the first molding die 127. The door trim 11 is formed so as to correspond to the above. On the other hand, the core 13 is set on the molding surface 129a of the second molding die 129 which is the upper mold of the door trim molding device 125 so that the opening 13a thereof corresponds to the through hole 129b of the second molding die 129. And the protrusion 13b projected around the opening 13a of the core material 13 in the closed state of the first molding die 127 and the second molding die 129 is brought into contact with the skin back surface layer 5 of the skin material 1, and the corresponding portion And a foamed resin material such as polyurethane is injected into a cavity 131 formed between the skin material 1 (skin back layer 5) and the core material 13 to integrally form the foam layer 15 to form a three-layer structure. The door trim 11 is formed.
[0035]
  At this time, since the skin material 1 has the opening formation scheduled portion A and the opening portion 1a is not yet formed, a situation in which the foamed resin material injected into the cavity 131 leaks is avoided, and the design surface of the door trim 11 The surface of the skin material 1 can be protected from contamination due to leakage of the foamed resin material.
[0036]
  A fluid pressure cylinder (not shown) having an upwardly extending piston rod 133 is disposed in the through hole 127b of the first mold 127, and a thick metal plate having a right triangle is formed at the tip of the piston rod 133. Two block-shaped pressing tools 135 are attached via a plate 137. Then, with the door trim 11 molded as described above in the mold, that is, with the mold closed, the above two pressing tools 135 are moved upward from the first mold 127 side by the extension operation of the fluid pressure cylinder. To the outer peripheral edge of the opening formation scheduled portion A of the skin material 1, thereby pressing the annular thin portion 9 of the skin material 1 and opening 1a in the skin material 1 as shown in FIG. Form.
[0037]
  As described above, the annular thin portion 9 of the skin material 1 is pushed through to form the opening 1a in the skin material 1, so that the skin back surface layer 5 is formed along the inner periphery of the opening 3a of the skin surface layer 3. It can be easily and neatly removed and the desired opening 1a can be formed in the skin material 1.
[0038]
  In the above embodiment, the non-product portion 113b of the molding surface 113 of the slash molding die 111 is positioned at the substantially central portion of the molding surface 113, and the non-product portion 113b is surrounded by the product portion 113a. Even when the one end side of the non-product portion 113b extends to the end portion of the molding surface 113, the same effect can be obtained.
[0039]
  Further, in the above embodiment, the closed injection method in which the foamed resin material is injected into the cavity 131 after the first molding die 127 and the second molding die 129 are closed, but the first molding die 127 and the second molding die 129 are used. An open injection method in which the mold is closed after the foamed resin raw material is injected while the mold 129 is opened.
[0040]
  Furthermore, although the door trim 11 was shown as a molded object, it may be other than an instrument panel, other automotive interior parts, and further automotive interior parts. Further, the structure is not limited to the three-layer structure in which the foam layer 15 is integrally formed between the skin material 1 and the core material 13, and the structure includes two layers of the skin material and the core material without the foam layer. Can be applied.
[0041]
【The invention's effect】
  As described above, according to the invention according to claim 1, the skin back surface layer is formed so as to cover the entire area including the opening formation planned portion on the back surface of the skin surface layer provided in the region excluding the opening formation planned portion. Since it is provided, it is possible to close the opening of the skin surface layer corresponding to the opening formation planned portion at the time of forming the molded body with the skin back surface layer to prevent leakage of the molten resin and to finish the surface of the skin material cleanly.
[0042]
  Further, an annular thin groove portion is formed by an annular groove between the inner peripheral edge of the skin surface layer corresponding to the inner peripheral edge of the opening of the core material and the skin back surface layer.And deepen this annular grooveTherefore, after molding the molded body, simply and cleanly remove the skin back layer corresponding to the opening formation planned portion along the inner peripheral edge of the skin surface layer.For skin materialA desired opening can be formed.
[0043]
  According to the invention which concerns on Claim 2, the cyclic | annular protrusion part protrudingly provided by the molding surface of the slash shaping | molding die so as to correspond to the inner periphery of the opening part of a core materialInner peripheryElastic seal material for cover memberOuter peripheryThePressureIn addition to the function and effect of claim 1,The seal around the annular ridge can be ensured,It is possible to eliminate the stringing phenomenon caused by resin leakage and adhesion of molten resin to the periphery of the cover member, avoiding the situation where resin waste adheres to the skin surface layer to be molded thereafter, and molding a high quality skin material it can.
[Brief description of the drawings]
FIG. 1 is a front view of a slush mold.
FIG. 2 is a perspective view of a first raw material storage box.
FIG. 3 is a cross-sectional view showing a state in which a slush mold is set in a first raw material storage box.
FIG. 4 is a cross-sectional view showing a state where the first raw material storage box is inverted and the first powder resin raw material is dropped and welded to the slush mold, and the skin surface layer is formed on the slush mold.
FIG. 5 is an enlarged view of part B in FIG. 4;
FIG. 6 is a cross-sectional view showing a state in which a skin material is formed by molding a skin back layer on the back surface of a skin surface layer molded in a slush mold.
7 is an enlarged view showing a state in which the skin material is directed upward in a portion C of FIG. 6. FIG.
FIG. 8 is a view corresponding to FIG. 7 of the skin material removed from the slush mold.
FIG. 9 is a cross-sectional view of the door trim molding apparatus showing a state in which the press cut tool is arranged corresponding to the opening formation scheduled portion of the skin material corresponding to the opening portion of the door trim immediately after molding.
FIG. 10 is a cross-sectional view of the door trim forming apparatus showing a state in which an opening formation scheduled portion of the skin material corresponding to the opening portion of the door trim is pushed down by raising the pressing tool.
[Explanation of symbols]
      1 Skin material
      1a opening
      3 Epidermis surface layer
      5 Skin back layer
      7 Annular groove
      9 Annular thin part
    11 Door trim (molded body)
    13 Core
  101 First raw material storage box
  103 Second raw material storage box
  111 Slash Mold
  113 Molding surface
  113c Annular ridge
  117 Cover member
  123 Elastic sealing material
      A opening formation planned part
      R1 First powder resin raw material
      R2 Second powder resin raw material

Claims

Powder slush molding skin having an opening forming scheduled portion corresponding to the opening (13a) of at least the core material (13) integral said core member constitutes a design surface of the molded with the molded body (11) (13) (A) Material (1) ,
An epidermis surface layer (3) provided in a region excluding the opening formation planned portion (A) ;
It consists of a skin back surface layer (5) provided on the back surface of this skin surface layer (3) so as to cover the entire region including the opening formation scheduled portion (A) ,
An annular groove (7) is formed between the inner periphery of the skin surface layer (3) corresponding to the inner periphery of the opening (13a) and the skin back layer (5). The groove (7) corresponds to the thickness of the skin back layer (5) and has a thin annular portion (9) that is thinner than the total thickness of the skin surface layer (3) and the skin back layer (5), which is a general part. A powder slush molding skin material, characterized in that the skin back surface layer (5) formed and surrounded by the annular groove (7) protrudes to the surface side from the skin surface layer (3) of the general part .

Powder slush molding skin having an opening forming scheduled portion corresponding to the opening (13a) of at least the core material (13) integral said core member constitutes a design surface of the molded with the molded body (11) (13) (A) A molding apparatus for molding the material (1) ,
An annular ridge (113c) is projected on the molding surface (113) so as to correspond to the inner peripheral edge of the opening (13a) and is surrounded by the annular ridge (113c) with the inner peripheral edge protruding more than the outer peripheral edge. A slush mold (111), which is provided with a molding surface (113) positioned lower than the molding surface (113) outside the annular ridge (113c ) and welds the powder resin material to the molding surface (113 ). When,
A cover member (117) having a heat-resistant elastic seal material (123) is provided, and the outer peripheral edge of the elastic seal material (123) of the cover member (117) is in a state where the slash mold (111) is assembled. the annular ridge (113c) in the annular ridges contact pressure on the peripheral cover portion which is surrounded by (113c), the slush molding die powder resin ingredients contained therein (R1) by inverting A first raw material storage box (101) for dropping and welding to the molding surface (113 ) of (111) and molding the skin surface layer (3) in a region excluding the opening formation scheduled portion (A) ;
The cover member (117) is not provided, and the slush mold (111) in which the skin surface layer (3) is molded is inverted in the assembled state, and the powder resin raw material (R2) accommodated inside is reversed. It is dropped and welded to the molding surface (113) of the slush mold (111) corresponding to the skin surface layer (3) and the opening formation scheduled portion (A) , and the opening is formed on the back surface of the skin surface layer (3). A skin back surface layer (5) is formed so as to cover the entire region including the planned formation portion (A), and the inner periphery of the skin surface layer (3) corresponding to the inner periphery of the opening (13a) and the skin back layer. An annular groove groove (7) is formed between (5) and the outer surface groove layer (3) corresponding to the thickness of the skin back layer (5) and being a general part by the annular groove groove (7). And an annular thin part (9) which is thinner than the total thickness of the skin back layer (5) The skin back surface layer (5) that is formed and surrounded by the annular groove (7) is formed of a powder slush molding skin material (1) that protrudes to the surface side from the skin surface layer (5) of the general part. further comprising a second ingredient containing box forming (103) molding apparatus powder slush molding the skin material, characterized in.