JP3717098B2 - Method for forming laminated molded body - Google Patents

Description

【００３９】
従って、表１並びに図１３から明らかなように、従来方法に比べ表皮原反Ｓをカット処理したものであれば、変形歪みを小さく抑えることができ、更に、表皮原反Ｓ及び熱可塑性樹脂板Ｐの双方にカット処理を施したものになれば変形歪みをより有効に抑えることができる。
【００４０】
尚、上述した実施形態は、ドアトリムアッパー２０の下縁部分に本発明方法を適用したが、ドアトリムアッパーのウエスト部分に適用すれば、ドアトリムアッパー２０のウエスト部分の変形歪みを抑えることも可能である。
【００４１】
【発明の効果】
以上説明した通り、本発明は、以下に記載する格別の作用効果を有する。
【００４３】
（１）請求項１記載の発明は、予熱軟化処理した熱可塑性樹脂板と表皮原反とをプレス一体化して樹脂芯材と表皮材とからなる積層成形体を成形する積層成形体の成形方法において、プレス成形金型にカット機構を設置し、製品の高展開率部位に相当する表皮原反及び熱可塑性樹脂板に、成形前に上記カット機構によりスリットを形成しておき、プレス成形時、表皮原反及び熱可塑性樹脂板に設けたスリットの双方が幅方向に拡開変形することにより、表皮原反及び熱可塑性樹脂板に加わるテンションを緩和できることから、積層成形体の変形歪みをより有効に規制でき、製品の初期形状を良好に維持でき、かつ相手部品との間の間隙等が生じることがないより意匠性の高い製品を提供できるという効果を有する。
【図面の簡単な説明】
【図１】本発明方法により成形したドアトリムアッパーを備えた自動車用ドアトリムを示す正面図。
【図２】図１中II−II線断面図。
【図３】本発明方法の第１実施形態に使用するプレス成形金型の構成説明図。
【図４】図３に示すプレス成形金型におけるプレス下型の平面図。
【図５】本発明方法の第１実施形態におけるコールドプレス成形工程を示す断面図。
【図６】図５に示すコールドプレス成形時におけるスリット形状の変化を示す説明図。
【図７】本発明方法の第１実施形態におけるトリムカット工程を示す断面図。
【図８】本発明方法の第２実施形態における各素材のセット工程を示す断面図。
【図９】本発明方法の第２実施形態における先行カット工程を示す断面図。
【図１０】本発明方法の第２実施形態におけるコールドプレス成形工程を示す断面図。
【図１１】ドアトリムアッパーを示す外観図。
【図１２】測定ポイントａにおける各サンプルの変形歪みを示す説明図。
【図１３】従来の自動車用ドアトリムの構成を示す断面図。
【図１４】従来のドアトリムにおけるドアトリムアッパーのコールドプレス成形工程を示す説明図。
【図１５】（ａ）は従来の積層成形体の成形後の変形歪みを示す説明図、（ｂ）は従来の積層成形体のトリムカット後の変形歪みを示す説明図。
【図１６】従来の上下二分割タイプの自動車用ドアトリムにおける接合部分の不具合を示す説明図。
【符号の説明】
１０ 自動車用ドアトリム
２０（２０Ａ，２０Ｂ） ドアトリムアッパー
２１ 樹脂芯材
２２ 表皮材
３０ ドアトリムロア
４０ プレス下型
４１ａ，４１ｂ キャビティ
５０ プレス上型
６０ 表皮原反投入装置
７０，７１，７２ スリット
７０ａ，７１ａ，７２ａ 開口
８０ カット刃
８１ 受け溝
Ｓ 表皮原反
Ｐ 熱可塑性樹脂板[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for forming a laminated molded body suitable for automobile interior parts, and more particularly to a method for molding a laminated molded body in which deformation distortion does not occur.
[0002]
[Prior art]
Usually, various interior parts are installed in the interior of a passenger car or the like. FIG. 13 is a cross-sectional view showing a configuration of an automotive door trim 1 mounted on a door panel. The door trim 1 has a door trim upper 2, a door trim lower 3, It is comprised from the upper and lower divided parts.
[0003]
The door trim upper 2 is a laminate in which the skin material 2b is adhered to the surface of the resin core material 2a press-molded into a curved shape by cold press molding the preheat-softening thermoplastic resin plate and the skin raw material. The door trim lower 3 is composed of an injection molded body of synthetic resin such as PP resin.
[0004]
As a joining structure of the door trim upper 2 and the door trim lower 3, an ultrasonic boss 3 a is projected on the rear surface of the upper edge side of the door trim lower 3, and the door trim upper 2 has a mounting hole corresponding to the ultrasonic boss 3 a. 2c is opened and the ultrasonic boss 3a is inserted into the mounting hole 2c, and then the tip of the ultrasonic boss 3a is subjected to ultrasonic caulking, thereby joining and fixing the door trim upper 2 and the door trim lower 3 to each other. ing.
[0005]
By the way, as a molding method of the door trim upper 2 in the door trim 1, considering the mass productivity of the door trim 1, as shown in FIG. 14, the door trim upper 2 of the left and right side door trims 1 is press lower mold 4 and press upper mold. 5, the left and right symmetrical door trim uppers 2A and 2B are simultaneously molded, and after molding, the left and right door trim uppers 2A and 2B are separated and formed.
[0006]
[Problems to be solved by the invention]
In this way, when a laminated molded body is formed by cold press molding the preheat-softening-processed thermoplastic resin plate and the skin raw material, particularly in the high development rate portion a, as shown in FIG. Deformation is likely to occur, and as described above, when the laminated molded body is cut, the cut portion b tends to be further promoted as shown in FIG.
[0007]
Accordingly, when the lower portion of the door trim upper 2 molded by the conventional molding method is deformed, as shown in FIG. 16, it is attached to the panel side by applying stress in the direction of the arrow in the figure so as to regulate the deformation. In the joint portion between the door trim upper 2 and the door trim lower 3, a gap indicated by a symbol “c” is generated in the drawing, and it has been pointed out that the design is deteriorated.
[0008]
In addition to the joint portion between the door trim upper 2 and the door trim lower 3, the same deformation tends to occur in a portion having a high expansion rate, such as a door waist portion.
[0009]
The present invention has been made in view of such circumstances, and in a molding method of a laminated molded body obtained by cold press molding a preheat-softening thermoplastic resin plate and a skin raw material into a required shape using a press die. An object of the present invention is to provide a method for forming a laminated molded body in which deformation distortion does not occur and molding accuracy is improved.
[0011]
[Means for Solving the Problems]
In order to achieve the above object, the invention according to claim 1 of the present application is based on a resin core material and a skin material obtained by press-molding a preheat-softening thermoplastic resin plate and a skin raw material in a molding die. In the method for forming a laminated molded body, a cutting mechanism is installed in the molding die, and a slit is formed in the raw material of the skin and the high expansion rate portion of the thermoplastic resin plate before clamping the molding die. At the time of press molding, the portion where the slit is formed is formed along the mold surface shape of the portion with a high development rate in the molding die, so that the slit is expanded and deformed in the width direction to form an opening. Thus, the tension applied to the skin raw fabric and the thermoplastic resin plate is relaxed to avoid the deformation distortion generated in the high development rate portion .
[0014]
Therefore, according to the first aspect of the present invention, after the slit is formed in the high development rate portion of both the thermoplastic resin plate and the skin raw material when the press mold is clamped by the cutting mechanism provided in the press mold. This is a method of press molding. At the time of press molding, the slit forming part is molded along the shape of the high development rate of the mold, and the slits formed on the skin raw material and the thermoplastic resin plate respectively expand in the width direction. Therefore, both the tension applied to the skin raw material and the tension applied to the thermoplastic resin plate during press molding can be greatly relaxed.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment in which a molding method of a laminated molded body according to the present invention is applied to a door trim will be described in detail with reference to the accompanying drawings.
[0017]
FIG. 1 is a front view showing an automobile door trim manufactured by applying the method of the present invention, FIG. 2 is a cross-sectional view showing the structure of the door trim for the automobile, and FIG. 3 is a press molding used in the first embodiment of the method of the present invention. FIG. 4 is a plan view showing a lower press mold used in the method of the present invention, FIG. 5 is a cross-sectional view of a cold press forming process showing a first embodiment of the method of the present invention, and FIG. 6 is a cold press. FIG. 7 is a sectional view showing a trim cut process after molding in the first embodiment of the method of the present invention.
[0018]
FIGS. 8 to 10 show a second embodiment of the method of the present invention. FIG. 8 is a cross-sectional view showing a setting process of the raw skin and the thermoplastic resin plate, and FIG. 9 is a cross-section showing a preceding cutting process. 10 and 10 are cross-sectional views showing the cold press molding process.
[0019]
Further, FIG. 11 to FIG. 12 show the contents of the measurement test of the laminated molded body according to the present invention, FIG. 11 is an explanatory view showing measurement points, and FIG. 12 is an explanatory view showing deformation distortion after forming.
[0020]
1 and 2, the configuration of the automotive door trim 10 manufactured by the method of the present invention will be briefly described. The automotive door trim 10 is composed of an upper and lower divided body of a door trim upper 20 and a door trim lower 30. The door trim upper 20 is composed of a laminated molded body in which a skin material 22 is integrally bonded to the surface of a resin core material 21 molded into a desired curved surface shape. In this embodiment, the cost, strength, and moldability are reduced. In consideration of this, the raw material of the sheet extruded by mixing wood powder into the polypropylene resin is preheat-softened and then molded into the required shape by cold press molding. The skin material 22 is made of polyethylene foam on the back of the cloth. A laminated laminated sheet material is used, and the skin material 22 is integrated at the time of cold press molding of the resin core material 21.
[0021]
On the other hand, the door trim lower 30 is made of an injection molded body of synthetic resin such as PP resin, and the door pocket opening 31 and the speaker grill 32 are integrally formed.
[0022]
The door trim upper 20 and the door trim lower 30 are joined together by wrapping the upper edge portion of the door trim lower 30 on the lower surface of the door trim upper 20 and arranging an appropriate space on the rear surface of the upper edge of the door trim lower 30 so as to be super The ultrasonic boss 33 is erected, and the ultrasonic boss 33 is inserted into the mounting hole 23 provided corresponding to the lower edge of the door trim upper 20, and then the tip portion of the ultrasonic boss 33 is caulked by ultrasonic processing. As a result, the door trim upper 20 and the door trim lower 30 are joined and fixed.
[0023]
In the automobile door trim 10 formed of the upper and lower divided bodies of the door trim upper 20 and the door trim lower 30, the door trim upper 20 and the door trim lower 30 are closely joined along the joining line of the door trim upper 20 and the door trim lower 30. In addition, a good design property with no gap is ensured.
[0024]
Next, a first embodiment in which the method of the present invention is applied to the molding method of the door trim upper 20 will be described with reference to FIGS.
[0025]
As shown in FIG. 3, the cold press mold is roughly composed of a press lower mold 40, a press upper mold 50, and a skin raw material feeding device 60, and this mold is used for the door trim 10 of the left and right doors. As shown in FIG. 4, symmetrical cavities 41 a and 41 b are formed on the mold surface of the lower mold 40 so that the door trim uppers 20 </ b> A and 20 </ b> B can be molded simultaneously.
[0026]
In order to form the pair of left and right door trim uppers 20A and 20B, the thermoplastic resin plate P preheated and softened is placed on the mold surface of the lower press mold 40, and the upper and lower molds 40, 50 is supplied via the skin raw material feeding device 60. The method of the present invention is characterized in that a slit 70 is formed in the skin raw material S in advance.
[0027]
Therefore, as shown in FIG. 5, when the press upper die 50 is moved down by a predetermined stroke and the press upper and lower dies 40, 50 are clamped, the left and right symmetrical door trim uppers 20A, 20B are formed in a desired curved surface shape. In particular, since the part where the slit 70 is opened in the skin raw fabric S is a high development rate part, as shown in FIG. 6, the slit 70 is expanded in the width direction to become an opening 70a.
[0028]
Thereafter, as shown in FIG. 7, the central portion of the integrally molded product may be cut to separate the door trim uppers 20A and 20B.
[0029]
Therefore, in the present embodiment, the cut portion is a high development rate portion, and deformation distortion is likely to occur. However, as described above, the slit 70 is formed in advance in the skin raw material S, and the slit 70 is slit during press molding. Since the opening 70a is expanded in the width direction, the tension applied to the skin raw fabric S at the time of press molding can be relaxed, and the deformation distortion generated in the high development rate portion can be effectively suppressed.
[0030]
Although the resin core material 21 is exposed at the cut portion, this portion is covered with the door trim lower 30, so there is no problem with the design of the product.
[0031]
Next, a second embodiment of the present invention will be described with reference to FIGS.
[0032]
This second embodiment is also a method of simultaneously forming a pair of left and right door trim uppers 20A and 20B. That is, as shown in FIG. 8, a cutting blade 80 is provided at substantially the center of the upper press die 50, and a receiving groove 81 is provided on the die surface of the lower press die 40 at a position corresponding to the cutting blade 80. It has been. The thermoplastic resin plate P as a material of the resin core material 21 is placed on the mold surface of the lower press mold 40 as in the first embodiment, but is supplied through the skin raw material feeding device 60. Slit processing is not performed for anti-S.
[0033]
Then, after the thermoplastic resin sheet P and the skin raw material S are put into the press upper and lower molds 40 and 50, the press upper mold 50 is moved downward by a predetermined stroke as shown in FIG. The high unfolding rate portions of the skin raw fabric S and the thermoplastic resin plate P are cut, and the slits 71 and 72 are formed before molding.
[0034]
Further, as shown in FIG. 10, the slit 71 formed in the skin raw fabric S is expanded in the width direction and deformed into the opening 71a at the time of press molding, and at the slit 72 formed in the thermoplastic resin plate P. Is also expanded in the width direction and deformed to 72a, and the slits 71 and 72 formed in the high development rate portion of the skin original fabric S and the thermoplastic resin plate P are expanded and deformed in the width direction, whereby the surface material S The tension applied to the thermoplastic resin plate P can be relaxed.
[0035]
As in the first embodiment, after the molds 40 and 50 are opened, the center of the molded product is cut and separated into a pair of door trim uppers 20A and 20B.
[0036]
Next, a comparison of deformation strains in the laminated molded body molded by the conventional method and the laminated molded body molded by the first embodiment and the second embodiment of the method of the present invention will be described below.
[0037]
First, based on the conventional method, the method according to the first embodiment of the present invention (skin raw fabric cut treatment), and the method according to the second embodiment of the method of the present invention (cut treatment on both the raw skin fabric and the thermoplastic resin plate). For example, the deformation distortion of each sample at the point a is shown in FIG. 12 for the three measurement points a, b, and c after molding the laminated molded body having the shape shown in FIG. And the comparison of the deformation | transformation distortion in the measurement points a, b, and c of each sample is shown in FIG.
[0038]
[Table 1]

[0039]
Therefore, as is apparent from Table 1 and FIG. 13, if the skin raw fabric S is cut compared to the conventional method, the deformation distortion can be suppressed, and further, the skin raw fabric S and the thermoplastic resin plate can be suppressed. Deformation distortion can be suppressed more effectively if both P are cut.
[0040]
In the above-described embodiment, the method of the present invention is applied to the lower edge portion of the door trim upper 20. However, if the method is applied to the waist portion of the door trim upper 20, deformation deformation of the waist portion of the door trim upper 20 can be suppressed. .
[0041]
【The invention's effect】
As described above, the present invention has the special effects described below.
[0043]
(1) The invention according to claim 1 is a method for forming a laminated molded body in which a pre-softening-softened thermoplastic resin plate and a skin raw material are press-integrated to form a laminated molded body comprising a resin core material and a skin material. In the press-molding mold, a cutting mechanism is installed, and a slit is formed by the above-described cutting mechanism on the surface raw material and the thermoplastic resin plate corresponding to the high development rate part of the product, and at the time of press molding, Since both the raw skin and the slits provided in the thermoplastic resin plate are expanded and deformed in the width direction, the tension applied to the raw skin and the thermoplastic resin plate can be relaxed, making the deformation distortion of the laminated molded body more effective. Therefore, it is possible to provide a product having a higher design property, in which the initial shape of the product can be satisfactorily maintained, and a gap between the parts and the like does not occur.
[Brief description of the drawings]
FIG. 1 is a front view showing an automobile door trim provided with a door trim upper formed by the method of the present invention.
FIG. 2 is a cross-sectional view taken along line II-II in FIG.
FIG. 3 is a configuration explanatory view of a press mold used in the first embodiment of the method of the present invention.
4 is a plan view of a press lower mold in the press mold shown in FIG. 3. FIG.
FIG. 5 is a cross-sectional view showing a cold press molding process in the first embodiment of the method of the present invention.
6 is an explanatory view showing a change in slit shape during the cold press molding shown in FIG. 5. FIG.
FIG. 7 is a cross-sectional view showing a trim cut process in the first embodiment of the method of the present invention.
FIG. 8 is a cross-sectional view showing a setting process of each material in the second embodiment of the method of the present invention.
FIG. 9 is a cross-sectional view showing a preceding cutting step in the second embodiment of the method of the present invention.
FIG. 10 is a cross-sectional view showing a cold press molding process in a second embodiment of the method of the present invention.
FIG. 11 is an external view showing a door trim upper.
FIG. 12 is an explanatory diagram showing deformation distortion of each sample at a measurement point a.
FIG. 13 is a cross-sectional view showing a configuration of a conventional automobile door trim.
FIG. 14 is an explanatory view showing a cold press molding process of a door trim upper in a conventional door trim.
FIG. 15A is an explanatory diagram showing deformation distortion after molding of a conventional laminated molded body, and FIG. 15B is an explanatory diagram showing deformation distortion after trim cutting of a conventional laminated molded body.
FIG. 16 is an explanatory diagram showing a defect in a joint portion in a conventional upper and lower split type automobile door trim.
[Explanation of symbols]
10 Automotive Door Trim 20 (20A, 20B) Door Trim Upper 21 Resin Core Material 22 Skin Material 30 Door Trim Lower 40 Press Lower Die 41a, 41b Cavity 50 Press Upper Die 60 Skin Material Feeding Device 70, 71, 72 Slit 70a, 71a, 72a Opening 80 Cutting blade 81 Receiving groove S Skin raw fabric P Thermoplastic resin plate

Claims (1)

The pre-softening-softened thermoplastic resin plate (P) and the skin raw material (S) are press-molded in a molding die (40, 50), and consist of a resin core material (21) and a skin material (22). In the method for forming a laminated molded body for molding the laminated molded body (20),
A cutting mechanism (80, 81) is installed in the molding die (40, 50), and before the clamping of the molding die (40, 50), the surface material (S) and the height of the thermoplastic resin plate (P) are increased. Slits (71, 72) are formed in the unfolding rate portion, and the portion where the slits (71, 72) are opened at the time of press molding follows the mold surface shape of the high unfolding rate portion in the molding die (40, 50) . By forming the slits, the slits (71, 72) are expanded and deformed in the width direction to form openings (71a, 72a), so that they are added to the skin raw fabric (S) and the thermoplastic resin plate (P). A method for forming a laminated molded body, wherein tension is relaxed to avoid deformation distortion occurring in a portion with a high expansion ratio .

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