JP3745933B2 - Method for forming laminated molded body - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for forming a laminated molded article suitable for automobile interior parts such as an automobile door trim, and in particular, wrinkles or the like are not generated in a skin material in a deep drawing portion such as a door armrest, thereby improving moldability. The present invention relates to a method for forming a laminated molded body .
[0002]
[Prior art]
FIG. 13 is a cross-sectional view showing the configuration of the automobile door trim 1. The automobile door trim 1 has a good feel and cushioning property on the surface of the resin core material 1a having rigidity and shape retention to the vehicle body panel. The resin core material 1a is made of polypropylene (PP) composite resin, and PP resin mixed with wood powder is formed into a sheet by a T-die extruder. Then, the sheet-shaped raw material is preheat-softened and then drawn into a required shape in a cold press mold. Further, as the skin material 1b, a foamed PVC sheet is used, and is integrally molded when the resin core material 2 is molded.
[0003]
Next, a conventional method for forming the door trim 1 and a conventional molding apparatus will be described. FIG. 14 is a schematic configuration diagram of the molding apparatus 2, and the molding apparatus 2 is generally composed of a pair of upper and lower press molds 3, a lower press mold 4, and a core material feed machine 5. Further, the press upper die 3 is attached to the lower surface of a movable table 3 a that can move up and down by a predetermined stroke in the vertical direction, and a skin set pin 6 for setting the skin raw fabric sheet S along the outer peripheral wall surface of the upper die 3. A guide post 7 is erected downward on the lower surface of the movable table 3a along the outer periphery of the skin set pin 6, and a deformed blade 8 is provided on the guide post.
[0004]
The lower press die is attached to the upper surface of the fixed table 4a. The fixed table 4a is provided with a through hole 7a through which the guide post 7 penetrates when the upper press die 3 is raised and lowered.
[0005]
First, as shown in FIG. 14, after the skin raw sheet S, which is the material of the skin material 1b, is inserted and held in the set pin 6 provided on the outer periphery of the press upper die 3, as shown in FIG. The raw material feeding machine 5 slides to place the core material raw material M of the resin core material 1 a on the mold surface of the press lower die 4.
[0006]
Thereafter, as shown in FIG. 16, the movable table 3 a is lowered by driving an elevating cylinder (not shown), so that the core material fabric M and the skin material fabric sheet S are moved between the upper press die 3 and the lower press die 4. The door trim 1 made of a laminate of the resin core material 1a and the skin material 1b is press-molded into a required shape. At the time of this cold press molding, the guide post 7 is inserted into the through hole 7a, and the excess core material M is trim-cut by the deformed blade 8 supported by the guide post 7.
[0007]
After the completion of molding, as shown in FIG. 17, when the press upper die 3 is raised, the door trim 1 is also raised together with the press upper die 3, but the operator removes the peripheral edge of the skin material 1b from the set pin 6. Thus, the door trim 1 is removed.
[0008]
If desired, as shown in FIG. 18, when the upper press mold 3 is raised, the set pin 6 is detached from the skin material 1b, the door trim 1 is placed on the lower press mold 4, and the door trim 1 is moved to the lower press mold. 4 may be taken out.
[0009]
[Problems to be solved by the invention]
Thus, in the conventional method for molding the door trim 1 and the molding apparatus 2, the set pins 6 that hold the peripheral edge of the skin material 1 b are provided at predetermined intervals along the outer periphery of the press upper die 3. Since this set pin 6 is fixed to the press upper die 3, when the press upper and lower dies 3 and 4 are clamped, an appropriate tension cannot be applied to the skin material 1b. It has been pointed out that there are frequent defects in molding such as wrinkles on the skin material 1b in the deep drawing portion.
[0010]
As a countermeasure against this molding defect, it is conceivable to use an expensive material of a grade excellent in stretchability as the material of the skin material 1b, but the material cost is high and it is not a practical measure.
[0011]
Furthermore, after press molding, the work of removing the skin material 1b located at the periphery of the molded body from the set pin 6 is troublesome, and there is also a problem that it is difficult to smoothly remove the molded body.
[0012]
The present invention has been made by paying attention to such problems, and the skin raw sheet and the heat softened core material raw material are supplied into a cold press mold and cold pressed into a required shape. In the method for forming a laminated molded article, the skin material is not wrinkled even in the deep-drawn portion, and excellent moldability is obtained, and after molding, the set pin and the skin material are smoothly separated. Therefore, an object of the present invention is to provide a method for forming a laminated molded body that can be expected to have a smooth demolding operability.
[0013]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides a laminate comprising a resin core material and a skin material by supplying an original skin sheet and a core material into a press upper and lower molds, and clamping the press upper and lower molds. In a molding method of a laminated molded body for forming a molded body into a required shape, a core material sheet is set on a set pin in a skin setting mechanism provided along the outer periphery of a press upper mold, and then a core material on the lower mold of the press Place the original fabric, drive the forward / backward movement cylinder in the skin setting mechanism, move the set pin away from the mold center, and clamp the upper and lower dies with the tension applied to the outer skin sheet after press molding process of the resin core member and a skin material which performs a press integrated with the resin core material and the skin material, by driving the vertical motion acting cylinder in the epidermis setting mechanism, raised operating the set pin, Table Characterized in that disengaging the periphery of the timber from the set pins.
[0016]
Therefore, according to the present invention, using a molding apparatus equipped with a skin setting mechanism, the laminated molded body is molded, and the skin setting mechanism includes a vertically moving cylinder for vertically moving a set pin, Since there is a forward / backward movement cylinder that moves at least a part of the set pins in the direction to make contact with / separate from the upper die of the press, the forward / backward movement cylinder is operated before press molding to apply tension to the raw material sheet. It is possible to apply an appropriate tension to the skin raw fabric sheet to faithfully form the deep drawn portion and the like, and the skin material is not wrinkled.
[0017]
In addition, if the set pin is raised by operating the vertical movement cylinder after press molding, the set pin stuck in the peripheral edge of the skin material can be automatically detached, and when the upper die of the press is raised, The molded product is not brought into the press upper die, and a smooth demolding operation is possible.
[0018]
Therefore, it is not necessary to manually remove the peripheral portion of the skin material from the set pin at the time of demolding, the work can be simplified, and the problem that the skin material of the laminated molded body is caught by the set pin and dropped can be effectively solved.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a method for forming a laminated molded body according to the present invention will be described below by applying it to a method for forming an automobile door trim.
[0020]
1 and 2 are a front view and a cross-sectional view showing an automobile door trim formed by the method of the present invention, FIG. 3 is a structural explanatory view showing an embodiment of a forming apparatus used in the method of the present invention , and FIG. FIG. 5 to FIG. 12 are explanatory views showing respective steps in which the method of the present invention is applied to a method for forming an automobile door trim.
[0021]
1 and 2, this automobile door trim 10 is mounted on the front door panel of a passenger car, and this automobile door trim 10 has a resin core material having appropriate shape retention and mounting rigidity to the door panel. 11 and a skin material 12 that is integrally attached to the surface of the resin core material 11 and imparts cushioning properties, good hand feeling, and product design.
[0022]
More specifically, the resin core material 11 is formed by extruding a polypropylene resin mixed with wood powder into a sheet shape by a T-die extrusion molding machine, heat-softening the sheet material, and then forming into the required shape shown in the figure by cold press molding. As the skin material 12, an inexpensive material in which a knitted cloth 12b is backed on the back surface of the foamed PVC sheet 12a is used, and a cold press is performed using a hot melt film (for example, a polyethylene resin film) 13 as an adhesive medium. The skin material 12 is integrated on the product surface side of the resin core material 11 at the time of molding.
[0023]
The automobile door trim 10 has no wrinkles or the like on the surface of the product even in the deep drawing portion such as the armrest portion 10a, and has a good touch feeling in appearance. The molding method described below is applied. Can be produced.
[0024]
Before describing the embodiment of the molding method of the automobile door trim 10, the general configuration of the molding apparatus 20 will be described with reference to FIGS. 3 and 4. The forming apparatus 20 includes a press upper die 30 that is a movable side, a skin setting mechanism 40 that is provided along the outer periphery of the press upper die 30, and a press side that is a fixed side located below the press upper die 30. The mold 50 and the core material raw material conveyer 60 for supplying the core material raw material that is the material of the resin core material 11 are roughly configured.
[0025]
More specifically, the press upper and lower dies 30 and 50 are provided with cooling pipes (not shown), and the press upper die 30 is attached to the lower surface of the movable table 31. It is configured to be able to move up and down by a predetermined stroke in connection with a lifting cylinder (not shown).
[0026]
Next, the skin setting mechanism 40 provided along the outer periphery of the press upper die 30 is characterized by adopting a movable set pin 41 instead of the conventional fixed type, and along the outer periphery of the press upper die 30. The set pins 41 provided at predetermined pitch intervals are, according to the driving direction, in addition to the up and down direction, the two-way set pins 41a that move along two directions of contact with and away from the press upper die 30; A one-way set pin 41b that can move only in the direction is used in combination. 4 shows the arrangement of the two-way set pin 41a and the one-way set pin 41b, the two-way set pin 41a and the one-way set pin are considered in consideration of the molding surface of the molded product and the material of the skin material 12. You may select the combination of 41b suitably.
[0027]
Next, the configuration of the two-way set pin 41a will be described with reference to FIG. 3. The two-way set pin 41a is connected to a piston rod (not shown) of the vertical movement cylinder 42, and the bracket 42a of the vertical movement cylinder 42 is The set pin 41 is connected to a piston rod 44 of an advancing / retracting cylinder 43 that drives the set pin 41 in a direction in which the set pin 41 is moved toward and away from the press upper die 30.
[0028]
That is, the piston rod 44 of the forward / backward movement cylinder 43 is connected to the bracket 42a of the vertical movement cylinder 42, and the bracket 43a of the forward / backward movement cylinder 43 is fixed to the lower surface of the movable table 31, while the vertical movement cylinder The bracket 42 a of 42 is connected to a slider 46 that slides along an LM guide 45 provided on the lower surface of the movable table 31.
[0029]
As described above, the two-way set pin 41a is moved along the two directions, that is, the vertical direction and the direction of contact with and away from the press upper die 30 perpendicular to the vertical direction by the operation of the vertical movement cylinder 42 and the forward / backward movement cylinder 43. Can be moved. Although not shown, the vertical set pin 41b is movable only in one direction only by the vertical movement cylinder. A guide post 33 that supports the deformed blade 32 is attached to the lower surface of the movable table 31 on the outer periphery of the skin setting mechanism 40.
[0030]
On the other hand, the lower press die 50 is attached to the upper surface of the fixed table 51. The fixed table 51 is formed with a guide hole 52 through which the guide post 33 passes when the upper press die 30 is lowered. . Further, the core material transport conveyor 60 is configured to enter the mold only when the core material is supplied, and to reciprocate so as to avoid outward when the material supply is completed. .
[0031]
Next, the molding process of the automobile door trim 10 shown in FIGS. 1 and 2 will be described using the molding apparatus 20 described above. First, as shown in FIG. 5, when the press upper die 30 is at the uppermost position. The raw material sheet S, which is the material of the skin material 12, is set on the upper press die 30 side. At this time, in the skin setting mechanism 40, both the up / down operation cylinder 42 and the advance / retreat operation cylinder 43 are in the extended state, and the two-way set pin 41a is located inside and below. Therefore, the raw skin sheet S can be easily engaged and fixed to the two-way set pin 41a and the one-way set pin 41b (not shown).
[0032]
And after setting the skin raw fabric sheet S to the skin setting mechanism 40, as shown in FIG. 6, the core raw material transport conveyor 60 on which the core raw fabric M, which is the material of the resin core 11, is placed. The press upper and lower molds 30 and 50 are entered, and as shown in FIG. 7, when the conveyor 60 reaches a predetermined position, the conveyor 60 is stopped.
[0033]
Next, as shown in FIG. 8, the conveying conveyor 60 is held between the pressing upper and lower molds 30, 50 in a state where one end of the core material M is held from the conveying conveyor 60 and positioned at one end of the pressing lower mold 50. If it avoids to the exterior, the core raw material M can be mounted on the press lower mold | type 50. FIG. The core material M is heat-softened to a predetermined temperature by a heater.
[0034]
In addition, when the core material M is placed on the lower press mold 50, the skin original sheet S is given a desired tension necessary for molding. That is, when the forward / backward movement cylinder 43 in the skin setting mechanism 40 is contracted by a predetermined stroke, the two-way set pin 41a moves in the direction of the arrow in FIG. Retained.
[0035]
At this time, due to the movement of the forward / backward movement cylinder 43 in the skin setting mechanism 40, the bracket 42a of the vertical movement cylinder 42 attached to the piston rod 44 slides smoothly along the LM guide 45. Therefore, the skin setting mechanism 40 can satisfactorily hold the skin original sheet S even against a tensile load from the skin original sheet S, and can reliably hold the skin original sheet S even when tension is applied. Is possible.
[0036]
Next, as shown in FIG. 9, the movable table 31 moves downward, and the skin raw sheet S and the core raw material M are drawn into a required shape between the press upper and lower molds 30 and 50. When the upper and lower press molds 30 and 50 are clamped, the guide post 33 is inserted into the guide hole 52 of the press lower mold 50 as the movable table 31 descends, and the extra portion of the resin core material 11 is cut by the deformed blade 32. Removed.
[0037]
When the press molding is completed, the vertical movement cylinder 42 in the skin setting mechanism 40 operates, the two-way set pin 41a rises, and the one-way set pin 41b (not shown) also rises. It automatically detaches from the skin material 12, and there is no need to remove the skin material 12 manually as in the prior art, and the molded body does not lift with the press upper die 30.
[0038]
Thereafter, as shown in FIG. 11, the forward / backward movement cylinder 43 in the skin setting mechanism 40 extends, the two-way set pin 41 a moves to a position close to the press upper die 30, returns to the initial position, As shown in FIG. 12, the upper press mold 30 is lifted, and the door trim 10 is held by the deformed blade 32 along with it, and is removed from the lower press mold 50.
[0039]
As described above, according to the method of the present invention, an appropriate tension can be applied to the skin material 12 during cold press molding of the resin core material 11 and the skin material 12, so that a deep drawing shape like the armrest portion 10a in the door trim 10 is provided. It is possible to form a complex curved surface shape having a deep drawn portion without causing wrinkles, and it is possible to improve productivity and increase the elasticity of the skin material 12 as much as possible. Inexpensive materials can be used, and the degree of freedom of modeling and the choice of materials can be expanded.
[0040]
Moreover, since the set pins 41a and 41b are lifted after press molding and automatically disengage from the skin material 12, the automobile door trim 10 can be smoothly removed from the press upper and lower molds 30 and 50, as in the conventional case. The trouble of removing the skin material manually from the set pin is not forced, and it is possible to effectively solve the problem that the molded body falls and causes damage, and the demolding work can be performed well. .
[0041]
Furthermore, the method of the present invention is applied to a door trim for automobiles, but can be applied to various interior parts other than the door trim as long as the resin core material and the skin material are integrated by cold press molding.
[0042]
【The invention's effect】
As described above, according to the method for forming a laminated molded body according to the present invention, as the skin setting mechanism provided around the upper die of the press, the set pin can be moved up and down, and some of the set pins can be moved up and down. In addition to the direction, by adopting a so-called two-way set pin that can be moved in the direction of contact with and away from the upper die, it is possible to apply an appropriate tension to the skin material by the operation of the set pin, and a complicated shape Even in the laminated molded body of the above, it is possible to perform good molding without generating wrinkles in the skin material, and it is possible to increase productivity, and it is possible to increase the degree of freedom of product shaping and the choice of skin material. Has an effect. Further, the operation of the set pin allows the skin material and the set pin to be automatically detached, and has the effect of improving the demolding operability in the molded body.
[Brief description of the drawings]
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 taken along the line II-II in FIG. 1, and is a cross-sectional view showing a configuration of an automobile door trim.
FIG. 3 is a schematic view showing the configuration of an embodiment of a molding apparatus used in the method of the present invention .
4 is an explanatory view showing an arrangement of a skin support mechanism in the molding apparatus shown in FIG. 3. FIG.
FIG. 5 is an explanatory view showing a setting process of the raw skin sheet in the method of the present invention.
FIG. 6 is an explanatory view showing a state in which a core material is charged in the method of the present invention.
FIG. 7 is an explanatory view showing a supply state of a core raw material into a mold in the method of the present invention.
FIG. 8 is an explanatory view showing a setting operation of the core material raw material to the lower mold in the method of the present invention.
FIG. 9 is an explanatory view showing a cold press molding step in the method of the present invention.
FIG. 10 is an explanatory view showing a drawing process of a set pin after press forming in the method of the present invention.
FIG. 11 is an explanatory view showing the operation of returning the set pin to the initial position after press forming in the method of the present invention.
FIG. 12 is an explanatory view showing a demolding step of a laminated molded body in the method of the present invention.
FIG. 13 is a cross-sectional view showing a configuration of a conventional automobile door trim.
FIG. 14 is an explanatory view showing a setting process of an original skin sheet in a conventional door trim molding method.
FIG. 15 is an explanatory view showing a core raw material setting process in a conventional door trim molding method.
FIG. 16 is an explanatory view showing a press forming step in a conventional door trim forming method.
FIG. 17 is an explanatory view showing a conventional door trim removal step.
FIG. 18
It is explanatory drawing which shows the demolding process of the conventional door trim.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Automotive door trim 11 Resin core material 12 Skin material 20 Molding device 30 Press upper mold 31 Movable table 32 Deformed blade 33 Guide post 40 Skin setting mechanism 41 Set pin 41a Two-way set pin 41b One-way set pin 42 Vertical movement cylinder 43 Forward / backward movement cylinder 45 LM guide 46 Slider 50 Press lower mold 51 Fixed table 52 Guide hole 60 Conveyor S for core material transport sheet S Raw material sheet M for core material

Claims (1)

The raw material sheet (S) and core material (M) are supplied into the press upper and lower molds (30, 50), and the resin core material (11) is secured by clamping the press upper and lower molds (30, 50). In a molding method of a laminated molded body for molding a laminated molded body (10) consisting of the outer skin material (12) and a required shape,
After setting the skin raw fabric sheet (S) on the set pin (41) in the skin setting mechanism (40) provided along the outer periphery of the upper press die (30), the core material raw material is placed on the lower press die (50). Place the counter (M) and drive the forward / backward movement cylinder (43) in the skin setting mechanism (40) to move the set pin (41) away from the center of the mold to the skin original fabric sheet (S) With the tension applied, the press upper and lower molds (30, 50) are clamped, and the resin core material (11) and the skin material (12) are integrated with the resin core material (11) and the skin material (12). After the press molding process with the upper and lower movement cylinders (42) in the skin setting mechanism (40), the set pin (41) is lifted to move the peripheral portion of the skin material (12) to the set pin (41). ) Molding method of the molded laminate to.

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