JP3881118B2

JP3881118B2 - Mold for partial decorative integral molding of skin material and partial decorative molding method for skin material

Info

Publication number: JP3881118B2
Application number: JP34785098A
Authority: JP
Inventors: 和則高橋; 浩治松岡; 実安井
Original assignee: Inoac Corp
Current assignee: Inoac Corp
Priority date: 1998-11-19
Filing date: 1998-11-19
Publication date: 2007-02-14
Anticipated expiration: 2018-11-19
Also published as: JP2000153542A

Description

【０００１】
【発明の属する技術分野】
本発明は、意匠面が樹脂成形面の他に表皮材で部分的に加飾されるようにした表皮材の部分加飾一体成形品用金型および表皮材の部分加飾成形方法に関する。
【０００２】
【従来の技術】
自動車の内装部品などでは、意匠面の一部領域に表皮材で風合いや高級感を付与した部分加飾の一体成形品がある。
斯る一体成形品は、従来、図１７のような製法等で造ってきた。まず、外周がトリミングされた所定大きさの表皮材９１をキャビティ型９４へセットし、真空引きにより該表皮材９１を固定する。次いで、型閉じを進行させ、その進行途中で溶融樹脂９３を射出する。そうして、型閉じを完了しプレスして一体成形品Ｙを造るのである（図１８）。符号９２はコア型、符号９５は成形樹脂を示す。
【０００３】
【発明が解決しようとする課題】
しかるに、上述の製法では、表皮材９１のトリミングカットで寸法誤差が生まれ易く、これが即品質に影響を与えた。また、表皮材９１のセット時にも狂いが発生し、一体成形品Ｙにおける表皮材の端末ライン９１ａが一定にならない問題があった。
【０００４】
本発明は上記問題点を解決するもので、表皮材の部分加飾一体成形品用金型および表皮材の部分加飾成形方法を提供することを目的とする。
【０００５】
【課題を解決するための手段】
上記目的を達成すべく、請求項１に記載の本発明の要旨は、コア型とキャビティ型とを備え、該コア型には表皮材が配される領域より外のキャビティ壁の一部を担って上面にコア型キャビティ壁をつくり進退動可能なクランプ体が設けられると共に該コア型上に該クランプ体をおさめる凹所が確保されて、該凹所は表皮材が配されるコア型凸部を取囲み、さらに該凹所に接するコア型凸部には第一樹脂層のキャビティ用の段差が設けられ、且つ該段差の下に樹脂溜り用の凹部が形成される一方、キャビティ型はクランプ体の内周縁に対向する部分が突出して突起部を形成し、該クランプ体とコア型との間に表皮材を介在してクランプ体が退動し、表皮材の周縁部をキャビティ壁の外へ引き出し表皮材がクランプ体とコア型との挟持によりセットされるようにし、さらに、型閉じで、表皮材に覆われたコア型の内側領域に表皮材と一体成形される前記第一樹脂層用のキャビティと、該キャビティに加え、表皮材に接するコア型部分に前記凹部が形成され、また表皮材の外側領域に第二の樹脂層用のキャビティが形成されることを特徴とする表皮材の部分加飾一体成形品用金型にある。
請求項２に記載の表皮材の部分加飾一体成形品用金型は、請求項１で、凹部が凹所に面する側を開口し、前記クランプ体と前記コア型との挟持により表皮材がセットされることにより上面開口の凹部になり、さらに該凹部へ前記コア型凸部の本体中央部から張り出すリブが複数設けられることを特徴とする。
請求項３に記載の本発明の要旨は、コア型とキャビティ型とを備え、該コア型には表皮材が配される領域より外のキャビティ壁の一部を担って上面にコア型キャビティ壁をつくり進退動可能なクランプ体が設けられると共に該コア型上に該クランプ体をおさめる凹所が確保されて、該凹所は表皮材が配されるコア型凸部を取囲み、さらに該凹所に接するコア型凸部には第一樹脂層のキャビティ用の段差が設けられ、且つ該段差の下に樹脂溜り用の凹部が形成される一方、キャビティ型はクランプ体の内周縁に対向する部分が突出して突起部を形成し、該クランプ体とコア型との間に表皮材を介在してクランプ体が退動し、表皮材の周縁部をキャビティ壁の外へ引き出し表皮材がクランプ体とコア型との挟持によりセットされるようにし、さらに、型閉じで、表皮材に覆われたコア型の内側領域に表皮材と一体成形される前記第一樹脂層用のキャビティと、該キャビティに加え、表皮材に接するコア型部分に前記凹部が形成され、また表皮材の外側領域に第二の樹脂層用のキャビティが形成される表皮材の部分加飾一体成形品用金型を用い、
コア型の所定領域を表皮材で覆うようにして該表皮材の周縁部をキャビティ壁の外へ引き出しクランプ体とコア型とで挟持し、次いで、該表皮材で覆われた内側領域にあるゲートからキャビティへ多めの溶融樹脂を射出し、該内側領域に溶融樹脂を充満させると共に余剰の溶融樹脂を凹部へ逃して溜め込み樹脂圧の上昇を回避し、その後、該表皮材の外側領域に配されたゲートからキャビティへ溶融樹脂を射出しキャビティを埋め尽くして表皮材と一体成形させることを特徴とする表皮材の部分加飾成形方法にある。
【０００６】
【実施形態】
以下、本発明に係る表皮材の部分加飾一体成形品用金型および表皮材の部分加飾成形方法について詳述する。
図１〜図１０は本発明の表皮材のの部分加飾一体成形品用金型および表皮材の部分加飾成形方法の一形態で、図１〜図７は成形過程を示す断面説明図である。図１は型開き状態にある表皮材の部分加飾成形品用金型（以下、単に「金型」という）の断面説明図、図２は図１の状態から工程が進んで表皮材を係止セットした断面説明図、図３は型閉じ後、表皮材で覆われた内側領域にあるゲートからキャビティへ溶融樹脂を射出した断面説明図、図４は図３のＡ部拡大図、図５は図４の要部斜視図、図６は表皮材の外側領域に配されたゲートからキャビティへ溶融樹脂を射出した断面説明図、図７は脱型の断面説明図、図８は図１のコア型及びクランプ体の平面図、図９は表皮材の部分加飾一体成形品の斜視図、図１０は図９のIV−IV線断面図である。
【０００７】
（１）表皮材の部分加飾一体成形品用金型
表皮材の部分加飾一体成形品を造る金型について説明する。図１に示した金型は、表皮材の部分加飾一体成形品に用いる金型の一例で、コア型３とクランプ体４とキャビティ型５とを具備する。
【０００８】
コア型３はここではその略中央にコア型凸部３ａがある固定型（下型）になっている。コア型３にはキャビティ壁３１が形成されるが、表皮材１が配される領域より外のキャビティ壁の一部はクランプ体４に担わせている（図２）。そのため、コア型上にクランプ体４をおさめる凹所３６が確保される。
コア型凸部３ａは島状になっており（図８）、凹所３６がコア型凸部３ａを取囲む。凹所３６に接するコア型凸部３ａには第一樹脂層２ａのキャビティＣ₁用の段差３ａ₁があり、該段差３ａ₁の下に樹脂溜り用の凹部３７が形成される（図４）。凹部３７は凹所３６に面する側が開口しているが、クランプ体４とコア型３との挟持により表皮材１がセットされるようになると（後述）、文字どおり上面開口の凹部となる。凹部３７は、成形過程で溶融樹脂Ｇ_2aの余剰分を十分溜め込めるよう、凹所３６の底面近くまで深く掘られている。凹部３７へは図５のようにコア型凸部３ａの本体中央部から張り出すリブ３８が適当な間隔で複数設けられる。該リブ３８の側面３８１は型閉じで、クランプ体４に近接し、リブ３８とクランプ体４とでも表皮材周縁部１ａを挟持できるようになっている。なお、段差３ａ₁の下で全てに亘り凹部３７が形成される必要はなく、表皮材１の部分加飾成形で表皮材１が破れ易いところに形成するだけで足りる。
コア型３には、表皮材１で覆われる内側領域（内包領域）と表皮材１の外側領域のキャビティ壁のそれぞれに溶融樹脂Ｇ_2a，Ｇ_2bを射出するゲート３２，３３が形成される（図３，図６）。
【０００９】
クランプ体４は、表皮材１で覆われる前記コア型凸部３ａ（一領域）の外周縁に沿って設けられる。クランプ体４は、表皮材１が配されるコア型凸部３ａの部分が開口Ｏした環状ブロックで（図８）、コア型側に設置され、クランプ体上面に前述のごとくコア型キャビティ壁４１をつくる。クランプ体４は、その下面が可動軸７１に支えられ（図７参照）、該可動軸を作動させる油圧シリンダ（図示せず）によってコア型３から浮上したりコア型３に密着したり進退動可能に設けられる。クランプ体４がコア型３に引き下がった状況下、クランプ体４の接合部４２に係る内周縁４９とコア型凸部外周縁３９とは全周にわたって近接状態にある（図８）。従って、クランプ体４を浮上させた後、コア型３とクランプ体４の間に表皮材１を介在させてクランプ体４を下降させれば、コア型３とクランプ体４の接合部４２とで表皮材１を挟持し、コア型凸部３ａ上に表皮材１を配して係止セットできる構成である。
【００１０】
キャビティ型５は下面にキャビティ壁５１が形成された可動型（上型）である。キャビティ型５は、クランプ体４の内周縁４９詳しくは接合部４２に対向する部分が楔状に突出して突起部５２を形成する。突出部５２の両側壁はキャビティ壁５１からなだらかな弧を描き、その底面５２ａをフラットにする（図２）。意匠面Ｅに現われる表皮材端末ラインＬの見栄えを良くするためである。
クランプ体４とコア型３との間に表皮材１を挟んでクランプ体４をコア型３に引き込み表皮材１を挟持した後、キャビティ型５を下降させ、型閉めすると、表皮材１による部分加飾一体成形品用のキャビティＣが形成される。このとき、表皮材１に覆われたコア型３の内側領域には、表皮材１と一体成形される樹脂層（第一樹脂層２ａ）用のキャビティＣ₁と、該キャビティＣ₁に加え、表皮材１に接するコア型部分に樹脂溜り用の凹部３７が形成される。また、表皮材１の外側領域には第二の樹脂層２ｂ用のキャビティＣ2が形成される。キャビティＣの厚み幅は２〜３ｍｍである。
【００１１】
（２）表皮材の部分加飾成形方法
上記金型を用いて、表皮材の部分加飾成形方法は以下のごとく実施される。
まず、成形操作に先立ち、所定大きさに裁断カットした平板状の表皮材１を準備する。該表皮材１は一体成形品Ｐが出来上った後にその周縁部１ａがカットされるので、従来技術のようにシビアな寸法カットする必要はない。製品となる所定寸法の表皮材より若干大きめの表皮材１が用意される。表皮材１には例えば真空成形トリムされた樹脂製のレザー表皮材が用いられる。
そして、金型を型開状態とし、さらにクランプ体４を上動させ、クランプ体４がコア型３から浮上した状態とする。
【００１２】
次いで、コア型３とクランプ体４の間に表皮材１を配設する（図１）。
続いて、図示しない油圧シリンダを作動させ、クランプ体４をコア型側に引き込むことにより前記表皮材１をコア型上に係止する（図２）。表皮材１の部分加飾一体成形品ＰをつくるキャビティＣ内で表皮材１をセットするにあたり、コア型３の凸部３ａ（一領域）を表皮材１で覆うようにしてその表皮材１の周縁部１ａをキャビティ壁３１の外へ引き出しクランプ体４とコア型３とで挟持しセットする。表皮材１はコア型凸部３ａを覆って、その表皮材周縁部１ａがキャビティ壁の外（具体的にはコア型凸部とクランプ体の間隙）へ引き出され、係止セットされる。クランプ体４が下降してコア型３に密着すると、表皮材外周全域に亘って、コア型凸部３ａの外周縁３９とクランプ体４の内周縁４９とで表皮材周縁部１ａを挟持する（図５）。多少小さめに裁断カットされた表皮材周縁部１ａにあっても、クランプ体４とリブ３８との間に挟んで確実にセットされる。
【００１３】
しかる後、型閉じを進行させる。キャビティ型５を閉めていくと、キャビティ内（ここでは、完全な型閉じ状態でない）で部分的にその領域を表皮材１が占有する格好になる。
次に、表皮材１で覆われた内側領域Ｃ₁にあるゲート３２を開き、通路３４を通ってゲート３２からキャビティへ溶融樹脂Ｇ_2aを射出し、部分加飾用の表皮材１との一体成形を行う。この段階での射出成形は、完全な型閉じ状態下で実施してもよいが、表皮材１の一体成形状態をよくするため、金型を少し開き加減として低圧成形法を採用するのがより好ましい。溶融樹脂Ｇ_2aがコア型凸部上に団子状に盛られることになる。
溶融樹脂Ｇの材料には、例えばポリエチレン，ポリプロピレン等の熱可塑性プラスチックが使用される。溶融樹脂Ｇ（Ｇ_2a，Ｇ_2b）の材料は部分加飾用の表皮材１と相溶性のものとなる。
【００１４】
斯る溶融樹脂Ｇ_2aの射出を終えたら、続いて、少し開き加減にあったキャビティ型５を完全に閉じ、型閉じを完了させる（図３）。
この過程で、係止セットされた表皮材１とコア型凸部上で団子状に盛られた上述の溶融樹脂Ｇ_2aがプレスされる。充満する溶融樹脂Ｇ_2aで、表皮材１はキャビティ型５のキャビティ壁に押しつけられ、意匠面Ｅを形成する表皮材部分がきれいに形成されていく。このとき、クランプ体４とコア型３とで周縁部１ａを挟持した表皮材１で、キャビティ型５からコア型３に横切る横断部１ｂでは、溶融樹脂Ｇ_2aが横断部１ｂに直撃しないようその流れを凹部３７へ向うよううまくかわしている。もし、該凹部３７がないと、横断部３７へ溶融樹脂Ｇ_2aが図１１の矢印のごとく表皮材の横断部１ｂにストレートにぶつかって表皮材１を破ってしまう（図１２）。その結果、表皮材１に覆われる内側領域Ｃ₁が溶融樹脂Ｇ_2aで完全充填されないためショートショットが発生したり、表皮材端縁１ｆが意匠面Ｅに現われたりする不具合を招くことになる。また、表皮材１に覆われたコア型３のキャビティＣ₁中へ溶融樹脂Ｇ_2aの必要量を過不足なく充満させるのは至難であり、通常は若干多めの溶融樹脂Ｇ_2aが供給される。溶融樹脂Ｇ_2aの余剰分が多いと、樹脂圧を上げ同様に表皮材１を破ることにつながる（図１２）。しかし、この場合も、樹脂溜り用の凹部３７が形成されることによって、内側領域Ｃ₁に溶融樹脂Ｇ_2aを充満させると共に余剰の溶融樹脂Ｇ_2aを凹部３７へ逃して溜め込み、樹脂圧の上昇を回避する。
【００１５】
本出願人は、前記表皮材の横断部１ｂでの破れを防ぐために、図１３，図１４に示すごとく、表皮材１に接する部分でクランプ体４とキャビティ型５とでつくる横断面の隙間形状が所定間隔ごとに切欠かれた切欠部４２ｂを設けながらもスリット状の隙間Ｓにした表皮材１の部分加飾一体成形品用金型を先に出願している。ただ、この出願の場合、ゲート部３２の位置関係が微妙であり、横断部１ｂがときとしてゲート部３２の付近になると、表皮材１を破って外側領域Ｃ₂へ溶融樹脂Ｇαが侵入してしまう事態が起きている（図１５）。斯る事態になると、意匠面側にウェルドラインやツヤムラが発生し、外観を悪くする。図１４で、切欠部４２ｂや隙間Ｓの幅εを小さくすることも考えられるが、表皮材１が覆っている加飾部と意匠面が樹脂成形のところとの密着性を上げるには、切欠部４２ｂ，幅εの値をある程度大きく取らざるを得ず、必然的に横断部１ｂへ直撃してくる溶融樹脂Ｇ_2aの流れを止めるのは困難な状況にある。
これに対し、本発明では、凹部３７の形成によって溶融樹脂Ｇ_2aの流れを表皮材１に沿わせて凹部３７へ向わせ、溶融樹脂Ｇ_2aの流れが横断部１ｂに真っ向からぶつかるのをかわし、表皮材１が破られるのをうまく防いでいる。
【００１６】
その後、表皮材１の外側領域に配されたゲート３３を開き、通路３５を経てゲート３３からキャビティＣへ溶融樹脂Ｇ_2bを射出する（図６）。
表皮材１の外側領域のキャビティＣ₂へ充填された該溶融樹脂Ｇ_2bは、キャビティＣ₂を埋め、表皮材１に接合しこれと一体化する。第一の樹脂層２ａを覆った表皮材１のキャビティＣ₂に面した部分（横断部１ｂ）に第二の樹脂層２ｂが接合する。こうして、溶融樹脂Ｇ_2bで表皮材外側にある残りのキャビティＣを埋め尽くして表皮材１で部分加飾された一体成形品Ｐを造る。
ところで、第二の樹脂層２ｂをバージン材で形成する一方、第一の樹脂層２ａをリサイクル材で形成すると、より好ましくなる。第一の樹脂層２ａは意匠面側に現われないため、外観に不都合がなく、リサイクル材を用いることによってコストダウンが図れる。リサイクル材には、市場に出て回収される素材の他、工場の生産過程で不良品やバリなどとなって排出されたものを粉砕利用した素材等を含む。リサイクル材については、相溶性があれば混ざりものであっても構わない。また、その色なども第一の樹脂層２ａが意匠面側に現われてこないことからリサイクル材と同一になる必要はない。
【００１７】
かくのごとく成形された表皮材１の部分加飾一体成形品Ｐは、冷却固化された後、脱型工程に移る。クランプ体４と図示しないエジェクタピンとで一体成形品Ｐを突き上げて脱型する（図７）。
金型から一体成形品Ｐを取出した後、最後に、成形品裏面から伸びる表皮材周縁部１ａ及び凹部３７に溶融樹脂Ｇ_2aが入り込んで硬化した余剰分２９を作業者が手やハサミ等で取り除くと、所望の表皮材の部分加飾一体成形品Ｐが得られる。なお、一体成形品Ｐの裏面側のゲートランド部分２３も適宜カットされる。
【００１８】
上述の一体成形法で得られた表皮材１の部分加飾一体成形品は、図９，図１０ごとくの形状になっている。表皮材１との一体成形品Ｐで、意匠面Ｅは樹脂層２ｂがつくる意匠面の他に、表皮材１が島状に存在し、部分加飾が施されている。表皮材１は、意匠面Ｅの一部を形成すると共にその周縁部１ａが意匠面側から樹脂層２を横切って裏面側へ貫通している。表皮材１が樹脂層２を横切るところの横断部１ｂに、表皮材１で覆われた内側領域で成形される第一の樹脂層２ａが接合し、また、表皮材１の外側領域で成形される第二の樹脂層２ｂが外側から接合する。
なお、本実施形態は表皮材外周全域に亘ってコア型３とクランプ体４とで挟持することによって図９のような島状の部分加飾一体成形品Ｐとしたが、他形態として図１６のような部分加飾一体成形品Ｐとすることもできる。
【００１９】
（３）効果
このように構成した表皮材の部分加飾一体成形品用金型および表皮材の部分加飾成形方法によれば、表皮材周縁部１ａがキャビティ壁の外へ引き出され、且つコア型３とクランプ体４により常に決まった位置に挟持セットされるので、意匠面サイドに現われる表皮材端末ラインＬが一定できれいに仕上がる。表皮材１の意匠面Ｅを形成した後、ゲート３３から溶融樹脂Ｇ_2bを表皮材外側のキャビティＣ2に供給して製品外周部にあたる樹脂部分を形成するから、表皮材１の意匠面の境界が乱れない。
そして、成形工程で、まずゲート３２を開き、表皮材１に覆われた箇所に溶融樹脂Ｇ_2aを供給して表皮材１との一体成形を行うが、凹部３７を設けることによって横断部１ｂの手前で溶融樹脂Ｇ_2aが表皮材１とほぼ平行に流れるので、表皮材１の横断部１ｂに対するダメージを低減させることができる。その結果、表皮材１の破れがなくなり、さらに表皮材加飾部のショートショットがなくなる。溶融樹脂Ｇ_2aの注入量が内側領域Ｃ₁の容量より多めになっても、凹部３７が樹脂溜りになって溶融樹脂Ｇ_2aの余剰分２９を収容するので、成形操作を円滑に進めることができる。第一の樹脂層２ａの原料計量はあまり精度を要せず、調整が簡単になる。前記余剰分２９は後でカット除去できるので何ら問題ない。
また、表皮材１は一体成形品Ｐが出来ると、表皮材端縁１ａが成形品裏面側に現われ、この部分は不要部分となってカットされるので、成形時における表皮材１は所定寸法より若干大きめのものを用いれば足り、裁断にシビアにならずに済む。表皮材１が所定寸法より小さめになっても、リブ３８とクランプ体４とで表皮材の周縁部１ａを挟持できるので、何ら不都合がない。表皮材端縁のトリミング処理もいらず作業性に優れる。
【００２０】
コア型３とクランプ体４とで表皮材１をコア型上に係止セットできるので、従来必要とした真空引きの機器はいらなくなる。また、図３の表皮材１との一体成形で、型を少し開き加減にしてキャビティＣへ溶融樹脂Ｇを射出し、さらにプレスする低圧成形法を用いた場合は、表皮材１のダメージが少なくなるメリットがある。
【００２１】
尚、本発明においては前記実施形態に示すものに限られず、目的，用途に応じて本発明の範囲で種々変更できる。表皮材１，樹脂層２，コア型３，クランプ体４，キャビティ型５等の形状，大きさ，材質，個数等は用途に合わせて適宜選択できる。
【００２２】
【発明の効果】
以上のごとく、本発明の表皮材の部分加飾一体成形品用金型および表皮材の部分加飾成形方法は、意匠面に現われる表皮材端末ラインを綺麗に整えることができ、品質安定に優れた効果を発揮する。
【図面の簡単な説明】
【図１】本発明の表皮材の部分加飾成形方法の一形態で、型開き状態にある金型の断面説明図である。
【図２】図１の状態から工程が進んで表皮材を係止セットした断面説明図である。
【図３】型閉じ後、表皮材で覆われた内側領域にあるゲートからキャビティへ溶融樹脂を射出した断面説明図である。
【図４】図３のＡ部拡大図である。
【図５】図４の要部斜視図である。
【図６】表皮材の外側領域に配されたゲートからキャビティへ溶融樹脂を射出した断面説明図である。
【図７】脱型の断面説明図である。
【図８】図１のコア型及びクランプ体の平面図である。
【図９】表皮材の部分加飾一体成形品の斜視図である。
【図１０】図９のIV−IV線断面図である。
【図１１】図４に対応する説明断面図である。
【図１２】図４に対応する説明断面図である。
【図１３】図４に対応する説明断面図である。
【図１４】図１３で表皮材なしのＶ矢視図である。
【図１５】不具合の状況を説明する斜視図である。
【図１６】別形態の表皮材の部分加飾一体成形品の斜視図である。
【図１７】従来技術の説明断面図である。
【図１８】従来技術の説明図である。
【符号の説明】
１表皮材
１ａ周縁部
２ａ第一の樹脂層（樹脂層）
２ｂ第二の樹脂層（樹脂層）
３コア型
３ａコア型凸部
３ａ _１段差
３２，３３ゲート
３７凹部
３８リブ
４クランプ体
４１キャビティ壁
４９内周縁
５キャビティ型
５２突起部
Ｃキャビティ
Ｃ₁ 内側領域（キャビティ）
Ｃ₂ 外側領域（キャビティ）
Ｅ意匠面
Ｇ_2a，Ｇ_2b，Ｇ溶融樹脂
Ｐ成形品（一体成形品）[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a mold for a partially-decorated integral molded product of a skin material and a method for partially decorating a skin material, in which a design surface is partially decorated with a skin material in addition to a resin molding surface.
[0002]
[Prior art]
For interior parts of automobiles, there are partially-decorated integrally molded products that have a texture and luxury feeling with a skin material in a part of the design surface.
Such an integrally molded product has been conventionally produced by a manufacturing method as shown in FIG. First, the skin material 91 having a predetermined size whose outer periphery is trimmed is set in the cavity mold 94, and the skin material 91 is fixed by vacuuming. Next, the mold closing is advanced, and the molten resin 93 is injected during the progress. Then, the mold closing is completed and pressed to produce the integrally molded product Y (FIG. 18). Reference numeral 92 denotes a core mold, and reference numeral 95 denotes a molding resin.
[0003]
[Problems to be solved by the invention]
However, in the above-described manufacturing method, a dimensional error is likely to occur due to the trimming cut of the skin material 91, which immediately affects the quality. Further, there is a problem in that a deviation occurs when the skin material 91 is set, and the terminal line 91a of the skin material in the integrally molded product Y is not constant.
[0004]
This invention solves the said problem, and it aims at providing the partial decorating and shaping | molding method of a skin material, and the partial decoration integrated molding product of a skin material.
[0005]
[Means for Solving the Problems]
In order to achieve the above object, the gist of the present invention described in claim 1 is provided with a core mold and a cavity mold, and the core mold bears a part of the cavity wall outside the region where the skin material is disposed. The core mold cavity wall is formed on the upper surface, and a clamp body capable of moving forward and backward is provided , and a recess for securing the clamp body is secured on the core mold, and the recess is a core mold convex portion on which a skin material is disposed. The core-type convex part that surrounds the concave part is provided with a step for the cavity of the first resin layer, and a concave part for resin reservoir is formed under the step, while the cavity type is clamped The part facing the inner peripheral edge of the body protrudes to form a protrusion , the skin body is interposed between the clamp body and the core mold, the clamp body is retracted, and the peripheral edge of the skin material is placed outside the cavity wall. The outer skin is set by clamping the clamp body with the core mold. So as to be further in the mold closed, a cavity for said first resin layer which is integrally molded with the skin material in the inner region of the core mold covered with the skin material, in addition to the cavity, the core in contact with the skin material said recess is formed on the mold portion, also in part decorated molded article mold for the skin material, characterized in Rukoto cavity for the second resin layer is formed on the outer region of the skin material.
The mold for a partially decorated integrally molded article of a skin material according to claim 2 is the skin material according to claim 1, wherein the concave portion opens on the side facing the recess, and is sandwiched between the clamp body and the core mold. Is set to be a recess having an opening on the upper surface, and a plurality of ribs projecting from the central part of the main body of the core-shaped protrusion are provided in the recess.
The gist of the present invention according to claim 3 is provided with a core mold and a cavity mold, and the core mold bears a part of the cavity wall outside the region where the skin material is disposed, and the core mold cavity wall on the upper surface. is secured recess fit the clamp body on said core mold with a make forward and backward movement clamp member is provided, the recess surrounds the core mold protrusions skin material is placed, further depressions The core-type convex part in contact with the place is provided with a step for the cavity of the first resin layer, and a concave part for resin reservoir is formed under the step, while the cavity type is opposed to the inner peripheral edge of the clamp body. The part protrudes to form a protrusion , the skin member is interposed between the clamp body and the core mold, the clamp body is retracted, the peripheral edge of the skin material is pulled out of the cavity wall, and the skin material is the clamp body. To be set by holding the In the mold closing, a cavity for said first resin layer which is integrally molded on the inner region of the core mold covered with the skin material and the skin material, in addition to the cavity, said recesses in the core mold portion in contact with the skin material is formed, also using partial decorative molded article mold for the second skin material cavity Ru is formed of resin layer in the outer region of the skin material,
Cover the predetermined area of the core mold with the skin material, pull the peripheral edge of the skin material out of the cavity wall and clamp it between the clamp body and the core mold, and then the gate in the inner area covered with the skin material A large amount of molten resin is injected into the cavity from the inside to fill the inner region with the molten resin, and the excess molten resin is allowed to escape into the recesses to avoid a rise in the resin pressure , and then disposed on the outer region of the skin material. In the method of partially decorating a skin material, the molten resin is injected from the gate into the cavity, and the cavity is filled to be integrally formed with the skin material.
[0006]
Embodiment
Hereinafter, the mold for a partially decorated integrally molded product of the skin material and the method of partially decorating the skin material according to the present invention will be described in detail.
FIGS. 1 to 10 show one embodiment of a partially decorated integrally molded mold for a skin material and a method for partially decorating a skin material according to the present invention, and FIGS. 1 to 7 are cross-sectional explanatory views showing the molding process. is there. FIG. 1 is a cross-sectional explanatory view of a mold for a partially decorated molded product (hereinafter simply referred to as “mold”) in a mold open state, and FIG. 2 relates to the skin material as the process proceeds from the state of FIG. FIG. 3 is a sectional explanatory view in which the molten resin is injected into the cavity from the gate in the inner region covered with the skin material after closing the mold, FIG. 4 is an enlarged view of a part A in FIG. 4 is a perspective view of the main part of FIG. 4, FIG. 6 is a cross-sectional explanatory view in which the molten resin is injected from the gate disposed in the outer region of the skin material into the cavity, FIG. 7 is a cross-sectional explanatory view of demolding, and FIG. 9 is a plan view of the core mold and the clamp body, FIG. 9 is a perspective view of a partially decorated integrally molded product of the skin material, and FIG. 10 is a sectional view taken along line IV-IV in FIG.
[0007]
(1) Mold for partially decorated integrally molded product of skin material A mold for producing a partially decorated integrally molded product of a skin material will be described. The mold shown in FIG. 1 is an example of a mold used for a partially decorative integrated product of a skin material, and includes a core mold 3, a clamp body 4, and a cavity mold 5.
[0008]
Here, the core mold 3 is a fixed mold (lower mold) having a core mold convex portion 3a at substantially the center thereof. A cavity wall 31 is formed in the core mold 3, but a part of the cavity wall outside the region where the skin material 1 is disposed is held by the clamp body 4 (FIG. 2). Therefore, a recess 36 for holding the clamp body 4 is secured on the core mold.
The core-type convex portion 3a has an island shape (FIG. 8), and the recess 36 surrounds the core-type convex portion 3a. The core-shaped convex part 3a in contact with the concave part 36 has a step 3a ₁ for the cavity C ₁ of the first resin layer 2a, and a concave part 37 for resin reservoir is formed under the step 3a ₁ (FIG. 4). . The recess 37 is open on the side facing the recess 36, but when the skin material 1 is set by clamping the clamp body 4 and the core mold 3 (described later), the recess 37 literally becomes a recess having an upper surface opening. The concave portion 37 is dug deeply to the vicinity of the bottom surface of the concave portion 36 so that a surplus of the molten resin G _2a can be sufficiently stored during the molding process. As shown in FIG. 5, a plurality of ribs 38 projecting from the center of the main body of the core-type convex portion 3a are provided in the concave portion 37 at appropriate intervals. The side surface 381 of the rib 38 is closed, is close to the clamp body 4, and the rib material 38 and the clamp body 4 can also sandwich the skin material peripheral portion 1 a. It is not necessary to recess 37 across all under step 3a ₁ is formed, it is only necessary to form at prone skin material 1 is broken at a portion decorative molding of the skin material 1.
In the core mold 3, gates 32 and 33 for injecting molten resins G _2a and G _2b are formed on the inner wall (encapsulation region) covered with the skin material 1 and the cavity walls in the outer region of the skin material 1 ( 3 and 6).
[0009]
The clamp body 4 is provided along the outer peripheral edge of the core-type convex portion 3 a (one region) covered with the skin material 1. The clamp body 4 is an annular block in which the core-type convex portion 3a on which the skin material 1 is disposed is open O (FIG. 8), is installed on the core mold side, and the core-type cavity wall 41 on the upper surface of the clamp body as described above. Make. The lower surface of the clamp body 4 is supported by a movable shaft 71 (see FIG. 7). The clamp body 4 is lifted from the core mold 3 or is brought into close contact with the core mold 3 by a hydraulic cylinder (not shown) that operates the movable shaft. Provided possible. Under the condition that the clamp body 4 is pulled down to the core mold 3, the inner peripheral edge 49 and the core-shaped convex outer peripheral edge 39 of the joint portion 42 of the clamp body 4 are in close proximity over the entire periphery (FIG. 8). Accordingly, after the clamp body 4 is levitated and the clamp body 4 is lowered with the skin material 1 interposed between the core mold 3 and the clamp body 4, the joint 42 between the core mold 3 and the clamp body 4 In this configuration, the skin material 1 is sandwiched and the skin material 1 is arranged on the core-shaped convex portion 3a to be locked.
[0010]
The cavity mold 5 is a movable mold (upper mold) in which a cavity wall 51 is formed on the lower surface. In the cavity mold 5, the inner peripheral edge 49 of the clamp body 4, specifically, a portion facing the joint portion 42 protrudes in a wedge shape to form a protrusion 52. Both side walls of the projecting portion 52 draw a gentle arc from the cavity wall 51 and flatten the bottom surface 52a (FIG. 2). This is to improve the appearance of the skin material terminal line L appearing on the design surface E.
After the skin material 1 is sandwiched between the clamp body 4 and the core mold 3, the clamp body 4 is drawn into the core mold 3, the skin material 1 is sandwiched, and then the cavity mold 5 is lowered and the mold is closed. A cavity C for a decorative integrally formed product is formed. At this time, the inner region of the core mold 3 covered by the skin material 1 is provided with a cavity C ₁ of the resin layer which is integrally molded with the skin material 1 (first resin layer 2a), in addition to the cavity C _1, A concave portion 37 for retaining the resin is formed in the core mold portion in contact with the skin material 1. A cavity C2 for the second resin layer 2b is formed in the outer region of the skin material 1. The thickness width of the cavity C is 2 to 3 mm.
[0011]
(2) Partial decoration molding method of skin material Using the above mold, the partial decoration molding method of the skin material is carried out as follows.
First, prior to the molding operation, a flat skin material 1 cut to a predetermined size is prepared. Since the outer peripheral portion 1a of the skin material 1 is cut after the integrally molded product P is completed, it is not necessary to cut severely as in the prior art. A skin material 1 slightly larger than a skin material having a predetermined dimension as a product is prepared. As the skin material 1, for example, a resin leather skin material that is trimmed by vacuum molding is used.
Then, the mold is opened, and the clamp body 4 is further moved upward so that the clamp body 4 is lifted from the core mold 3.
[0012]
Next, the skin material 1 is disposed between the core mold 3 and the clamp body 4 (FIG. 1).
Subsequently, a hydraulic cylinder (not shown) is operated to pull the clamp body 4 toward the core mold side, thereby locking the skin material 1 on the core mold (FIG. 2). When setting the skin material 1 in the cavity C that forms the partially decorated integrally molded product P of the skin material 1, the convex material 3a (one region) of the core mold 3 is covered with the skin material 1, and the skin material 1 The peripheral edge 1a is pulled out of the cavity wall 31 and clamped between the clamp body 4 and the core mold 3 and set. The skin material 1 covers the core-shaped convex portion 3a, and the skin material peripheral edge portion 1a is drawn out of the cavity wall (specifically, the gap between the core-shaped convex portion and the clamp body) and is set to be locked. When the clamp body 4 descends and comes into close contact with the core mold 3, the outer peripheral edge 1a of the core mold convex portion 3a and the inner peripheral edge 49 of the clamp body 4 are sandwiched across the entire outer periphery of the outer skin material ( FIG. 5). Even in the outer periphery 1a of the skin material cut and cut to be slightly smaller, it is securely set by being sandwiched between the clamp body 4 and the rib 38.
[0013]
Thereafter, the mold closing is advanced. As the cavity mold 5 is closed, the skin material 1 partially occupies the area within the cavity (here, not a complete mold closed state).
Next, the gate 32 in the inner region C ₁ covered with the skin material 1 is opened, the molten resin G _2a is injected from the gate 32 to the cavity through the passage 34, and integrated with the skin material 1 for partial decoration. Perform molding. The injection molding at this stage may be performed in a completely mold-closed state. However, in order to improve the integral molding state of the skin material 1, it is more preferable to adopt a low-pressure molding method by slightly opening and subtracting the mold. preferable. Molten resin G _2a is to be served in a dumpling shape on the core-shaped convex portion.
As the material of the molten resin G, for example, a thermoplastic plastic such as polyethylene or polypropylene is used. The material of the molten resin G (G _2a , G _2b ) is compatible with the skin material 1 for partial decoration.
[0014]
When the injection of the molten resin G _2a is finished, the cavity mold 5 that has been slightly opened and closed is then completely closed to complete the mold closing (FIG. 3).
In this process, the above-described molten resin G _2a piled up in the form of dumplings is pressed on the set skin material 1 and the core-shaped convex portion. The skin material 1 is pressed against the cavity wall of the cavity mold 5 by the filled molten resin G _2a , and the skin material portion forming the design surface E is formed cleanly. At this time, in the skin material 1 in which the peripheral edge portion 1a is sandwiched between the clamp body 4 and the core mold 3, the molten resin G _2a does not directly hit the transverse section 1b in the transverse section 1b that crosses from the cavity mold 5 to the core mold 3. The flow is well diverted to the recess 37. If the concave portion 37 is not provided, the molten resin G _2a hits the transverse portion 1b of the skin material straightly as shown by the arrow in FIG. 11 and breaks the skin material 1 to the transverse portion 37 (FIG. 12). As a result, the inner region C ₁ covered with the skin material 1 is not completely filled with the molten resin G _2a , so that a short shot occurs or the skin material edge 1 f appears on the design surface E. Further, it is extremely difficult to fill the required amount of molten resin G _2a into the cavity C ₁ of the core mold 3 covered with the skin material 1 without excess or deficiency, and usually a slightly larger amount of molten resin G _2a is supplied. . If excess molten resin G _2a is large, similarly raise the resin pressure leads to breaking the skin material 1 (FIG. 12). However, in this case also, by the recess 37 of the resin reservoir is formed, entrapment excess molten resin G _2a missed into the recess 37 causes filling the molten resin G _2a in the inner area C _1, increase of the resin pressure To avoid.
[0015]
In order to prevent tearing at the crossing portion 1b of the skin material, the applicant of the present invention, as shown in FIGS. 13 and 14, forms a gap shape in a cross section formed by the clamp body 4 and the cavity mold 5 at a portion in contact with the skin material 1. Has previously filed a mold for a partially decorated integrally molded product of the skin material 1 having a slit-like gap S while providing cutout portions 42b cutout at predetermined intervals. However, in this application, a subtle positional relation between the gate portion 32, the transverse section 1b is sometimes made in the vicinity of the gate portion 32, the molten resin Gα outside region C ₂ beating skin material 1 invades A situation has occurred (FIG. 15). In such a situation, a weld line and gloss unevenness are generated on the design surface side, and the appearance is deteriorated. In FIG. 14, it is conceivable to reduce the width ε of the notch 42 b and the gap S. However, in order to increase the adhesion between the decorative portion covered by the skin material 1 and the design surface, the notch It is difficult to stop the flow of the molten resin G _2a that inevitably hits the crossing part 1b inevitably with the values of the part 42b and the width ε.
On the other hand, in the present invention, the formation of the concave portion 37 causes the flow of the molten resin G _2a to be directed along the outer skin material 1 toward the concave portion 37, so that the flow of the molten resin G _2a strikes the transverse portion 1b from the head. The skin material 1 is well prevented from being broken.
[0016]
Thereafter, the gate 33 arranged in the outer region of the skin material 1 is opened, and the molten resin G _2b is injected from the gate 33 into the cavity C through the passage 35 (FIG. 6).
The molten resin G _2b filled in the cavity C _{2 in} the outer region of the skin material 1 fills the cavity C ₂ and is joined to and integrated with the skin material 1. Second resin layer 2b is joined to the portion (cross section 1b) facing the cavity C ₂ of skin material 1 covering the first resin layer 2a. In this way, the remaining cavity C on the outer side of the skin material is filled with the molten resin G _2b to make an integrally molded product P partially decorated with the skin material 1.
By the way, it is more preferable that the second resin layer 2b is formed of a virgin material while the first resin layer 2a is formed of a recycled material. Since the first resin layer 2a does not appear on the design surface side, there is no inconvenience in appearance, and the cost can be reduced by using a recycled material. Recycled materials include not only materials that are collected on the market, but also materials that are pulverized and used as defective products or burrs in the factory production process. The recycled materials may be mixed as long as they are compatible. Further, since the first resin layer 2a does not appear on the design surface side, the color and the like need not be the same as the recycled material.
[0017]
The partially decorated integrally formed product P of the skin material 1 formed as described above is cooled and solidified, and then proceeds to a demolding step. The integrally molded product P is pushed up by the clamp body 4 and an ejector pin (not shown) to be removed (FIG. 7).
After taking out the integrally molded product P from the mold, the operator finally uses the hand or scissors to remove the surplus 29 that has been melted by the molten resin G _2a entering the outer periphery 1a and the recess 37 extending from the back surface of the molded product. When it removes, the partial decoration integral molded product P of a desired skin material will be obtained. The gate land portion 23 on the back side of the integrally molded product P is also appropriately cut.
[0018]
The partially decorated integrally molded product of the skin material 1 obtained by the above-described integral molding method has a shape as shown in FIGS. In the integrally molded product P with the skin material 1, the design surface E has an island shape in addition to the design surface formed by the resin layer 2b, and is partially decorated. The skin material 1 forms a part of the design surface E, and the peripheral edge 1a penetrates the resin layer 2 from the design surface side to the back surface side. The first resin layer 2a molded in the inner region covered with the skin material 1 is joined to the transverse portion 1b where the skin material 1 crosses the resin layer 2, and is molded in the outer region of the skin material 1. The second resin layer 2b is joined from the outside.
In addition, although this embodiment was made into the island-shaped partial decoration integrated molded product P like FIG. 9 by pinching with the core type | mold 3 and the clamp body 4 over the outer periphery whole surface material, as FIG. It can also be set as the partial decoration integral molded product P like.
[0019]
(3) Effects According to the mold for the partially decorated integrally molded product of the skin material and the method of partially decorating the skin material thus configured, the skin material peripheral edge 1a is drawn out of the cavity wall, and the core Since the mold 3 and the clamp body 4 are always clamped and set at a fixed position, the skin material terminal line L appearing on the side of the design surface is finished cleanly. After the design surface E of the skin material 1 is formed, the molten resin G _2b is supplied from the gate 33 to the cavity C 2 outside the skin material to form a resin portion corresponding to the outer peripheral part of the product. Not disturbed.
In the molding step, first, the gate 32 is opened, and the molten resin G _2a is supplied to the portion covered with the skin material 1 to perform integral molding with the skin material 1. Since the molten resin G _2a flows almost parallel to the skin material 1 in front, damage to the transverse portion 1b of the skin material 1 can be reduced. As a result, the skin material 1 is not torn and a short shot of the skin material decoration portion is eliminated. Even if the injection amount of the molten resin G _2a is larger than the capacity of the inner region C ₁ , the concave portion 37 becomes a resin reservoir and accommodates the surplus portion 29 of the molten resin G _2a , so that the molding operation can proceed smoothly. it can. The measurement of the raw material of the first resin layer 2a does not require much precision, and adjustment is easy. Since the surplus portion 29 can be cut and removed later, there is no problem.
Further, when the skin material 1 is formed as an integral molded product P, the skin material edge 1a appears on the back side of the molded product, and this portion is cut as an unnecessary portion. It is sufficient to use a slightly larger one, and it will not become severe in cutting. Even if the skin material 1 becomes smaller than a predetermined size, the peripheral edge 1a of the skin material can be sandwiched between the rib 38 and the clamp body 4, so there is no inconvenience. Excellent workability with no trimming of skin edges.
[0020]
Since the skin material 1 can be locked and set on the core mold by the core mold 3 and the clamp body 4, no conventionally required vacuuming device is required. In addition, when the low-pressure molding method is used in which the mold is slightly opened and closed and the molten resin G is injected into the cavity C and pressed further, the skin material 1 is less damaged. There are benefits.
[0021]
The present invention is not limited to those shown in the above embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application. The shape, size, material, number, etc. of the skin material 1, the resin layer 2, the core mold 3, the clamp body 4, the cavity mold 5, etc. can be appropriately selected according to the application.
[0022]
【The invention's effect】
As described above, the mold for the partially decorated integrally molded product of the skin material and the method of partially decorating the skin material of the present invention can neatly arrange the skin material terminal line that appears on the design surface, and is excellent in quality stability. Show the effect.
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a cross-sectional explanatory view of a mold in a mold open state in one form of a method for partially decorating a skin material of the present invention.
FIG. 2 is an explanatory cross-sectional view in which a process progresses from the state of FIG. 1 and a skin material is locked and set.
FIG. 3 is an explanatory cross-sectional view in which molten resin is injected from a gate in an inner region covered with a skin material into a cavity after mold closing.
4 is an enlarged view of a part A in FIG. 3;
FIG. 5 is a perspective view of a main part of FIG. 4;
FIG. 6 is a cross-sectional explanatory diagram in which molten resin is injected from a gate disposed in an outer region of the skin material into a cavity.
FIG. 7 is a cross-sectional explanatory view of demolding.
8 is a plan view of the core mold and the clamp body of FIG. 1. FIG.
FIG. 9 is a perspective view of a partially decorated integrally molded product of a skin material.
10 is a cross-sectional view taken along line IV-IV in FIG.
FIG. 11 is an explanatory sectional view corresponding to FIG. 4;
FIG. 12 is an explanatory sectional view corresponding to FIG. 4;
FIG. 13 is an explanatory sectional view corresponding to FIG. 4;
FIG. 14 is a V arrow view without a skin material in FIG.
FIG. 15 is a perspective view for explaining a situation of a defect.
FIG. 16 is a perspective view of a partially decorated integrally molded product of a skin material according to another embodiment.
FIG. 17 is an explanatory sectional view of the prior art.
FIG. 18 is an explanatory diagram of a conventional technique.
[Explanation of symbols]
1 skin material 1a peripheral edge 2a first resin layer (resin layer)
2b Second resin layer (resin layer)
3 Core type
3a Core type convex part
3a ₁ step 32, 33 gate 37 recess
38 Rib 4 Clamp body 41 Cavity wall 49 Inner edge 5 Cavity mold
52 Protrusion C Cavity C ₁ Inner area (cavity)
C ₂ outer area (cavity)
E Design surface G _2a , G _2b , G Molten resin P Molded product (Integrated molded product)

Claims

A core mold and a cavity mold, and the core mold bears a part of the cavity wall outside the region where the skin material is disposed , and is provided with a clamp body capable of moving forward and backward by creating a core mold cavity wall on the upper surface. A recess for holding the clamp body is secured on the core mold, the recess surrounds the core mold convex portion on which the skin material is disposed, and the core mold convex portion in contact with the recess has a first resin. A step for the cavity of the layer is provided, and a concave portion for resin reservoir is formed under the step, while the cavity mold protrudes from the portion facing the inner peripheral edge of the clamp body to form a protrusion, and the clamp The clamp body is retracted with the skin material interposed between the body and the core mold, and the peripheral edge of the skin material is pulled out of the cavity wall so that the skin material is set by clamping the clamp body and the core mold. Furthermore, the mold is closed and covered with the skin material. A cavity for said first resin layer which is integrally molded with the skin material in the inner area of the mold, in addition to the cavity, wherein the recess is formed in the core mold portion in contact with the skin material and the second outside region of the skin material partial decorative molded article mold for the cavity for layers of resin forming the skin material, characterized in Rukoto.

The concave portion opens on the side facing the concave portion, and the skin material is set by sandwiching the clamp body and the core mold, thereby forming a concave portion of the upper surface opening. A mold for a partially decorated integrally molded product of a skin material according to claim 1, wherein a plurality of ribs projecting from the central portion are provided.

A core mold and a cavity mold, and the core mold bears a part of the cavity wall outside the region where the skin material is disposed , and is provided with a clamp body capable of moving forward and backward by creating a core mold cavity wall on the upper surface. A recess for holding the clamp body is secured on the core mold, the recess surrounds the core mold convex portion on which the skin material is disposed, and the core mold convex portion in contact with the recess has a first resin. A step for the cavity of the layer is provided, and a concave portion for resin reservoir is formed under the step, while the cavity mold protrudes from the portion facing the inner peripheral edge of the clamp body to form a protrusion, and the clamp The clamp body is retracted with the skin material interposed between the body and the core mold, and the peripheral edge of the skin material is pulled out of the cavity wall so that the skin material is set by clamping the clamp body and the core mold. Furthermore, the mold is closed and covered with the skin material. A cavity for said first resin layer which is integrally molded with the skin material in the inner area of the mold, in addition to the cavity, wherein the recess is formed in the core mold portion in contact with the skin material and the second outside region of the skin material with parts decorated molded article mold for the skin material which cavity Ru is formed of resin layer,
A predetermined area of the core mold is covered with a skin material, and the peripheral edge of the skin material is pulled out of the cavity wall and clamped between the clamp body and the core mold, and then the gate in the inner area covered with the skin material A large amount of molten resin is injected into the cavity from the inside to fill the inner region with the molten resin, and the excess molten resin is allowed to escape into the recesses to avoid the increase in the resin pressure , and then disposed on the outer region of the skin material A method for partially decorating a skin material, comprising injecting molten resin from the gate to the cavity, filling the cavity and integrally molding the skin material.