JP3891472B2 - Manufacturing method of two-color molded products - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of manufacturing a two-color molded article suitable for automobile interior parts such as automobile door trims, luggage side trims, and trunk room trims. In particular, the number of processes can be reduced, the weight can be reduced, and the cost can be significantly reduced. The present invention relates to a method for manufacturing a two-color molded product that can bring down the product and further improve the appearance quality of the product.
[0002]
[Prior art]
Normally, various interior parts are installed in the interior of a car, contributing to ensuring the safety of passengers and improving the aesthetics of the room.
[0003]
FIG. 11 is a front view showing an automotive door trim mounted on the indoor side of the door panel. In order to reduce the size of the molding tool and improve the appearance design, the automotive door trim 1 includes a door trim upper 2 and a door trim lower. 3 and upper and lower divided parts. As shown in FIGS. 12 and 13, the door trim upper 2 is a skin bonded molded product in which a skin 2 b is integrally bonded to the surface of a resin core material 2 a molded into a desired curved shape, and the door trim lower 3 is It is composed of a single resin injection molded product.
[0004]
More specifically, the door trim upper 2 has a skin 2b attached to the surface of the resin core material 2a, and a middle sheet 2c such as a cloth is mounted on the middle part. A speaker grill 3a is integrally formed on the door trim lower 3, and a pocket opening 3b is opened as a door pocket capable of accommodating various equipment, and a pocket back cover 3c is mounted on the back side thereof.
[0005]
And as a manufacturing method of the door trim 1 for automobiles of the upper and lower divided structure mentioned above, the door trim upper 2 and the door trim lower 3 are each shape | molded using an exclusive molding die. The door trim upper 2 has a skin 2b set in advance in a molding die (not shown), and by injecting molten resin into the cavity of the molding die, the resin core 2a is molded into a desired curved shape, The skin 2b is integrally attached to the surface side.
[0006]
The door trim lower 3 is an injection molding method in which a molten resin is injected into an injection mold and molded into a required shape, or after the molten resin is injected into a mold press mold, the mold is clamped. Thus, it is formed into a desired curved surface shape.
[0007]
And as shown in FIG. 13, the joining method of the door trim upper 2 which is a skin-bonded molded product and the door trim lower 3 which is a resin single-molded product has a lapping margin indicated by hatching in FIG. In this lap allowance portion, the door trim lower 3 is superposed on the front side of the door trim upper 2, and the attachment boss 4 provided on the back surface of the door trim lower 3 is provided in the lap allowance portion of the door trim upper 2. After the insertion, the front end portion of the mounting boss 4 is subjected to ultrasonic caulking, or the door trim upper 2 and the door trim lower 3 are integrated with each other by mechanically fixing the finisher or the like. Has completed production.
[0008]
[Problems to be solved by the invention]
The method for manufacturing a two-color molded product represented by the above-described automobile door trim 1 is obtained by molding the door trim upper (skin-bonded molded product) 2 and the door trim lower (resin single-molded product) 3 with separate molds. The door trim upper 2 and the door trim lower 3 are joined and the mounting boss 4 is integrated by caulking or mechanical fastening, and a plurality of mold facilities are required, respectively. The number of processes, such as a process and the joining process of both members, is large, and there is a problem that the cost is increased.
[0009]
Further, when the door trim upper 2 and the door trim lower 3 are joined, there is a lapping allowance for each, so that the weight is increased and the material loss is large, and the joint portion between the door trim upper 2 and the door trim lower 3 is a step. For example, the appearance of the mating part was not preferable.
[0010]
The present invention has been made in view of such circumstances, and is a method for manufacturing a two-color molded article suitable for automobile interior parts such as automobile door trims, luggage side trims, trunk room trims, etc. An object of the present invention is to provide a method for producing a two-color molded product, which can ensure excellent appearance performance, simplify die equipment, reduce the number of steps, and can greatly reduce costs.
[0011]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides a two-color molded product obtained by integrally molding a skin-bonded molded product obtained by integrating a skin with the surface of a resin core material and a single resin molded product using the same mold. In the manufacturing method, an elevating block capable of moving up and down is disposed in the lower mold along the boundary line between the skin bonded molded product and the resin single molded product, and the edge of the skin in the skin bonded molded product The first molten resin is supplied to the lower surface side of the skin through the first step of setting the skin on the lifting block and the first injection machine connected to the lower mold, and the upper mold is lowered. The upper edge of the skin and the lifting block are sealed at the edge of the skin, and the resin core material is molded along the first cavity shape defined by the molding upper and lower molds and the lifting block, to form a skin bonded product. The formation of a laminated product The process and the lifting block are lowered until the lifting block is flush with the mold surface of the molding lower mold, and the molding upper mold is raised by a certain clearance, thereby forming a second cavity that forms a resin single-molded product. Then, by injecting the second molten resin into the second cavity through a second injection machine connected to the lower mold, the resin core material of the skin-bonded molded product and the single resin molded product are integrated. And a molding process of a single resin molded product in which an extended flange of the skin is insert-molded inside the single resin molded product.
[0012]
Here, the application of the two-color molded product can be applied to all automotive interior parts, for example, automotive door trims, luggage side trims, trunk room trims, and the like.
[0013]
And according to this invention , the resin core material and the resin single-piece molded product in the skin-bonded molded product are welded and integrated with each other, without wrapping the skin-bonded molded product and the resin single-piece molded product on the front and back sides. At the same time, since the edge portion of the skin in the skin-bonded molded product is inserted into the resin single-molded product as an extended flange, the rigidity at both joint portions can be maintained firmly.
[0014]
In addition, the end of the skin in the skin-bonded molded product is insert-treated inside the resin single-piece molded product, so there is no fraying of the skin and peripheral lines meandering, ensuring a good appearance appearance at the joint. it can.
[0016]
Further, according to the present invention , when setting the skin used for the skin bonded molded product on the mold surface of the molding lower mold, if the edge portion of the skin is set on the upper surface of the lifting block, the molding upper mold is lowered. When this is done, the edge portion of the skin is satisfactorily clamped between the elevating block and the upper mold, and the elevating block has a weir function that prevents the first molten resin from flowing out. A skin-bonded molded product can be molded well.
[0017]
Next, when the upper mold is raised by a certain stroke and the elevating block is lowered until it is flush with the mold surface of the lower mold, a second cavity is formed, and the second cavity is formed in the second cavity. When the molten resin is injected, the resin core material and the single resin molded product in the skin bonded molded product can be integrated, and the extended flange of the skin can be inserted into the single resin molded product.
[0018]
Therefore, the skin-bonded molded product and the single resin molded product can be integrally molded in the same mold, and the conventional troublesome joining process can be eliminated.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF EMBODIMENTS Hereinafter, preferred embodiments of a method for producing a two-color molded product according to the present invention will be described in detail with reference to the accompanying drawings. In addition, it demonstrates taking the case of the door trim for motor vehicles mounted in a door panel as a 2-color molded product.
[0020]
FIGS. 1 to 3 show an automotive door trim as a two-color molded article according to the present invention, FIG. 1 is a front view showing the automotive door trim, FIG. 2 is a sectional view showing the automotive door trim, and FIG. It is sectional drawing which expands and shows the junction part of the door trim upper and door trim lower in the door trim for the motor vehicles. 4 to 9 show a first embodiment of the method of the present invention, FIG. 4 is an overall view of a manufacturing apparatus used in the method of the present invention, FIG. 5 is a plan view of a molding lower mold in the manufacturing apparatus, FIG. 6 is an explanatory view showing the skin setting process in the method of the present invention, FIG. 7 is an explanatory view showing the molding process of the door trim upper in the method of the present invention, and FIGS. 8 and 9 are the molding steps of the door trim lower in the method of the present invention. It is explanatory drawing shown. FIG. 10 is a cross-sectional view showing a configuration of an automobile door trim which is another embodiment of the two-color molded product according to the present invention.
[0021]
First, the configuration of an automobile door trim 10 manufactured by the method of the present invention will be briefly described with reference to FIGS. The automobile door trim 10 is composed of an upper and lower divided body of a door trim upper 20 and a door trim lower 30.
[0022]
The door trim upper 20 is a skin-bonded molded product, and a skin 22 is integrally attached to the surface of a resin core material 21, and a centering sheet 23 is attached to a center part. On the other hand, the door trim lower 30 is a single resin molded product, and the speaker grille 31 is integrally formed, and a pocket opening 32 is opened, and a drawing pattern transferred from a mold at the time of molding is formed on the surface of the door trim lower 30. Is engraved.
[0023]
Further, as shown in an enlarged view in FIG. 3, the joint portion between the door trim upper 20 and the door trim lower 30 is set so that the product surfaces of the door trim upper 20 and the door trim lower 30 are flush with each other, and the door trim upper 20 and the door trim lower 30. Is firmly welded and integrated at the joint, and in particular, since the extended flange 22a of the skin 22 of the door trim upper 20 is inserted inside the door trim lower 30, the joint between the door trim upper 20 and the door trim lower 30 is inserted. It is the structure which strengthens the joint strength of. The extending flange 22a may be arbitrarily set within a range of 1 to 50 mm.
[0024]
Therefore, it is possible to eliminate the conventional caulking process of the mounting boss or the mechanical fixing process such as the fixture as in the prior art, and the troublesome joining work is not required, so that the man-hour can be greatly simplified.
[0025]
In addition, conventionally, the door trim upper and door trim lower were wrapped to fix the mounting boss, and the machine was fixed, so a large amount of lapping was required and a step was created on the product surface, reducing the appearance. In the structure of the present invention, as described above, since the product surface is the same, not only the appearance appearance is improved, the lapping cost is eliminated, the weight is reduced, the material loss is small, and the material is effectively used. Has various advantages such as
[0026]
Next, a manufacturing method of the automobile door trim 10 shown in FIGS. 1 to 3 and a manufacturing apparatus used therefor will be described below.
[0027]
4 to 9 show an embodiment of the method and apparatus for manufacturing the automobile door trim 10. As shown in FIGS. 4 to 5, the manufacturing apparatus 40 can be moved up and down by a predetermined stroke. A mold 50, a molding lower mold 60 paired therewith, two injection machines 70 and 71 connected to the molding lower mold 60, a door trim upper 20 and a door trim lower 30 are molded using upper and lower molds 50 and 60. Thus, it is generally composed of a lifting block 80 provided on the molding lower mold 60 so that it can be molded at the same time.
[0028]
More specifically, the molding upper die 50 can be moved up and down by a predetermined stroke by an elevating cylinder 51, a step portion 52 is formed along the boundary line between the door trim upper 20 and the door trim lower 30, and the product surface of the door trim lower 30 A drawing pattern 53 is engraved on the mold surface of the molding upper mold 50 corresponding to the above.
[0029]
On the other hand, the molding lower mold 60 is provided with a manifold 61 and a gate 62 as resin passages for supplying a molten resin from the first injection machine 70, and the resin core material 21 in the door trim upper 20 is passed through the manifold 61 and the gate 62. The first molten resin to be formed is supplied into the first cavity C1. Further, the second molten resin is supplied from the second injector 71 to the second cavity C <b> 2 that forms the door trim lower 30 through the manifold 63 and the gate 64.
[0030]
Further, a step portion 65 is also formed on the mold surface of the molded lower mold 60 corresponding to the boundary portion between the door trim upper 20 and the door trim lower 30, and the lifting block 80 extends from the step portion 65 to the second cavity C <b> 2 side. Is provided. The lifting block 80 is supported by a shaft 81 and driven by a hydraulic cylinder 82 connected to the shaft 81.
[0031]
Next, each step of manufacturing the automobile door trim 10 using the manufacturing apparatus 40 having the above-described configuration will be described. FIG. 6 shows the setting process of the skin 22, and in the setting process of the skin 22, the molding upper mold 50 is in the mold open state, and the lifting block 80 in the molding lower mold 60 is also located above. First, the outer skin 22 of the door trim upper 20 is set on the molding lower mold 60. At this time, the extending flange 22a (edge portion) of the outer skin 22 is placed on the upper surface of the elevating block 80. It can be completed easily.
[0032]
When the setting of the skin 22 is completed, the molding upper mold 50 is lowered by a predetermined stroke by the operation of the lifting cylinder 51, and when the molding upper and lower molds 50, 60 reach a predetermined clearance, the first injection machine 70 is reached. The first molten resin M1, which is the material of the resin core material 21 of the door trim upper 20, is supplied to the lower surface side of the skin 22 through the manifold 61 and the gate 62, and as shown in FIG. The resin core material 21 and the skin 22 are simultaneously molded by moving down to the position, and the molding of the door trim upper 20 is completed.
[0033]
At this time, the elevating block 80 is raised, and the extending flange 22a of the skin 22 is well clamped by the molding upper die 50 and the elevating block 80. The elevating block 80 has a clamping function for clamping the skin 22. In addition, since it has a dam function for damming the molten resin M1, the molten resin M1 does not flow out to the second cavity C2 side, and the resin core material 21 and the skin 22 can be molded integrally. Can do.
[0034]
Next, when the molding of the door trim upper 20 is completed, the second trim for the door trim lower 30 which is a single resin molded product from the second injector 71 through the manifold 63 and the gate 64, as shown in FIG. The second molten resin M <b> 2 is supplied into the cavity C <b> 2, and the door trim lower 30 is formed into a required shape and integrated with the door trim upper 20.
[0035]
At this time, as shown in an enlarged view in FIG. 9, the molding upper die 50 is raised by a certain stroke, and the elevating block 80 is lowered to the mold surface of the molding lower die 60 by driving the hydraulic cylinder 82. Since the corner portion 52a of the step portion 52 provided in the molding upper mold 50 can maintain a good sealing relationship with the corner portion 20a of the door trim upper 20, the extended flange 22a of the skin 22 is inserted into the door trim lower 30. The door trim lower 30 can be formed.
[0036]
Then, after the molding, when the molding upper mold 50 is opened, if the lifting block 80 is raised by operating the hydraulic cylinder 82, the door trim upper 20 and the door trim lower 30 can be pushed up, and the demolding operability is improved. be able to.
[0037]
As described above, according to the above-described embodiment, after the skin 22 on the door trim upper 20 side is set on the mold surface of the molding lower mold 60, the first molten resin M1 is supplied from the first injection machine 70 to the first mold. Injection into the cavity C1 to mold the door trim upper 20, and then the second cavity from the second injection machine 71 with the molding upper die 50 raised by a certain stroke and the lifting block 80 lowered. Since the door trim lower 30 can be formed integrally with the door trim upper 20 by supplying the second molten resin M2 into C2, the same upper and lower molds 50 and 60 are used to form the door trim 10 for an automobile. Because molding is possible, the mold equipment can be simplified, the number of processes can be greatly shortened, and the automotive door trim 10 can be mass-produced with an improved appearance of the mating part. .
[0038]
Next, FIG. 10 shows another embodiment in which the two-color molded product according to the present invention is applied to the door trim 100 for an automobile. The automobile door trim 100 has a door trim upper 110 and a door trim lower 120 with different product appearances 2. It consists of a single resin molded product, and the door trim upper 110 and the door trim lower 120 are firmly integrated along the joint 130, so that the mounting boss is welded and fixed at the lap portion as in the past. Alternatively, there is no need for caulking and fixing, and the integral molding can be easily performed by operating the lifting block with the same molding die. In this case, the door trim upper 110 and the door trim lower 120 are required to use compatible resin materials.
[0039]
In the embodiment described above, the present invention is applied to an automobile door trim 10 having a vertically divided structure composed of a door trim upper 20 that is a skin-bonded molded product and a door trim lower 30 that is a single resin molded product. A two-color molded product composed of a skin-bonded molded product and a single resin molded product can be applied to, for example, a left and right divided structure other than the upper and lower divided parts, and can be applied to various uses such as a luggage side trim and a trunk room trim.
[0040]
【The invention's effect】
As described above, according to the method for producing a two-color molded product according to the present invention, the skin-bonded molded product and the resin single-molded product can be simultaneously molded in a single molding die. In addition to being able to reduce mold costs and simplifying the die equipment, it can lead to significant cost reductions, and there is no lapping cost compared to conventional two-color molded products, contributing to weight reduction and less material loss. In addition, it has various effects that a useful two-color molded product that can enhance the appearance performance of the mating portion can be mass-produced.
[Brief description of the drawings]
FIG. 1 is a front view showing a door trim for an automobile which is an embodiment of a two-color molded product according to the present invention.
2 is a cross-sectional view taken along line II-II in FIG.
3 is an enlarged cross-sectional view showing a main part in FIG. 2. FIG.
FIG. 4 is an overall side view showing a manufacturing apparatus used in the method for manufacturing a two-color molded product according to the present invention.
5 is a plan view of a molded lower mold in the manufacturing apparatus shown in FIG. 4. FIG.
FIG. 6 is an explanatory view showing a skin setting step in an embodiment of the method for producing a two-color molded product according to the present invention.
FIG. 7 is an explanatory view showing a molding process of a door trim upper in an embodiment of a method for producing a two-color molded product according to the present invention.
FIG. 8 is an explanatory view showing a door trim lower molding process in an embodiment of a method for producing a two-color molded article according to the present invention.
FIG. 9 is an explanatory diagram showing an integration process of a door trim upper and a door trim lower in an embodiment of the method for manufacturing a two-color molded product according to the present invention.
FIG. 10 is a cross-sectional view showing a configuration of an automobile door trim which is another embodiment of the two-color molded product according to the present invention.
FIG. 11 is a front view showing a conventional automobile door trim.
FIG. 12 is a perspective view in which a conventional automobile door trim is divided into a door trim upper and a door trim lower.
13 is a cross-sectional view taken along line XIII-XIII in FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Automotive door trim 20 Door trim upper 21 Resin core material 22 Skin 22a Extending flange 23 Centering sheet 30 Door trim lower 31 Speaker grill 32 Pocket opening 40 Manufacturing apparatus 50 Molding upper mold 51 Lifting cylinder 52 Step part 53 Drawing pattern 60 Lower mold 61, 63 Manifold 62, 64 Gate 65 Step 70 First injection machine 71 Second injection machine 80 Lifting block 81 Shaft 82 Hydraulic cylinder M1 First molten resin M2 Second molten resin C1 First Cavity C2 Second cavity

Claims (1)

Two-color molded product formed by integrally molding a skin-bonded molded product (20) obtained by integrating the skin (22) on the surface of the resin core (21) and a single resin molded product (30) using the same mold. 10) a manufacturing method,
An elevating block (80) that can move up and down is arranged in the lower mold (60) along the boundary line between the skin-bonded molded product (20) and the resin single-piece molded product (30). An epidermis setting step of placing the edge portion of the epidermis (22) in the article (20) on the elevating block (80);
The first molten resin (M1) is supplied to the lower surface side of the skin (22) through the first injection machine (70) connected to the molding lower mold (60), and the molding upper mold (50) is lowered. The first upper cavity (50) and the lifting block (80) seal the edge portion of the skin (22), and the first cavity is defined by the molding upper and lower molds (50, 60) and the lifting block (80). (C1) forming the resin core material (21) along the shape and forming the skin-bonded molded product (20);
The lift block (80) is lowered until the lift block (80) is flush with the mold surface of the molded lower mold (60), and the molded upper mold (50) is raised by a certain clearance, so that a single resin molded product is obtained. The second cavity (C2) that forms (30) is formed, and the second molten resin (M2) is passed through the second cavity (C2) through the second injection machine (71) connected to the molding lower mold (60). (C2) By injecting, the resin core material (21) of the skin-bonded molded product (20) and the single resin molded product (30) are integrated, and the skin is formed inside the single resin molded product (30). A molding step of a resin single-molded product for insert-molding the extended flange (22a) of (22);
A process for producing a two-color molded product comprising:

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