JP4158599B2 - Method for molding board product and mold used therefor - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a board product such as a door trim, which is an interior part of an automobile, and more particularly to a method for molding a board product having an opening for a pocket or the like and a molding apparatus used therefor.
[0002]
[Prior art]
As for this type of molding technique, for example, the technique disclosed in Patent Document 1 is already known. In this technique, a fiber mat made of a mixed material of natural fibers such as kenaf and resin fibers and a skin material are set in a mold in a preheated state. In this case, the fiber mat is set on the molding surface of the lower mold, and the skin material is set on the molding surface of the upper mold. Prior to clamping, the cutting tool block incorporated in the upper mold is advanced to form a winding allowance in which a cut is made in the skin material at a location corresponding to the opening of the board product. Thereafter, by retracting the blade block, the winding allowance is drawn into the inner side of the mold.
[0003]
Next, by clamping the mold, the board base material is formed into a predetermined shape, and the board base material and the skin material are bonded together. In parallel with this, the blade block is advanced again, and an opening is formed in the board base material in a state in which an allowance for the skin material is secured. Thereafter, the board product is taken out from the mold, and the covering margin of the skin material is wound around the back side of the board base material so as to cover the edge of the opening.
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 2003-62846
[Problems to be solved by the invention]
In the conventional technique, the cutter block is advanced and retracted in order to secure the allowance for the skin material prior to the mold clamping. Moreover, in order to form an opening part in a board base material, the cutter block is advanced also at the time of mold clamping. That is, a step of moving the blade block back and forth is required separately from the steps of clamping the mold and opening the mold. For these reasons, the molding process of the board product having the opening and the structure of the mold become complicated.
The present invention is intended to solve the conventional problems, and one object thereof is to simplify the process of finishing a board product in which the edge of the opening is covered with a skin.
Another object of the present invention is to simplify the structure of the mold and reduce the cost.
[0006]
[Means for Solving the Problems]
The present invention is for achieving the above object, and is configured as follows.
According to the first aspect of the present invention, the board base material is molded and the board base material and the skin material are bonded together by setting the heated fiber mat and the skin material in a mold and clamping the mold. A board product molding method, in which a board base material and a skin material are punched out by leaving a predetermined bending margin to form an opening by clamping a molding die, and at the same time, the bending margin is removed from the board base material. Pre-bending molding is performed toward the back side of the sheet, and incision processing for winding is performed at the bending margin. Thereafter, the board product is taken out of the mold, and the folding margin is wound around the back side of the board base to finish the opening.
In this way, the opening is punched out while leaving the bending allowance in each of the board base material and the skin material, and this bending allowance is finally wound around the back side of the board base material, so that the edge of the opening is the skin. It is possible to simplify the molding process until finishing the covered board product.
[0007]
The invention according to claim 2 is a method for molding a board product according to claim 1, in which the molding surfaces of the fixed mold and the movable mold constituting the mold are paired in an uneven relationship with each other. the molding portion for forming the opening portion provided so as, when the mold clamping, the opening for the board substrate and skin materials punching, preliminary bending of the bending margin, and, for entrainment notch machining Do each.
Thereby, in addition to simplifying the molding process of the board product, the molding die basically does not require any operating means other than the movable type operating mechanism, thereby simplifying the structure and reducing the cost. be able to.
[0008]
The invention according to claim 3 is a method for forming a board product according to claim 1 or 2, wherein the bending allowance is smaller than that of the other portions during the pre-bending forming of the bending allowance. Compress to
Thereby, the operation | work for winding a bending allowance into the back side of a board base material and finishing an opening part becomes easy.
[0009]
Invention of Claim 4 is a shaping | molding die used for the shaping | molding method of the board product described in Claim 2, Comprising: One of the fixed mold | type and movable mold | type which comprises this shaping | molding mold is a heated fiber mat. A molding surface that can be set is provided, and the other is provided with a molding surface that can set a heated skin material. On these molding surfaces, there are provided molding parts that make a pair in a concave-convex relationship at locations where openings are formed in the board base material and the skin material . This forming part includes an opening forming part for punching out the opening portion by leaving the bending allowance on the board base material and the skin material by clamping the forming die, and a preliminary bending forming for making the bending allowance toward the back side of the board base material. A bending portion and a notching portion for processing a notch for winding at a bending margin are provided.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below.
FIG. 1 is an external perspective view showing a door trim of a vehicle side door as a board product. 2 is a cross-sectional view taken along the line II-II in FIG. As shown in these drawings, the door trim 10 is provided with a pocket opening 14 penetrating from the surface of the board base material 11 to the back surface while the surface of the board base material 11 is covered with a skin material 12. In addition, the board | substrate base material 11 shape | molds the fiber mat 11A in a predetermined shape with the press so that it may demonstrate later. Further, the fiber mat 11A in the present embodiment may be a material formed by pressing a mixed material of natural fibers such as kenaf or cotton and thermoplastic resin fibers such as polypropylene into a mat shape, or a preform formed into a board shape. Including.
[0011]
FIG. 3 is a cross-sectional view showing the open state of a board mold (press mold). FIG. 4 is a cross-sectional view showing the clamping state of the mold. A press die 20 shown in these drawings is composed of a lower die 21 (fixed die) and an upper die 22 (movable die), and the molding surfaces 23 and 24 have molding portions that are paired in a concave-convex relationship with each other. There are 25 and 26. These molding portions 25 and 26 are for molding the pocket opening 14 of the door trim 10. A vacuum chamber 28 is provided inside the upper mold 22. A negative pressure can be applied to the vacuum chamber 28 from a vacuum pump (not shown) or the like. The vacuum chamber 28 and the molding surface 24 of the upper mold 22 communicate with each other through a plurality of small holes 28a.
[0012]
5A and 5B are perspective views showing the molding portions 25 and 26. FIG. 6 and 7 are cross-sectional views showing the locations of the forming portions 25 and 26 in the clamped state of the press die 20. FIG. 6 shows a portion where a pre-bending process for a bending margin, which will be described later, is performed simultaneously with the punching of the portion where the pocket opening 14 is to be formed. Further, FIG. 7 shows a portion where a cut process described later is performed simultaneously with the punching of the portion where the pocket opening 14 is to be formed. As is clear from these drawings, the molding part 25 of the lower die 21 is set to a concave shape, and the molding part 26 of the upper die 22 is set to a convex shape. As shown in FIG. 5 (B), the concave shaped portion 25 is provided with a plurality of groove blades 25a around it. These groove blades 25a are radially located in the molding portion 25 in a state of communicating with the recesses.
[0013]
As shown in FIG. 5 (A), the convex shaped portion 26 includes a plurality of protruding blades 26a around it. These projecting blades 26a are arranged at intervals corresponding to the respective groove blades 25a of the molding portion 25, and each of the projecting blades 26a can enter each of the groove blades 25a at the time of mold clamping. Preliminary bending surfaces 25b and 26b having inclination angles corresponding to each other are formed around the molding portions 25 and 26, respectively. In addition, the shaping | molding part 25 is provided with the boarding surface 25c in the outer peripheral side of the preliminary | backup bending surface 25b.
[0014]
Next, molding of the door trim 10 will be described.
First, in the mold open state of the press mold 20 shown in FIG. 3, the fiber mat 11 </ b> A heated by a far infrared heater or the like is set on the molding surface 23 of the lower mold 21 in a process not shown. Similarly, the heated skin material 12 is set on the molding surface 24 of the upper mold 22, and negative pressure is applied to the vacuum chamber 28. As a result, the skin material 12 is sucked to the molding surface 24 through the small holes 28a, and the skin material 12 is held (evacuated) in a shape following the molding surface 24.
[0015]
With the negative pressure applied to the vacuum chamber 28, the upper mold 22 is lowered to bring the press mold 20 into the mold clamping state shown in FIG. As a result, the fiber mat 11A is compressed between the molding surfaces 23 and 24 of the lower mold 21 and the upper mold 22 to mold the board base material 11, and at the same time, the skin material 12 is bonded to the surface side of the board base material 11. Is done. This adhesion is due to the adhesive strength of the resin contained in the heated fiber mat 11A. Note that suction to the vacuum chamber 28 is stopped after mold clamping.
[0016]
As the press die 20 is clamped, the molding portions 25 and 26 of the lower die 21 and the upper die 22 punch out portions where the board base 11 and the skin material 12 should be formed with the pocket openings 14, thereby opening 14 A. Is formed. However, the opening 14A is punched out with a bending margin 16 around it (FIGS. 6 and 7), and the opening area of the opening 14A is smaller than the opening area of the pocket opening 14 by the bending margin 16. Simultaneously with the punching of the opening 14A, the bending margin 16 is preliminarily bent at a predetermined angle toward the back side of the board substrate 11 by the prebending surfaces 25b and 26b of the forming portions 25 and 26 (FIG. 6).
[0017]
Simultaneously with the punching of the opening 14A, the base portion of the bending margin 16 is compressed by the plate filling surface 25c of the molding portion 25, and the plate thickness of the bending margin 16 is compressed to about half of the other portions. Further, simultaneously with the punching of the opening portion 14A, each projecting blade 26a of the molding portion 26 enters each groove blade 25a of the molding portion 25, and the winding notch 17 is processed into the bending allowance 16 (FIG. 7). The board product (door trim 10) processed in this way is taken out from the press die 20 that has been opened.
[0018]
FIG. 8 is a perspective view showing the periphery of the opening 14A in the board product taken out from the press die 20. As shown in this drawing, the bending allowance 16 is pre-bent (braded) toward the back side of the board base material 11, and the plate thickness is compressed and thinner than other portions. Further, a plurality of cuts 17 are formed in the bending margin 16 from the opening portion 14 </ b> A to the base portion of the bending margin 16. These processes facilitate the operation of winding the bending allowance 16 (the board base material 11 and the skin material 12) around the back side of the board base material 11, as will be described next.
[0019]
Next, the front and back of the board product are inverted so that the board base material 11 is the upper surface and the skin material 12 is the lower surface, and set on the mold surface 31 of the jig base 30 shown in FIGS. 9 and 10. And the base part of the bending allowance 16 is reheated from the board | substrate base material 11 side with the heater 32 shown in FIG. Thereafter, as shown in FIG. 10, the bending allowance 16 (the board base material 11 and the skin material 12) is wound around the back side (upper side) of the board base material 11 to finish the edge of the opening 14 </ b> A. To do.
[0020]
In addition, it is possible to automate shaping | molding of the door trim 10 by performing each next operation | work with a robot.
a. The operation of setting the fiber mat 11A and the skin material 12 on the press die 20 (FIG. 3).
b. The operation | work which takes out the door trim 10 after shaping | molding from the press metal mold | die 20, and sets it to the jig base 30 (FIG. 9).
c. An operation of winding the bending allowance 16 into the back side of the board base 11 (FIG. 10).
[0021]
As is clear from the above description, in the molding portions 25 and 26 of the press die 20, the uneven portions themselves correspond to the “opening molding portion” of the present invention. Further, the groove blade 25a and the projecting blade 26a correspond to the “cutting portion” of the present invention, and the preliminary bending surfaces 25b and 26b correspond to the “preliminary bending portion” of the present invention.
[Brief description of the drawings]
1 is an external perspective view showing a door trim of a vehicle side door as a board product. FIG. 2 is a cross-sectional view taken along line II-II in FIG. 1. FIG. FIG. 4 is a sectional view showing a clamping state of a board mold. FIG. 5 is a perspective view showing a molding part for molding an opening. FIG. 6 is a diagram showing a portion of the molding part in the clamping state. Cross-sectional view [Fig. 7] Cross-sectional view showing the location of the molded part in the clamped state [Fig. 8] Perspective view showing the periphery of the opening in the board product [Fig. 9] Reheating work for the bending allowance in the board product Cross-sectional view [Figure 10] Cross-sectional view showing the work involving the bending allowance [Explanation of symbols]
10 Door trim (board product)
11 Board base material 11A Fiber mat 12 Skin material 14A Opening portion 16 Bending allowance 20 Press die (molding die)
21 Lower mold (fixed mold)
22 Upper mold (movable)
25, 26 Molding part

Claims (4)

A board product molding method in which a heated fiber mat and a skin material are set in a mold and clamped to mold a board base material, and the board base material and the skin material are bonded together. By clamping the mold, the board base material and the skin material are punched out leaving a predetermined bending allowance to form an opening, and at the same time, the bending allowance is directed toward the back side of the board base material and pre-bending molding is performed. A board product molding method characterized in that a cutting process for winding is performed at a bending margin, and then the board product is taken out from the mold, and the opening is finished by winding the folding margin onto the back side of the board base. . The board product molding method according to claim 1, wherein openings formed so as to form a pair in a concave-convex relationship are formed on the molding surfaces of the fixed mold and the movable mold constituting the mold. The molding part for performing the punching of the opening, the pre-bending forming of the bending allowance, and the cutting process for entrainment with respect to the board base material and the skin material when the mold is clamped Molding method for board products. The board product forming method according to claim 1 or 2, wherein the bending allowance is compressed at the time of pre-bending forming of the bending allowance so that the plate thickness becomes smaller than other portions. Molding method for finished board products. It is a shaping | molding die used for the shaping | molding method of the board product described in Claim 2, Comprising: One of the fixed type | mold and movable mold | type which comprises this shaping | molding die is equipped with the shaping | molding surface which can set the heated fiber mat, and the other Are provided with molding surfaces on which the heated skin material can be set, and these molding surfaces are provided with molding parts that form a pair in a concave-convex relationship with each other at the positions where the openings are formed in the board base material and the skin material , This forming part includes an opening forming part for punching out the opening portion by leaving the bending allowance on the board base material and the skin material by clamping the forming die, and a preliminary bending forming for making the bending allowance toward the back side of the board base material. A mold comprising a bending portion and a cutting portion for processing a winding cut at a bending margin.

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