JP4850445B2 - Molding method of resin product and molding apparatus used for molding method - Google Patents

Description

  The present invention relates to a molding method for molding a resin product obtained by integrally molding a skin material on the surface of a resin base material, and a molding apparatus used in the molding method.

  BACKGROUND ART Conventionally, a door trim that is an interior material of an automobile is known as a resin product obtained by integrally molding a skin material on the surface of a resin base material (see, for example, Patent Document 1). The terminal of the skin material of the door trim is formed so as to wind the outer peripheral portion of the base material from the front surface to the back surface, thereby constituting a winding portion. Thus, by comprising a winding | wrapping part with the terminal of skin material, the terminal of skin material can be processed inconspicuously and the door trim of favorable appearance can be obtained.

Patent Document 1 discloses a molding apparatus for molding the door trim. The molding apparatus includes an upper mold and a lower mold, and a skin material holding member that holds a skin material between the upper mold and the lower mold. Around the molding surface of the upper mold, there are a plate-like abutting member that abuts on the outer peripheral surface of the skin material held by the skin material holding member, and a cylinder that moves the contact member inward and outward of the molding surface. Is provided. When molding a resin product using the molding apparatus configured as described above, first, the skin material is disposed between the upper mold and the lower mold and is held by the skin material holding member, and then these upper molds In addition, the lower mold is closed, and a molten resin material is supplied from a resin discharge port opened on the molding surface of the lower mold. At this time, the contact member is moved in the direction approaching the molding surface of the lower mold by the cylinder. If it carries out like this, an outer peripheral side of a skin material will be formed so that the outer peripheral part of the base material shape | molded by a shaping | molding surface may be wound by an abutting member. On the other hand, the resin material supplied from the resin discharge port becomes a base material by being molded and solidified by the molding surfaces of the upper mold and the lower mold. Thereby, an intermediate molded product in which the skin material is integrally formed on the surface of the base material is obtained. At this time, the entrainment part of the skin material is in a state of entraining the outer peripheral part of the base material. And after removing the said intermediate molded product from an upper mold | type and a lower mold | type, a door trim is obtained by excising the excess part outside an entrainment part of a skin material.
JP-A-6-270179

  However, in the molding apparatus of Patent Document 1, an excess part of the skin material is cut off after removing the intermediate molded product molded by the upper mold and the lower mold. Therefore, in addition to the excision work for excising the surplus portion of the skin material, a transfer work for removing the intermediate molded product and transferring it to the place where the excision work is performed is required, which increases the number of manufacturing steps and increases the cost. Invite. Furthermore, when cutting off the surplus part of the skin material of the intermediate molded product, it is necessary to secure a space for the cutting operation in the factory, so that the factory must be enlarged accordingly. Depending on this, the cost will rise.

  The present invention has been made in view of such a point, and the object of the present invention is a resin formed so that the terminal of the skin material integrally formed on the surface of the base material is wound around the outer peripheral portion of the base material. When obtaining a product, when forming an intermediate molded product in which the base material and the skin material are integrated, the surplus portion of the skin material can be cut out in the same process, reducing the number of manufacturing steps and Thus, it is necessary to reduce the cost by eliminating the space for excising the surplus portion of the skin material.

  In order to achieve the above object, in the invention of claim 1, as an invention of a resin product molding method, after forming the outer peripheral portion of the skin material so that the outer peripheral portion of the base material is wound by the contact member, the corresponding contact is made. The surplus portion of the skin material was cut off by the skin material cutting portion between the member and the mold.

  Specifically, a resin product in which a skin material is integrally formed on the surface of a resin base material, and an end of the skin material is formed so as to wind the outer peripheral portion of the base material from the front surface to the back surface. The molding method is the target.

The skin material is placed between the first molding surface provided on the first molding die and the second molding surface provided on the second molding die so that the back surface of the skin material faces the second molding surface. The first and second molds are closed after the outer skin material holding step and the outer skin material holding step, and the molten resin material to be the base material is second The resin supply step of supplying the resin material from the resin discharge port that opens to the molding surface to reach the outer peripheral portion of the skin material, and the resin material supplied in the resin supply step reaches the outer peripheral portion of the second molding surface. An abutting member is brought into contact with the outer peripheral surface of the skin material, and the corresponding contact member is moved toward the outer peripheral portion of the second molding surface, whereby the back surface on the outer peripheral side of the skin material is moved to the second molding surface. Is the resin material reaching the outer periphery of the skin material between the skin material and the second molding surface? Thereby preventing the leaking of the outer peripheral side of said surface skin material, and the step winding is formed so as to involve the outer peripheral portion of the substrate to be formed by the first molding surface and the second molding surface from the surface to the back surface, the winding It is set as the structure provided with the excision process of excising the outer part outside the winding-up part of the said skin material by the skin material cutting part between the said contact member and the 2nd shaping | molding die after a process.

  According to this configuration, the molten resin material supplied from the resin discharge port in the resin supply step is between the back surface of the skin material held in the skin material holding step prior to the resin supply step and the second molding surface. The second molding surface flows and spreads toward the outer peripheral side. The contact member is moved toward the outer periphery of the second molding surface until the resin material flowing through the second molding surface reaches the outer periphery of the second molding surface. By moving this contact member, the outer peripheral side of the skin material is formed so as to involve the outer peripheral portion of the base material formed by the first molding surface and the second molding surface, and the first molding surface and the second molding are formed. It is possible to avoid the resin material from leaking from between the surfaces. Thereby, even if the resin material reaches the outer peripheral portion of the second molding surface, the resin material does not leak from between the first molding surface and the second molding surface, and is molded by the first molding surface and the second molding surface. It solidifies and becomes a base material. In the process that this resin material becomes the base material, the resin material is integrated with the skin material, and the entrainment portion of the skin material is formed in a state where the outer peripheral portion of the base material is wound, and the skin material is integrated on the surface of the base material. A molded intermediate molded product is obtained. In this intermediate molded product, the outer side of the enveloping part of the skin material retained in the skin material retaining step remains as an excess portion. Since the surplus portion of the skin material is cut by the skin cutting portion between the contact member and the second mold, the resin is formed without removing the intermediate molded product from the first mold and the second mold. It becomes possible to obtain a product.

  In the invention of claim 2, as an invention of a molding apparatus for resin products, the outer peripheral side of the skin material is moved to the outer periphery of the base material by moving the contact member contacting the outer peripheral part of the skin material by the contact member moving means. A surplus portion of the skin material is cut off by a skin material cutting portion provided on at least one of the contact member and the mold.

  Specifically, a resin product in which a skin material is integrally formed on the surface of a resin base material, and an end of the skin material is formed so as to wind the outer peripheral portion of the base material from the front surface to the back surface. The target is a molding apparatus.

And the 1st shaping | molding die provided with the 1st shaping | molding surface which shape | molds the surface side of the said base material, the 2nd shaping | molding surface which shape | molds the back surface side of the said base material, and the resin discharge opening opened to this 2nd shaping | molding surface A skin material holding member for holding the skin material between the first molding surface and the second molding surface, and a skin holding member provided on the first molding die. abutting contact member retained outer peripheral side surface of the skin material to, provided in the first mold, the contact that the contact member is moved toward the outer periphery of the second molding surface A skin material provided on at least one of the member moving means, the abutting member, and the second mold so as to face the outer peripheral side of the skin material, and excising an excess portion outside the entrained portion of the skin material and a cutting portion, said from the second mold resin discharge port, in a molten state becomes the base material The grease material is supplied so as to reach the outer peripheral portion of the skin material, and the contact member moving means is configured so that the resin material supplied from the resin discharge port reaches the outer peripheral portion of the second molding surface. The contact member is brought into contact with the outer peripheral surface of the material, and the corresponding contact member is moved toward the outer peripheral portion of the second molding surface, so that the rear surface on the outer peripheral side of the skin material is brought into contact with the second molding surface. The resin material reaching the outer peripheral portion of the skin material is prevented from leaking from between the skin material and the second molding surface, and the outer peripheral side of the skin material is connected to the first molding surface and the first molding surface. It is assumed to be configured to form an outer peripheral portion of the substrate to be formed by the second shaping surface to engulf the surface to the back surface.

  According to this configuration, the first molding die and the second molding die are closed while the skin material is held by the skin material holding member, and the molten resin material is supplied from the resin discharge port of the second molding surface. Then, this resin material flows between the back surface of the skin material and the second molding surface and flows toward the outer peripheral side through the second molding surface. When the contact member is moved toward the outer periphery of the second molding surface by the contact member moving means until the resin material flowing through the second molding surface reaches the outer periphery of the second molding surface, The outer peripheral side is formed so as to involve the outer peripheral portion of the base material, and it is possible to avoid the resin material from leaking between the first molding surface and the second molding surface. And while the said resin material is shape | molded and solidified by the 1st shaping | molding surface and the 2nd shaping | molding surface, it forms in the state in which the entrainment part of the skin material entrained the outer peripheral part of the base material. This makes it possible to obtain an intermediate molded product in which the skin material is integrally molded on the surface of the base material. In this intermediate molded product, the outer side of the enveloping portion of the skin material held by the skin material holding member remains as an excess portion. A resin product is obtained by cutting off the surplus portion of the skin material by the skin material cutting portion. Since the skin material cutting portion is provided on at least one of the contact member and the second mold so as to face the skin material, when the surplus portion of the skin material is cut off, the intermediate molded product is the first molded product. It is not necessary to remove the mold from the mold and the second mold.

  In the invention of claim 3, in the invention of claim 2, the skin material cutting portion is constituted by a cutting blade protruding from the contact member toward the skin material.

  According to this configuration, the surplus portion of the skin material can be excised by moving the contact member by the contact member moving means and pressing the cutting blade against the skin material.

  According to a fourth aspect of the present invention, in the second aspect of the present invention, the skin material cutting portion is constituted by a heating element that generates heat when an electric current is passed.

  According to this configuration, when the heating element is brought into contact with or close to the skin material, an electric current is passed through the heating element so that the temperature of the heating element is equal to or higher than the melting temperature of the skin material. The material can be melted and cut.

  According to the invention of claim 1, the outer peripheral side of the skin material is formed by the contact member so that the outer peripheral portion of the base material is wound, so that an intermediate molded product in which the skin material and the base material are integrated can be obtained. . Then, without removing the intermediate molded product from the first mold and the second mold, the surplus portion of the skin material of the intermediate molded product is cut between the contact member and the second mold. Can be excised. As a result, it is possible to reduce the number of manufacturing steps of the resin product formed so that the end of the skin material is wound around the outer peripheral portion of the base material, and cut off the surplus portion of the skin material in the factory for molding the resin product. It is possible to eliminate the need for a space for doing so, and the cost can be reduced.

  According to the invention of claim 2, by moving the contact member that contacts the surface of the skin material by the contact member moving means, the outer peripheral side of the skin material is formed so as to involve the outer peripheral portion of the base material, An intermediate molded product in which the skin material and the base material are integrated can be obtained. And the surplus part of the skin material of this intermediate molded product can be cut off by the skin material cutting part without removing the intermediate molded product from the first mold and the second mold. Thereby, the cost can be reduced as in the first aspect of the invention.

  According to the invention of claim 3, since the skin material cutting portion is constituted by the cutting blade protruding from the contact member toward the skin material, the surplus of the skin material can be obtained only by moving the contact member by the contact member moving means. A part can be excised and the structure of the molding apparatus can be simplified.

  According to the invention of claim 4, since the skin material is cut with a heating element that generates heat when an electric current is passed, for example, a cutting blade like a skin material made of fibers leaves part of the fibers uncut. When there is a possibility that it will occur, the skin material can be melted and reliably cut.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. It should be noted that the following description of the preferred embodiment is merely illustrative in nature, and is not intended to limit the present invention, its application, or its use.

(Embodiment 1)
1 and 2 show a molding apparatus 1 for a resin product according to Embodiment 1 of the present invention. The molding apparatus 1 is used when molding a car door trim 2 (a part of which is shown in FIG. 10) as a resin product. In the description of this embodiment, the structure of the door trim 2 will be described before the structure of the molding apparatus 1 is described. The door trim 2 includes a panel-like base material 3 and a skin material 4 integrally formed on the vehicle interior side, which is the surface side of the base material 3. The base material 3 includes a main body portion 3a extending along the vehicle interior side of a door (not shown), and a peripheral wall portion 3b protruding from the periphery of the main body portion 3a to the vehicle interior outside. 3a and the peripheral wall part 3b are integrally molded. The skin material 4 is provided so as to cover the corner portion of the base material 3, and is formed so as to extend from the main body portion 3 a of the base material 3 to the front end portion in the protruding direction of the peripheral wall portion 3 b. The end of the skin material 4 is formed so that the end portion of the peripheral wall portion 3b of the base material 3 is wound from the surface of the base material 3, and forms a winding portion 4a.

  The base material 3 is formed by molding a resin material such as polypropylene, for example. The skin material 4 is formed by cutting a soft resin sheet such as a vinyl chloride sheet. In addition, you may comprise the skin material 4 with the sheet | seat of a multilayer structure, cloth material, etc. which adhered polyethylene foam etc. to the back surface of the soft sheet, for example.

  Next, the structure of the molding apparatus 1 will be described. As shown in FIGS. 1 and 2, the molding apparatus 1 includes a molding die 10 and an injection machine 11 that injects a molten resin constituting the base material 3. The mold 10 includes an upper mold 12 as a first mold and a lower mold 13 as a second mold. The lower mold 13 is fixed to a fixed platen 14. The upper mold 12 is moved up and down by a mold moving device (not shown) so as to contact and separate from the lower mold 13. By this mold moving device, the upper mold 12 and the lower mold 13 can be switched between a mold open state and a mold closed state. Further, the mold 10 is provided with a mold clamping mechanism (not shown) for clamping the upper mold 12 and the lower mold 13 when the upper mold 12 and the lower mold 13 are closed.

  An upper molding surface 17 as a first molding surface for molding the front side of the door trim 2 is formed on the lower surface of the upper mold 12, and a second molding for molding the rear surface side of the door trim 2 on the upper surface of the lower mold 13. A lower molding surface 18 is formed as a surface. When the upper mold 12 and the lower mold 13 are closed, a cavity S is formed by the upper molding surface 17 and the lower molding surface 18.

  The lower molding surface 18 is formed so as to bulge upward as a whole, and a central surface portion 18a for molding the main body portion 3a of the base material 3 and a side surface portion 18b for molding the peripheral wall portion 3b of the base material 3. It consists of and. Similarly, the upper molding surface 17 includes a central surface portion 17a for molding the main body portion 3a of the base material 3 and a side surface portion 17b for molding the peripheral wall portion 3b of the base material 3.

  The lower mold 13 is provided with a skin material holding member 20 for holding the skin material 4 during molding. The skin material holding member 20 has a frame shape surrounding the lower molding surface 18 in plan view. A plurality of pins (not shown) are provided on the upper surface of the skin material holding member 20 so as to prevent the skin material 4 from being caught and displaced. A support bar 21 for supporting the skin material holding member 20 is provided outside the lower molding surface 18 of the lower mold 13. The support bar 21 extends in the vertical direction, and the skin material holding member 20 is fixed to the upper end portion thereof. The lower side of the support bar 21 is supported so as to be able to reciprocate in the vertical direction while being inserted into the lower mold 13. The support bar 21 is biased upward by a biasing means (not shown), and when the upper mold 12 and the lower mold 13 are opened as shown in FIG. 2, the skin material holding member 20 is moved to the lower molding surface 18. 1, on the other hand, when the mold is closed as shown in FIG. 1, the skin material holding member 20 is pushed downward by the upper mold 12 and moves, so that the movement of the upper mold 12 is not hindered. Yes.

  The lower mold 13 is formed with a resin passage 22 through which the molten resin constituting the substrate 3 passes. The resin passage 22 is constituted by a so-called hot runner. The upstream end of the resin passage 22 is open to the side surface of the lower mold 13, and the downstream end of the resin passage 22 is connected to a resin discharge port 19 that is open at a substantially central portion of the central surface portion 18 a of the lower molding surface 18. Has been. An injection nozzle 23 of the injection machine 11 is connected to the upstream end of the resin passage 22. The injection machine 11 is conventionally used when molding a resin material, and includes a cylinder 24 and a screw 25 that is inserted into the cylinder 24 and rotated by a driving device (not shown). And a hopper 26 for introducing a resin material into the cylinder 24.

  On the lower surface of the upper mold 12, an annular ridge 28 surrounding the central surface 17 a of the upper molding surface 17 is formed so as to protrude downward. The inner peripheral surface of the protruding portion 28 is a side surface portion 17 b of the upper molding surface 17. A lower part of the upper mold 12 is provided with a slide block 30 as a contact member and a fluid pressure cylinder 31 for moving the slide block 30. As shown in FIGS. 3 and 4, the slide block 30 is divided into a plurality of portions corresponding to the corner portions of the base material 3 on the upper molding surface 17 so as to surround the side surface portion 17 b of the upper molding surface 17. Has been placed. As shown in FIG. 5A, each slide block 30 is made of the same metal material as that forming the mold 10, and has a substantially rectangular parallelepiped base portion 32 and an upper side from the lower side of the base portion 32. And a thick plate-like projecting portion 33 projecting inward of the molding surface 17. A fitting portion 34 is provided on the opposite side of the base portion 32 from the protruding portion 33 to which the tip of the rod 31a of the fluid pressure cylinder 31 is fitted. The rod 31a tip is fitted to the fitting portion 34 so that the rod 31a and the slide block 30 are connected. As shown in FIG. 6, the surface of the base portion 32 on the side of the protruding portion 33 faces the outer peripheral surface of the protruding portion 28.

  The upper surface of the protruding portion 33 of the slide block 30 is in sliding contact with the lower end surface of the ridge 28. Further, as shown in FIG. 5, the upper half of the tip end surface 33a of the projecting portion 33 extends substantially vertically, and the lower half is inclined so as to be positioned closer to the base 32 as it goes downward. As shown in an enlarged view in FIG. 5 (b), a cutting blade as a skin material cutting portion for cutting off an excess portion of the skin material 4 at the time of molding, which will be described later, is provided on the upper half of the distal end surface 33a of the protruding portion 33. 35 (shown only in FIG. 5) is projected. The cross-sectional shape of the cutting blade 35 is substantially triangular.

  As shown in FIGS. 3 and 4, each of the fluid pressure cylinders 31 is arranged so that the expansion and contraction direction of the rod 31 a is directed to the inside and outside directions of the upper molding surface 17 and is fixed to the side surface of the upper mold 12. These fluid pressure cylinders 31 are separately controlled by a control device (not shown). When each fluid pressure cylinder 31 contracts the rod 31a as shown in FIG. 3, the slide block 30 moves toward the outside of the upper molding surface 17 to the outer end position, while the rod 31a as shown in FIG. Is extended, the slide block 30 moves toward the inner side of the upper molding surface 17 to the inner end position. When the slide block 30 moves between the outer end position and the inner end position, the upper surface of the protruding portion 33 is in sliding contact with the lower end surface of the ridge portion 28.

  When the slide block 30 is at the outer end position, as shown in FIG. 2, the tip surface 33 a of the projecting portion 33 is substantially flush with the inner surface of the ridge portion 28, that is, the side surface portion 17 b of the upper molding surface 17. It is supposed to be located. Further, when the slide block 30 is at the inner end position, the distal end surface 33a is positioned inside the side surface portion 17b. As shown in FIG. 9, the inner end position of the slide block 30 is determined by the surface of the base portion 32 on the protruding portion 33 side coming into contact with the outer peripheral surface of the protruding portion 28. That is, the protrusion 28 serves as a stopper for the slide block 30.

  As shown in FIG. 9, when the upper mold 12 and the lower mold 13 are closed, and the slide block 30 is at the inner end position, the cutting blade 35 of the protruding portion 33 is formed on the lower molding surface. 18 is in contact with the side surface 18b (shown in phantom in FIG. 5B). In order to allow the movement of the slide block 30 as described above, as shown in FIG. 3, when the slide block 30 is at the outer end position, a gap is formed between the adjacent slide blocks 30. It has become.

  Next, the point which shape | molds the door trim 2 using the shaping | molding apparatus 1 comprised as mentioned above is demonstrated. First, as shown in FIG. 6, the upper mold 12 and the lower mold 13 are in the mold open state, and the slide block 30 is set to the outer end position. At this time, the skin material holding member 20 is located above the lower molding surface 18. The skin material 4 is arranged on the upper surface of the skin material holding member 20 so that the back surface of the skin material 4 faces downward, and the outer periphery of the skin material 4 is pierced and held by the pins of the skin material holding member 20. . When the skin material 4 is held, the skin material 4 is kept stretched. This step is a skin material holding step in which the skin material 4 is arranged and held so that the back surface of the skin material 4 faces the lower molding surface 18.

  Then, the upper mold 12 is lowered by the mold moving device. When the upper mold 12 is lowered, the lower surface of the slide block 30 of the upper mold 12 comes into contact with the upper surface which is the surface of the skin material 4 as shown in FIG. When the upper mold 12 is further lowered, the skin material holding member 20 is pushed downward by the slide block 30 via the skin material 4 and moves.

  The injection of the molten resin material is started by the injection machine 11 substantially in synchronization with the start of lowering the upper mold 12. The molten resin injected from the injection machine 11 is supplied from the resin discharge port 19 of the lower molding surface 18 through the resin passage 22. After that, when the upper mold 12 is lowered to the lower end position, the upper mold 12 and the lower mold 13 are in the mold closed state and are clamped by the mold clamping mechanism, and as shown in FIG. A cavity S is formed between the lower molding surface 18. The expected amount of molten resin is supplied before the mold is closed, and supply of the molten resin is stopped when the mold is clamped. The molten resin supplied from the resin discharge port 19 flows and spreads between the back surface of the skin material 4 and the lower molding surface 18 on the lower molding surface 18 toward the outer peripheral side. This step is a resin supply step of supplying a molten resin material from the resin discharge port 19 formed on the lower molding surface 18.

  The slide block 30 is moved toward the inside of the upper molding surface 17 as shown in FIG. 8 immediately after the upper mold 12 starts to descend and immediately after the predetermined time elapses. Thus, by moving the slide block 30 immediately before the mold is closed, it is possible to prevent the cutting blade 35 of the slide block 30 from coming into strong contact with the surface of the skin material 4 while the lower mold 12 is being lowered. Thus, the surface of the skin material 4 is hardly damaged by the cutting blade 35.

  When the slide block 30 is moved to the inside of the upper molding surface 17, the front end surface 33 a of the slide block 30 comes into contact with the outer circumferential surface of the skin material 4, and the outer circumferential side of the skin material 4 is directed to the inner side of the upper molding surface 17. It is pushed toward. Thereby, while the outer peripheral side of the skin material 4 becomes a shape which winds up the surrounding wall part 3b of the base material 3 formed with the upper side molding surface 17 and the lower side molding surface 18, it is in the side part 18b of the lower side molding surface 18 Abut. This step is a winding step in which the outer peripheral side of the skin material 4 is formed so as to involve the outer peripheral portion of the base material 3 formed by the upper molding surface 17 and the lower molding surface 18.

  By moving the slide block 30 to the inside of the upper molding surface 17, it is possible to avoid leakage of molten resin from between the upper molding surface 17 and the lower molding surface 18. The timing for moving the slide block 30 to the inside of the upper molding surface 17 is that the skin material 4 is moved to the lower molding surface 18 until the molten resin supplied from the resin discharge port 19 reaches the outer periphery of the lower molding surface 18. Any timing may be used as long as it can be brought into contact.

  Further, by moving the slide block 30 to the inside of the upper molding surface 17, the adjacent slide blocks 30 approach each other and come into contact with each other when the inner end position is reached as shown in FIG. When the slide blocks 30 approach each other, the skin material 4 is held by the skin material holding member 20 in a stretched state, so that the skin material 4 is sandwiched between the adjacent slide blocks 30. In other words, wrinkles remain on the skin material 4 of the door trim 2 after molding.

  As shown in FIG. 8, the molten resin in the cavity S is molded by the upper molding surface 17 and the lower molding surface 18 and solidifies to become the base material 3. In the process in which the molten resin becomes the base material 3, the molten resin is integrated with the skin material 4, and the entrainment portion 4 a of the skin material 4 is formed in a state where the peripheral wall portion 3 b of the base material 3 is entrained. An intermediate molded product Y in which the skin material 4 is integrally formed on the surface is obtained.

  In the process of solidifying the molten resin, as shown in FIG. 9, when the slide block 30 is further moved to the inside of the upper molding surface 17, the cutting blade 35 comes into pressure contact with the cut portion of the skin material 4, and the cut portion is Disconnected. Thereby, the surplus part outside the winding part 4a of the skin material 4 is excised. This process is an excision process in which the surplus portion of the skin material 4 is excised with the cutting blade 35 between the slide block 30 and the lower mold 13.

  Then, as shown in FIG. 10, after the upper mold 12 and the lower mold 13 are opened, the intermediate trim product Y is removed from the upper mold 12 and the lower mold 13 to obtain the door trim 2.

  Therefore, according to this embodiment, the outer peripheral side of the skin material 4 is formed so that the peripheral wall 3b of the base material 3 is wound by the slide block 30 and the skin material 4 and the base material 3 are integrated. Y can be obtained. Then, without removing the intermediate molded product Y from the upper mold 12 and the lower mold 13, the surplus portion of the skin material 4 of the intermediate molded product Y is cut between the slide block 30 and the lower mold 13 by the cutting blade 35. Can be excised. As a result, the number of manufacturing steps of the door trim 2 can be reduced, and a space for cutting off the surplus portion of the skin material 4 in the factory for molding the door trim 2 can be eliminated, thereby reducing the cost. be able to.

  Further, since the surplus portion of the skin material 4 is cut off by the cutting blade 35 protruding from the tip end surface 33a of the slide block 30 toward the skin material 4, the surplus portion of the skin material 4 is simply moved by moving the slide block 30. The structure of the molding apparatus 1 can be simplified.

  It should be noted that the timing for cutting off the surplus portion of the skin material 4 can be set by the operation timing of the fluid pressure cylinder 31, and the cutting may be performed with the molten resin completely solidified, or the molten resin may be completely removed. It may be excised before solidifying. In the case of cutting before the molten resin is completely solidified, the molten resin can be held at the inner end position even after the skin material 4 is cut, so that the molten resin becomes the upper molding surface 17 and the lower molding surface. It is possible to prevent leakage from between the two.

(Embodiment 2)
FIG. 11 shows an upper mold 12 of the molding apparatus 1 according to the second embodiment of the present invention. The molding apparatus 1 of the second embodiment is different from that of the first embodiment in that it includes a heating element 50 for excising the surplus portion of the skin material 4 with heat, and the other parts are the same. Hereinafter, the same parts as those in the first embodiment are denoted by the same reference numerals, and different parts will be described in detail.

  That is, the slide block 30 is moved by the fluid pressure cylinder 31 as in the first embodiment. Each slide block 30 is provided with a heating element 50 that generates heat when a cutting blade is omitted and a current flows. A DC power supply device 51 attached to the upper mold 12 is connected to each heating element 50.

  The heating element 50 is formed by molding a thin plate material made of, for example, nichrome or the like, and as shown in FIG. 12, a cut portion 50a extending along the distal end surface 33a of the protruding portion 33 of the slide block 30, It is composed of a pair of connecting portions 50b extending from both ends of the cut portion 50a to the base 32 side of the slide block 30. The cut part 50a is formed thinner than the connection part 50b in plan view.

  A stepped portion 52 for arranging the cut portion 50a of the heating element 50 is formed on the front end side of the upper surface of the protruding portion 33. As shown in an enlarged view in FIG. 13, a plate-like lower insulating member 53 made of, for example, mica is disposed on the lower surface of the cut portion 50a, and the lower surface of the lower insulating member 53 is made of, for example, bakelite or the like A plate-like heat insulating member 54 is disposed. In addition, a plate-like upper insulating member 55 is disposed on the upper surface of the cut portion 50a. The upper insulating member 55 is formed by spraying alumina on the outer surface of the same metal material as that constituting the slide block 30. The upper insulating member 55, the lower insulating member 53, and the heat insulating member 54 are formed with through holes 57 through which screws 56 are inserted. The screws 56 allow the upper insulating member 55, the lower insulating member 53, and the heat insulating member to be inserted. 54 is fastened to the slide block 30, and the cut portion 50a is fixed by this fastening force.

  Note that the upper insulating member 55 and the lower insulating member 53 are not limited to those described above, and can be formed of members that can insulate the cut portion 50a. Moreover, the heat insulation member 54 is not restricted to a bakelite, It can comprise with a member whose heat transfer rate is lower than a metal member.

  The pair of connection portions 50b are fixed in a state of being inserted into grooves formed on the side surface of the slide block 30. At least one of the inner surface of the groove into which the connection portion 50b is inserted and the outer surface of the connection portion 50b is covered with an insulating material.

  The ends of the connection portions 50b opposite to the cut portions 50a protrude from the slide block 30, respectively. The positive electrode side output terminal and the negative electrode side output terminal of the DC power supply device 51 are respectively connected to portions protruding from the slide block 30 of the connection part 50b via wiring 51a. As shown in FIG. 11, the output terminals of the DC power supply devices 51 are connected such that adjacent connecting portions 50b of adjacent slide blocks 30 have the same pole. Thereby, even if the slide block 30 is moved to the inner end position and the connecting portions 50b of the adjacent slide blocks 30 come into contact with each other, an electrical failure does not occur.

  Further, the DC power supply device 51 is controlled separately by a control device (not shown). The value of the current flowing through the heating element 50 of each slide block 30 is set independently, and the heating value of the heating element 50 is set. Can be adjusted arbitrarily. Thereby, it is possible to suppress the temperature of the heating element 50 from varying between the slide blocks 30.

  The cut portion 50a slightly protrudes from the distal end surface 33a of the slide block 30, and is surely in contact with the skin material 4 when the slide block 30 is at the inner end position. Further, since the cut portion 50a is formed thinner than the connection portion 50b to make the resistance value of the cut portion 50a relatively large, the heat generation amount of the cut portion 50a is larger than the heat generation amount of the connection portion 50b. The amount of heat generated by the cut portion 50 a is set so that the temperature of the cut portion 50 a is equal to or higher than the melting temperature of the skin material 4.

  Next, the point which shape | molds the door trim 2 using the shaping | molding apparatus 1 of Embodiment 2 is demonstrated. The process until the resin material supplied from the resin discharge port 19 is integrally formed with the skin material 4 is the same as when the molding apparatus 1 of the first embodiment is used. When the slide block 30 is set to the inner end position, the cut portion 50a comes into contact with the skin material 4, and in this state, when a current is passed through the heating element 50 by the DC power supply device 51, the temperature of the cut portion 50a is the melting temperature of the skin material 4. That's it. The cut portion of the skin material 4 is heated and melted and cut by the cut portion 50a. Note that the timing of supplying the current to the heating element 50 may be after the molten resin is completely solidified or before it is completely solidified.

  Therefore, according to the second embodiment, as in the first embodiment, the number of manufacturing steps of the door trim 2 can be reduced, and the surplus portion of the skin material 4 can be cut out in the factory where the door trim 2 is molded. Space can be eliminated and costs can be reduced.

  In Embodiment 2, since the skin material 4 is cut by heat, for example, in the case of a cutting blade like a skin material made of fiber, there is a possibility that a part of the fiber may remain uncut, The cut portion of the skin material 4 can be melted and reliably cut.

  Further, as in the modification shown in FIG. 14, a groove 58 may be formed in the tip end surface 33 a of the protruding portion 33 of the slide block 30. The groove 58 is formed by cutting a part of the fixing member 55, the mica 53, and the bakelite 54, and the cut portion 50 a is disposed so as not to protrude from the groove 58. By disposing the cut portion 50a in the groove 58 in this way, it is avoided that the cut portion 50a strongly slides on the surface of the skin material 4 when the lower mold 13 is lowered. Thereby, a deformation | transformation of the cut part 50a can be suppressed and the skin material 4 can be cut | disconnected as aimed.

  Although not shown, for example, alumina is sprayed on the tip surface 33a of the slide block 30 to form an insulating layer, and nichrome is linearly sprayed on the surface of the insulating layer. Also good. When the heating element is configured by thermal spraying as described above, the heating element can be provided along the shape of the distal end surface 33a even if the distal end surface 33a of the slide block 30 is curved. Further, for example, nichrome is sprayed on the tip surface 33a of the slide block 30 to form a heating element, and alumina is sprayed on the surface of the heating element so as to expose the heating element in a linear shape. May be formed. The insulating layer may be made of a nonconductor other than alumina, and the heating element may be made of a conductor other than nichrome.

  In the first and second embodiments, the case where the present invention is applied to the molding of the door trim 2 has been described. However, in addition to the door trim 2, the present invention includes a terminal of a skin material integrally molded on the surface of the base material. The present invention can be applied when molding a resin product formed so as to involve the outer periphery of the substrate.

  In the first and second embodiments, the slide block 30 is moved by the fluid pressure cylinder 31, but the slide block 30 may be moved by an actuator other than the fluid pressure cylinder 31.

  As described above, the resin product molding method and molding apparatus according to the present invention can be used, for example, to mold a door trim attached to an automobile door.

FIG. 3 is a cross-sectional view of the molding apparatus according to Embodiment 1 when the molding die is in a closed state. FIG. 2 is a view corresponding to FIG. 1 in which the mold is in an open state. It is a bottom view of the upper mold | type in the state which has a slide block in an outer end position. FIG. 4 is a view corresponding to FIG. 3 in a state where the slide block is at the inner end position. (A) is a side view of a slide block, (b) is an enlarged view near the front end surface of the slide block. It is an enlarged view of a shaping | molding apparatus in case a shaping | molding die exists in a mold open state. FIG. 7 is a view corresponding to FIG. 6 in which the mold is in a closed state. FIG. 7 is a view corresponding to FIG. 6 in a state in which a slide block is moved inward to form a winding portion. FIG. 7 is a view corresponding to FIG. 6 in a state in which the skin material is cut with the slide block as the inner end position. FIG. 7 is a view corresponding to FIG. 6 in a state in which the door trim is obtained by opening the mold and removing the intermediate molded product. FIG. 3 is a diagram corresponding to FIG. 3 according to a second embodiment. The slide block which concerns on Embodiment 2 is shown, (a) is a side view, (b) is a top view. FIG. 6 is an enlarged view of the vicinity of a tip surface of a slide block according to a second embodiment. FIG. 14 is a diagram corresponding to FIG. 13 according to a modification of the second embodiment.

3 base material 4 skin material 4a entrainment part 12 upper mold | type (1st shaping | molding die)
13 Lower mold (second mold)
17 Upper molding surface (first molding surface)
18 Lower molding surface (second molding surface)
19 Resin outlet 30 Slide block (contact member)
35 Cutting blade (cutting material cutting part)
50a Cut part (cutting material for skin material)
20 Skin material holding member 31 Fluid pressure cylinder (contact member moving means)
50 Heating element

Claims (4)

A method of molding a resin product in which a skin material is integrally formed on the surface of a resin base material, and the end of the skin material is formed so as to wind the outer peripheral portion of the base material from the front surface to the back surface. And
The skin material is arranged between the first molding surface provided in the first molding die and the second molding surface provided in the second molding die so that the back surface of the skin material faces the second molding surface. And holding the skin material,
After the skin material holding step, the first molding die and the second molding die are closed, and the skin material from the resin discharge port that opens the molten resin material serving as the base material to the second molding surface. A resin supply process for supplying the outer peripheral part of the resin,
By the time the resin material supplied in the resin supply step reaches the outer periphery of the second molding surface, an abutting member is brought into contact with the outer peripheral surface of the skin material, and the corresponding member is brought into contact with the second molding surface. By moving toward the outer peripheral portion, the resin material reaching the outer peripheral portion of the skin material by bringing the back surface of the outer peripheral side of the skin material into contact with the second molding surface is formed between the skin material and the second molding surface. A winding step of forming the outer peripheral portion of the skin material so that the outer peripheral portion of the base material formed by the first molding surface and the second molding surface is wound from the front surface to the rear surface. ,
After the step of winding, the resin comprises a cutting step of cutting off an excess portion outside the winding portion of the skin material by the skin material cutting portion between the contact member and the second mold Product molding method. An apparatus for molding a resin product in which a skin material is integrally formed on the surface of a resin base material, and an end of the skin material is formed so as to wind the outer peripheral portion of the base material from the front surface to the back surface. And
A first molding die provided with a first molding surface for molding the surface side of the substrate;
A second molding die provided with a second molding surface for molding the back surface side of the substrate and a resin outlet opening in the second molding surface;
A skin material holding member for holding the skin material between the first molding surface and the second molding surface;
An abutting member provided on the first mold and abutting on an outer peripheral surface of the skin material held by the skin holding member;
Provided in the first mold, and the abutment member moving means that the contact member is moved toward the outer periphery of the second molding surface,
A skin material cutting part is provided on at least one of the contact member and the second mold so as to face the outer peripheral side of the skin material, and cuts off a surplus portion outside the entrained part of the skin material. ,
From the resin discharge port of the second mold, the molten resin material to be the base material is supplied so as to reach the outer peripheral portion of the skin material,
The contact member moving means causes the contact member to contact the outer peripheral surface of the skin material until the resin material supplied from the resin discharge port reaches the outer peripheral portion of the second molding surface. By moving the contact member toward the outer peripheral portion of the second molding surface, the resin material reaching the outer peripheral portion of the skin material by bringing the back surface on the outer peripheral side of the skin material into contact with the second molding surface While preventing leakage from between the skin material and the second molding surface, the outer peripheral side of the skin material, the outer peripheral portion of the substrate formed by the first molding surface and the second molding surface from the front surface to the back surface An apparatus for molding a resin product, characterized in that the apparatus is formed so as to be wound around . In the molding apparatus of the resin product according to claim 2,
An apparatus for molding a resin product, wherein the skin material cutting portion is constituted by a cutting blade protruding from the contact member toward the skin material. In the molding apparatus of the resin product according to claim 2,
The apparatus for molding a resin product, characterized in that the skin material cutting part is composed of a heating element that generates heat when an electric current is applied.

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