JP4906421B2 - Method for molding laminated molded body and molding die - Google Patents

Description

  The present invention relates to a molding method and a molding die for a laminated molded article suitable for automobile interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, luggage side trims, roof trims, rear side trims, and more particularly cushions. The present invention relates to a method for molding a laminated molded body and a molding die that can maintain good performance and can faithfully display a sharp external shape.

  Conventionally, automotive interior parts such as door trims, luggage side trims, rear side trims, etc., have a surface texture and softness on the surface of the resin core material that has mounting rigidity and shape retention to the body panel. It is often configured by sticking. For example, the door trim 1 will be described with reference to FIGS. 14 and 15. The door trim 1 is configured by integrally attaching a skin 3 to the surface of a resin core material 2. As the resin core material 2, a composite polypropylene resin material in which a filler is appropriately mixed with a polypropylene resin is used in consideration of cost, moldability, and the like. Further, as the skin 3, a two-layer laminated sheet material composed of a cloth 3a and a polyurethane foam 3b is used from the product surface side. The skin 3 has a function of ensuring a good surface texture by the cloth 3a and maintaining a soft feeling by the cushioning property of the polyurethane foam 3b. In addition, the code | symbol 1a in a figure shows an armrest.

  Next, a conventional molding die 4 used in the method for molding the door trim 1 will be described with reference to FIG. The molding die 4 is generally composed of a molding upper mold 5 that is a movable side, a molding lower mold 6 that is positioned below the molding upper mold 5, and an injection machine 7 that is connected to the molding lower mold 6. . The molding upper mold 5 is configured to be movable up and down by a predetermined stroke by a cylinder 5a. By the vertical movement of the molding upper mold 5, the molding upper and lower molds 5 and 6 are clamped and opened. Further, the molding lower mold 6 is provided with a manifold 6a and a gate 6b as resin passages for the molten resin M supplied from the injection machine 7. Then, when the molding die 4 is in the mold open state, the peripheral edge of the skin 3 is put into the molding die 4 while being held by the clamp frame 8. Next, the molding upper mold 5 is lowered by a predetermined stroke, and as shown in FIG. 17, when the mold clearance of the molding upper and lower molds 5 and 6 reaches a predetermined value, the molten resin M is supplied from the injection machine 7 to the manifold 6a and the gate. It is distributed and supplied to a predetermined position on the mold surface of the molding lower mold 6 through 6b.

  Furthermore, when the lowering operation of the molding upper mold 5 continues and the mold clearances of the molding upper and lower molds 5 and 6 reach a constant value (when the molding upper mold 5 reaches the bottom dead center), the molten resin M is molded. The resin core material 2 having a desired shape is formed along the cavity shape between the upper and lower molds 5 and 6, and the skin 3 is integrally attached to the surface of the resin core material 2 to complete the molding. (See FIG. 18). A conventional laminated molded body and a molding method thereof are described in detail in Patent Document 1.

Japanese Patent Laid-Open No. 10-100196

  Thus, in the simultaneous molding of the resin core material 2 and the skin 3 by the conventional molding die 4, the polyurethane foam 3 b in the skin 3 is heated by the heat of the molten resin M when supplying the molten resin M shown in FIG. It has been pointed out that the cushion layer is damaged, the cushion performance is lowered after molding, and the soft feeling is inferior. For example, the Shore C hardness of the product surface is about 62.

  Furthermore, since the shape retention of the skin 3 depends on the resin core material 2, a sharp shape such as a corner portion of the armrest 1 a cannot be formed, and the appearance design is not good. For example, the curvature of the corner portion of the armrest 1a is R5 (R is 2.5 is ideal). In addition, in the case where a drawn pattern is provided on the raw material of the skin 3 itself, the drawn pattern is elongated and deformed at a portion where the unfolding rate is high, such as the armrest 1a. It has become.

  The present invention has been made in view of such circumstances, and is a method for molding a laminated molded body and a molding die obtained by integrating a skin having a cushion layer lined with a cushion layer with excellent cushion performance when molding a resin core material. An object of the present invention is to provide a molding method and a molding die for a laminated molded body that can provide a good soft feeling and can produce a sharp appearance.

  In order to solve the above-mentioned problems, the present invention forms a resin core into a required shape by setting a skin in a molding upper and lower molds and supplying molten resin into a cavity formed between the molding upper and lower molds. In the method of forming a laminated molded body in which the skin is integrated on the surface of the resin core material, a vacuum suction mechanism is attached to the molding upper mold, and the pedestal provided from the set area of the skin to the molding die Using a mold with an assist model in which a slide base that supports the model mold is installed so that it can move forward and backward, the heat-softened skin is assembled into the assist model together with the skin set frame, and the mold upper and lower are in the mold open state It is put into the mold, the model mold in the assist model and the skin set frame holding the skin are raised, and the skin is press-bonded between the molding upper mold and the model mold. By operating the vacuum suction mechanism on the molding upper mold, vacuuming and press molding the skin along the mold surface of the molding upper mold, thereby forming the skin into a thin-walled molding process, and the molding process With the molded skin held on the molding upper mold, the model mold is lowered, and after the model mold is retracted to the outside of the molding die, the molding upper mold holding the skin is lowered by a predetermined stroke. The molten resin is supplied into the cavity immediately before or after the mold reaches the bottom dead center, and the resin core material is molded into a desired curved shape, and the skin is applied to the surface of the resin core material. It consists of the integration process of the resin core material and skin which are laminated and integrated.

  Here, the laminated molded body is composed of a resin core material and an outer skin, and a thermoplastic resin is used as a material for the resin core material, but one type of thermoplastic resin or two or more types of heat is used. It may be made of a plastic resin. Preferably, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / Styrene (ABS) resin or the like can be used. Further, a filler may be mixed in the thermoplastic resin. Examples of the filler include inorganic fibers such as glass fiber and carbon fiber, and inorganic particles such as talc, clay, silica, and calcium carbonate. Furthermore, various additives such as an antioxidant, an ultraviolet absorber, a colorant, a flame retardant, and a low shrinkage agent may be blended. On the other hand, as a skin, a single sheet material of a thermoplastic resin sheet or a thermoplastic resin sheet as a top layer for transferring a drawn pattern from a mold, polyurethane foam, polyethylene foam, polypropylene foam on the back surface It is possible to use a laminated sheet material lined with a cushion layer made of a foamed resin molding such as the above. If desired, a backing sheet or knitted fabric may be laminated on the back surface.

  In addition to being applicable to automotive interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, luggage side trims, roof trims, rear side trims, laminated molded products can be used for interior panels such as railway vehicles. It can also be applied to interior panels of houses.

  Next, the molding die used when carrying out the method of the present invention is a molding die for a laminated molded body for molding a laminated molded body in which the skin is integrated on the surface of the resin core material into a required shape, The molding die includes a movable upper molding die that moves up and down by a predetermined stroke, and a fixed molding lower die positioned below the molding upper die. The molding upper die is a vacuum for vacuum forming the skin. In addition to a suction mechanism, an assist model for press-bonding the skin is attached, and this assist model has a slide base that slides along the rail of the pedestal placed from the set area of the skin to the mold. The slide base is equipped with the model mold and the skin set frame holder so that it can be moved up and down, so that the skin setting process and the model mold in-molding process can be performed simultaneously, When the upper die of the press crimping and Del type, model type, characterized in that it is stably supported by the pedestal.

  The molding upper die in this molding die is connected to a press machine and can be moved up and down for a predetermined stroke, and the vacuum suction mechanism can be operated in a state where the skin is vacuum molded or held in the molding upper die. Is equipped. A clamper that supports the skin set frame that holds the skin and a cylinder that moves the clamper back and forth are provided in the upper mold. On the other hand, the molding lower mold is provided with a manifold and a gate as a resin passage for the molten resin supplied from an injection machine connected to supply the molten resin. Furthermore, in order to form the skin with high accuracy, a mold structure in which an assist model is attached to the upper and lower molds is employed. That is, the assist model is provided with a pedestal that extends between the inside and outside of the mold, and a guide rail is installed on the top surface of the pedestal, and a slide base that supports the model mold along the guide rail is a mold. It is slidably mounted so as to reciprocate between the inside of the mold and the outside of the mold. And this model type | mold is supported by the drive of a cylinder etc. with respect to a slide base so that vertical movement is possible, and the holder for skin set frame which hold | maintains a skin set frame along the periphery of a model type | mold is provided. That is, this assist model also has a skin setting function by the skin set frame holder provided in the assist model, and the model mold and the skin set frame holder move up and down, The structure is such that the skin can be drawn into a required shape with the model mold. And even if a great press pressure is applied between the molding upper die and the model die, it has the strength to be firmly supported by the pedestal.

  Furthermore, the method of the present invention is roughly divided into a skin molding step and an integration step of the skin and the resin core material. As the skin molding step, the peripheral edge of the skin is held by the skin set frame as a previous step, A heating process is necessary in which a heat softening treatment is performed at a predetermined temperature with a heater device. Then, after heat-softening the skin, the skin set frame holder is held by the skin model frame holder of the assist model. In the assist model, the slide base that supports the model mold is configured to be able to reciprocate between the positions inside the mold and outside the mold (skin set position) along the guide rail on the base. The model mold can be easily put into the mold along the guide rail in a state where the heat-softened skin is held together with the set frame in the holder for the skin set frame. When the molding upper and lower molds are in the mold open state, the assist model is inserted into the mold, and then the model mold and the skin set frame holder are raised by a predetermined stroke by driving the cylinder of the assist model. At this time, by operating the vacuum suction mechanism of the molding upper mold, the skin is vacuum molded so as to be in close contact with the mold surface of the molding upper mold. Then, when the skin is vacuum-formed on the mold surface of the molding upper mold, the model mold is simultaneously raised by driving the cylinder, and press pressure is applied between the mold surface of the molding upper mold and the model mold, and the skin Is formed into a thin and uniform thickness by vacuum and press molding. At this time, even if a large pressing pressure is applied, the model mold is firmly supported by the pedestal, so that the thickness of the skin does not vary.

  Next, in the process of integrating the skin and the resin core material, after forming the skin, the cylinder of the skin set frame clamper on the molding upper mold side is driven, and the skin set frame is held by the clamper on the molding upper mold side. The model mold including the model-side skin set frame holder is lowered, and the slide base including the model mold and the skin set frame holder is retracted outside the molding die. Thereafter, when the upper mold is lowered by a predetermined stroke while the skin is held and the mold clearance of the upper and lower molds reaches a predetermined value, molten resin is supplied from the injection machine to the mold surface of the lower mold through the manifold and gate. The When the molding upper die is lowered to the bottom dead center, the molten resin spreads to every corner by the press pressure between the molding upper and lower molds, and the resin core is molded into the required shape, and the skin is integrated on the surface. Is done.

  Then, according to the method of the present invention, after the heat-softened skin is put into the mold upper and lower molds in the mold open state, the vacuum suction mechanism of the press upper mold is operated to vacuum mold the skin and assist By pressing the skin between the model and the upper mold, the skin can be formed uniformly and thinly. Next, since the molten resin is supplied into the cavity while the skin is held in the mold by vacuum suction, thermal damage from the molten resin does not reach the skin, and the cushion performance of the cushion layer is improved. Can be maintained. In addition, since the skin is vacuum molded and pressed into a product shape and held in the molding upper mold, and the molten resin is supplied, the fluidity of the molten resin can be maintained well and sharp lines such as product highlight lines can be maintained. Can be faithfully displayed. Furthermore, since the skin can be formed well by the vacuum suction mechanism of the forming upper mold and the press pressure between the forming upper mold and the assist model, the drawn pattern can be transferred well from the mold surface of the forming upper mold. Therefore, it is possible to transfer a drawn pattern with high accuracy even when an inexpensive sheet without diaphragm is used without using a conventional expensive sheet with diaphragm.

  Furthermore, according to the method of the present invention, since the heat-softened skin is held together with the skin set frame in the assist model and put into the molding die, the skin can be set easily and the skin is heat-treated. Since the waiting time from molding to molding is short, the moldability can be maintained well, and the model mold is firmly supported by the pedestal when pressing the model mold and molding upper mold in the assist model. Since a constant posture can be maintained even when a large pressing pressure is applied, there is no variation in the thickness of the skin, and a uniform drawn pattern can be transferred, and the moldability and designability can be maintained well.

  As described above, the method for molding a laminated molded body according to the present invention includes vacuum-molding the heat-softened skin along the mold surface of the molding upper mold, and a model mold firmly supported on the pedestal and molding mold. By pressing and pressing with the mold, the skin is formed to have a uniform thickness and thin shape. When supplying molten resin immediately before or after mold clamping, the skin and lower mold Sufficient clearance is secured between them, so there is little thermal damage to the cushion layer of the epidermis. Furthermore, since it is shaped into the product shape and retains the shape, the laminated molded body is excellent in softness and can appear sharply, such as sharp highlight lines. Moreover, it has the various effect that a moldability can be improved by improving the fluidity | liquidity of resin.

  Furthermore, in the method for molding a laminated molded body according to the present invention, the skin is heated and softened, and then the skin is molded between the molding upper mold and the assist model. The drawn pattern can be accurately transferred from the upper mold during vacuum forming. Therefore, appearance defects such as squeezing flow do not occur even at sites with a high development rate, and it is possible to provide a low-priced laminated molded article with a good appearance and a waiting time until the skin is heated and molded. Since there are few, a skin has the effect that a suitable temperature can be hold | maintained and a moldability can be improved.

  Hereinafter, examples of a molding method and a molding die of a laminated molded body according to the present invention will be described in detail by illustrating a molding method of a door trim and a molding die used therefor. Note that the gist of the present invention is as described in the scope of claims, and the contents of the embodiments described below are merely examples of the present invention.

  1 to 13 show an embodiment of the present invention. FIG. 1 is a front view showing a door trim formed by the method of the present invention, FIG. 2 is a sectional view showing the structure of the door trim, and FIG. FIG. 4 is an explanatory view showing the overall configuration of a molding die used in the method, FIG. 4 is an explanatory view showing the relationship between the holder for the skin set frame provided in the assist model and the clamper of the skin set frame in the molding upper die, and FIGS. FIG. 13 is an explanatory view showing each step of the door trim molding method according to the present invention.

  1 and 2, a door trim 10 is formed into a desired curved surface shape, and a skin having excellent surface appearance and surface feel on the surface of a resin core member 20 having rigidity and shape retention to a door panel (not shown). 30 is laminated and integrated. Various accessory parts are attached to the door trim 10. For example, an inside handle escutcheon 11 is attached to the middle part, and the armrest 12 located below the middle part is formed in a shape that bulges indoors, and a pull handle unit 13 is formed on the upper surface of the armrest 12. A power window switch escutcheon 14 is attached. In addition, a door pocket 15 that can accommodate equipment is provided below the armrest 12, and a speaker grill 16 is attached to the front side of the door pocket 10 integrally with or separately from the door trim 10.

  And as the resin core material 20 in the said door trim 10, the material of a thermoplastic resin is used, Various molding methods, such as an injection molding method, other than the mold press molding method mentioned later are employable. The thermoplastic resin materials used are polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin. Resin, acrylonitrile / butadiene / styrene (ABS) resin, and the like.

  On the other hand, as the skin 30, in this embodiment, a sheet material composed of a two-layer laminate of a top layer 31 and a cushion layer 32 is used. As the top layer 31, a TPO (thermoplastic olefin) resin, a PVC resin, A thermoplastic resin sheet such as PP resin is used, and as the cushion layer 32, a foamed resin sheet such as polyurethane foam, polyethylene foam, or polypropylene foam is used.

  By the way, the door trim 10 formed by the method of the present invention is improved in the softness of the product and the external shape (sharp shape) of the product as compared with the conventional mold press forming method and vacuum forming method. That is, it has a Shore C hardness of 56, an excellent cushioning performance, and an R that is substantially equal to the R of the molding die, such as R2.5. Furthermore, the appearance of the skin 30 in the door trim 10 is that the drawn pattern is transferred from the molding die, the appearance of the drawn pattern is very good, and the design is excellent.

  Next, the configuration of the molding die 40 for molding the door trim 10 will be described with reference to FIG. The mold 40 is connected to the molding upper mold 50, the molding lower mold 60, and the molding lower mold 60, which can mold-mold the resin core material 20 and the skin 30 together, and can be mold-clamped and opened. An injection machine 70 for supplying molten resin, which is a material of the resin core material 20, and the skin 30 are put into molding upper and lower molds 50 and 60 so that the outer skin 30 can be molded in cooperation with the molding upper mold 50. This is mainly composed of an assist model 80 supported by the lower mold 60 and a skin set frame 90 used when the skin 30 is set in the molded upper and lower molds 50 and 60.

  More specifically, the forming upper die 50 is connected to the press machine 51 and can move up and down by a predetermined stroke, and can maintain the die-clamping and die-opening states, respectively. A clamper 52 that holds the skin set frame 90 is supported by a cylinder 53. Further, the upper mold 50 is provided with a vacuum suction mechanism Vc for molding the skin 30. That is, a large number of vacuum suction holes 54 are formed in the mold surface of the molding upper mold 50, and a vacuum suction pipe 57 is provided between the air chamber 55 communicating with the vacuum suction hole 54 and the vacuum suction pump 56. The vacuum suction pipe 57 is provided with an opening / closing valve 58, and a vacuum suction force can be selectively applied to the upper mold 50 by opening / closing the opening / closing valve 58 by a control device (not shown). On the other hand, the molding lower mold 60 located below the molding upper mold 50 is provided with a manifold 61 and a gate 62 that serve as a resin passage for the molten resin M supplied from the injection machine 70, and through the manifold 61 and the gate 62. The molten resin M is supplied onto the mold surface of the molded lower mold 60.

  By the way, in the method of the present invention, the skin setting frame 90 on which the skin 30 is set is held on the assist model 80 side, whereby the cooperative operation of the assist model 80 with the molding upper mold 50 and the skin setting operation are performed collectively. Thus, the productivity is improved, and the support strength at the time of press-bonding with the upper molding die 50 in the assist model 80 is increased to improve the molding performance. Moreover, the assist model 80 thrown in the shaping | molding upper / lower molds 50 and 60 is comprised as follows. That is, the model die 82 is supported on the slide base 81 so as to be movable up and down by the cylinder 83, the skin set frame holder 84 is supported by the guide rod 84a on the periphery of the model die 82, and the skin set by the biasing spring 84b. The frame holder 84 is always spring-biased upward. The slide base 81 can reciprocate in the direction of the arrow in FIG. 3 along the guide rail 85. When the slide base 81 is at the right position in the figure, the set when the skin set frame 90 is set to the skin set frame holder 84 is set. If it is operated to the left in the figure, it is a movable position when the skin 30 is molded by the upper and lower molds 50 and 60. And the guide rail 85 is supported by the upper surface of the base 86 supported by 4 points | pieces. Although not shown, a guide rail 85 may be attached to the base 86 via a table. Further, the skin set frame 90 that holds the skin 30 may be configured such that the holding needle 92 that protrudes and holds the skin 30 at a predetermined pitch interval is provided on the upper surface of the aluminum frame body 91 or is hinged to the base frame. It is also possible to employ a sandwiching type skin set frame 90 in which an opening / closing frame is rotatably attached via the portion and supported so as to sandwich the skin 30 between the base frame and the opening / closing frame.

  Here, the relationship between the skin set frame holder 84 incorporated in the assist model 80 and the clamper 52 of the upper mold 50 will be described with reference to FIG. That is, the skin set frame holder 84 has a function of holding the set frame 90 that supports the peripheral edge of the heat-softened skin 30, and comes into close contact with the mold surface of the upper mold 50 from the setting process of the set frame 90. In the meantime, the set frame 90 is supported by the skin set frame holder 84. As shown in the drawing, the skin set frame holder 84 and the clamper 52 are set at positions where they do not interfere with each other. After the skin 30 is sucked and adhered to the mold surface of the molding upper mold 50 by vacuum forming, the clamper 52 The cylinder 53 is extended and the clamper 52 enters the lower surface side of the skin set frame 90 to switch from the skin set frame holder 84, and the skin set frame 90 is supported by the clamper 52 of the upper mold 50. become.

  Next, each step of the method for forming the door trim 10 will be described in order with reference to FIGS. First, as shown in FIG. 5, the skin 30 is heated and softened to a predetermined temperature by the heater device H. At this time, the outer skin 30 is conveyed to the heater device H in a state where the periphery thereof is held by the outer skin set frame 90. After that, as shown in FIG. 6, the skin set frame 90 that holds the periphery of the skin 30 is set on the assist model 80. At this time, the set frame 90 is placed on the skin set frame holder 84, but the slide base 81 is positioned on the right side of the pedestal 86 in the figure, and the operator can easily set the skin set frame 90. . After holding the skin set frame 90 on the skin set frame holder 84, the slide base 81 is moved along the guide rail 85 on the pedestal 86 in the left direction as shown in FIG. A sliding operation is performed to lock the molding upper and lower molds 50 and 60 at predetermined positions.

  Then, after the assist model 80 is put into the molding upper and lower molds 50 and 60, as shown in FIG. 8, the cylinder 83 is driven to raise the model mold 82 and the skin set frame holder 84 by a predetermined stroke, thereby forming the upper mold. 50 and the model die 82 are pressed to press the skin 30 and the skin set frame 90 is brought into close contact with the mold surface of the molding upper die 50 by the skin set frame holder 84.

  Then, as shown in FIG. 9, in the process of molding the skin 30, the skin 30 is vacuum-formed along the mold surface of the molding upper mold 50 by driving a vacuum suction mechanism Vc disposed in the molding upper mold 50. At the same time, the model mold 82 is pressed against the molding upper mold 50 by driving the cylinder 83, and both the vacuum suction force and the pressing pressure are applied, so that the skin 30 can be molded with a uniform thickness and a thin wall. At this time, even if a large pressing pressure is applied between the molding upper mold 50 and the model mold 82, the slide base 81 that receives the pressing pressure from the model mold 82 is supported on the solid base 86. Compared with a method in which a model die is cantilevered into a molding die, stable press working can be performed, the moldability of the skin 30 is improved, and the drawn pattern is transferred from the mold surface of the molding upper die 50 In addition, there is no squeezing flow, and the squeezed pattern can be faithfully transferred.

  When the formation of the skin 30 is completed, as shown in FIG. 10, the cylinder 53 of the upper mold 50 is extended and the skin set frame 90 is held by the clamper 52, and then the cylinder 83 in the assist model 80 is contracted. As a result, the model mold 82 and the skin set frame holder 84 are lowered. As a result, the skin set frame holder 84 on the assist model 80 side is detached from the skin set frame 90, and the cooperation between the assist model 80 and the upper mold 50 is released. Further, as shown in FIG. 11, the slide base 81 that supports the model die 82 is slid along the slide rail 85 in the right direction in FIG. Thereafter, as shown in FIG. 12, the molding upper die 50 is lowered by a predetermined stroke by driving the press machine 51, but the skin 30 is thinly and uniformly molded on the mold surface of the molding upper die 50. When the mold clearance of the upper and lower molds 50 and 60 reaches a predetermined value, the molten resin M is supplied from the injector 70 to the mold surface of the lower mold 60 through the manifold 61 and the gate 62. As the material of the molten resin M, the general-purpose thermoplastic resin material described above can be used. In the present embodiment, Sumitomo Noblen BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 min) is used, and talc may be mixed in an appropriate ratio.

  As described above, in the method of the present invention, the molten resin M is supplied in the state in which the thin skin 30 is held along the mold surface of the molding upper mold 50 in the molten resin M supplying step. The clearance between the back surface of the cushion layer 32 of the skin 30 and the mold surface of the molded lower mold 60 is ensured to be substantially constant, the fluidity of the molten resin M can be maintained well, and the skin 30 is not in a tent tension state. Therefore, thermal damage from the molten resin M hardly reaches the cushion layer 32, the cushion performance of the cushion layer 32 can be maintained well, and the softness of the product can be emphasized. Then, as shown in FIG. 13, if the molding upper die 50 is lowered to the bottom dead center by driving the press machine 51, the molten resin M reaches all corners of the cavity, or the resin core material 20 has a desired curved surface. In addition to being molded into a shape, the skin 30 is integrated with the surface side of the resin core member 20 to complete the molding of the door trim 10. Next, after the molding is completed, the upper mold 50 is raised by driving the press machine 51, the mold is opened, and then the door trim 10 which is a laminated molded body molded into a required shape may be taken out.

  As described above, according to the method of the present invention, the skin 30 in the door trim 10 is formed into a required shape before being press-integrated with the resin core material 20, and thus the shape retainability of the skin 30 is good. A sharp exterior shape such as a highlight line at a corner of the armrest 12 or the like can be accurately displayed, and the door trim 10 having excellent exterior performance can be formed. In the method of the present invention, the injection timing of the molten resin M is performed before the upper mold 50 is clamped. However, an injection molding method in which injection filling is performed after the upper and lower molds 50 and 60 are clamped is used. It can also be adopted.

  Furthermore, in the method of the present invention, the skin set frame 90 that holds the skin 30 is set in advance in the assist model 80, and the skin 30 can be set at the same time when the assist model 80 is press-bonded to the molding upper die 50. Can be easily performed, and after the skin 30 is heat-treated, there is little waiting time until molding starts, and the skin 30 can be maintained at an appropriate temperature, so that the moldability and the drawing transfer property are maintained well. it can. Further, the slide base 81 is firmly supported by the pedestal 86 even when a large pressing pressure is applied between the model die 82 and the molding upper die 50, and therefore, for example, compared to a cantilever type model die, the skin There is no variation in the thickness of 30 and the moldability is more excellent.

  In the embodiment described above, the method of the present invention is applied to the molding method of the door trim 10 formed by simultaneously molding the skin 30 on the surface of the resin core material 20, but the rear parcel shelf, floor trim, trunk trim, luggage side trim, The present invention can be applied to a molding method for general automobile interior parts such as a roof trim and a rear side trim, and can also be applied to a molding method for an interior panel of a railway vehicle or an interior panel of a house. Further, a mold press molding method is used in which the molten resin M is supplied immediately before the molding upper and lower molds 50 and 60 are clamped. However, after the molding upper and lower molds 50 and 60 are clamped, the injection molding is performed by injection filling the molten resin M. It can also be applied to the construction method. Further, if a movable and removable structure is adopted as the pedestal 86, it can be applied to the molding without a skin.

It is a front view which shows the door trim for motor vehicles manufactured by applying the method of this invention. It is the II-II sectional view taken on the line in FIG. It is a general view which shows the structure of one Example of the shaping die used for the shaping | molding method of the laminated molded body which concerns on this invention. FIG. 4 is an explanatory view showing a relationship between an assist model side skin set frame holder and a molding upper mold clamper in the molding die shown in FIG. 3. It is explanatory drawing which shows the preheating process of the skin in the molding method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows the setting process to the assist model of the skin set frame in the molding method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows the injection | throwing-in process in the shaping die of the assist model in the shaping | molding method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows the raising operation | movement of the model type | mold in the assist model in the molding method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows the shaping | molding process of the skin in the shaping | molding method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows the removal process from the shaping | molding upper mold | type of the model type | mold in the molding method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows the retraction | saving process to the model die outside in the molding method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows the supply process of the molten resin in the molding method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows the integration process of the skin and the resin core material in the molding method of the door trim which uses the shaping die shown in FIG. It is a front view which shows the conventional door trim for motor vehicles. It is the XV-XV sectional view taken on the line in FIG. It is a schematic diagram which shows the structure of the shaping die which shape | molds the conventional door trim. It is explanatory drawing which shows the supply process of the molten resin in the shaping | molding method of the conventional door trim. It is explanatory drawing which shows the mold press molding process in the shaping | molding method of the conventional door trim.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Door trim 20 Resin core material 30 Skin 31 Top layer 32 Cushion layer 40 Molding die 50 Molding upper mold 51 Press machine 52 Clamper 53 Cylinder 54 Vacuum suction hole 55 Air chamber 56 Vacuum pump 57 Vacuum suction pipe 58 Opening and closing valve 60 Molding lower mold 61 Manifold 62 Gate 70 Injection machine 80 Assist model 81 Slide base 82 Model type 83 Cylinder 84 Skin set frame holder 84a Guide rod 84b Energizing spring 85 Guide rail 86 Base 90 Skin set frame H Heater device M Molten resin Vc Vacuum suction mechanism

Claims (2)

A resin core material (20) is obtained by setting the skin (30) in the upper and lower molds (50, 60) and supplying the molten resin (M) into the cavity formed between the upper and lower molds (50, 60). In the molding method of the laminated molded body (10) in which the skin (30) is integrated with the surface of the resin core (20)
A vacuum suction mechanism (Vc) is attached to the molding upper mold (50), and a model mold (82) is placed on a pedestal (86) provided from the set area of the skin (30) to the molding die (40). A skin mold (40) provided with an assist model (80) in which a slide base (81) that supports the body is installed so as to be able to advance and retreat is used to heat and soften the skin (30) together with the skin set frame (90). A skin set frame (90) that is incorporated in the assist model (80) and placed in the mold upper and lower molds (50, 60) in the mold open state to hold the model mold (82) and the skin (30) in the assist model (80). ) Is raised and the outer skin (30) is press-bonded between the molding upper die (50) and the model die (82), and the vacuum suction mechanism (Vc) is operated on the molding upper die (50). Molding By the mold surface vacuum-press forming a skin (30) along the mold (50), a forming step of the epidermis (30) for molding the skin (30) to the thin-walled,
The model mold (82) is lowered while the skin (30) molded in the molding process is held on the molding upper mold (50), and the model mold (82) is retracted outside the molding mold (40). After that, the molding upper die (50) holding the skin (30) is lowered by a predetermined stroke, and the molding upper die (50) enters the cavity either before or after reaching the bottom dead center. The molten resin (M) is supplied to the resin core material (20), the resin core material (20) is molded into a desired curved surface shape, and the skin (30) is laminated and integrated on the surface of the resin core material (20). And the integration process of the skin (30),
A method for forming a laminated molded body comprising: A molding die (40) of a laminated molded body (10) for molding a laminated molded body (10) formed by integrating a skin (30) on the surface of a resin core material (20) into a required shape, the molded metal The mold (40) includes a movable upper mold (50) that moves up and down a predetermined stroke, and a fixed lower mold (60) positioned below the upper mold (50). 50) is provided with a vacuum suction mechanism (Vc) for vacuum forming the skin (30) and an assist model (80) for press-bonding the skin (30). In the model (80), a slide base (81) is slidably provided along a rail (85) of a pedestal (86) installed from the set area of the skin to the molding die (40). ) Model type (82) and epidermis The frame frame holder (84) is mounted so as to be movable up and down, so that the setting process of the skin (30) and the in-mold loading process of the model mold (82) can be performed simultaneously, and the model mold (82) A molding die for a laminated molded body, wherein the model die (82) is stably supported by the pedestal (86) during press-bonding of the molding upper die (50).

Images