JP4917907B2 - Method and apparatus for molding laminated molded body - Google Patents

Description

  The present invention relates to a molding method and a molding apparatus 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 the like. The present invention relates to a molding method and a molding apparatus for a laminated molded body capable of obtaining a soft feeling and improving drawing transferability and faithfully displaying a sharp appearance 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. 11 and 12. 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. 14, when the mold clearances of the molding upper and lower molds 5 and 6 reach 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. 15). 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

  As described above, 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, the corner portions of the armrest 1 a and the like cannot be sharply shaped, 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 and apparatus for forming a laminated molded body in which an outer skin and a resin core material are integrated, and provides a good soft feeling and sharpness. An object of the present invention is to provide a molding method and a molding apparatus for a laminated molded body that can display a suitable external shape, can shorten the molding cycle, and reduce the cost.

  In order to solve the above problems, the present invention forms a resin core into a required shape by setting a skin in a molding upper and lower molds and then supplying a molten resin into a cavity formed between the molding upper and lower molds. In addition, in the molding method of the laminated molded body in which the skin is integrated on the surface of the resin core material, the molding upper and lower molds provided with a vacuum suction mechanism on the molding upper mold, and the molding upper and lower molds are put into the molding upper mold. Using a molding device consisting of an assist model that forms the skin in cooperation with the mold, the heat softened skin is set directly or via the skin frame in the assist model that is put into the molding upper and lower molds. When the cylinder is extended in this assist model, the model mold and the skin are raised, and when the skin is press-bonded between the molding upper mold and the model mold, the vacuum suction mechanism is operated on the molding upper mold. By vacuum forming the skin, the elastic action of the flexible layer laminated on the surface of the hard model mold body absorbs the variation in the crimping posture of the model mold and the thickness variation of the skin, and the mold surface of the molded upper mold The skin is formed with a uniform thickness and a thin-walled vacuum / press molding process, and the skin molded in the molding process is held in the molding upper mold by the vacuum suction force of the molding upper mold. After the assist model is retracted to the outside of the molding upper and lower molds, the molding upper mold holding the skin is lowered by a predetermined stroke, and the molding upper mold immediately before reaching the bottom dead center. Alternatively, the molten resin is supplied into the cavity at any timing after reaching, and the resin core material is molded into a desired curved shape, and the skin is laminated and integrated on the surface of the resin core material. Characterized by comprising the an integrated process of the core material and the skin.

  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 apparatus used when carrying out the method of the present invention is the molding apparatus for a laminated molded body used for molding a laminated molded body having a surface integrated with the surface of a resin core material into a required shape. The molding apparatus is charged into a movable upper molding die that moves up and down by a predetermined stroke, a fixed molding lower die positioned below the molding upper die, and the molding upper and lower molds in cooperation with the upper molding die. And a vacuum suction mechanism for forming a skin on the molding upper mold, and the assist model is formed on a base plate that is lifted and lowered by a cylinder. A model mold having an outer shape matching the shape is supported, and this model mold is composed of a laminated structure in which a flexible layer having elasticity is laminated on the outer surface of a hard model mold body, Completion During, the elastic action of the flexible layer, characterized by being adapted to absorb variation or scatter of the thickness of the skin of a model type of the crimping position.

  More specifically, the upper mold is connected to a press machine and can be moved up and down for a predetermined stroke, and the outer skin is vacuum-formed while vacuum suction is performed to hold the outer skin on the upper mold when molten resin is injected and filled. It has a mechanism. On the other hand, the molding lower die is provided with a manifold and a gate as a resin passage for a molten resin supplied from an injection machine.

  In addition, an assist model is placed in the upper and lower molds in order to accurately mold the skin. This assist model is equipped with a model die that almost matches the shape of the core part of the lower mold, so that the outer skin is sandwiched between the upper mold and the thin mold. A support mechanism for transporting the assist model from the mold to the mold, and a lifting mechanism that pushes the model mold toward the upper mold and presses the outer skin against the upper mold. Has a holder function. As a holder function to set and hold the skin, a skin set frame may be provided on the upper side of the assist model, and a skin frame setting jig for receiving the skin frame that supports the skin is the upper part of the assist model. It may be provided on the side. Furthermore, the model mold has a model mold body formed by molding a hard resin so as to substantially match the shape of the core portion, and a flexible layer made of a silicone resin or a rubber-based material so as to cover the outer surface of the model mold body. Are laminated and integrated. Further, if desired, a blow hole may be provided in the model mold, and an air blow mechanism for blowing air for speeding up cooling of the skin through the blow hole may be provided.

  And this invention method is divided roughly into the shaping | molding process of a skin, and the integration process of a skin and a resin core material. First, as the skin molding process, when using an assist model with an integrated skin set frame, the heat-treated skin can be set in the skin model frame of the assist model located in the molding upper and lower molds, It may be set on the assist model in a standby state. Subsequently, the lifting mechanism (lifting cylinder) of the assist model is driven to raise the model mold and the skin set frame. At this time, the vacuum suction mechanism of the molding upper mold is also operating, and the skin is vacuum-formed along the mold surface of the molding upper mold, and the skin is sandwiched between the molding upper mold and the model mold, and press-bonded. Thus, the skin is quickly formed after heating by vacuum and press bonding. At this time, the variation in the pressure bonding posture of the model mold and the thickness variation of the skin can be absorbed by the elastic action of the model flexible layer. Accordingly, the shape of the corner portion and the like can be accurately formed, and the drawn pattern can be faithfully displayed.

  On the other hand, when a skin frame setting jig for receiving the skin frame is provided in the assist model, the skin model that supports the heat-softened skin after the assist model is placed in the mold upper and lower molds in the mold open state. Attach to the assist model skin frame setting jig, and then lift the model mold and skin frame toward the molding upper mold, vacuum form the skin by the vacuum suction action of the molding upper mold, and mold the upper mold The skin can be accurately formed into a thin-walled shape by the press pressure between the surface and the model die. Even in this case, the elastic action of the model-type flexible layer can absorb variations in the pressure-bonding posture of the model-type and the thickness variation of the skin. Can appear. Since the skin frame that supports the heat-softened skin can be attached to the assist model skin frame setting jig, the skin can be easily set by one person.

  Next, after the skin is molded, the vacuum suction action of the molding upper mold continues, so that the assist model is in the state that the skin is held on the mold surface of the molding upper mold, and the model mold and the skin set frame by the contraction action of the cylinder, or The skin frame setting jig holding the skin frame is lowered, and then the assist model is retracted to a position where it does not interfere with the mold clamping of the molding upper and lower molds. Furthermore, after 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, 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 molding upper die, the skin can be uniformly and thinly molded. 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 if an inexpensive sheet without diaphragm is used without using a conventional expensive sheet with diaphragm.

  Further, according to the method of the present invention, the model model in the assist model is formed by integrating a flexible layer made of a silicone resin, a rubber-based material, or the like on the outer surface of the model body made of hard resin. When the model mold is crimped to the mold surface, even if there is a variation in the crimping posture of the model mold or a variation in the thickness of the skin, the variation can be absorbed by the elastic action of the flexible layer, and a good drawing pattern In addition, the moldability and design properties can be maintained well, such that a sharp appearance can be formed with higher accuracy.

  As described above, the method for forming a laminated molded body according to the present invention sets the skin that has been heat-softened to the skin set frame integrated with the assist model, or assists the skin frame that supports the skin that has been heat-softened. After setting the heat-softened skin on the assist model according to the method of mounting it on the model skin frame setting jig, vacuum forming the skin along the mold surface of the molding upper mold, and molding upper mold and model Since the outer skin is press-bonded to the mold, the outer skin can be formed into a thin and uniform thickness. When supplying molten resin immediately before or after clamping, the gap between the outer skin and the lower mold Sufficient clearance is ensured, and there is little thermal damage to the cushion layer of the epidermis. In addition, the molded product is shaped into the product shape and retains the shape, so the laminated molded product has a soft feel and can show the sharp appearance of sharp highlight lines and the like. By improving, since a short shot etc. do not arise, it has various effects that a moldability can be improved.

  Further, in the method for molding a laminated molded body according to the present invention, the assist model used for preforming the skin after being put into the molding upper and lower molds is a model made of a hard resin as a configuration of the model mold supported by the base plate. When the outer surface of the mold body is laminated and integrated with a flexible layer with elasticity, when the outer skin is crimped between the upper mold and the model mold, the model's crimping posture varies. In addition, this variation can be absorbed by the elasticity of the flexible layer, and even if there is a variation in the skin thickness at the deep drawing part in the molding upper die, the difference in the press-bonding force is caused by the elastic action of the flexible layer. Since there is no such thing, the drawn pattern can be made to appear well. Therefore, as a model type configuration in the assist model, a configuration having elasticity on the surface is adopted, so that it is possible to display a sharp appearance shape and to accurately display a drawn pattern, The appearance performance can be improved.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments of a molding method and a molding apparatus of a laminated molded body according to the present invention will be described in detail by exemplifying a door trim molding method and a molding apparatus 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.

  FIG. 1 to FIG. 10 show an embodiment of the present invention. FIG. 1 is a front view showing a two-tone type 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 a perspective view showing the inside of a die body of an assist model used in the molding apparatus, and FIG. 5 is a plan view of the model model of the assist model. 6 to 10 are explanatory views showing the steps of the method of the present invention.

  1 and 2, the door trim 10 includes a door trim upper 20 and a door trim lower 30 which are divided into upper and lower parts, and various accessory parts are mounted on the door trim 10. For example, an inside handle escutcheon 11 is attached to the middle portion, and an armrest 12 located below the middle portion is formed in a shape that bulges toward the vehicle interior side. A pull handle unit 13 is formed on the upper surface of the armrest 12. A power window switch escutcheon 14 is attached. A pocket opening 15 that can accommodate equipment is opened below the armrest 12, and a pocket back cover (shown in FIG. 2) 16 is attached to the back side of the pocket opening 15. A speaker grill 17 is provided on the front side of the pocket opening 15 integrally with the door trim lower 30 or separately.

  More specifically, the door trim upper 20 is formed in a desired curved surface shape, and a skin 22 excellent in surface appearance and surface feel is laminated and integrated on the surface of a resin core material 21 having rigidity and shape retention to a door panel. The door trim lower 30 is a single piece of synthetic resin, and the joint structure of the door trim upper 20 and the door trim lower 30 is such that a plurality of mounting bosses 31 are provided on the upper edge of the door trim lower 30 toward the back side. A mounting hole 23 is formed in the door trim upper 20 so as to correspond to the mounting boss 31. Then, after the mounting boss 31 is inserted into the mounting hole 23, the door trim upper 20 and the door trim lower 30 are firmly joined and integrated by applying ultrasonic welding caulking and heat welding to the tip of the mounting boss 31. ing.

  And as the resin core material 21 in the said door trim upper 20, 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 22, in this embodiment, a sheet material made of a two-layer laminate of a top layer 22a and a cushion layer 22b is used. As the top layer 22a, a TPO (thermoplastic olefin) resin, a PVC resin, A thermoplastic resin sheet such as PP resin is used, and a foamed resin sheet such as polyurethane foam, polyethylene foam, or polypropylene foam is used as the cushion layer 22b. Further, as the material of the door trim lower 30, a resin material is used as in the resin core material 21 of the door trim upper 20.

  By the way, the door trim upper 20 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 22 in the door trim upper 20 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 apparatus 40 for molding the door trim upper 20 will be described with reference to FIG. The molding apparatus 40 can mold-mold the resin core material 21 and the skin 22 integrally with each other, and can mold and mold the molds together. The molding upper mold 50, the molding lower mold 60, and the skin 22 can be molded into the molding upper mold 50. The assist model 70 is generally composed of the upper and lower molds 50 and 60 so that the molding can be performed in cooperation with the upper and lower molds 50 and 60.

  More specifically, the forming upper die 50 is connected to the press machine 51 and is configured to be movable up and down by a predetermined stroke by driving the press machine 51, and matches the product surface shape of the door trim 10 that forms the product surface of the door trim 10. A mold surface 52 is formed, and a drawing pattern is engraved on the mold surface. Further, the molding upper die 50 is provided with a vacuum suction mechanism Vc. That is, a large number of vacuum suction holes 53 are formed in the mold surface 52 of the molding upper mold 50, and the vacuum suction pipe 56 is disposed between the air chamber 54 communicating with the vacuum suction holes 53 and the vacuum pump 55. The vacuum suction pipe 56 is provided with an open / close valve 57, and the open / close valve 57 can be opened and closed to selectively apply a vacuum suction force to the upper mold 50. In this embodiment, in addition to the vacuum suction hole 53, an outer peripheral vacuum suction hole 53a having a function of holding the skin 22 is provided. Although not shown, the outer peripheral vacuum suction hole 53a may employ a vacuum suction pump or the like of a system different from the vacuum suction mechanism Vc, or may be connected to the vacuum suction mechanism Vc via a switching valve. . On the other hand, the molding lower mold 60 located below the molding upper mold 50 is provided with a manifold 62 and a gate 63 that serve as a resin passage for the molten resin M supplied from the injection machine 61, and through the manifold 62 and the gate 63. The molten resin M is distributed and supplied onto the mold surface of the molding lower mold 60.

  Incidentally, the molding apparatus 40 used in the method of the present invention is characterized in that the skin 22 can be molded between the molding upper die 50 and the assist model 70 with high accuracy and in a short time. 70 has a holder function of the skin 22 that can directly set the skin 22. That is, the assist model 70 is provided with a transport table 71 as a transport mechanism so that the assist model 70 can reciprocate between an external standby position and a work position inside the molding upper and lower molds 50 and 60. The transfer table 71 is connected to a driving mechanism (not shown) such as a cylinder or a conveyor. Cylinders 72 are attached to the upper surface of the transfer table 71 at a plurality of locations such as four locations, and a base plate 73 is attached to the cylinder 72. Is supported to be movable up and down. Furthermore, a model die 74 that matches the shape of the core portion of the lower molding die 60 is attached to the center of the upper surface of the base plate 73, and the skin 22 is between the model die 74 and the mold surface 52 of the upper molding die 50. It has a function that can be molded into a thin wall.

  By the way, the present invention is characterized by the structure of the assist model 70. The model mold 74 is made of a hard resin and has a flexibility such as a silicone resin or a rubber material on the outer surface of the model mold body 75 having a thickness of about 5 to 6 mm. A flexible layer 76 having a heat resistance and a thickness of about 2 mm is laminated. In particular, due to the elastic action of the flexible layer 76, variations in the crimping posture of the model die 74 can be corrected, and thickness variations in the skin 22 can be absorbed. Further, inside the model mold main body 75, reinforcing wooden frames 751 are arranged in the vertical and horizontal directions as shown in FIG. Further, as shown in FIG. 5, a blow hole 752 is formed on the outer surface of the model die 74, and an air pipe 77 communicating with the model die 74 and an external air supply mechanism (not shown) is connected. In addition, cooling air is blown from the outer surface of the model die 74 to the skin 22 through the blow hole 752 from the air supply mechanism so that forced cooling can be performed.

  Further, a skin frame setting jig 78 is provided on the upper surface of the base plate 73 so as to surround the model die 74. The skin frame setting jig 78 is supported by support rods 781 at the four corners, and the support rods 781 can be inserted into the through holes 731 of the base plate 73 and are biased upward. Therefore, the skin frame setting jig 78 is always spring-biased upward. Further, a skin frame 80 that holds the skin 22 is placed and fixed on the skin frame setting jig 78 in the assist model 70. As the skin frame 80, skin fixing pins 82 are erected on the frame 81 at predetermined pitch intervals, and the skin 22 is pierced into the skin fixing pins 82 and the skin 22 is held by the skin frame 80.

  Next, a process of molding the door trim upper 20 using the molding apparatus 40 will be described with reference to FIGS. First, as shown in FIG. 6, when the molded upper and lower molds 50 and 60 are in the mold open state, the assist model 70 is put into the molds of the molded upper and lower molds 50 and 60. As shown in the figure, after setting the skin 22 on the skin frame 80, the skin frame 80 is set on the skin frame setting jig 78 of the assist model 70 while being heated to a predetermined temperature. It should be noted that the skin frame 80 may be set on the skin frame setting jig 78 before the assist model 70 is put into the molding upper and lower molds 50, 60. , 60, it is preferable to set the skin frame 80 holding the skin 22 to the assist model 70 placed in the view of formability.

  Next, as shown in FIG. 7, the assist model 70 is driven upward. Specifically, when the cylinder 72 mounted on the transfer table 71 is extended, the base plate 73 is raised by a predetermined stroke, whereby the model die 74 is raised by the same stroke as the stroke of the base plate 73, and The skin 22 also rises integrally. Then, in synchronization with the ascending operation of the assist model 70, the vacuum suction mechanism Vc of the upper mold 50 is operated.

  At this time, the vacuum suction mechanism Vc on the inner surface of the molding upper die 50 is activated when the skin frame 80 holding the peripheral portion of the skin 22 comes into contact with the molding upper die 50, and the skin 22 is passed through the vacuum suction hole 53. Is vacuum formed along the mold surface of the molding upper mold 50, and when the assist model 70 is completely raised, a vacuum suction mechanism (not shown) on the outer periphery of the molding upper mold 50 is operated, and the outer vacuum suction hole 53a is operated. A vacuum suction force acts, and the skin 22 can be reliably held on the mold surface of the molding upper mold 50.

  Therefore, as shown in FIG. 7, the peripheral portion of the skin 22 is sealed at the peripheral portion of the skin 22 by the upper mold 50 and the skin frame setting jig 78 of the assist model 70. The outer skin 22 is vacuum-formed along the upper and lower surfaces, and the outer skin 22 is press-bonded between the mold surface 52 of the molding upper die 50 and the model die 74 of the assist model 70, whereby the outer skin 22 is formed into a thin shape. .

  In the model model 74 in the assist model 70, since the flexible layer 76 is laminated and integrated on the outer surface of the hard model mold body 75, the upper mold 50 of the model mold 74 is adjusted by adjusting the stroke of the cylinder 72, for example. Even when variations occur in the crimping posture for crimping to the inner surface of the sheet, the variation can be absorbed by regulating the press-bonding force applied to the skin 22 by the elastic action of the flexible layer 76 almost uniformly. In the part of the mold surface 52 of the mold 50 where the expansion rate is high, even when the skin 22 is stretched thinly and the thickness of the skin 22 varies, the elastic layer 76 of the model mold 74 causes the thickness to increase. Variations can be absorbed, and shapes and drawn patterns can be accurately displayed. Therefore, the drawn pattern engraved on the mold surface 52 of the molding upper mold 50 is faithfully transferred to the surface of the skin 22 and sharp shapes such as corner portions can be formed. Furthermore, the skin 22 is formed into a substantially uniform thickness and a thin wall shape by vacuum molding in the molding upper die 50 and press-compression molding between the molding upper die 50 and the assist model 70, and the skin 22 is heated and softened. Since the molding is performed immediately after processing, the waiting time is small, a sharp shape can be obtained, and the drawn pattern can be transferred with higher accuracy.

  Thereafter, the cylinder 72 in the assist model 70 contracts while the molded skin 22 is held in the molding upper mold 50 by vacuum suction, so that the model mold 74 and the assist model 70 are integrated with each other as shown in FIG. The converted skin frame 80 is lowered. At this time, the skin 22 is attracted and held by the molding upper die 50 by vacuum suction force, and the skin frame 80 is joined to the skin frame setting jig 78 in the assist model 70 by magnetic suction force or the like. The skin 22 is easily peeled off from the skin frame 80. Thereafter, in the assist model 70, the transport table 71 is retracted by the operation of a transport mechanism (not shown) and retracts out of the molding upper and lower molds 50 and 60.

  Next, as shown in FIG. 9, when the press machine 51 is driven, the molding upper die 50 is lowered by a predetermined stroke, but the mold surface 52 of the molding upper die 50 is in a state where the skin 22 is thin and is vacuum-formed. When the mold clearance of the upper and lower molds 50 and 60 reaches a predetermined position, the molten resin M is supplied from the injection machine 61 to the mold surface of the lower mold 60 through the manifold 62 and the gate 63. 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.

  Thus, in the method of the present invention, as described above, by setting the skin 22 directly on the assist model 70, the setting work of the skin 22 can be easily performed and the moldability of the skin 22 can be improved. Since the molten resin M is supplied in a state in which the skin 22 molded in a thin shape is held along the mold surface of the molding upper mold 50, the back surface of the cushion layer 22b of the skin 22 and the mold surface of the molding lower mold 60 are provided. And the fluidity of the molten resin M can be maintained satisfactorily, and the skin 22 is not in a tent tension state, so that the cushion layer 22b is thermally damaged from the molten resin M. The cushioning performance of the cushion layer 22b can be maintained well, and the softness of the product can be emphasized.

  Then, as shown in FIG. 10, 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 the corners of the cavity, and the resin core material 21 has a desired curved surface. In addition to being molded into a shape, the skin 22 is integrated with the surface side of the resin core material 21 to complete the molding of the door trim upper 20. 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 22 in the door trim upper 20 is formed into a required shape before being press-integrated with the resin core material 21, and thus the shape retainability of the skin 22 is good. A sharp exterior shape such as a highlight line in a corner portion 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, as the configuration of the model mold 74 in the assist model 70, a configuration in which a flexible layer 76 having high flexibility and heat insulation is laminated and integrated on the surface of the model mold body 75 made of a hard resin is adopted. Thus, even when variations occur in the crimping posture of the model die 74 when press-bonding to the inner surface of the molding upper die 50 of the assist model 70, the variation is absorbed by the elastic action of the flexible layer 76, and a high deployment rate portion. Even if the thickness of the skin 22 varies, the elastic action of the flexible layer 76 does not cause a difference in the press-bonding force applied to the skin 22 and can maintain a sharp external shape and faithfully transfer the drawn pattern. The moldability and the drawing transferability can be maintained well.

  In the embodiment described above, the method of the present invention is applied to the molding method of the upper and lower split type door trim 10 that partially employs the door trim upper 20 formed by simultaneously molding the skin 22 on the surface of the resin core material 21. The present invention can be applied to all automotive interior parts such as rear parcel shelves, floor trims, trunk trims, luggage side trims, roof trims, rear side trims, interior panels for railway vehicles, etc. The present invention can also be applied to the molding method. 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 used for construction methods.

It is a front view showing a two-tone type automobile door trim manufactured by applying the method of the present 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 | molding apparatus used for the shaping | molding method of the laminated molded body which concerns on this invention. It is a perspective view which shows the reinforcement wooden frame of the assist model in the shaping | molding apparatus shown in FIG. It is a top view which shows the assist model in the shaping | molding apparatus shown in FIG. It is explanatory drawing which shows the skin setting process in the shaping | molding method of the door trim upper which uses the shaping | molding apparatus shown in FIG. It is explanatory drawing which shows the shaping | molding process of the skin by the raise of the assist model in the shaping | molding method of the door trim upper which uses the shaping | molding apparatus shown in FIG. It is explanatory drawing which shows the descent | fall operation of the assist model in the shaping | molding method of the door trim upper which uses the shaping | molding apparatus shown in FIG. It is explanatory drawing which shows the supply process of the molten resin in the shaping | molding method of the door trim upper which uses the shaping | molding apparatus shown in FIG. It is explanatory drawing which shows the integral formation process of the resin core material and skin in the molding method of the door trim upper which uses the shaping | molding apparatus shown in FIG. It is a front view which shows the conventional door trim. FIG. 12 is a cross-sectional view taken along line XII-XII in FIG. 11. It is a schematic diagram which shows the structure of the conventional door trim shaping | molding apparatus. 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 Door trim upper 21 Resin core material 22 Skin 22a Top layer 22b Cushion layer 30 Door trim lower 40 Molding device 50 Molding upper mold 51 Press machine 52 Mold surface 53 Vacuum suction hole 53a Peripheral vacuum suction hole 54 Air chamber 55 Vacuum pump 56 Vacuum Suction pipe 57 Open / close valve 60 Molded lower mold 61 Injection machine 62 Manifold 63 Gate 70 Assist model 71 Transfer table 72 Cylinder 73 Base plate 74 Model mold 75 Model mold body 751 Reinforcement wooden frame 752 Blow hole 76 Flexible layer 77 Air piping 78 Skin Frame setting jig 80 Skin frame 81 Frame 82 Skin fixing pin M Molten resin Vc Vacuum suction mechanism

Claims (2)

After setting the skin (22) in the molding upper and lower molds (50, 60), the molten resin (M) is supplied into the cavity formed between the molding upper and lower molds (50, 60), thereby the resin core (21 ) In a required shape, and in the molding method of the laminated molded body (20) formed by integrating the skin (22) on the surface of the resin core material (21),
The upper and lower molds (50, 60) in which the vacuum suction mechanism (Vc) is attached to the upper mold (50) and the upper and lower molds (50, 60) are put in and cooperate with the upper mold (50). Then, using a molding apparatus (40) composed of an assist model (70) for molding the skin (22), the assist model (70) put into the molding upper and lower molds (50, 60) has a heat softening treatment. The outer skin (22) is set directly or through the outer skin frame (80), and the model (74) and the outer skin (22) are separated by the extension operation of the cylinder (72) in the assist model (70). When the skin (22) is press-bonded between the molding upper die (50) and the model die (74) by raising the vacuum suction mechanism (Vc) to the molding upper die (50), (22) is vacuum formed and hard By the elastic action of the flexible layer (76) laminated on the surface of the mold body (75), the variation in the crimping posture of the model mold (74) and the variation in the thickness of the skin are absorbed, and the mold surface of the molding upper mold (50) A step of forming the skin (22) with a uniform thickness and a vacuum and press-molding the skin (22) along
The skin (22) molded in the molding step is held on the molding upper mold (50) by the vacuum suction force of the molding upper mold (50), while the model mold (74) is lowered by the expansion / contraction operation of the cylinder (72). After the assist model (70) is retracted outside the molding upper and lower molds (50, 60), the molding upper mold (50) holding the skin (22) is lowered by a predetermined stroke to form the molding upper mold (50). The molten resin (M) is supplied into the cavity at any timing immediately before or after reaching the bottom dead center, and the resin core (21) is molded into a desired curved surface shape. An integration step of the resin core material (21) and the skin (22), in which the skin (22) is laminated and integrated on the surface of the material (21);
A method for forming a laminated molded body comprising: In the molding apparatus (40) of the laminated molded body (20) used for molding the laminated molded body (20) formed by integrating the skin (22) on the surface of the resin core material (21) into a required shape,
The molding apparatus (40) includes a movable upper molding die (50) that moves up and down a predetermined stroke, a fixed molding lower die (60) positioned below the molding upper die (50), and a molding upper die ( 50, 60) and an assist model (70) that applies press pressure to the skin (22) in cooperation with the molding upper die (50). The skin (22) is applied to the molding upper die (50). ) Is formed, and the assist model (70) is arranged on the base plate (73) that is moved up and down by the cylinder (72) to match the cavity shape. A model mold (74) having a shape is supported, and the model mold (74) is a laminated structure in which a flexible layer (76) having elasticity is laminated on the outer surface of a hard model mold body (75). Constructed from the body, when molding the skin (22) Oite, by the elastic action of the flexible layer (76), modeling (74) of the molding apparatus of the molded laminate, characterized in that so as to absorb the variations in thickness variation and the epidermis of the crimping position (22).

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