JP5610564B2 - Molding method and molding apparatus for laminated molded product - Google Patents

Description

  The present invention relates to a molding method and a molding apparatus suitable for automotive interior parts such as door trims, rear side trims, luggage side trims, roof trims, and the like, and more particularly, to a skin by heat fusion of a resin core material by resin heat. As a result, it is possible to reduce equipment and man-hours without using adhesives, and to eliminate defects such as floating and peeling. The present invention relates to a molding method and a molding apparatus.

  FIG. 8 is a cross-sectional view showing a door trim mounted on the indoor surface side of the door panel of the vehicle. The door trim 1 is composed of an upper and lower divided body of a door trim upper 2 and a door trim lower 3. The door trim upper 2 is made of a laminate molded product having a skin 2b adhered to the surface of the core material 2a, and the door trim lower 3 is made of an injection molded product of synthetic resin. The cost is reduced by making the molding die compact.

  And conventionally, as shown in FIG. 9, the manufacturing method of the laminated molded product represented by the door trim upper 2 is as follows. Adhesive agent a is applied to a core material 2a having air permeability such as a pre-formed wood core material. After the application, as shown in FIG. 10, the adhesive a is dried by the drying heater 4 to volatilize the organic solvent. On the other hand, as shown in FIG. 11, the skin 2 b is heated and softened by the heater device 5. Then, as shown in FIG. 12, the core material 2a coated and dried with the adhesive a is set on the vacuum forming die 6, and the heat-softened skin 2b is overlaid, and then the surface of the core material 2a is formed by vacuum forming. The skin 2b is stuck to the surface. Furthermore, as shown in FIG. 13, the excess skin 2b is removed by the piercing die 7, and the necessary opening setting portion is punched together with the core material 2a and the skin 2b. Then, as shown in FIG. 14, after applying the adhesive a to the winding edge 2c of the peripheral edge of the skin 2b, as shown in FIG. 15, it is dried with a drying heater 4, and as shown in FIG. The winding 2c of the skin 2b is wound around the back surface of the core material 2a to complete the manufacture of the door trim upper 2. A conventional example in which the skin 2b is adhered to the surface of the core material 2a using the vacuum forming method is described in detail in Patent Document 1.

JP 2001-310378 A

  Thus, in the conventional method of manufacturing the door trim upper 2 by attaching the skin 2b to the surface of the core material 2a by vacuum forming, the organic solvent-based adhesive a is applied to the surface of the core material 2a. For this reason, while the working environment in the factory is deteriorated, the VOC (Volatile Organic Compounds) in the passenger compartment increases, and the environment in the passenger compartment cannot be said to be preferable. On the factory side, in addition to ventilation equipment, the cost of equipment such as the coating booth and drying furnace for adhesive a increases, and the number of processing steps such as the coating and drying processes for adhesive a increases, and work in progress Problems such as the need for inventory storage space have been pointed out. Furthermore, problems such as floating and peeling are likely to occur due to variations in the application of the adhesive a, and when performing the winding process, the adhesive a must be applied and dried again. At the same time, a new problem has been pointed out that deformation, shrinkage, etc. occur in the drying process of the material 2a and induce molding defects.

  The present invention has been made in view of such circumstances, and achieves simplification of the process and reduction of VOC, and a molding method and molding of a laminated molded product that can effectively eliminate defects such as skin floating and peeling. The object is to provide a device.

  In order to solve the above-mentioned problems, the present inventors, as a result of earnest research, supply the heated skin into the molding die, perform drawing transfer and shaping by vacuum / pneumatic action, and further inject into the molding die Focusing on the fact that the resin core material and the skin are integrated by the resin heat of the molten resin, the process can be simplified and the adhesive can be eliminated, and the present invention has been completed.

That is, the present invention relates to a molding method for a laminated molded article comprising a resin core material molded into a required shape in a molding die and a skin layer laminated and integrated on the surface of the resin core material. A heating heater is arranged above the mold, and the skin is pulled down from the skin roll set above it, and before being fed into the molding die, it is brought to a predetermined temperature by the heating heater located above the molding die. The heating process of the skin to be heat-treated, the heated skin is suspended between the cavity mold and the core mold, the cavity mold and the core mold are clamped, and then the vacuum suction mechanism and the compressed air arranged in the molding die The mechanism is driven to form the skin into the required shape so as to follow the mold surface shape of the cavity mold, and the vacuum and pressure forming process of the skin, and the molten resin from the injection unit connected to the core mold, Formed between Required operating and injection filled in the cavity, the operation for discharging the compressed air air supplied into the cavity (C) from the air discharge groove (524) to the outside by driving the pressure mechanism (55), the resin core member It is characterized by comprising an integration step of forming into a shape and laminating and integrating the skin on the surface of the resin core material by heat fusion.

  Here, the laminated molded product has a structure in which the skin is adhered to the surface of the resin core molded into the required shape, and is used for all automotive interior parts such as door trims, rear side trims, luggage side trims, and roof trims. be able to. As the resin core material, since an injection molding method is used, thermoplastic resins in general can be used.

  In addition, since the skin is formed by vacuum and pressure forming, it must be non-breathable, and is a single sheet material of a thermoplastic resin sheet such as a TPO (thermoplastic olefin) sheet or a vinyl chloride sheet, or A laminated sheet material lined with a cushion layer such as polyurethane foam, polyethylene foam, or polypropylene foam that imparts cushioning properties to the back surface of these single sheets can be used. And the shaping | molding method of the laminated molded product which concerns on this invention is comprised from the following processes.

(1) Heating process of skin (2) Vacuum / pneumatic forming process of skin (3) Integration process of resin core material and skin

(1) Heating process of the skin The drawer end of the skin wound around the skin roll is pulled down, heated to a predetermined temperature by a heater located above the molding die, and then the skin is further pulled down to form a mold. The epidermis is drooped inside.

(2) Vacuum / Pneumatic Forming Process for Skin The drought treatment is applied to the heat-softened skin in a mold that is open. After the mold is clamped, the skin is molded by applying vacuum suction from the mold surface of the mold on the product surface side and injecting compressed air from the mold surface of the opposite mold. Vacuum and pressure molding is performed along the mold surface, and the drawn pattern is transferred to the product surface of the skin. At this time, the surplus portion of the skin located at the outer peripheral edge is cut and removed by a hot blade provided on the outer periphery of the molding die.

(3) Integration process of resin core material and outer skin After the outer skin is vacuum-compressed to the required shape, a prescribed amount of molten resin is injected into the cavity from the injection unit connected to the molding die, Residual air in the cavity is discharged outside through the air discharge groove. Then, the molten resin is cooled and solidified to form the resin core material into a required shape, and the resin core material is integrated with the skin by the resin heat of the resin core material, thereby completing the formation of the laminated molded product. In addition, about the molded product which shaping | molding was completed, a final product is obtained by performing the outer periphery winding process of a piercing process and a skin.

Next, the molding device used in the device of the present invention is a molding device for a laminated molded product in which the skin is laminated and integrated on the surface of the resin core material. The molding device slides in the lateral direction and clamps each other. A mold comprising a cavity mold and a core mold that can be opened, a heater provided above the mold , and a skin roll positioned and set above the heater , and drawn from the skin roll The outer skin is heated to a predetermined temperature with a heater and is suspended between the cavity mold and the core mold, and the cavity mold in the molding die is provided with a vacuum suction mechanism for vacuum suction of the skin , the said core mold, by supplying the pressure air into the cavity formed between the skin and the core mold, and pressure mechanism for forming the skin to the required shape, the molten resin into the cavity injection charging A gate which, are equipped, furthermore, the molding apparatus, at the time of injection filling of molten resin into the cavity, characterized in that it comprises an air discharge groove for discharging the pressure air in the cavity to the outside .

  Here, a heater is set above the mold that can be opened and clamped, and the skin roll is positioned further above the heater. Therefore, if the pull-out end of the skin is pulled down from the skin roll, the skin is automatically heated to a predetermined temperature with a heater, and further, the skin is pulled down and drooped into the mold. Can automatically supply epidermis. The molding die is composed of a fixed-side core mold and a movable-side cavity mold, and an injection unit for injecting and filling molten resin, which is a resin core material, is connected to the core mold. The molten resin supplied from is injected and filled into the cavity between the cavity mold and the core mold through the hot runner and gate. Further, a pressure-increasing tank for supplying compressed air is connected to the core mold, and the compressed air from the pressure-increasing tank is supplied into the cavity of the molding die at the time of vacuum / pressure forming of the skin. In addition, the outer periphery of a core type | mold is provided with the hot blade for cutting and removing the excess part of an outer_skin | epidermis.

  On the other hand, the cavity mold is connected to a cylinder for performing mold clamping and mold opening, and a vacuum suction mechanism for attaching a vacuum suction force when vacuuming and vacuum forming the skin is attached. A vacuum suction hole is formed in the mold surface of the cavity mold, and a drawn pattern is engraved.

  As is clear from the above configuration, the method for molding a laminated molded product according to the present invention is such that the skin drawn from the skin roll is supplied in a heating heater and a molding die in a suspended state. Heat treated. After the mold is clamped, vacuum suction is started from the cavity mold, and compressed air is injected into the cavity from the core mold to vacuum and compress the skin, and the surplus part of the skin is placed on the outer periphery of the mold. Cut processing is performed with the provided hot blade. Furthermore, after vacuum / pressure forming of the skin, the resin core material is molded into the required shape by injecting and filling molten resin into the cavity on the back side of the skin from the injection unit connected to the core mold. And a laminated molded product can be formed into a required shape.

  Therefore, since the skin roll can be set as it is, the conventional skin charging machine becomes unnecessary, the equipment can be simplified, and no adhesive is used, so the equipment such as the adhesive application booth and drying furnace can be reduced. The number of man-hours such as the application of an adhesive and the drying process can be greatly reduced. In addition, since no adhesive is used, there are no problems such as floating and peeling on the skin, and the appearance performance can be maintained well, and the molding of the skin and the integration of the resin core material and the skin within one molding die. Therefore, it is possible to provide a laminated molded article having excellent appearance performance with fewer man-hours.

  As explained above, in the method for molding a laminated molded product according to the present invention, the skin that has been drooped downward from the skin roll is heated to an arbitrary temperature with a heater, and then supplied into the molding die. After the mold is clamped, the skin is molded into the required shape by vacuum / pneumatic molding, and then the molten resin is injected and filled into the cavity to integrally mold the resin core and the skin. Since it is not used, the application of the adhesive, the drying process and the curing process are not required, and the number of man-hours can be greatly reduced, and the stock storage space for work-in-process can be saved, resulting in excellent space efficiency. Furthermore, since there is no variation in the application of the adhesive, it is possible to eliminate problems such as skin lifting and peeling, and to improve productivity.

  In addition, since it can be integrated with the skin by the resin heat of the molten resin, which is the material of the resin core material, solvent-based adhesives are not required, VOCs caused by it can be reduced, and the working environment and vehicle interior environment are improved While maintaining a large ventilation facility and the like, the facility can be simplified. On the other hand, a series of molding steps are performed with a single molding die, so that productivity can be improved.

It is a front view which shows the door trim provided with the door trim upper shape | molded by the method of this invention. It is the II-II sectional view taken on the line in FIG. It is explanatory drawing which shows schematic structure of the shaping | molding apparatus used for this invention method. It is explanatory drawing which shows the heating process of the outer skin in this invention method. It is explanatory drawing which shows the vacuum and pressure forming process of the skin in the method of this invention. It is explanatory drawing which shows the integration process of the resin core material and skin in the method of this invention. It is explanatory drawing which shows the terminal process process of the door trim upper shape | molded by this invention method. It is sectional drawing which shows the conventional door trim. It is explanatory drawing which shows the application | coating process of the adhesive agent to the core material in the manufacturing method of the conventional door trim upper. It is explanatory drawing which shows the drying process of the adhesive agent apply | coated to the core material in the manufacturing method of the conventional door trim upper. It is explanatory drawing which shows the heating process of the skin in the manufacturing method of the conventional door trim upper. It is explanatory drawing which shows the vacuum sticking process of the outer skin in the manufacturing method of the conventional door trim upper. It is explanatory drawing which shows the piercing process in the manufacturing method of the conventional door trim upper. It is explanatory drawing which shows the application | coating process of the adhesive agent in the terminal treatment process of the outer skin in the manufacturing method of the conventional door trim upper. It is explanatory drawing which shows the drying process of the adhesive agent in the terminal treatment process of the outer skin in the manufacturing method of the conventional door trim upper. It is explanatory drawing which shows the winding process of the winding white in the terminal treatment process of the skin in the manufacturing method of the conventional door trim upper.

  Embodiments of a method for molding a laminated molded product and a molding apparatus according to the present invention will be described below in detail with reference to the accompanying drawings. 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 7 show an embodiment of the present invention. FIGS. 1 and 2 are front and sectional views showing a door trim employing a door trim upper formed by the method of the present invention, and FIG. 3 is a method of the present invention. FIG. 4 to FIG. 6 are explanatory views showing the steps of the method of the present invention, and FIG. 7 is an explanatory view showing the terminal treatment process of the door trim upper formed by the method of the present invention. It is.

  1 and 2, the configuration of a door trim 10 manufactured by applying the method of the present invention will be briefly described. The door trim 10 is composed of an upper and lower divided body of a door trim upper 20 and a door trim lower 30 and can be expected to reduce the cost due to the accent effect on the appearance and the compactness of the mold. The door trim 10 is composed of an upper and lower divided body of a door trim upper 20 and a door trim lower 30, and various functional parts are mounted on the door trim 10. For example, functional parts such as an inside handle unit 11, a pull handle unit 12, and a power window switch unit 13 are attached to the door trim upper 20 side, and a pocket back is provided on the back side of the pocket opening 14 on the door trim lower 30 side. A cover 15 is attached, and a speaker grill 16 is provided integrally with or separately from the door trim lower 30 on the front side thereof.

  Furthermore, the door trim upper 20 is a laminated molded product in which a skin 22 is adhered to the surface of a resin core material 21 having appropriate rigidity and shape retention. The resin core material 21 is formed into a required shape by an injection molding method, and the material of the resin core material 21 may be one kind of thermoplastic resin or two or more kinds of thermoplastic resins. 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, the skin 22 is formed into a required shape by a vacuum / pressure forming method, and a drawn pattern is transferred onto the surface of the product. Therefore, a non-breathable sheet material such as a TPO (thermoplastic olefin) sheet can be thermoformed. A single sheet material of a thermoplastic resin sheet such as a vinyl chloride sheet or a laminated sheet material formed by lining a cushion layer of polyurethane foam, polyethylene foam, polypropylene foam or the like on the back surface of these single sheets can be used. In the present embodiment, a skin 22 is used in which a cushion layer 22b made of polyethylene foam is lined on the back surface of the top layer 22a made of a TPO sheet.

  Further, the door trim lower 30 is molded into a desired curved surface shape by an injection molding method using a thermoplastic resin material as a raw material, and a joint structure between the door trim upper 20 and the door trim lower 30 is not shown, but one side For example, by opening a boss on the door trim lower 30 side and an attachment hole on the other side door trim upper 20 side and applying ultrasonic caulking to the tip of the boss inserted into the attachment hole, the two can be joined and integrated. it can.

  By the way, the method of the present invention is directed to a method of forming a laminated molded product such as the door trim upper 20 in the door trim 10. Hereinafter, the method of the present invention will be described by illustrating a method for forming the door trim upper 20.

  First, the method for molding a laminated molded product according to the present invention includes the following steps.

(1) Heating process of skin 22 (2) Vacuum / pressure forming process of skin 22 (3) Integration process of resin core material 21 and skin 22

  Hereinafter, before describing each step (1) to (3) over time, the configuration of the molding apparatus 40 used in the method of the present invention will be briefly described. In FIG. 3, the molding apparatus 40 is generally constituted by a molding die 50, a heater 60 positioned above the molding die 50, and a skin roll 70 positioned further above.

  More specifically, the molding die 50 includes a cavity die 51 and a core die 52, and the cavity die 51 moves forward and backward with respect to the core die 52 by a cylinder 511 provided in the cavity die 51. Performing, mold clamping and mold opening. Further, the cavity mold 51 is equipped with a vacuum suction mechanism 53, and the vacuum suction mechanism 53 operates during vacuum / pressure forming of the skin 22 described later. In addition, a diaphragm pattern 512 is engraved on the mold surface of the cavity mold 51, and a number of vacuum suction holes are formed although not shown.

  On the other hand, the core mold 52 is provided with an injection unit 54 for supplying the material of the resin core material 21, and the molten resin M supplied from the injection unit 54 is clamped through the hot runner 521 and the gate 522. The cavity C to be formed is injection filled. Further, the core mold 52 is provided with a pressure increasing tank 55 for introducing compressed air into the cavity C. The pressure increasing tank 55 includes an air supply pipe 551 and an air pipe 523 in the core mold 52. By communicating, compressed air is supplied from the pressure increasing tank 55 into the cavity C when the molding die 50 is clamped. Furthermore, an air discharge groove 524 is provided at the periphery of the core mold 52, and the air in the cavity C is discharged to the outside when the resin core material 21 is molded. A hot blade 525 for cutting off and removing the excess portion of the skin 22 is provided on the peripheral edge of the parting surface of the core mold 52.

  Next, each step (1) to (3) in the method for forming the door trim upper 20 using the forming apparatus 40 shown in FIG. 3 will be described below.

(1) Heating Step of the Skin 22 As shown in FIG. 4, the skin 22 is wound around the skin roll 70, and the skin roll 70 is set above the heater 60. And if the drawing end of the skin 22 is pulled down from this skin roll 70 and the drooping state of the skin 22 is maintained in the heater 60, the front and back sides of the skin 22 are heated by the heater 60. 22 is heat-treated at an arbitrary temperature. The heat-treated skin 22 is further suspended and supplied between the cavity mold 51 and the core mold 52.

(2) Vacuum / Pneumatic Forming Process of Skin 22 When the cavity mold 51 and the core mold 52 are in the mold open state, the skin 22 suspended from the skin roll 70 is heated to a predetermined temperature by the heater 60 and molded into a mold. Inserted into the mold 50. Then, as shown in FIG. 5, the cavity mold 51 approaches the core mold 52 by driving the cylinder 511, and the cavity mold 51 and the core mold 52 are clamped. Further, after clamping the mold, the vacuum suction mechanism 53 of the cavity mold 51 is driven to apply a vacuum suction force to the skin 22 and to inject compressed air into the cavity C from the pressure increasing tank 55 attached to the core mold 52. Thus, the skin 22 is formed into a required shape by vacuum / pressure forming. In addition, the drawing pattern attached to the mold surface of the cavity mold 51 is faithfully transferred to the surface of the skin 22. At this time, the surplus portion of the skin 22 is removed by breaking with the hot blade 525.

(3) Integration Step of Resin Core Material 21 and Skin 22 Thereafter, as shown in FIG. 6, the molten resin M is supplied from the injection unit 54 to the hot runner 521 and the gate 522 on the back side of the skin 22 formed into a required shape. The resin core material 21 is injection-filled into the cavity C through the desired shape, and the resin core material 21 is injection-molded into a required shape, and the resin core material 21 and the skin 22 are firmly integrated by the resin heat at this time. At this time, the air in the mold is discharged to the outside through the air discharge groove 524 provided on the periphery of the core mold 52. Therefore, the door trim upper 20 having excellent appearance performance can be easily molded with simple equipment using the single molding die 50.

  Further, after forming the door trim upper 20 using the molding die 50, as shown in FIG. 7, the winding trim 23 along the peripheral edge of the outer skin 22 is wound, so that the door trim upper 20 is finally obtained. Is completed. At this time, since no adhesive is used in the method of the present invention, the winding scissors 23 are fixed to the peripheral back surface of the resin core material 21 by heat welding or via a fixing tool such as staples.

  Thus, if the method of the present invention is applied to the molding method of the door trim upper 20, the following special effects can be expected. That is, according to the method of the present invention, the skin 22 is formed by vacuum / compression molding and integrated with the skin 22 when the resin core material 21 is injection-molded. And the adhesive curing process can be abolished, and the number of man-hours can be greatly reduced, and the stock storage space for work in progress can be saved, resulting in variations in performance due to adhesive application variations, skin floats and peeling, etc. This eliminates this problem and can greatly improve productivity.

  In addition, VOCs caused by organic solvents in solvent-based adhesives can be reduced, the work environment and the interior of the vehicle interior can be maintained well, large ventilation equipment, etc. can be dispensed with, contributing to simplification of equipment. . In addition, the door trim upper 20 can be molded in a short time by continuously performing vacuum / pressure forming of the skin 22 and the injection molding process of the resin core material 21 using a single mold 50. In addition, since the drawing pattern can be accurately transferred to the surface of the product by performing vacuum / pressure forming on the skin 22, the door trim upper 20 having excellent appearance performance can be formed in a short time.

  In the embodiment described above, the method of the present invention is applied to the molding method of the door trim upper 20 in the door trim 10, but it can be applied to all laminated molded products in which the skin 22 is laminated on the surface of the resin core material 21.

DESCRIPTION OF SYMBOLS 10 Automotive door trim 20 Door trim upper 21 Resin core material 22 Skin 30 Door trim lower 40 Molding device 50 Molding die 51 Cavity mold 511 Cylinder 512 Drawing pattern 52 Core mold 521 Hot runner 522 Gate 523 Air piping 524 Air discharge groove 525 Hot blade 53 Vacuum suction mechanism 54 Injection unit 55 Pressure increasing tank 551 Air supply pipe 60 Heating heater 70 Skin roll C Cavity M Molten resin

Claims (2)

Laminated molded product (21) composed of a resin core (21) molded into a required shape in a molding die (50) and a skin (22) laminated and integrated on the surface of the resin core (21) 20) In the molding method,
A heater (60) is disposed above the molding die (50), and the skin (22) is drawn downward from the skin roll (70) set above the molding die (50) and supplied into the molding die (50). Before, the heating step of the skin (22) heat-treated to a predetermined temperature by the heater (60) located above the molding die (50),
The heated skin (22) is suspended between the cavity mold (51) and the core mold (52), the cavity mold (51) and the core mold (52) are clamped, and then the mold (50) The vacuum suction mechanism (53) and the pressure pneumatic mechanism (55) disposed in the upper surface are driven to form the outer skin (22) into a required shape so as to follow the mold surface shape of the cavity mold (51). Vacuum and pressure forming process,
An operation of injecting and filling the molten resin (M) into the cavity (C) formed between the skin (22) and the core mold (52) from the injection unit (54) connected to the core mold (52) ; With the operation of discharging the compressed air supplied into the cavity (C) by driving the compressed air mechanism (55) to the outside from the air discharge groove (524) , the resin core material (21) is molded into a required shape, An integration step of laminating and integrating the skin (22) on the surface of the resin core (21) by thermal fusion;
A method for forming a laminated molded product comprising: In the molding device (40) of the laminated molded product (20) formed by laminating and integrating the skin (22) on the surface of the resin core material (21),
Said forming device (40) is slid laterally, mutually clamping, the cavity mold that can mold opening (51) and a core mold (52) consisting of a molding die (50), the molding die ( A heater (60) provided above 50) and a skin roll (70) positioned and set above the heater (60) ,
The skin (22) pulled out from the skin roll (70) is heat-treated at a predetermined temperature by a heater (60) and droops between the cavity mold (51) and the core mold (52),
The cavity mold (51) is provided with a vacuum suction mechanism (53) for vacuum suction of the skin (22) ,
The core mold (52) is molded into the required shape by supplying compressed air to the cavity (C) formed between the skin (22) and the core mold (52). A pneumatic mechanism (55) and a gate (522) for injecting and filling molten resin (M) into the cavity (C) ,
Further, the molding device (40) includes an air discharge groove (524) for discharging the compressed air in the cavity (C) to the outside when the molten resin (M) is injected and filled into the cavity (C). An apparatus for forming a laminated molded product characterized by the above.

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