JP6910705B2 - Manufacturing method of multi-layer member - Google Patents

Description

The present invention relates to a method for manufacturing a multi-layer member.

As a multi-layer member molded by a two-color molding method or the like, for example, an instrument panel of a passenger car is provided with pseudo-stitches colored differently from the main part of the design surface for the purpose of improving the design. .. This pseudo-stitch expresses a shape like a seam of a thread by intermittently forming a linear ridge portion protruding toward the design surface side when the multi-layer member is formed.

Various methods have already been invented as a method for manufacturing such a multi-layer member. For example, Patent Document 1 discloses a method for manufacturing a multi-layer panel member made of a resin material and a foam material, and a pseudo stitch is formed by the foam material.

In the manufacturing method of Patent Document 1, as shown in FIG. 9A, the panel member is molded by the first molding die 100 having the concave groove portion 100a and the second molding die 101. A first cavity 102 is defined between the first molding die 100 and the second molding die 101.

First, a resin material is injected into the first cavity 102 and cured in the cavity to form a base material 110 (see FIG. 9b). At this time, the ridge portion 110a is formed by the resin material injected into the concave groove portion 100a.

Next, as shown in FIG. 10A, while maintaining the state in which the ridge portion 110a is fitted into the recessed groove portion 100a, the entire first molding die 100 and the second molding die 101 are attached to the ridge portion 110a. The first core back is performed so that they are relatively separated along the projecting direction. By this first core back, a second cavity 103 is defined between the first molding die 100 and the second molding die 101. Then, the second cavity 103 is filled with a foaming material (see FIG. 10b), and the skin layer 111 is formed. At this time, the ridge portion 110a fitted in the concave groove portion 100a prevents the foaming material from entering the concave groove portion 100a.

Then, as shown in FIG. 10C, when the filling of the foaming material is completed, the first molding die 100 and the entire second molding die 101 are relatively separated along the projecting direction of the ridge portion 110a. A third cavity 104 is defined by expanding the second cavity 103. The foam 112 is formed by foaming and expanding the foam material in the third cavity 104.

As shown in FIG. 11, the panel member 120 having a two-layer structure of the base material 110 and the foam 112 can be molded by the above manufacturing method. The design surface side of the panel member 120 is covered with the foam 112, and a plurality of ridges 110a exposed from between the foam 112 form pseudo stitches.

Japanese Unexamined Patent Publication No. 2012-139966

Like the panel member of Patent Document 1, in order to expose the ridge portion 110a from between the foams 112 to the design surface side to form a pseudo stitch, a concave groove portion 100a for forming the ridge portion 110a is provided. When it is provided in the molding die and when the foam 112 is formed, it is necessary that the concave groove portion 100a is closed so that the foam material does not invade the concave groove portion 100a.

On the other hand, in the manufacturing method of Patent Document 1, when the layer of the base material 110 having the ridge portion 110a is first molded and the foaming material is injected into the molding mold, the formed ridge portion 110a is concave. By closing the groove 100a, the foam material is prevented from entering the concave groove 100a (see FIG. 10b).

However, the ridge portion 110a is formed by cooling and hardening the resin material injected into the concave groove portion 100a, and the shrinkage of the ridge portion 110a due to this cooling causes the ridge portion 110a and the concave groove portion 100a to be formed. There is a gap between them. When such a gap is generated, the ridge portion 110a cannot sufficiently prevent the foaming material from entering the concave groove portion 100a, and there is a possibility that the ridge portion as described above cannot be formed correctly.

Further, in the method of Patent Document 1, after performing the first core back to fill the second cavity 103 with the foaming material (see FIGS. 10a and 10b), the second core back is performed to perform the third cavity. 104 is defined, and then the foam 112 is formed by foaming and expanding the foam material (see FIG. 10c). As described above, a two-step core back is required for molding the foam 112, and the number of steps for molding the multi-layer member is increased.

On the other hand, it is also possible to fill the second cavity 103 with a non-foaming material such as a resin material as the second material, omit the step of foaming and expanding the foaming material, and form the second layer with one core back. Conceivable. However, in this case, the second material is injected with only the tip of the ridge 110a inserted into the recess 100a (see FIG. 10c), and the recess 100a is formed only by the tip of the ridge 110a. Considering that the ridge portion 110a must be closed and the above-mentioned shrinkage of the ridge portion 110a is taken into consideration, it becomes more difficult to prevent the second material from invading the concave groove portion 100a.

Therefore, an object of the present invention is to provide a method for manufacturing a multi-layer member capable of forming a ridge portion without requiring a complicated process.

In order to solve the above problems, the present invention relates to a method for manufacturing a multilayer member having a first molded layer having a design surface and a second molded layer having linear ridges exposed on the design surface. , A flat portion, a linear recess that is concave with respect to the flat portion and for forming the ridge portion, and a linear recess that is provided on the opposite side of the flat portion with the flat portion interposed therebetween, with respect to the flat portion. By molding the first molding die having another concave recess and the second molding die having a linear convex portion, the first cavity is defined in a state where the convex portion closes the concave portion. Then, the step of the other concave portion and the flat portion facing the first cavity, the step of injecting the first material into the first cavity to form the first molding layer, and the first molding mold. By moving all or a part of one of the second molding dies to the side away from the other molding dies, the convex portion is separated from the concave portion, and the first molding dies and the first molding dies are separated from each other. between the secondary mold and the step of defining a second cavity, possess a step of forming a second molded layer by injecting a second material into the second cavity, the first mold, the The flat surface portion and the other concave portion are provided on either one side or both sides of the linear concave portion in a direction intersecting the linear direction with respect to the concave portion .

In such a configuration, a recess for forming a ridge portion is provided on the side of the first molding die. Then, after molding the first molding layer having the design surface, the second molding layer having the ridge portion is molded. By forming the ridge portion afterwards, the concave portion can be closed by the convex portion provided in the second molding mold when the first molding layer is molded. In this way, by closing the recesses by contact between the molding dies, there is no gap between the recesses due to shrinkage after molding, as compared with the case where the recesses are closed by a part of the multi-layer member. , The intrusion of the first material into the recess can be prevented more reliably. Further, since the second cavity can be defined and the second molding layer can be molded by moving the molding die once, a complicated manufacturing process is not required.

According to the present invention, it is possible to prevent the first material from entering the recess by closing the recess by contact between the molds. Further, since the second cavity can be defined and the second molding layer can be formed by moving the molding die once, the ridge portion can be formed without requiring a complicated process.

It is a perspective view which shows the appearance of an instrument panel. FIG. 1 is a cross-sectional view taken along the line AA of FIG. FIG. 2 is a cross-sectional view taken along the line BB of FIG. It is sectional drawing which shows the molding mold of a panel of the part corresponding to FIG. It is sectional drawing which shows the molding mold of a panel of the part corresponding to FIG. It is sectional drawing of the molding die which shows the state at the time of molding | molding the 1st molding layer. It is sectional drawing of the molding mold which shows the state at the time of drawing a 2nd cavity. It is sectional drawing of the molding die which shows the state at the time of molding the 2nd molding layer. It is sectional drawing which shows the manufacturing method of the conventional multi-layer member. It is sectional drawing which shows the manufacturing method of the conventional multi-layer member. It is a perspective view which shows the conventional multi-layer member.

Hereinafter, embodiments according to the present invention will be described with reference to the drawings. In each figure, the same or corresponding parts are designated by the same reference numerals, and the duplicated description thereof will be appropriately simplified or omitted.

As shown in FIG. 1, the panel 1 includes a first molding layer 2 formed of a first resin material (first material) and a second molding layer 3 formed of a second resin material (second material). The first molded layer 2 and the second molded layer 3 are colored differently. On the side of the design surface 1a of the panel 1, linear ridges 3a are intermittently provided to form pseudo-stitches having a shape as if sewn with a thread.

FIG. 2 shows a cross-sectional view taken along the line AA of FIG. 1, and FIG. 3 shows a cross-sectional view taken along the line BB of FIG. As shown in FIG. 2, both the first molding layer 2 and the second molding layer 3 form a design surface, and a part of the second molding layer 3 wraps around to the back side of the first molding layer 2. It is provided in. Then, as shown in FIG. 3, the second forming layer 3 that wraps around to the back side is partially exposed from between the first forming layers 2 to the design surface side to form the ridge portion 3a.

In the present embodiment, the first molding layer 2 and the second molding layer 3 are molded by a two-color molding method by injection molding, and the panel 1 is molded. Hereinafter, a method for manufacturing the panel 1 will be described.

4 and 5 are cross-sectional views showing a state of the molding die for molding the panel 1 before molding the panel 1, FIG. 4 shows a cross section of the molding die corresponding to the portion of the panel 1 of FIG. 2, and FIG. 5 shows a cross section of the molding die. It shows the cross section of the molding die corresponding to the part of the panel 1 of FIG.

As shown in FIGS. 4 and 5, fixed molds 10 as a first molding mold and movable molds 20 as a second molding mold are provided as molding molds for molding the panel 1.

The fixed mold 10 has a first molding surface 10a for molding the design surface of the first molding layer 2 and a second molding surface 10b for molding the design surface of the second molding layer 3. Further, as shown in FIG. 5, the fixed mold 10 has a recess 10c for forming a ridge portion. The recess 10c has a tapered surface 10c1 that extends toward the movable mold 20 side.

As shown in FIGS. 4 and 5, the movable type 20 has a main type 21 and a slide type 22. The main mold 21 has a first molding surface 21a for molding the back surface of the second molding layer 3 and a second molding surface 21b for molding the back surface of the first molding layer 2. The slide mold 22 has a molding surface 22a for molding the back surface of the second molding layer 3. The slide type 22 is movable with respect to the main type 21, and can move in a direction away from the fixed type 10 (downward in FIG. 5). As shown in FIG. 5, a convex portion 22b is provided on a part of the molding surface 22a. The convex portion 22b has a tapered surface 22b1 that extends toward the side of the main mold 21.

Next, the steps of molding the panel 1 will be described in order with reference to FIGS. 5 to 8. Note that FIGS. 6 to 8 use the same cross section as that of FIG.

As shown in FIG. 5, first, by molding the fixed mold 10 and the movable mold 20, the fixed mold 10 and the movable mold 20 come into contact with each other. In this state, the first cavity 30 is defined between the fixed mold 10 and the movable mold 20. Further, the convex portion 22b of the slide type 22 is inserted into the concave portion 10c so that the tapered surface 10c1 and the tapered surface 22b1 are fitted to each other, and the concave portion 10c is closed.

In this state, the first resin material softened by heating is injected (injected) into the first cavity 30. Then, as shown in FIG. 6, the first resin material filled in the first cavity 30 is cooled and cured to form the first molding layer 2.

When the first molded layer 2 is molded, the concave portion 10c is closed by the convex portion 22b to prevent the first resin material from entering the concave portion 10c, and the first forming layer 2 is formed with a ridge portion. Not done. In this way, by closing the recess 10c by the contact between the molding dies, for example, as compared with the case where the recess 10c is closed by the member to be molded (panel 1 in this embodiment), the member shrinks after molding. It is possible to form a configuration in which there is no gap between the concave portion 10c and the convex portion 22b as much as possible.

Further, in the present embodiment, the convex portion 22b and the concave portion 10c are surely brought into contact with each other by fitting the tapered surface 22b1 of the convex portion 22b and the tapered surface 10c1 of the concave portion 10c to close the concave portion 10c. It is possible to prevent the first resin material from entering the recess 10c.

With the configuration of the present embodiment as described above, it is possible to more reliably prevent the first resin material from entering the recess 10c during molding of the first molding layer 2. As a result, even if the first resin material is injected at a higher pressure, it is possible to prevent the resin material from invading the recess 10c, so that the first resin material can be injected at a higher pressure. Therefore, even if the first forming layer 2 (see FIG. 1) has a complicated shape in which a plurality of holes are formed in the portion corresponding to the ridge portion 3a, the first resin is formed in the first cavity 30 at the time of forming. The material can be sufficiently distributed.

Next, as shown in FIG. 7, after molding the first molding layer 2, the slide mold 22 is moved away from the fixed mold 10 in the mold opening direction (in the direction of the arrow in the figure) to cause the second cavity. 31 is defined. By this movement, the convex portion 22b is separated from the concave portion 10c, and the concave portion 10c is opened to the second cavity 31.

When the movement of the slide mold 22 is completed, the second resin material is injected into the second cavity 31. Then, as shown in FIG. 8, the second resin material filled in the second cavity 31 is cooled and cured to form the second molding layer 3. At this time, the ridge portion 3a is formed by the second resin material filled in the recess 10c.

As described above, the instrument panel 1 composed of two layers, the first forming layer 2 and the second forming layer 3 having the ridge portion 3a, can be formed.

By molding the panel 1 by the two-color molding method in this way, the ridge portion 3a can be formed by coloring differently from that of the first molding layer 2, and the pseudo stitch can be distinguished from the surroundings and conspicuous. It is possible to expand the range of expression of pseudo stitches.

Further, by defining the second cavity 31 using the slide mold 22 as described above, the range in which the second molding layer 3 is molded corresponds to the entire parting surface of the fixed mold 10 and the movable mold 20. Instead, it can be provided on a part of it. As a result, the second molded layer 3 can be provided in the minimum necessary range, which not only increases the degree of freedom in design, but also wastes the second resin material and wastes energy for molding the second molded layer. Can be eliminated. In the present embodiment, the second forming layer 3 forms a part of the design surface, but for example, the second forming layer 3 may be provided only in the range where the ridge portion 3a is formed. ..

Further, when molding the second molded layer 3, the second cavity 31 can be defined and the second molded layer 3 can be molded only by the operation of moving the slide mold 22 as described above. Therefore, the second molding layer 3 can be molded by a simpler method without replacing the molding molds or requiring a plurality of different steps for defining the second cavity 31. It is possible to save energy and time for molding the panel 1.

By the way, when the slide mold 22 is provided as a part of the movable mold 20, the second resin material enters between the main mold 21 and the slide mold 22 (see the portion X in FIG. 8) and enters the second molding layer 3. There is a risk of burrs. However, in the present embodiment, since the slide type 22 is provided on the back surface side of the panel 1, it is possible to prevent burrs from occurring on the design surface side.

Further, as in the present embodiment, by making a part of the movable type 20 a slide type 22, the slide type 22 is moved in a direction different from the mold opening direction of the movable type 20 to define the second cavity 31. You can also do it. As a result, the protruding direction of the convex portion 22b, that is, the protruding direction of the ridge portion 3a can be set to a direction different from the mold opening direction. The degree of freedom in designing the ridges is increased, such as being able to incline with respect to the mold opening direction.

When the second resin material flows into the second cavity 31 and the second molding layer 3 is molded, as shown in FIG. 8, the first molding layer 2 has a structure having a recess on the back side thereof. , The second resin material flows into the back side portion and presses the first molded layer 2 from the back side (see the arrow in FIG. 8). As a result, it is possible to prevent a gap from being formed between the first molded layer 2 and the fixed mold 10, and to more reliably prevent the second resin material from invading the design surface side of the first molded layer 2.

Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and it goes without saying that various modifications can be made without departing from the gist of the present invention.

In the above embodiment, as shown in FIG. 1, the ridge portion 3a is provided so as to intermittently project from between the first forming layers 2, but the ridge portion 3a is continuously provided. It may be composed of only one line portion. Further, the line portion is not limited to the line portion in one direction, but may be a line portion extending in a plurality of directions, and a necessary shape can be appropriately selected as the shape of the ridge portion.

In the above embodiments, the first resin material and the second resin material are different colored materials, but the present invention is not limited to this, and materials having different materials and physical properties may be used.

In the above embodiment, the slide type 22 is provided in a part of the movable type 20, and the second cavity 31 is defined by the movement of the slide type 22. However, it is not always necessary to provide the slide type 22, and the second cavity 31 may be defined by core backing the entire movable type 20.

Further, the slide type may be provided on the side of the fixed type, and the movable type may be provided with a recess. In this case, the convex portion of the slide type closes the concave portion of the movable type, and the slide type moves to the side away from the movable type, so that the convex portion separates from the concave portion and the second cavity is defined.

1 Instrument panel (multi-layer member)
1a Design surface 2 First molding layer 3 Second molding layer 10 Fixed mold (first molding mold)
10c recess 10c1 tapered surface 20 movable type (second molding type)
21 Main type 22 Slide type 22b Convex part 22b1 Tapered surface 30 First cavity 31 Second cavity

Claims (1)

In a method for manufacturing a multi-layer member having a first molded layer having a design surface and a second molded layer having linear ridges exposed on the design surface.
A flat surface portion, a linear concave portion that is concave with respect to the flat surface portion and for forming the ridge portion, and a linear concave portion that is provided on the opposite side of the flat surface portion so as to sandwich the flat surface portion and are provided on the opposite side to the flat surface portion. By molding the first molding die having another concave recess and the second molding die having a linear convex portion, the first cavity is defined in a state where the convex portion closes the concave portion. Then, the step of the other concave portion and the flat surface portion facing the first cavity, and
The step of injecting the first material into the first cavity to form the first molding layer, and
By moving all or a part of one of the first molding die and the second molding die to the side away from the other molding die, the convex portion is separated from the concave portion, and the convex portion is separated from the concave portion. The process of defining the second cavity between the first molding die and the second molding die,
Possess a step of forming a second molded layer by injecting a second material into the second cavity,
The first molding mold is a multi-layer member having the flat surface portion and the other recesses on either one side or both sides of the linear recesses in a direction intersecting the linear direction with respect to the recesses. Production method.

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