JPH0313970B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION As shown in FIG. 1a or FIG. The present invention relates to an apparatus for manufacturing a composite molded body A consisting of a three-layer laminated skin material layer 2.

The base layer 1 is made of hard or semi-hard synthetic resin, resin bead foam, or the like. The skin material layer 2 is made of a soft solid or foamed sheet, synthetic leather, woven fabric, knitted fabric, non-woven fabric, or the like. The intermediate material layer 3 is made of synthetic resin foam, felt, or the like.

The composite molded product A having the layered structure described above can be used, for example, in vehicle interior parts such as door trim boards, front seat back panels, ceiling lining boards, instrument panels, etc., as well as various interior materials for architecture, furniture,
It is often used for exterior parts of electrical appliances, etc.

Conventional methods for producing the composite molded body A can be roughly divided into a board molding method in which each layer is laminated in one piece, and a method in which each layer is laminated sequentially.

In the former method, each constituent layer 1, 2, or 1,
A laminated flat plate made by bonding 3 and 2 together is used as a material and is formed into a desired shape by thermoforming (vacuum forming, pressure forming, plug forming, etc.), press molding, etc.

In the latter method, the material of the base layer 1 is molded into the desired shape by an appropriate means, and then the skin material layer 2 or the intermediate material layer 3 is formed manually according to the surface shape of the molded base layer 1. The skin material layer 2 is sequentially
Alternatively, the intermediate material layer 3 and the skin material layer 2 which have been previously pasted together are pasted together. Alternatively, a product is obtained by covering the surface of the molded base layer 1 with the material 2 or 3, 2 in a sewing-wrapping manner.

However, the former method of forming a board by laminating each layer in one piece: ●Since the constituent layers 1, 2, or 1, 3, and 2 of the material board have different properties from each other, when the board is formed by thermoforming. It takes a high degree of skill, skill, and time to heat-soften the board uniformly and well throughout the process. Regardless of whether the forming is done by thermoforming or press forming, the thickness of the finished board will vary. As the thickness of the material becomes thicker, the overall shape of the molded product inevitably becomes so-called vague. 2 or 1, 3, and 2, it is impossible in most cases to remelt it and recycle it as a raw material, resulting in a low material utilization rate and high product cost. In many cases, a molded product is made into a final product by trimming the outer periphery, but if only the trimming is performed, the laminated cross section of each layer will be exposed on the cut surface, that is, the outer peripheral end surface of the composite molded product A, and the appearance of each layer will be poor. is likely to turn over from this cross section and cause peeling.
Therefore, in cases where the cut surface needs to be hidden, it is common practice to attach a separately produced molding material around the edge of the trimmed molded body to hide the cut surface and make the final product, but the process for attaching the molding material This requires materials and labor, resulting in high costs. Furthermore, the edges of the molded body are often framed with molding material, which is not preferred as a form.

There are drawbacks such as.

On the other hand, the latter method of laminating each layer sequentially requires manual labor and is low in productivity.Moreover, in cases where the surface has a complex uneven surface shape, the intermediate material layer 3 and the skin material layer 2 must be placed on one base layer with the complex uneven surface shape. This method has the disadvantage that it becomes difficult or impossible to make beautiful bonding of each part in close contact with each other, and it is an inefficient method that is limited to manufacturing small quantities of relatively simple-shaped articles.

The present invention was proposed in view of the above, and although it is classified as a method of laminating each layer sequentially, it combines a vacuum forming method, an injection molding method, a pressure molding method, or a resin bead foam molding method. Through a series of continuous processes, even products with complex uneven shapes can be efficiently mass-produced according to the designed shape with less material loss. The present invention provides an automatic manufacturing apparatus for this type of composite molded body, which has other major features, such as being able to easily obtain a composite molded body in which the edges are neatly hidden and edged with a continuous thin coating layer 4. The purpose is to provide.

A detailed explanation will be given below based on an embodiment of the apparatus shown in the figure.

In this example device, the base layer 1 is molded by a resin injection molding method, and the skin material layer 2 is vacuum-formed using a synthetic resin foamed cushion sheet 3 pasted as an intermediate material layer on the back surface of the skin material layer 2. However, the composite molded body A is obtained by closely fitting and joining the molded base layer 1, molded skin layer 2+cushion material layer 3 together.

Figure 2 is an overall plan view of the device, Figure 3 is the third
Fig. 4 is a partially cutaway side view of the mechanism for advancing and retracting and rotating the third mold, and Fig. 5 is a partially cutaway front view of the injection molding mechanism with the mold advanced. FIG. 3 is a front view of the transport mechanism portion.

This example equipment is broadly divided into injection molding mechanisms (horizontal type).
It consists of three mechanical parts: a third mold advancing/retracting/rotating mechanism, and a material sheet heating/conveying mechanism.

Injection molding mechanism (Figures 2 and 3) Reference numerals 5 and 6 are a pair of first and second molds for resin injection molding to form the base layer 1 of the composite molded object A, and when the molds are clamped together, the base layer is inside. A cavity with a spatial shape corresponding to layer 1 is constructed.
In this example, the first mold 5 is a mold for molding the front side of the base layer 1, and is firmly attached to and held by a fixed die plate 8. The second mold 6 is a mold for molding the back side of the base layer 1, and is firmly attached to and held by a movable die plate 9. The movable die plate 9 is supported by four horizontal tie bars 10 in the upper, lower, left, and right directions, and is driven forward or backward with respect to the fixed die plate 8 along the tie bars 10 as a ram 12 of a hydraulic device 11 advances or retreats.

That is, when the movable die plate 9 is driven forward in a state in which the vacuum forming die 7 as a third forming die, which will be described later, is released from between the first and second forming dies 5 and 6 to the side, the movable die plate 9 is fixed. The first on the die plate 8 side
The second mold 6 is butted against the mold 5, and both the molds 5 and 6 are in a clamped state. Conversely, when the movable die plate 9 is driven backward, the mold is opened.

Reference numeral 13 denotes a nozzle part of a resin injection (or pressure feeding) device, which is not shown in the figure, and is fitted into the insertion hole of the fixed die plate 8 from the back side of the plate, and the resin injection hole at the tip is connected to the sprue 52 of the first mold 5. Connection is communicating.

51 is the molding surface of the first mold 5, 53 is the mold mating surface (butting surface) with the second mold, and 54 is the first molding surface.
A cooling water pipe buried within the wall thickness of the mold 5, 61 a molding surface of the second mold, 62 a mold mating surface with the first mold 5 or a third mold 7 to be described later, and 63 a second mold Ejector pin built into 6, 64
65 is the hydraulic unit for advancing and retracting the pin (disposed inside the ram 12 for moving the movable die plate forward and backward), and 65 is the second hydraulic unit for moving the pin forward and backward.
This is a cooling water pipe buried within the thickness of the mold 6.

The hydraulic device 11 drives the movable die plate 9 forward based on a mold clamping signal from a control circuit (not shown), and the second mold 6 is brought into a mold clamping state with the first mold 5 or a third mold 7 to be described later. A sensor (not shown, micro switch,
Further forward driving of the movable die plate 9 is stopped by a signal from a photoelectric sensor/timer circuit, etc. (the same applies hereinafter). Furthermore, the movable die plate 9 is driven backward by a mold opening signal from the control circuit, and when the second mold 6 has retreated to a predetermined retreat position, a signal from a sensor (not shown) that detects this causes the movable die plate 9 to move further. Stop the reverse drive.

3rd mold forward/backward movement/rotation mechanism (2nd, 3rd, 4th
Figure) 7 is a vacuum molding mold as a third molding mold for molding the laminated sheet materials 2 and 3 of the skin material layer + cushion material layer, and this third molding mold 7 is a vacuum molding mold 7 that is used when the injection molding mechanism is opened. The molding surface 71 is placed between a pair of upper and lower guide rails 14, 14, which are disposed laterally in the upper and lower portions between the first and second molds 5, 6, perpendicular to the advancing and retracting direction of the second mold 6. It is engaged and held in a vertical position on the side of the mold 6 so as to be able to freely slide. The rod 16 of the advance/retreat rod device 15 is driven forward and pushed, and moves along the guide rails 14, 14 between the first and second molds 5, 6 in the open state.

Conversely, when the rod 16 is driven backward, it is pulled and moves backward from between the first and second molds 5 and 6 in the opened state to the side.

The advancing/retracting rod device 15 has a rod 16 formed with rack teeth 17 on its longitudinal side and supported by a bearing support 18 so as to be able to slide freely in the longitudinal direction.
A pinion 19 driven by a forward/reverse motor M1 is meshed with the rack teeth 17 of No. 6.

Reference numerals 20 and 21 denote outwardly protruding shafts that are integrally provided at the central portions of the front end side surface and the rear end side surface of the third mold 7 so that their axes coincide with each other, and the front end shaft 20 is provided between the upper and lower guide rails 14, The rear end shaft 21 is rotatably connected and held to the center portion of the sliding column 22 which is engaged and held by the rear end shaft 21. 23
2 is a friction wheel fixed to the rear end side shaft 21, and 24 is a friction wheel driven by a forward/reverse rotation motor M2.

The motor M1 is driven in normal rotation based on the third mold advance signal from the control circuit to move the rod 16 forward. As a result, the third mold 7 moves along the guide rails 14, 14 between the first and second molds 5, 6 in the open state. When the third mold 7 moves forward to a position exactly facing the second mold 6, a signal from a sensor (not shown) that detects this causes the motor M1 to rotate forward, that is, the third mold 7 is driven forward. will be stopped.

Further, this motor M1 is driven in the reverse direction based on a third mold retraction signal from the control circuit to move the rod 16 backward. As a result, the third mold 7 moves along the guide rails 14, 14 to the first and second molds 5,
Move backward from 6 to the side. Then, the third mold 7 eventually comes off from the guide rails 14, 14 (shown by two-dot chain lines in Figures 2 and 4), and the friction wheel 23 fixed to the rear end side shaft 21 of the mold 7 moves toward the motor M2. comes into pressure contact with the friction wheel 24 of. When the third mold 7 moves backward to reach this state, a sensor (not shown) that detects this stops the reverse drive of the motor M1, that is, the backward drive of the third mold 7.

After the backward movement of the third mold 7 is stopped, the motor M2 is driven to rotate forward based on the third mold tilting rotation signal from the control circuit to rotate the friction wheel 23, that is, the shaft 21 on the third mold 7 side, as shown in FIG. Rotate clockwise. This causes the third mold 7 to rotate clockwise around the shafts 21, 21. When the third mold 7 rotates through 90 degrees and is received by the stopper member 25, the forward rotation of the motor M2 is stopped by a signal from a sensor (not shown) that detects this.
By rotating this third mold 7 by 90 degrees, the mold 7
is in a substantially horizontal position with the molding surface 71 side facing upward (second,
4 and 5) (solid line shown in Figures 4 and 5).

In addition, when the motor M2 is driven in the reverse direction based on the third mold raising rotation signal from the control circuit in this posture, the third mold 7 is reversely rotated by 90 degrees in the counterclockwise direction, and the stopper member 26 rotates the third mold 7. When the rotation is received, a signal from a sensor (not shown) that detects this stops the reverse rotation of the motor M2. This 90° reverse rotation of the third mold 7 returns the mold 7 to its initial vertical position.

72 is a mold mating surface of the third mold 7 with the second mold 6; 73 (FIG. 3) is a large number of vacuum holes opened in the molding surface 71 and the mold mating surface 72 of the third mold 7; 74; is a cooling water pipe buried within the mold wall thickness.

Material sheet heating and conveying mechanism (Figs. 2 and 5) 27, 27 are a pair of parallel horizontal rails arranged in the left-right direction above the 90° rotation part of the third mold 7, 28 are the four corners of the upper surface Colo 2 placed in
9 is engaged with the rails 27, 27, and is arranged and supported substantially horizontally below the rails 27, 27.
A material sheet heating board mounting board that can be freely moved left and right along the rails 27, 27; 30 is the board 2;
A rack bar 8 has a distal end integrally connected to the center of the rear side thereof, and 31 is a pinion meshed with the rack bar, and the pinion is rotationally driven by a forward/reverse motor M3. When the pinion 31 is driven to rotate normally, the plate 28 is pushed by the forward motion of the rack bar 30 and moves forward to the left in FIG. 2 along the rails 27, 27. Conversely, when the pinion 31 is driven in the reverse direction, the disk 28 is pulled by the backward movement of the rack bar 30 and moves backward to the right along the rails 27, 27.

Reference numeral 32 is a hydraulic rod device in which a forward/retractable rod 33 is disposed downwardly at approximately the center of the upper surface of the panel 28 and protrudes from the lower surface of the panel 28. Reference numeral 34 is a hydraulic rod device having an approximately central portion of the upper surface connected to the lower end of the forward/retractable rod 33. The material sheet heating plates 35 are supported substantially horizontally, and the material sheet heating plates 35 are erected at the four corners of the upper surface of the material sheet heating plates, and the upper and lower material sheet heating plates 35 are respectively inserted into through holes drilled at the four corners of the mounting plate 28. It is a moving guide rod. Therefore, the advancing and retracting rod 3 of the hydraulic rod device 32
When the rod 3 is moved protrudingly, the material sheet heating plate 34 descends downward without rotation in a substantially horizontal position, and conversely, when the rod 33 is moved backward, the plate 3
4 moves upward. The material sheet heating plate 34 has a planar shape that is approximately the same size and shape as the material sheet, and has a heat source such as an electric heating element 36 and a steam pipe arranged within its wall thickness, and a number of small vacuum suction holes 37 on the bottom surface. has been formed.

Reference numeral 38 denotes a material sheet mounting table disposed to the right of the 90° rotating portion of the third mold 7, on which the material sheet, that is, the skin material layer 2 and the cushion material layer 3 are laminated in advance. A large number of cushioning material layers are stacked and set with the three surfaces of the cushioning material layers facing upward.

The material sheet heating plate 34 is always in a standby position right above the material sheet mounting table 38 as its home position. When a sheet material holding signal is issued from the control circuit in this state, each vacuum hole 37 on the bottom surface of the board 34 enters the air suction state, and the hydraulic rod device 32 is driven in the direction of the rod's downward protrusion, causing the board 34 to move downward. and the bottom surface is platform 3
The entire surface of the stacked material sheet on 8 is pressed into close contact with the upper surface. When detected by this pressure contact sensor (not shown), the hydraulic rod device 3
2 is switched and driven in the backward movement direction of the rod, and the plate 3
4 moves upward. At this time, only one of the stacked material sheets 2 and 3 on the table 38 is held in close contact with the entire bottom surface of the board by the vacuum suction force of the vacuum hole 37 on the bottom surface of the board and lifted.

When the board 34 rises to the initial position and returns, this is detected by a sensor (not shown), and the rod backward drive of the hydraulic rod device 32 is stopped in response to a signal from the sensor (not shown). Next, normal rotation of the motor M3 is started, and the rack bar 30 moves forward. As a result, the board 34 moves forward to the left along the rails 27, 27. When the plate 34 reaches directly above the third mold 7, which is converted into a horizontal position and held in the 90° rotating movement part of the third mold, it is detected by a sensor (not shown), and a signal is generated. As a result, the normal rotation drive of the motor M3, that is, the forward drive of the board 34 is stopped.

Next, the hydraulic rod device 32 is driven in the downward direction of the rod, the plate 34 moves downward, and the material sheets 2 and 3 held by vacuum suction on the lower surface of the plate are pressed onto the third mold 7 in a horizontal position and covered. At this point, the lowering movement of the hydraulic rod device 32, that is, the lowering movement of the plate 34, is stopped.

The material sheets 2 and 3 are held in close contact with the lower surface of the board 34 by vacuum suction on the table 38, and then
Before it covers the mold 7, it is heated by the plate 34, and all parts are uniformly heated and softened.

When the above-mentioned downward movement of the plate 34 is stopped, the signal causes the vacuum holes 37 of the plate 34 to release the material sheet from being held by vacuum suction. Or conversely, air is blown out from each vacuum hole 37. Further, each vacuum hole 73 of the third mold 7 is brought into a vacuum suction state. As a result, the material sheets 2 and 3 are vacuum formed or vacuum/pressure formed by the third mold 7.

Next, the hydraulic rod device 32 is driven in the rod backward direction, and the plate 34 rises to the initial position.
Next, the motor M3 is driven in the reverse direction to drive the rack bar 3.
The backward movement of 0 returns it to the initial home position on the right end side of the rail.

Manufacturing process (a) Equipment state before manufacturing starts The first and second molds 5 and 6 are held in an open state with the movable die plates 9 in the retracted position (FIG. 2). The third mold 7 is
The molding surface 71 is held in an upward horizontal position in the 90° rotation section (second, fourth,
Figure 5 shows the state shown by the solid line). The material sheet heating plate 34 is retreated to its home position directly above the material sheet mounting table 38 (FIG. 5).

(b) Molding of the base layer 1 Based on the mold clamping signal from the control circuit, the movable die plate 9 is driven forward, and the second mold 6 moves forward against the fixed first mold 5, bringing them into abutting state. Molds 5 and 6 are clamped.

Next, in response to a mold clamping end signal, molten resin is injected from the resin injection device through the nozzle 13 and spool 52 into the molding cavities in the clamped molds 5 and 6, and the base layer 1 is formed.

After resin injection, when a predetermined cooling time has elapsed, the movable die plate 9 is driven backward based on the mold opening signal from the control circuit, and the molding base layer 1 is held on the movable second mold 6 side (Fig. 3) and both The molds 5 and 6 are opened.

(c) Vacuum forming of the material sheet In parallel with the forming process of the base layer 1 in the above item (b), the operation of the material sheet heating and conveying mechanism is started by a material sheet holding signal from the control circuit. That is, as explained in the above section, the material sheet heating plate 34 is lowered to the upper surface of the loaded material sheet → the uppermost sheet materials 2 and 3 are held by vacuum suction → the third molding mold 7, which is the vacuum molding mold 7 in the horizontal position, is moved. Movement→A material sheet is applied to the mold, and the applied material sheet is vacuum formed or vacuum/pressure formed by the third mold 7. The molded material sheet is maintained as it is on the surface of the third mold 7 under suction. The board 34 then moves back to its home position.

(d) Lamination of molding base layer 1 and molding material sheets 2 and 3 When the material sheet heating plate 34 moves back to a position where it does not interfere with the third mold 7, the third mold advance/retract movement/rotation mechanism starts to operate. be done. That is, as explained in the above section, the motor M2 is driven in the reverse direction by the third mold raising rotation signal from the control circuit, and the third mold is rotated 90 degrees counterclockwise to take the vertical position (the second , 4, 5 (posture shown by the two-dot chain line in Figures 4 and 5). Next, the normal rotation of the motor M1 is started, and the third forming mold 7 in the vertical position moves forward to move the upper and lower guide rails 14,
The molding of the base layer 1 has already been completed in the step (b) above, along the rails 14, 14 by the forward movement of the rod 16 based on the forward rotation of the motor M1. It enters between the opened first and second molds 5 and 6. The advance is stopped by stopping the forward rotation of the motor M1 when the third mold 7 moves forward to a position exactly facing the second mold 6 (FIG. 3).

After the third mold 7 is stopped, the movable die plate 9, that is, the second mold 6 is driven forward, and the third mold 7 is moved forward.
The mold is clamped to the mold 7.
This advancement of the second mold 6 causes the mold base layer 1 held on the mold 6 side to fit into the cushion material layer 3 of the molding material sheets 2 and 3 held on the third mold 7 side. It is applied to the extent that it is pressed appropriately and becomes in close contact.

As a result, the molded base layer 1 and the molding material sheets 2 and 3 are integrated to form a composite molded body A. The base layer 1 and the cushion material layer 3 can be well integrated by forming a hot-melt or solvent-type adhesive layer on the free surface of the cushion material layer 3 of the material sheets 2 and 3 in advance. .
Furthermore, since the base layer 1 and the material sheets 2 and 3 both have a considerable amount of retained heat when laminated under pressure, it is also possible to integrate them by thermo-pressure bonding without using an adhesive.

Next, the movable die plate 9 is moved backward, and the second mold 6 is moved backward from the third mold 7. At this time, the ejector pin 63 is driven forward by the hydraulic unit 64, so that the tip of the pin 63 projects forward from the molding surface 61 of the second mold 6, and the molding base layer 1 is separated from the molding surface 61. Therefore, the composite molded body A is held on the third mold 7 side. The ejector pin 63 is then driven backward and returns to the initial retracted state in which the tip end surface is substantially flush with the molding surface 61 of the second mold 6.

(e) Removal of the composite molded product A After the second mold 6 is retracted, the motor M1 is driven in the reverse direction and the rod 16 is moved backward, as explained in the previous section, so that the third molding die 6 holding the composite molded product A is removed. The mold 7 moves backward from between the first and second molds 5 and 6 along the rails 14 and 14, and eventually comes out from between the rails 14 and 14, and the friction wheel 23 on the mold 7 side is connected to the motor M2. The backward movement of the third mold 7 stops when it comes into pressure contact with the friction wheel 24 on the side. Next, the third mold 7 is rotated 90 degrees clockwise by the forward rotation of the motor M2, thereby forming the composite molded product A.
The molding surface holding the molded surface is converted and held in an upward, substantially horizontal position. Then, the composite molded body held by vacuum suction in the third mold 7 is released from vacuum suction and held and taken out. This removal can also be automated using a robotic mechanism.

Thereafter, the steps (b) to (e) described above as one cycle are repeatedly executed to automatically and continuously produce the composite molded body A.

(f) Edge finishing of composite molded body A The composite molded body A taken out above has an extra extension of the laminated sheet material of the skin material layer 2 and cushion material layer 3 on the outer peripheral edge of the molded body A, as shown in Figure 6. Part 4a remains. Therefore, this extra extended portion 4a is trimmed along the outer periphery of the base layer 1 to form a product A. Alternatively, this extra extension material portion 4a is compressed between the abutting surfaces 62 and 72 of the second and third molds 6 and 7 and is considerably thinned, so that the outer periphery of the base layer 1 After performing a trimming process C2-C2 to a larger size than that shown in FIG.

The above trimming process C1-C1 or C2
- C2 is achieved by forming trimming cutting blades and recesses facing each other in the mold clamping abutting surfaces 62, 72 of the second and third molds 6, 7 in advance, thereby clamping the molds 6, 7. At the same time, it can also be done automatically.

(g) Modifications, etc. In the above example, the base layer 1 is molded by resin injection molding, but by using the first mold 5 as a resin bead foam molding mold, the base layer 1 can be made into a resin bead foam molded product. It is also possible to make a composite molded product. FIG. 7 shows an example of the first mold 5, with reference numeral 55 a foamable resin bead introduction tube opened in the molding surface 51 of the first mold 5, and 56 a plurality of openings in the molding surface 51. This is a small hole for blowing out hot air such as steam and hot air. That is, after the second mold 6 is clamped to the first mold 5, foamable resin beads are introduced and filled into the cavity through the introduction pipe 55, and then hot air is blown into the cavity from the small holes 56. As a result, the heat causes the foamable resin beads in the cavity to thermally foam and form a mass.

The thinning of the excess extension material portions 4a of the skin material layer 2 and cushion material layer 3 by the clamping force of the second and third molds 6 and 7 described in the above (f) can be done more effectively. Second to make
The mold abutting surface 62 of the mold 6 or/and the third
It is preferable to dispose a heater H (FIG. 3) on the mold abutting surface 72 of the mold 7 for heating and softening the material portion 4a to promote elongation due to compression.

Also, an eighth mold is formed on the mold abutting surface 72 of the third mold 7.
As shown in the figure, the annular groove portion 7 is quite deep.
5 and opening a small vacuum hole 73 at the bottom of the concave groove 75 allows the material to be removed during vacuum forming of the bonded material sheet of the skin material layer 2 and cushion material layer 3 using the third mold 7. The excess material portion 4a may be drawn into the groove 75 and subjected to vacuum forming treatment to be stretched thin.

In the case of a composite molded body A having a two-layer structure of a base layer 1 and a skin material layer 2 as shown in FIG. Just follow.

As shown in Figure 1b, the base layer 1, intermediate material layer 3,
In the case of a composite molded body A having a three-layer structure of the skin material layer 2, the skin material layer 2 does not have to be formed by pasting an intermediate material layer on the back side of the skin material layer 2 as in the above example. Before clamping the second mold 6 holding the molded base layer 1 to the third mold 7 holding the skin material layer 2 after vacuum forming with the third mold 7, as shown in FIG. The sheet material 3 for the intermediate material layer, which has been coated with a hot-melt type adhesive layer on both the front and back surfaces and has been appropriately heat-softened, is introduced between the two molds 6 and 7, and then the molds are clamped to form the intermediate material layer. The three layers 1, 3, and 2 may be laminated together by pressing and sandwiching the sheet material between the base layer 1 and the skin material layer 2 using a sandwich sandwich. Alternatively, as shown in FIG. 9, when the base layer 1 is molded by the first and second molds 5 and 6, a small vacuum hole 1' is formed through the thickness of the molded base layer.
form. Projecting pipe pin 66, advancement/retraction plate 67, hydraulic unit for advancing/retracting the plate 68, 6
The protruding tube pin mechanism consisting of 8 etc. is placed in the second mold 6.
Then, a substrate layer 1 is built into the ram 12 and has vacuum holes 1', 1' formed on its outer surface. and the second one as shown in Figure 9.
The intermediate material layer sheet material 3 in a thermally softened state introduced between the third molds 6 and 7 is formed into the base layer 1.
The small vacuum holes 1', 1' formed in the vacuum holes 1', 1' are used to vacuum form the base layer 1 into close contact with the base layer 1, and then the second mold 6 is moved to the third mold 7 to form the intermediate material layer 3. The three layers 1, 3, and 2 may be integrated as a whole by press-fitting the skin material layer 2 on the third mold 7 side.

As described above, the present invention provides: (1) The base layer 1 and the skin material layer 2 (or the skin material layer 2 + the intermediate material layer 3), which are the constituent layers of the composite molded article A, or the base layer 1, the intermediate material layer 3, and the skin material Since layer 2 is separately molded into the desired shape and then laminated and integrated in a fitting manner to obtain the desired molded product, the overall molded shape can be made without any so-called irregularities, even in the highlighted areas, even if the product has a complex uneven shape. It is possible to produce a sharp molded body according to a predetermined design.

(2) There is no so-called trimming loss in the base layer 1, and in the case of a molded product with a two-layer laminate structure of the base layer 1 and the skin material layer 2, the skin material layer 2 removed by trimming is a single material, and therefore, it If it is a thermoplastic resin, it can be remelted and reused, so resources can be saved without wasting it. Also, in the case of a laminated sheet of the skin material layer 2 and the intermediate material layer 3, by making both of them thermoplastic resins of the same type, they can be remelted and reused.

(3) It is also possible to easily produce a good-looking molded body A in which the thick end face around the molded body is hidden by the skin material layer 2 and a series of thin extension material pieces 4a and the edges are finished 4.

(4) This is because the opening/closing movements or positional movements of the first, second, and third molds are sequentially controlled in relation to each other as described above, and the steps (b) to (e) are continuously automated as one cycle. Composite molded bodies of seeds can be efficiently mass-produced.

[Brief explanation of the drawing]

Figures 1a and b are cross-sectional views showing the layer structure of the composite molded body, Figure 2 is an overall plan view of an apparatus according to an embodiment of the present invention, and Figure 3 is a state in which the third mold is inserted. Fig. 4 is a partially cutaway side view of the advancing/retreating/rotating mechanism of the third mold, and Fig. 5 is a front view of the material sheet heating and conveying mechanism. , FIG. 6 is a cross-sectional view of the manufactured composite molded body before edge treatment, FIG. 7 is a cross-sectional view of the first mold example in which the base layer is made of resin bead foam, and FIG. 8 is a cross-sectional view of the molding material sheet. FIG. 9 is a cross-sectional view of a part of the third mold in which the extra extension material portion is thinned by vacuum forming, and FIG. 9 is a cross-sectional view of the main part of the modified device. 8 is a fixed die plate, 9 is a movable die plate, 13 is a nozzle portion of a resin injection machine, and 14 is a guide rail of a third mold.

Claims (1)

[Scope of Claims] 1. A split mold consisting of a fixed first mold 5 and a movable second mold 6 for molding the base layer 1 by resin injection molding, resin pressure molding, or resin bead foam molding;
A second mold drive device 11 that moves the second mold 6 to close and open the first mold 5; and a forward/backward drive device 15 between the first and second molds 5 and 6 in the open state. A third forming mold 7 for vacuum forming a material sheet formed by laminating the sheet 2 for the skin material layer or the sheet 3 for the intermediate material layer on the back side of the sheet 2, which is freely disposed in and out by the molding die 7; And after molding the base layer 1 with the second molds 5 and 6, the molded base layer 1
is held on the second mold 6 side and the mold is opened, and the material sheet 2 or the material sheet 2 or 3 is placed between the molds 5 and 6.
The third mold 7, which has been vacuum-formed and held, is advanced and positioned opposite to the second mold 6.
is moved forward again to clamp or approach the third mold 7 and join the molded base layer 1 on the second mold 6 side and the molded sheet material 2 or 2 and 3 on the third mold 7 side together. 1. An apparatus for manufacturing a composite molded article, characterized in that the movements of the molds are sequentially controlled in a relational manner so as to cause the formation of the mold. 2. In the case of a composite molded body consisting of a laminated base layer 1, intermediate material layer 3, and skin material layer 2, a second mold 6 holding the molded base layer 1 and a second mold 6 holding the molded skin material layer 2 are used. The intermediate material layer sheet 3 is introduced between the third molding mold 7 and the second molding mold 6 is moved forward to insert the intermediate material layer sheet 3 between the molded base layer 1 and the molded skin material layer 2. The three layers 1, 3, and 2 are laminated together by sandwiching and pressing, or the introduced intermediate material layer sheet 3 is vacuum formed on one side of the molding base layer of the second mold 6. After the mold 6 is brought into close contact with the third mold 7, the mold 6 is moved forward to clamp or approach the third mold 7 to join and integrate the three layers 1, 2, and 3. Composite molded body manufacturing equipment.