JPH06190848A - Molding method and device for laminated molding - Google Patents

Abstract

PURPOSE:To provide a method and device for molding a laminated molding improved in molding properties of a skin material and enhanced in degree of freedom in shaping a product, in which a resin core material and a skin material are integrally molded in a mold of a mold press. CONSTITUTION:By incorporating a heater 65 in a transport plate 63 of a skin material supply mechanism 60, a skin material can be set to an upper mold 40 in the state that it is preheted and softened through the preheating means of the skin material supply mechanism 60. In this manner, the molding properties of the skin material is improved, a degree of freedom in shaping a product is enhanced, and a fraction defective is reduced to a great extent.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for molding a laminated molded article suitable for manufacturing automobile interior parts such as door trims for automobiles, and a molding apparatus used for the molding.

[0002]

2. Description of the Related Art Conventionally, the structure of automobile interior parts such as automobile door trims and rear corner trims that are installed in the body panels of automobiles will be described with reference to the automobile door trim shown in FIG. Is
Resin core material 2 molded to have a desired curved surface shape
And a skin-molded body that is integrally laminated on the surface side of the resin core material 2 and has a cushioning property.

As a method of molding the resin core material 2,
Recently, since a complicated three-dimensional shape is required for molding, a mold press molding method having excellent moldability tends to be used frequently.

In this case, the skin material 3 is integrated with the resin core material 2 at the time of mold press molding of the resin core material 2 for the purpose of shortening the process.

That is, as shown in FIG. 12, first, the set pin 4a of the upper die 4 for mold press molding is attached to the skin material 3.
Is set in advance, and the upper mold 4 for mold press molding is lowered to maintain a predetermined clearance between the upper and lower molds 4 and 5 on the mold surface of the lower mold 5 for mold press molding.
The resin material 7 distributed and supplied from the injection molding machine 6 through the hot runner 5a and the plurality of gates 5b branched from the hot runner 5a is press-molded into a desired shape by engaging and pressing the upper and lower molds 4 and 5. The resin core material 2 is molded by using the resin core material 2 and the skin material 3 is formed on the surface side of the resin core material 2.
The vehicle door trim 1 shown in FIG. 11 is formed into a product by integrating the above.

[0006]

However, in the conventional method in which the resin core material 2 and the skin material 3 are integrally press-molded by mold press molding to form a laminated molded article, the skin material 3 is at room temperature (10 (° C to 20 ° C) is put into the molds 4 and 5 for mold press molding, so that the skin material 3 cannot follow the highly expanded shape, and only the portion having a high expansion rate is intensively stretched. It has been pointed out that there is a problem in that resin is exuded due to the enlargement of the formed needle hole and that the skin material 3 becomes thin, resulting in surface defects such as avatars.

Therefore, in order to promote the elongation of the skin material 3, the set frame of the skin material 3 is made larger than the product shape,
Although it is possible to take measures to increase the size of the skin material,
In that case, although the elongation of the skin material 3 is slightly improved,
There is a problem that a large amount of scrap material is generated, resulting in cost increase due to material loss.

There is also a method of separately installing a heating furnace for heating the skin material 3, but this method is not a practical measure because the equipment layout becomes large.

The present invention has been made in view of the above circumstances, and an object of the present invention is to form a laminated molded article in which a resin core material and a skin material are integrated by a mold press molding method. In the method and the molding apparatus, the moldability of the skin material can be improved, and it is possible to surely prevent resin exudation and defective appearance of the skin material during mold press molding, and reduce the loss of the scrap material of the skin material. Another object of the present invention is to provide a method and apparatus for molding a laminated molded body that are economically excellent.

[0010]

To achieve the above object, the present invention provides a resin core material obtained by molding a molten resin into a required shape in a mold for molding, and a mold press for the resin core material. At the time of molding, in a method for molding a laminated molded body composed of a resin core material and a skin material integrated with the resin core material, the skin material is preheated and softened by a preheating means installed in a conveying mechanism, and then, an upper mold is formed. It is characterized in that the skin material is set and mold press molding is performed.

Further, the skin material is preheated and softened by a preheating means installed in the conveying mechanism, and is preformed by a vacuum suction means into a curved surface shape substantially equal to the shape of the upper mold surface, and then set on the upper mold. Then, mold press molding is performed.

Further, the molding apparatus according to the present invention is such that a mold press molding lower mold having a desired mold surface to which the molten resin is distributed and supplied, and a mold having a desired mold surface shape in which a skin material is set. An upper die for press molding, a molten resin supply mechanism that supplies a molten resin onto the mold surface of the lower die, and a skin material supply mechanism that supplies a skin material to the upper die. The skin material supply mechanism is a skin material. And preheat and soften the skin material,
It was equipped with a carrier plate with a built-in heater, a drive cylinder for raising the carrier plate and setting the skin material on the upper mold, and a carrier arm for reciprocating the carrier plate between the mold and the carrier body. Is characterized by.

In addition, the surface of the carrier plate is set to be substantially the same curved surface as the mold surface of the upper mold, and vacuum suction means for preforming the skin material by vacuum molding is attached to the carrier plate. To do.

[0014]

[Function] As is apparent from the above structure, the skin material is set in the upper mold in a preheated and softened state by the preheating means installed in the skin material supply mechanism. The elongation of the material can be promoted, and the skin material easily follows the complicated curved surface shape of the mold.

Further, after the skin material is preheated and softened by the skin material supply mechanism, it is preformed into a desired shape by vacuum forming, and the preformed skin material is set in an upper mold for mold press molding. The rate at which the skin material is stretched by the mold is low, and the moldability is improved.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The method and apparatus for molding a laminated molded article according to the present invention will be described in detail below with reference to the accompanying drawings.

FIG. 1 is a front view showing an automobile door trim manufactured by the method of the present invention, FIG. 2 is a sectional view showing the structure of the automobile door trim, and FIG. 3 is a first embodiment of a molding apparatus according to the present invention. FIG. 4 is a perspective view showing the structure of the carrier plate in the skin material supplying mechanism, and FIGS. 5 to 9 are cross-sectional views showing the steps of the method of the present invention using the molding apparatus shown in FIG. 10 is a sectional view showing the configuration of a second embodiment of the molding apparatus according to the present invention.

1 and 2, an automobile door trim 10 manufactured by the method of the present invention has a resin core material 11 formed into a required shape and a skin integrally laminated on the surface side of the resin core material 11. The material 12 is generally configured.

More specifically, the resin core material 11 is made of polypropylene resin mixed with talc, and is distributed and supplied in a molten state into a mold for press molding having a desired curved surface shape, and is then subjected to mold press molding. It is shaped into a complicated curved surface.

As the skin material 12, various specifications may be used depending on the application, but in this embodiment, a laminated sheet in which polyethylene foam is lined on the back surface of the vinyl chloride sheet is used.

Next, the structure of a molding apparatus for molding the above-described automobile door trim 10 by mold press molding will be described.

As shown in FIG. 3, the molding apparatus 20 has
A lower mold 30 for mold press molding having a desired mold surface,
An upper mold 40 for mold press molding which is located above the lower mold 30 and has substantially the same mold surface, and a mold die which is connected to the lower mold 30 and which is the material of the resin core material 11 is melted on the mold surface of the lower mold 30. Injection molding machine 50 which is a molten resin supply mechanism for supplying resin
And a skin material supply mechanism 60 that conveys and sets the skin material 12 to the upper mold 40.

More specifically, in the injection molding machine 50 which is a molten resin supply mechanism, the nozzle 51 is connected to the lower mold 30,
Hot runner 31 and gate 3 that are punched in the lower die 30
The molten resin is discharged from the nozzle 51 through the hot runner 3
1, it is distributed and supplied to a predetermined position on the mold surface of the lower mold 30 through the gate 32.

Next, the upper die 4 located above the lower die 30.
0 is configured to be movable up and down by an elevating cylinder 41, a set frame 42 for setting the skin material 12 is provided, and the set frame 42 is provided with a set pin 43.

The above is the same configuration as the conventional device, and the feature of the present invention is the configuration of the skin material supplying mechanism 60 described below.

That is, the skin material supplying mechanism 60 includes a carrier body 61, and a carrier arm 62 which slides between the carrier body 61 and the upper and lower molds 30 and 40 for mold press molding.
And the carrier plate 6 attached to the upper surface of the carrier arm 62.
3 and a drive cylinder 64 for moving the transport plate 63 up and down
And a heater 65 built in the transport plate 63.

More specifically, as shown in FIG. 4, the upper surface of the carrier plate 63, that is, the surface on which the skin material 12 is set is formed as a heat conducting surface 66 by a net made of metal such as copper or aluminum. The heat conducting surface 66 is heated to a predetermined temperature by the heater 65 installed inside 63, and a thermocouple 67 is provided on the heat conducting surface 66, and depending on the material of the skin material 12, 0 ° C to 200 ° C. Within this range, the skin material 12 is preheated and softened.

A heating means other than the heater 65 may be used as the heating device, and the heat conducting surface 66 may be a plate-shaped metal plate or the like.

Next, the method of the present invention will be described in detail with reference to FIGS.

As shown in FIG. 5, the skin material 12 set on the carrier plate 63 of the skin material supply mechanism 60 is preheated to a predetermined temperature, and in a softened state, the carrier arm 62 is driven to open the mold. It is supplied to a position below the mold 40.

In the previous step, the skin material 12 is transferred to the carrier plate 63.
0.8 ~ in the main body 61 of the carrier with it set above
It has been stored for 1.0 min and is in a state where it has been sufficiently preheated and softened.

Thereafter, as shown in FIG. 6, the operation of the drive cylinder 64 raises the conveying plate 63 to press the skin material 12 in the preheated and softened state against the set frame 42,
The peripheral portion of the skin material 12 preheated and softened by the set pin 43 of the set frame 42 is inserted and held.

Then, as shown in FIG. 7, after the carrier plate 63 is lowered by the operation of the drive cylinder 64, the carrier arm 62 is driven to store the carrier plate 63 in the carrier body 61, and the skin material of the next step is formed. Are set on the carrier plate 63 and preheated and softened during the mold press molding cycle.

Thereafter, as shown in FIG. 8, the upper mold 40 is
The descent is started by the operation of the lifting cylinder 41, and the upper and lower molds 3
The descending operation is performed until the clearance between the molds 0 and 40 becomes about 30 mm, and the mold is temporarily stopped. Then, the molten resin M flows from the injection molding machine 50 and the nozzle 51 to the hot runner 31 and the gate 3.
It is distributed and supplied to the mold surface of the lower mold 30 through 2.

Then, as shown in FIG. 9, the upper and lower mold press molding dies 30 and 40 are engaged and tightened to mold the molten resin M into a required shape to mold the resin core material 11, and The skin material 12 is integrated with the resin core material 11.

At this time, the skin material 12 is the skin material supply mechanism 6
Since it is preheated to a predetermined temperature by 0 and is in a softened state, even if the mold surfaces of the upper and lower molds 30 and 40 have complicated shapes, the skin material 12 easily follows the mold surface shape, and It is possible to form the door trim 10 having excellent appearance performance without causing surface defects such as pocking due to exudation and thinning of the skin.

Further, according to the method of the present invention, the skin material 12
Is preheated and softened by the skin material supply mechanism 60,
Since the expansion of the skin material 12 can be expected, a smaller set frame 42 can be used as the set frame 42 arranged in the upper mold 40.
Along with that, the size of the skin material 12 can be reduced, and the loss of end material can be reduced, which is an advantage that the material efficiency can be significantly improved.

Next, a second embodiment of the molding apparatus for laminated moldings according to the present invention will be described with reference to FIG.

The molding apparatus 20 has the same structure as the apparatus shown in FIG. 3 with respect to the mold press molding lower mold 30, the mold press molding upper mold 40, and the molten resin supply mechanism 50. Only the supply mechanism 60 will be described.

The skin material supplying mechanism 60 has a structure capable of preheating and softening the skin material 12 and preforming.

That is, the upper surface of the carrier plate 63 attached to the carrier arm 62 is set to have a curved surface shape that is substantially equal to the shape of the mold surface of the upper die 40 for mold press molding, and the vacuum suction holes 68 are provided inside the carrier plate 63. Is provided,
The vacuum suction hole 68 is connected to a vacuum pump 70 via a vacuum suction pipe 69.

Therefore, with the skin material 12 set on the surface of the carrier plate 63 and the peripheral edge held by the clamp device 71, the skin material 12 is heated by the heater 65 in the carrier plate 63.
Is softened by heating, and thereafter, the vacuum pump 70 is operated to perform vacuum suction through the vacuum suction hole 68 of the transport plate 63,
The skin material 12 is preformed so as to follow the surface shape of the carrier plate 63.

Then, through the steps shown in FIGS. 5 to 9, the preformed skin material 12 is set in the upper mold 40, and the molten resin M is press-molded to mold the resin core material 11.
And the resin core material 11 and the skin material 12 may be integrated.

As described above, according to the present embodiment, the skin material supplying mechanism 60 is provided with the preheating means and the vacuum suction means on the carrier plate 63, and the skin material 12 is preliminarily attached to the upper die 40 for mold press molding. Since it is preformed along the mold surface, the rate at which the skin material 12 is stretched in the mold press molding process is small, and in particular, the armrest portion of the door trim 10 or the like having a high expansion rate can be easily molded. There is an effect.

[0045]

As described above, according to the present invention, the following operational effects are achieved.

(1) According to the method of the present invention, in a method of molding and press-molding a laminated molding of a resin core material and a skin material, the skin material is set in a skin material supply mechanism and preheated by the preheating means. Since it is supplied to the upper mold in a softened state, the moldability of the skin material is improved, and during molding press molding, the skin material easily follows the mold surface shape of the mold press molding die, making the product shape complicated. Even if it is set to a different three-dimensional shape, the cutout of the skin material, resin leakage, surface defect of the skin material, etc. do not occur, greatly improving the flexibility of product shaping,
Moreover, there is an effect that the defect rate can be significantly reduced.

(2) According to the method of the present invention, in the method of molding and press-molding the laminated molding of the resin core material and the skin material, after the skin material is set in the skin material supply mechanism, the skin material supply mechanism is used. Since the skin material is preheated and softened and preformed, the moldability of the skin material can be further enhanced, and even if the product shape is set to a complicated developed shape, the skin material is stretched during mold press molding. The ratio is small, and it is possible to easily mold a molded product having a high expansion rate portion.

(3) According to the molding apparatus for laminated molded articles of the present invention, the preheating means is built in the conveying plate of the skin material supplying mechanism or the vacuum suction means is additionally provided, so that the skin material Since the moldability can be significantly improved, the equipment layout does not become large,
It has a great practical value because it can greatly improve the moldability of a molded product with a simple structure.

[Brief description of drawings]

FIG. 1 is a front view showing an automobile door trim manufactured by the method of the present invention.

FIG. 2 is a cross-sectional view showing the structure of the vehicle door trim shown in FIG.

FIG. 3 is a sectional view showing a configuration of an embodiment of a molding apparatus according to the present invention.

4 is a perspective view showing a carrier plate in a skin material supply mechanism of the molding apparatus shown in FIG.

FIG. 5 shows a method for molding a laminated molded body according to the present invention,
Sectional drawing which shows the advancing operation of a conveyance board.

FIG. 6 shows a method for molding a laminated molded body according to the present invention,
Sectional drawing which shows the state which sets a skin material to an upper mold.

FIG. 7 shows a method for molding a laminated molded article according to the present invention,
Sectional drawing which shows the state after setting a skin material to an upper mold.

FIG. 8 shows a method for molding a laminated molded body according to the present invention,
Sectional drawing which shows the supply process of molten resin.

FIG. 9 shows a method for molding a laminated molded body according to the present invention,
Sectional drawing which shows a mold press molding process.

FIG. 10 is a sectional view showing the configuration of another embodiment of the molding apparatus according to the present invention.

FIG. 11 is a cross-sectional view showing a general configuration of a vehicle door trim.

FIG. 12 is a sectional view showing a conventional mold press molding method.

[Explanation of symbols]

 10 Automotive Door Trim 11 Resin Core Material 12 Skin Material 20 Molding Device 30 Mold Press Molding Lower Mold 31 Hot Runner 32 Gate 40 Mold Press Molding Upper Mold 41 Elevating Cylinder 42 Set Frame 43 Set Pin 50 Injection Molding Machine 51 Nozzle 60 Skin Material supply mechanism 61 Conveyor body 62 Conveyor arm 63 Conveyor plate 64 Drive cylinder 65 Heater 66 Heat conduction surface 67 Thermocouple 68 Vacuum suction hole 69 Vacuum suction pipe 70 Vacuum pump 71 Clamp device M Molten resin

Claims (4)

[Claims] 1. A mold for molding press molding (30, 40)
A resin core material (11) formed by molding a molten resin (M) into a desired shape, and a skin material (which is integrated with the resin core material (11) during mold press molding of the resin core material (11) ( 12)
In the method for forming a laminated molded body including the above, the skin material (12) is preheated and softened by the preheating means (65) installed in the transport mechanism (60), and then the upper mold (4
A molding method for a laminated molded article, characterized in that the skin material (12) is set in (0) and mold press molding is performed. 2. A mold for molding press molding (30, 40)
A resin core material (11) formed by molding a molten resin (M) into a desired shape, and a skin material (which is integrated with the resin core material (11) during mold press molding of the resin core material (11) ( 12)
In the method for forming a laminated molded body including the above, the skin material (12) is preheated and softened by the preheating means (65) installed in the transport mechanism (60), and the upper die (40) is pressed by the vacuum suction means. ) A preform is formed into a curved surface shape that is substantially the same as the shape of the mold surface, and then is set in the upper mold (40) and mold press molding is carried out. 3. A lower die (30) for mold press molding having a desired mold surface to which the molten resin (M) is distributed and supplied, and a skin material (12) are set to provide a desired mold surface shape. Molten resin supply mechanism (5) for supplying the molten resin (M) onto the mold surfaces of the mold press molding upper mold (40) and the lower mold (30).
0) and a skin material supply mechanism (60) for supplying the skin material (12) to the upper die (40), and the molten resin (M) is press-molded into a required shape to form the resin core material (11). In the molding apparatus of the laminated molded body, which is formed by integrally molding the resin core material (11) and the skin material (12) during molding press molding of the resin core material (11), the skin material supply mechanism (60) ) Is a carrier plate (63) with a built-in heater (65) on which the skin material (12) is placed and which preheats and softens the skin material (12), and a carrier plate (63).
And a drive cylinder (64) for setting the skin material (12) on the upper die (40), and a conveyor plate (63) is reciprocally driven between the die (30, 40) and the conveyor body (61). A forming apparatus for a laminate formed body, comprising: a transfer arm (62). 4. The surface of the carrier plate (63) has an upper mold (4
The surface of the skin (1
Vacuum suction means (6) for preforming 2) by vacuum forming
8. The molding apparatus for a laminated molded body according to claim 3, wherein the conveying plate (63) is provided with 8, 69, 70).