JPH06285967A - Apparatus and method for manufacturing die-molded article - Google Patents

Abstract

PURPOSE:To make it possible to manufacture easily a die-molded article having a prescribed shape out of two or more sheet-shaped materials being the same or different in terms of quality and thickness, by a simple apparatus for manufacture. CONSTITUTION:A molding die 10 made up of a top force and a bottom force 11 and 12 of which the inner surfaces 13 and 14 are made to have prescribed shapes is provided. This molding die is so constructed that at least two sheet- shaped materials 1 and 2 can be disposed in an overlapping manner between the top force and the bottom force. Besides, a plurality of suction ports 20 for sucking air from inside of the die are opened in the inner surfaces of the top force and the bottom force and, moreover, an introduction port for introducing compressed air between the sheet-shaped materials from outside is provided so as to face parts of the inner surfaces of the die. Each of the sheet-shaped materials is molded into a necessary die-molded article 3 in a shape corresponding to each of the forces, and it is used as a molded article as it is or by separating and cutting each of the sheet-shaped materials.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for producing a molded article suitable for use as an interior part such as an instrument panel, a rear shelf, a trunk room, a door and the like in an automobile and a method for producing the same.

[0002]

2. Description of the Related Art For example, blow molding has hitherto been most commonly used for producing a molded product having a hollow portion. That is, in this blow molding, a bag-shaped molded body or a tubular or tubular resin molded body made of two resin sheet materials put together is put into a mold, and air is blown into the mold to obtain a desired shape. A molded product having a hollow portion is formed.

As a die-molded product, there is a die-shaped material in which a sheet-shaped material is pressed by a molding die to be molded into a predetermined shape, but conventionally, one sheet-shaped material is molded one by one by a molding die. It was just molded.

[0004]

However, according to the conventional blow molding as described above, a resin molded body prepared in advance to have a bag shape, a tubular shape, or a tubular shape is put into a mold and the inside is molded. By blowing air, the whole is only molded into the required shape, and it is necessary to prepare a bag-shaped resin molded body in advance for blow molding, and it is inevitable that manufacturing is complicated. there were.

That is, conventionally, a molding machine for molding a bag-shaped resin molded body is required prior to the blow molding machine, and at least two types of manufacturing apparatuses are required, and the apparatus structure is complicated. The molding work was also complicated. Moreover,
It is necessary to use a dedicated molding machine for these molding machines, resulting in high equipment cost and installation space. In particular, when molding such a molded product in a laminated state by using a plurality of sheet-shaped materials, the number of molding steps is increased, and the manufacturing work is troublesome and complicated.

Further, in the above-mentioned conventional apparatus, in order to mold a hollow mold-molded article with two kinds of sheet-shaped materials having different materials and thicknesses, at least two kinds of molding machines are used in two steps. Since it is necessary to perform molding, and complicated positioning such as shape matching between each sheet-shaped material and the molding die is required, complexity is inevitable.

Further, in the conventional blow-molded product, a problem is likely to occur in the strength of each part, it is necessary to take various reinforcing measures, and the molding shape is also restricted.
It was difficult to obtain a molded product having a free shape.

On the other hand, when a sheet-shaped material is molded to obtain a die-molded product having a predetermined shape, the molding work must be performed one by one, and the mass productivity is improved and the cost is reduced. There was a problem that it was difficult to do. Also,
Even when obtaining a die-molded product that is a small-volume product, it is necessary to prepare each molding die individually, and it is difficult to suppress the die cost, which tends to cause high costs. It is desired to obtain an apparatus and method for manufacturing a molded product that is simple and has excellent versatility.

The present invention has been made in view of the above circumstances, and has a high degree of freedom in design when molding a die-molded product having a hollow shape or a predetermined shape, and is used for a small amount of a wide variety of products. The object is to obtain a manufacturing apparatus for a molded product and a manufacturing method thereof with a simple mold structure that is also suitable, can reduce the material composition and cost, has a small number of working steps, and is advantageous in terms of workability. I am trying.

[0010]

In order to meet such a demand, the apparatus for manufacturing a die-molded article according to the present invention has an inner surface of a die having a required surface shape, and further comprises a die having a lower die, The molding die is configured such that at least two sheet-shaped materials can be arranged in a stacked state between the upper and lower dies, and a plurality of air suction members are provided on the inner surfaces of the upper and lower dies. The suction port is formed so as to be opened, and an introduction port for introducing compressed air from the outside is provided between the sheet-shaped materials facing a part of the inner surface of the mold.

Here, according to the present invention, as the sheet-shaped material, one made of a resin material such as the same or different thermoplastic material is selectively used, and even if each sheet has the same or different thickness. Is used selectively.

Further, according to the method for producing a molded product according to the present invention, at least two sheet-shaped materials are stacked and interposed between the lower mold and the lower mold, and the mold is clamped. Between the upper and lower molds, between the sheet-shaped materials, compressed air is introduced from the compressed air introduction port to form a hollow part inside both materials, and air is sucked from the air suction port on the inner surface of each mold to form a sheet. The shaped material is molded into a desired shape according to the shape of the inner surface of the mold, and then the mold is opened to take out a molded product having a predetermined shape.

Here, according to the present invention, as a molded product to be molded, a hollow mold having at least two sheet-shaped materials joined together at their end portions and having a hollow portion inside Molded products, or made of materials that can be separated from each other, or by separating the contacting surface with a release material so that they can be separated after molding. Alternatively, there is a molded product made of a sheet-shaped material having a different shape.

[0014]

According to the present invention, at least two sheet-like materials are stacked and interposed between the upper mold and the lower mold to form a mold, and the mold is clamped. In addition, compressed air is introduced from the compressed air introduction port to form a hollow portion inside the both materials, and air is sucked from the vacuum suction port or the air suction port serving as a vent hole on the inner surface of each mold to form a sheet-shaped material. Is molded into a desired shape according to the shape of the inner surface of the mold, the mold is then opened, and the molded product is taken out to obtain a hollow molded product.

According to the present invention, the sheet-shaped material is made of a resin material such as the same or different thermoplastic synthetic resin material, or a laminate of the synthetic resin material and the fabric. It is preferable to use the same or different thickness for each.

Further, according to the present invention, as a molded product to be molded, a hollow molded product which is integrally molded by joining the ends of at least two sheet-shaped materials and forms a hollow portion inside. It may be used after being cut after being molded, or by forming at least two sheet-shaped materials on the side to be the separation surface from materials that can be separated from each other, or by interposing a release material. By being configured to be separable, it may be obtained by simultaneously molding two molded products made of a sheet-like material and having the same or different shapes in the same step, and separating the two molded products after molding. .

[0017]

1 to 5 show an embodiment of an apparatus for producing a molded product and a method of producing the same according to the present invention. First, in this embodiment, a sheet made of a thermoplastic resin material or the like is used in an interior part for an automobile. A case where the present invention is applied to an interior material or the like which is a hollow molded product 3 obtained by joining the linear materials 1 and 2 will be described. Reference numeral 4 in the figure denotes a hollow portion of the molded product 3.

In these figures, a molding die generally designated by reference numeral 10 comprises a pair of upper and lower dies 11 and 12. The mold inner surfaces 13 and 14 of these molds 11 and 12 are
Each of them has a surface shape corresponding to the shape of the molded product 3 to be molded. And such a mold 10
Is configured so that at least two sheet-shaped materials 1 and 2 can be arranged between the upper and lower molds 11 and 12. The sheet-shaped materials 1 and 2 are P. P, P. E, made of thermoplastic synthetic resin material such as nylon, or other synthetic resin material or cloth, non-woven fabric,
P. with grain A laminate of P can be used.

At least two sheet-shaped materials 1 and 2 which are interposed in the fitting portions 15 and 16 between the upper and lower molds 11 and 12 in a stacked state between the two molds 11 and 12, respectively. Is provided with a trim blade 17 that cuts into a predetermined shape along the trim line, and mold matching surface portions 18 and 19 that closely join the side edge portions cut by the trim blade 17 as airtight.

Further, a plurality of suction ports 2 are provided on the inner surfaces 13 and 14 of the upper and lower molds 11 and 12 for sucking air from the inside of the mold by a vacuum or vent holes and letting the air escape to the outside.
No. 0 is opened, and a nozzle 21 as an inlet for introducing compressed air from the outside is provided between the sheet-shaped materials 1 and 2 so as to face a part of the inner surfaces of the molds 11 and 12. . Incidentally, reference numeral 22 in FIG. 1 denotes a compressed air introduction portion to the nozzle 21, as is apparent from FIG.

Here, an outline of an apparatus 30 for manufacturing the molded product 3 provided with the above-described molding die 10 will be briefly described with reference to FIGS. 2 to 5, in which 31 and 32 are upper and lower molds. 1
Vacuum portions 33, 34 provided in the suction holes 20 are provided in the upper and lower molds 11, 12, and cooling water passage holes are formed in the upper and lower molds 11, 12 for temperature control during molding. 35
Is a guide post that also serves as a stopper that guides and supports the upper and lower molds 11 and 12 so as to be vertically movable.

Further, 36 and 37 are the vacuum units 31 and 32.
A vacuum piping hole connected in communication with the reference numeral 38 is a movable device for moving the nozzle 21 of the compressed air introducing portion 22 back and forth between the two sheet-shaped materials 1 and 2.

The introduction of the compressed air by the compressed air introducing portion 22 is, as is apparent from FIGS. 5A, 5B and 5C, conducted at the introducing portion 22 elastically supported by the spring means 39. At the initial position of the nozzle 21, the sheet-shaped material 2 on the lower side is partially set at a position corresponding to the nozzle 21.

Next, the nozzle of the movable device 38 is moved to the cylinder 2
1 is advanced to face the sheet material 2. Thereafter, the upper sheet-shaped material 1 is also set on the nozzle 21, and further, the introduction part 22 provided with the nozzle 21 is elastically displaced by the lowering operation of the upper mold 11, so that both molds 11 and 12 are
With the mold clamped, compressed air may be introduced between the sheet-shaped materials 1 and 2 by the nozzle 21.

Nozzle 2 serving as the above-mentioned inlet for compressed air
In No. 1, it is preferable to retreat after molding and then the upper mold is raised.

According to the present invention, the sheet-shaped materials 1 and 2 may be made of the same or different materials, such as the same thermoplastic material or different thermoplastic materials. Also, the thickness of each
The thickness may be the same or different.

That is, according to the present invention, unlike the conventional blow molding, two or more sheet-shaped materials 1 and 2 are skillfully combined and mold-molded, so that FIGS. 6 (a) and 6 (b) are used. , (C)
As is clear from the above, even if the thicknesses of the materials 1 and 2 are changed, the materials are made different, or different skin materials 5 and 6 are used.
It is needless to say that the above may be used by overlapping the outer surfaces of the materials 1 and 2. As a result, the molded product 3 having the hollow portion 4 and two separable molded products can be molded in a desired state.

The molding equipment as described above can be easily molded by a general-purpose hydraulic press instead of a dedicated machine such as blow molding. Further according to the invention,
As shown in (c) of FIG. 6 described above, the skin materials 5 and 6 are stacked on the outside of the sheet-shaped materials 1 and 2 as base materials,
There is also an advantage that they can be joined at the time of molding. Further, according to the present invention, hollow molding of a material in which cloth and synthetic leather are laminated on the surface side of a base material made of a thermoplastic synthetic resin material is also possible.

Furthermore, in the present invention, the base material surface of the sheet-shaped material composed of two or more sheets is set with the thermoplastic synthetic resin material side facing inward as shown in FIG. It is possible to secure the hollow mold product 3 with integrated parts. Here, in the figure, 1a and 2a are inner substrate surfaces,
Reference numeral 7 denotes a portion in which both sheet-shaped members 1 and 2 are in close contact with each other and integrated.

Further, according to the present invention, also as a molded product to be molded, when at least two sheet-shaped materials 1 and 2 are molded, they are formed of a material which can be separated from each other, or a skin material. By making them separable by facing each other or interposing a release material (not shown) on the contact surface, a molded product 8 made of the sheet-shaped materials 1 and 2 having the same or different shape, 9 may be simultaneously molded in the same step, the two molded products 8, 9 may be simultaneously molded, and separated after molding.

That is, as is apparent from FIG. 8, two sheet-shaped materials 1 and 2 are laminated with the respective skin materials 5 and 6 set inside, and they are formed and then separated. , Molded articles 8, 9 of different shape or same shape
Can be simultaneously formed by one molding die 10 as a so-called two-piece production.

According to the above structure, at least two sheet-shaped materials 1 and 2 are stacked and interposed between the lower molds 11 and 12 to form the molding die 10, and the die is clamped. , The compressed air is introduced between the sheet-shaped materials 1 and 2 between the lower molds 11 and 12 from a nozzle 21 which is an inlet for compressed air to form a hollow portion 4 inside the materials 1 and 2. Air is sucked from the air suction ports 20 and 20 which are vacuum outlets or vent holes on the inner surfaces of the respective molds, and the sheet-shaped materials 1 and 2 are molded into a desired shape according to the shapes of the inner surfaces 13 and 14 of the mold, and thereafter, By opening the mold and taking out the molded product, the hollow molded product 3 or the molded products 8 and 9 can be obtained very easily by separating from each other.

At the time of mold clamping as described above, the materials 1 and 2 are cut into a predetermined shape by the trim line formed by the trim blade 17 provided on the fitting portions of the upper and lower molds 11 and 12, and the fitting portions are cut. Mold matching surface portions 18, which are adjacent to 15, 16
The side edge portions of each material cut in 19 are adhered as airtight.

According to this structure, the positions of the air suction ports 20 and the shapes of the mold inner surfaces 13 and 14 are diversified, so that the shapes of the molded products 3; 8 and 9 are diversified. Can be achieved.

Further, according to the present invention, the separation surface of at least two sheet-shaped materials 1 and 2 forming the molding die 10 is
By forming the material and the release material so as to be separable from each other and adopting a two-piece construction as individual molded products, it is possible to efficiently mold low-cost, multi-product molded products 8 and 9 at low cost. It has the advantage of being able to. In this case, the inner surfaces of both molds 11 and 12 may be formed in the same shape, and two identical molded products may be molded at the same time, or molded products having different shapes may be molded.

Further, when such two pieces are to be taken, if the airtight portions formed by the die-matching portions 18 and 19 can be drilled at the same time,
The versatility of the molded product can be further enhanced.

According to the above-mentioned structure, the upper and lower molds 11, 1 are obtained in order to obtain the required molded products 3; 8, 9.
It is a simple mechanical equipment for opening and closing 2, and can be configured by the molding die 10. Moreover, since the upper and lower guide posts 35 can be simple, the overall occupied area can be reduced and the overall equipment can be downsized. It will be possible.

Therefore, according to the molding die 10 described above, two or more sheet-shaped materials 1 and 2 are superposed,
The trim blade 17 formed in the fitting portion between the upper and lower molds 11 and 12 clamps the mold in a state where the trimmed blade 17 is cut into a desired external shape, and the cut side edge portion is the mold matching surface portion 1.
8 and 19 are bonded to each other in close contact with each other.

Here, according to the manufacturing apparatus 30 of the present invention, a skin material such as a cloth or a non-woven fabric can be molded without hair falling. In addition, with P. Even with a skin material such as a P resin sheet, it is possible to perform molding without crushing grain. Further, such a skin material can be evenly adhered to a thermoplastic resin sheet or the like as a base material.

Further, according to the present invention, the strength of the molded products 3; 8 and 9 after molding is high, and the reinforcing material is not necessary. Furthermore, since the both sides can be formed in different shapes by hollow molding of the component, the degree of freedom in design and design can be increased, and the rigidity of the component can be increased.

Here, of course, after the hollow molding, the foam from the nozzle 21 may be mixed with foam beads or the like to fill the inside of the foam to foam and to further increase the strength.

The present invention is not limited to the structure of the above-mentioned embodiment, and it is needless to say that the shape, structure, etc. of each part including the molded product and its manufacturing apparatus can be appropriately modified and changed. A modified example of is conceivable. Further, it will be easily understood that the molded product formed by employing the manufacturing apparatus and the manufacturing method according to the present invention can be applied to the molded products in various fields.

[0043]

As described above, according to the apparatus for producing a molded article and the method for producing the same according to the present invention, the inner surface of the die has different surface shapes, and the lower die has a forming die.
This molding die is configured so that at least two sheet-shaped materials can be disposed in a stacked state between the upper and lower dies, and a plurality of air suction members are provided on the inner surfaces of the upper and lower dies. Is formed by opening a suction port of the mold, and an introduction port for introducing compressed air from the outside is provided between the sheet-like materials so as to face a part of the inner surface of the mold, thereby molding a molded product having a desired shape. As a result, despite the simple structure, various excellent effects listed below can be obtained.

That is, it is possible to form a molded product having a desired shape from a plurality of sheet-shaped materials, and in the conventional blow molding of a cylindrical material, compressed air is taken in from a cylindrical end. , Any number of air intakes can be set at any position. Further, by forming a plurality of air inlets, it is possible to form a hollow molded article in which a plurality of independent hollow layer portions are provided in one component.
Furthermore, unlike blow-molded products made of conventional tubular materials,
It is possible to form a product that secures a high-strength portion in which two sheet-shaped materials are adhered to each other on the outer periphery of the molded product.

Further, according to the present invention, the contour of the molded product can be formed in a complicated line such as a cloud shape by simultaneously trimming the sheet-shaped material. Moreover, by providing the cylinder inside the molding die, there is an advantage that it is possible to form a hole at the same time when the two sheet-shaped materials are brought into close contact with each other during molding.

Further, according to the present invention, conventionally, when molding a molded product composed of two sheet-shaped materials, it is necessary to compensate for the lack of strength in the product pressed by the press, and for this reinforcement, Although metal fittings are sandwiched in the middle of the material, the rigidity can be increased by making them hollow, and the cost can be reduced by removing the reinforcing metal fittings. Then, in order to secure the strength in the product formed by press molding the conventional sheet-shaped material, the shape for ensuring the strength tends to be prioritized over the design as the product, but according to the present invention,
By hollowing out the molded product, the front side gives priority to the designer's sensibility and the back side can focus on the design to secure the strength.

Further, according to the present invention, since the hollow molded article is composed of a portion where two sheet-like members are in close contact with each other and a hollow portion, the molded article may be formed depending on the mounting specifications of the mating component. There is also an advantage that most of the two are molded products that are in close contact with each other, and a hollow seat surface is provided at the mounting site, which eliminates the need for a separate part to match the height of the conventional mounting surface. .

Further, according to the present invention, the molded product to be molded is also a hollow molded product which is integrally molded by joining at least two sheets of material and forms a hollow portion inside. Even if they are made of materials that are separable from each other or that they are separable by interposing a release material on the abutment surface, die-molded products made of sheet-like materials and having the same or different shapes can be processed simultaneously in the same process. It is also possible to mold and mold two molded products at the same time, and separate and cut after molding, which is excellent in productivity.

[Brief description of drawings]

FIG. 1 is a schematic view showing an embodiment of an apparatus for manufacturing a molded product and a method for manufacturing the same according to the present invention, and showing the manufacturing steps in (a) to (f).

FIG. 2 is a sectional view of an essential part showing an embodiment of an apparatus for manufacturing a molded product according to the present invention.

FIG. 3 is a schematic plan view of FIG.

FIG. 4 is a schematic side sectional view of FIG.

5A to 5C are schematic diagrams showing the schematic configuration of the compressed air introducing portion shown in FIG. 4 and its operating state in FIGS.

FIG. 6 is a schematic view illustrating a molded product molded by the manufacturing apparatus and the manufacturing method according to the present invention, as illustrated in (a) to (c).

FIG. 7 is a schematic view showing another modified example of the molded product according to the present invention.

FIG. 8 is a schematic view showing still another modified example of the molded product according to the present invention.

[Explanation of symbols]

 1 Sheet-shaped material 2 Sheet-shaped material 3 Molded product 4 Hollow part 8 Molded product 9 Molded product 10 Mold 11 Upper mold (upper mold) 12 Lower mold (lower mold) 13 Mold inner surface 14 Mold inner surface 15 Fitting Mating part 16 Fitting part 17 Trim blade 18 Mold matching surface part 19 Mold matching surface part 20 Suction port 21 Nozzle (introduction port) 22 Compressed air introduction part 30 Manufacturing equipment

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Claims (7)

[Claims] 1. A molding die comprising a lower mold and an inner surface of the mold having a required surface shape, wherein the molding mold is provided between the upper and lower molds.
At least two sheet-shaped materials can be arranged in a stacked state, and a plurality of suction ports for sucking air from the inside of the mold are formed on the inner surfaces of the upper and lower molds, and An apparatus for manufacturing a molded article, characterized in that an inlet for introducing compressed air from the outside is provided between the sheet-like materials facing a part of the inner surface of the mold. 2. The apparatus for producing a molded article according to claim 1, wherein the sheet-shaped material is made of the same or different material, and the thickness of each material is the same or different. An apparatus for manufacturing a molded product, characterized in that a product is selectively used. 3. Forming a molding die, stacking and interposing at least two sheet-like materials between the upper and lower dies to perform mold clamping, and then compressing air between the sheet-like materials between the upper and lower dies. Compressed air is introduced from the inlet of the to form a hollow part inside both materials, and air is sucked from the air suction port on the inner surface of each mold to mold the sheet material into the required shape according to the inner surface shape of the mold. Then, the method for producing a mold-molded product is characterized in that the mold-molded product having a predetermined shape is taken out by performing mold opening thereafter. 4. The method for producing a mold-molded product according to claim 3, wherein the mold-molded product molded by the mold is integrally molded by joining the ends of at least two sheet-shaped materials to each other and forming a hollow part. A method for producing a molded article, which comprises molding a molded article having: 5. The method for producing a molded article according to claim 4, wherein the hollow portion formed inside the molded article is filled with a foam to fill the hollow portion. . 6. The method for producing a mold-molded product according to claim 3, wherein at least two sheet-shaped materials interposed between the molding dies have a separating material interposed between materials which are separable from each other or contact surfaces. According to the present invention, the method for producing a molded article is characterized in that it is separable after molding. 7. The method for manufacturing a mold-formed product according to claim 3, claim 4, claim 5, or claim 6, wherein as the sheet-shaped material, materials made of the same or different materials are selectively used, and respectively. A method for producing a molded article, characterized in that the same thickness or different thicknesses are selectively used.