JPH0639861A - Skin integrated molded product and production thereof - Google Patents

Abstract

PURPOSE:To improve appearance by sufficiently distributing a reinforcing fiber throughout the protruding part such as a boss of a molded product to ensure the strength and rigidity of the protruding part of the molded product and eliminating the blistering of the surface of a skin material caused by the air contained in a resin material at the time of molding. CONSTITUTION:A first thermoplastic resin layer 3 having long glass fiber 5 mixed therewith so as to be oriented in a two-dimensional direction is integrally provided to the rear of a resin skin material 1. A second thermoplastic resin layer 7 having staple glass fibers 11 mixed therewith so as to be oriented in a three-dimensional direction is integrally provided to the rear of the first resin layer 3.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to improvements in a skin-integrated molded product and a method for molding the same, and more particularly to measures for improving the quality of a molded product in which reinforcing fibers are mixed.

[0002]

2. Description of the Related Art Conventionally, in order to increase the strength and rigidity of a resin molded product, as disclosed in, for example, Japanese Patent Application Laid-Open No. 4-27512, a thermoplastic resin material for press molding is used as a reinforcing fiber for glass. Fiber is mixed in.

[0003]

By the way, in the case of a resin press-molded product containing the above glass fiber, when a convex portion such as a boss or a rib is formed on the back surface of the molded product, the glass fiber is oriented in a three-dimensional direction. A thermoplastic resin material that is mixed in and formed into a mat by pressing is used. This resin material has good flowability of the glass fiber in the three-dimensional direction during molding, and can smoothly flow into the concave part of the mold to sufficiently distribute the glass fiber in the convex part of the molded product, Strength of part
The rigidity can be secured.

However, since this resin material is formed into a mat by pressing, a stress in the compression direction remains in the glass fibers oriented in the three-dimensional direction, and this stress is released in the heat softening step before molding. Therefore, the glass fibers unravel and expand,
A large amount of air is contained in the resin material.

Therefore, when the skin material is integrally joined to the surface of the molded product simultaneously with the molding by press molding, the air compressed by the pressure of the press is applied to the back surface of the skin material, that is, the joint portion between the resin material and the skin material. When the press pressure is released by releasing from the press die, the air expands, causing swelling on the surface of the skin material, resulting in a poor appearance.

As another resin material, there is a thermoplastic resin material in which glass fibers are mixed in a two-dimensional direction and are mixed and formed into a mat by pressing.

When the resin material is formed into a mat by pressing, no stress in the compressive direction remains in the glass fiber. Therefore, even if the resin material is heated and softened, it is not expanded by the glass fiber, and air is blown into the resin material. Not included. Therefore, when the skin material is integrally joined to the surface of the molded product by press molding using this resin material at the same time, air is not accumulated at the joint between the skin material and the resin material, and the skin material is removed after demolding. No blistering occurs on the surface of the.

However, in the latter resin material, since the glass fibers are oriented in a two-dimensional direction, it is difficult for the glass fibers to flow into the concave portions of the mold during press molding, and the strength and rigidity of the convex portions of the molded product cannot be secured. There is.

The present invention has been made in view of the above points, and an object thereof is to appropriately set the orientation of reinforcing fibers such as glass fibers in a resin so that the reinforcing fibers are provided with bosses or ribs. While ensuring sufficient strength and rigidity of the convex parts of the molded product by sufficiently distributing it on the convex parts of the molded product, the appearance of the skin material surface is not swollen due to the air contained in the resin material at the time of molding. To do so. Another object is to form such a molded product easily and surely.

[0010]

In order to achieve the above object, the solution means of the present invention according to claim 1 is to provide an integrally molded skin product with a resin skin material and a back surface of the skin material integrally. And the reinforcing fiber is oriented in the two-dimensional direction and mixed in, and the thermoplastic first resin layer is integrally provided on the back surface of the first resin layer, and the reinforcing fiber is oriented in the three-dimensional direction and mixed. It is characterized in that it is composed of a thermoplastic second resin layer.

In the solution means of the present invention according to claim 2, first, a resin skin material which is molded in a predetermined shape in advance is set in a molding die. Then, the thermoplastic first resin material mixed with the reinforcing fibers oriented in the two-dimensional direction and the thermoplastic second resin material mixed with the reinforcing fibers oriented in the three-dimensional direction are softened by heating, At the time of tightening, the first resin material is set in the molding die so that the first resin material comes into contact with the back surface of the skin material and the second resin material comes into contact with the back surface of the first resin material. Thereafter, the molding die is clamped and the skin material, the first resin material, and the second resin material are press-molded, so that the reinforcing resin is oriented in the two-dimensional direction and the mixed first resin layer is formed on the back surface of the skin material. The second resin layer integrally provided on the back surface of the first resin layer is integrally formed on the back surface of the first resin layer, and the second resin layer in which the reinforcing fibers are oriented and mixed in the three-dimensional direction is integrally formed. And

[0012]

With the above structure, in the present invention according to claim 1, since the reinforcing fibers are mixed in the thermoplastic second resin layer serving as the back surface of the molded article in the three-dimensional direction,
Even when there is a convex portion such as a boss on the back surface of the molded product, the reinforcing fiber is smoothly supplied to the concave portion of the mold and the reinforcing fiber is sufficiently supplied and distributed in the convex portion of the molded product, and distributed.
The strength and rigidity of the convex portion of the molded product are secured.

Further, since reinforcing fibers are mixed in a two-dimensional direction in the thermoplastic first resin layer interposed between the resin skin material and the second resin layer, this reinforcement is performed. The aggregate of fibers is hard to be unraveled by the heat of the heating process during molding, and therefore does not expand, so air is not contained in the resin material, and the occurrence of air accumulation at the joint between the resin material and the skin material is prevented, and the skin material Does not bulge on the surface.

In the second resin layer, since the reinforcing fibers are oriented in the three-dimensional direction, the reinforcing fibers are unraveled and expanded by the heat of the heating process at the time of molding, so that the second resin material contains air inside. In the pressing process, the air tries to move to the skin material side, but the movement of this air is blocked by the first resin layer as described above and does not reach the surface of the skin material. Does not adversely affect.

In the method of the present invention according to claim 2, a skin material,
Since only the first resin material and the second resin material are set in the molding die and press-molded, the first resin layer made of the first resin material in which the reinforcing fibers are mixed in the two-dimensional direction is the skin. Skin integral molding in which a second resin layer integrally provided on the back surface of the material and made of a second resin material in which reinforcing fibers are mixed by being oriented in a three-dimensional direction is integrally provided on the back surface of the first resin layer Goods are easily and reliably obtained.

[0016]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 shows a panel A as a skin-integrated molded product according to an embodiment of the present invention. In FIG. 1, reference numeral 1 denotes a resin skin material formed by vacuum molding or the like in advance so that a resin sheet such as polypropylene is fitted to the surface shape of the panel A, and the first resin is formed on the back surface of the skin material 1. The layer 3 is integrally molded. In the first resin layer 3, long glass fibers 5, 5, ... As reinforcing fibers are mixed in a thermoplastic resin, such as polypropylene, which is the same as the skin material 1, in a two-dimensional direction. A second resin layer 7 is integrally formed on the back surface of the first resin layer 3, and ribs 9 and 9 (one in FIG. 1 and two in FIG. 4 are formed on the back surface of the second resin layer 7). Will be)
Are projected integrally. The second resin layer 7 is made of the same thermoplastic resin as that of the first resin layer 3, for example, long glass fibers 11, 11, ... The skin material 1, the first resin layer 3, and the second resin layer 7 are preferably made of the same material because they are firmly integrated by press molding.

Next, a molding procedure of the panel A constructed as described above will be described with reference to FIGS.

First, long glass fibers are randomly mixed in a thermoplastic resin such as polypropylene, and the second resin material 21 in which the glass fibers 11 formed into a mat by pressing are mixed by being oriented in a three-dimensional direction, and the glass. A first resin material in which long fibers are oriented and solidified in a two-dimensional direction with a binder or the like, mixed into a thermoplastic resin such as polypropylene, and glass fibers 5 formed into a mat by a press are oriented in the two-dimensional direction and mixed. 25
And prepare. The three-dimensional direction also includes long glass fibers oriented in the two-dimensional direction.

Next, a skin material 1 made of polypropylene or the like, which has been molded in a predetermined shape by vacuum molding or the like, is prepared. As shown in FIG. 2, the skin material 1 is an upper mold 15 of a mold 13 in a mold open state. Set on the cavity surface 15a.
The procedure of this set is that the negative pressure passage 1 formed in the upper mold 15
By applying a negative pressure to the skin 7, the skin material 1 is moved to the upper mold 1 through the plurality of pores 19, 19, ... Connected to the negative pressure passage 17.
5 is held by suction on the cavity surface 15a.

Then, the glass short fibers 11, 11,
The second resin material 21 in the form of a mat, which is mixed in by being oriented in the three-dimensional direction, is heated and softened, placed on the core surface 23a of the lower mold 23 of the mold 13, and set. 5,
The mat-shaped first resin material 25 mixed by being oriented in the two-dimensional direction is heated and softened, and is placed and set on the second resin material 21. That is, when the mold is clamped, the first resin material 25 is set on the back surface of the skin material 1, and the second resin material 21 is set on the molding die 13 so as to contact the back surface of the first resin material 25, respectively.

Thereafter, as shown in FIG. 3, the upper mold 15 is lowered to evacuate the space 27 between the upper mold 15 and the lower mold 23 from the deaeration port 29.

After that, as shown in FIG. 4, the upper die 15 is further lowered to clamp the forming die 13, and the skin material 1, the first
By press molding the resin material 25 and the second resin material 21, the first resin layer 3 in which the long glass fibers 5, 5, ... Are oriented and mixed in the two-dimensional direction is integrally provided on the back surface of the skin material 1. The second resin layer 7 in which the long glass fibers 11, 11, ... Are mixed while being oriented in a three-dimensional direction is the first resin layer 3 described above.
A panel A integrally provided on the back surface of the is obtained. On the back surface of this panel A (second resin layer 7), the core surface 23 of the lower mold 23
The ribs 9 and 9 are projected by the mold recesses 31 and 31 formed in a.

As described above, in the panel A of this embodiment, the long glass fibers 11, 1 are formed in the second resin layer 7 which is the back surface of the panel A.
Since 1, ... are mixed in the three-dimensional orientation,
The long glass fiber 1 is formed in the mold recess 31 for molding each rib 9.
, 11, ... flow smoothly and each rib 9 of panel A
, Can be sufficiently supplied and distributed without being insufficient, and the strength and rigidity of each rib 9 can be secured.

Further, in the panel A of the above embodiment, the first
Since the glass long fibers 5, 5, ... Are mixed in the resin layer 3 in a two-dimensional direction, the glass long fibers 5, 5, ... Of the first resin material 25 constituting the first resin layer 3 It is possible to prevent unraveling due to heat in the heating step during molding of the aggregate, which prevents expansion of the aggregate and prevents air from being contained in the first resin material 25, and the first resin material 25 and the skin material 1
It is possible to prevent the occurrence of air accumulation at the joint portion with and to prevent swelling from occurring on the surface of the skin material 1.

The long glass fibers 11, 1 oriented in the three-dimensional direction of the second resin material 21 constituting the second resin layer 7 are formed.
Since the aggregate of 1, ... Contains a large amount of air inside as it unravels and expands due to the heat of the heating step during molding, the air tends to move to the skin material 1 side in the pressing step. However, the movement of the air can be prevented by the first resin layer 3 from reaching the skin material 1, and the adverse effect on the surface properties of the panel A can be prevented.

In the molding method of the above embodiment, the skin material 1 is placed on the upper mold 15 and the first resin material 25 and the second resin material 21 are used.
Are simply set in the lower mold 23 and press-molded, so that the first resin layer 3 in which the long glass fibers 5, 5, ... Are two-dimensionally oriented and mixed is integrally formed on the back surface of the skin material 1. , And the second resin layer 7 in which the short glass fibers 11, 11, ... Are mixed by being oriented in a three-dimensional direction is integrally and easily provided on the back surface of the first resin layer 3 in a panel A. Can be obtained.

Further, in the molding method of the above embodiment, the space 27 between the upper mold 15 and the lower mold 23 is degassed during the mold clamping, so that the air present between the first resin material 25 and the second resin material 21 is eliminated. Can be forcibly eliminated, and the frequency of occurrence of air accumulation on the back surface of the skin material 1 can be reduced.

Although the skin material 1 is set on the upper mold 15 in the above embodiment, the skin material 1 may be set on the lower mold 23. In this case, the skin material 1 is set on the skin material 1 of the lower mold 23. The first resin material 25 is placed and set, and the second resin is set on the upper mold 15.
The resin material 21 may be set.

[0030]

As described above, according to the present invention according to claim 1, the thermoplastic first resin layer in which the reinforcing fibers are mixed while being oriented in the two-dimensional direction is provided on the back surface of the resin skin material. Since the thermoplastic second resin layer in which the reinforcing fibers are oriented in the three-dimensional direction and mixed is integrally provided on the back surface of the first resin layer, the reinforcing fibers of the second resin layer are provided as a boss or the like. It is possible to secure the strength and rigidity of the convex portion of the molded article by sufficiently distributing it on the convex portion of the molded article, and to eliminate the blistering of the surface of the skin material caused by the air included in the molding of the first resin layer, which makes it look good. You can get better.

According to the method of the present invention as set forth in claim 2, after the resin-made skin material is set in the molding die, the reinforcing fibers are oriented in the two-dimensional direction and mixed, and the first thermoplastic resin material and the reinforcing fibers are mixed. Heats and softens the thermoplastic second resin material mixed by orienting in the three-dimensional direction, and at the time of mold clamping, the first resin material is on the back surface of the skin material, and the second resin material is the first resin material. The mold is set so that it contacts the back surface of the resin material, respectively, and then the mold is clamped and the skin material, the first resin material, and the second
Since the resin material is press-molded, a skin-integrated molded product having the strength and rigidity as described above and having no bulging on the surface of the skin material can be easily and surely molded.

[Brief description of drawings]

FIG. 1 is a vertical sectional view showing a part of a panel.

FIG. 2 is a set process diagram showing a state in which a skin material, a first resin material and a second resin material are set in a molding die.

FIG. 3 is a degassing process diagram for degassing a space between an upper mold and a lower mold.

FIG. 4 is a press molding process diagram of press molding a skin material, a first resin material, and a second resin material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Skin material 3 1st resin layer 5 Long glass fiber (reinforcing fiber) oriented in two dimensions 7 Second resin layer 11 Long glass fiber (reinforcing fiber) oriented in 3 dimension 13 Mold 21 Second resin material 25 1st resin material A panel (integrated skin product)

Claims (2)

[Claims] 1. A resin-made skin material, a thermoplastic first resin layer integrally provided on the back surface of the skin material, and containing reinforcing fibers oriented in a two-dimensional direction, and the first resin layer. A skin-integrated molded article, characterized in that it is integrally provided on the back surface and is composed of a thermoplastic second resin layer in which reinforcing fibers are oriented and mixed in a three-dimensional direction. 2. A thermoplastic first resin material and reinforcing fibers mixed with a reinforcing fiber oriented in a two-dimensional direction are set in a molding die in which a resin skin material molded in a predetermined shape in advance is set. A thermoplastic second resin material that is oriented in the original direction and mixed is heated and softened, and at the time of mold clamping, the first resin material is on the back surface of the skin material, and the second resin material is the first resin material. Set it in the mold so that it will contact the back of each, and then
By pressing the molding die and press-molding the skin material, the first resin material and the second resin material, the first resin layer in which the reinforcing fibers are oriented and mixed in the two-dimensional direction is integrally formed on the back surface of the skin material. The integral skin molding, characterized in that the integral skin molded article is obtained by integrally forming the second resin layer, which is provided on the backside of the first resin layer and is mixed with the reinforcing fibers in the three-dimensional direction. Molding method.