JPH07137058A - Apparatus for manufacturing composite molded body - Google Patents

Abstract

PURPOSE:To make it possible to obtain excellent cushioning properties throughout a cushion layer while enabling molding of a skin material in an excellent prescribed shape and also to eliminate breakdown of the cushion layer and to form clearly a grain pattern or the like. CONSTITUTION:In regard to a mold for molding a door trim, cooling water passages 10 are provided inside a bottom tool 5 with which a cushion layer comes into contact on the occasion when a skin material 2 is molded in a prescribed shape, and molding of the skin material 2 is conducted while cooling water is made to flow through these cooling water passages 10. The cushion layer being cooled down thereby, the skin material 2 can be molded in an excellent prescribed shape and a grain pattern or the like can be formed clearly at the time of monolithic molding of the skin material 2 and a base material, while excellent cushioning properties are obtained throughout the cushion layer and breakdown of the cushion layer is avoided.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in an apparatus for producing a composite molded body formed by laminating different kinds of materials.

[0002]

2. Description of the Related Art Conventionally, for example, a door trim of an automobile is made of a composite molded body in which different materials are laminated. The apparatus for producing the composite molded body is provided with a pair of upper and lower molds, and dissimilar materials are placed between the molds with the molds opened, and in this condition, the molds are closed and pressurized. As a result, a composite molded body can be obtained. Explaining the manufacturing process of the door trim concretely, between the pair of molds that have been opened, a laminated material of PVC and a cushion layer, a skin material that is preheated and molded into a predetermined shape and a texture pattern etc. is transferred. , A polypropylene base material (which is a molten resin material before molding) are placed one above the other, and the mold is closed while the skin material and base material are at a high temperature.
Pressurize to form the skin material and the base material into a predetermined shape along the molding surface shape of each mold, and bring the base material into contact with the cushion layer side of the skin material to integrate the skin material and the base material. I have to.

[0003]

However, in the manufacturing process of the door trim as described above, the skin material and the base material are in a high temperature state, and if the base material comes into contact with the cushion layer in this state, However, there is a problem that the cushioning property of the cushion layer is impaired or the cushion layer is damaged.

In order to avoid the occurrence of such a situation,
For example, as disclosed in Japanese Examined Patent Publication No. 3-27006, it is conceivable to attach a protective sheet to the cushion layer to prevent direct contact between the cushion layer and the base material. The manufacturing cost increases as the number of points increases.

Further, as disclosed in, for example, Japanese Patent Application Laid-Open No. 1-198315, one end of a mold on the side facing the cushion layer of the skin material is opened at the molding surface of the mold when molding the skin material. A plurality of cooling air passages are formed in advance, and at the time of mold closing during molding of the skin material, cooling air is supplied from this cooling air passage toward the cushion layer of the skin material to cool the cushion layer. It is also proposed to secure the cushioning property of the cushion layer and prevent the damage of the cushion layer at the time of integral molding with the base material without using such a protective sheet.

However, in the structure as disclosed in this publication, the cooling air supplied from the cooling air passage toward the cushion layer cools only the region facing the opening of the cooling air passage. However, the cushion layer does not evenly cool the entire cushion layer, and there is a portion that is insufficiently cooled. May be damaged or the cushion layer may be damaged. In addition, if the mold clearance of each mold when the skin material is molded is set to be relatively large, the cushion layer has high air permeability, and the entire cushion layer is uniformly cooled by the cooling air. However, with this, a sufficient mold closing force for the skin material cannot be obtained, and the skin material cannot be molded into a predetermined shape.
There is a possibility that the transfer of the grain pattern may be unclear. Further, in the case of such a configuration, the processing time becomes long and the workability deteriorates, and furthermore, the cooling air outlet of the cooling air passage must be closed during the integral molding with the base material. It was not practical because the number of steps would increase.

The present invention has been made in view of this point, and it is possible to form a skin material in a desired predetermined shape and form a textured pattern or the like clearly, and to improve the entire cushion layer. It is an object of the present invention to obtain an apparatus for producing a composite molded body that has cushioning properties and does not damage the cushion layer.

[0008]

In order to achieve the above object, the present invention provides a mold for cooling a skin material by uniformly cooling the entire molding surface of the mold. Was cooled evenly. Specifically, the invention according to claim 1 is provided with a pair of molding dies having a molding surface of a predetermined shape, and a skin material including a surface layer and a cushion layer is placed between the molding dies while being heated. By closing, this skin material is formed into a predetermined shape, and then, a base material is integrally formed on the cushion layer side of the skin material to produce a composite molded article. It is based on manufacturing equipment. Then, a molding surface cooling means for uniformly cooling the entire molding surface of the molding die is provided inside the molding die that contacts the cushion layer during molding of the skin material, of the pair of molding dies.

According to a second aspect of the present invention, in the apparatus for producing a composite molded body according to the first aspect, the clearance between the respective molding dies in a state where the molding dies are closed at the time of molding the skin material is determined by the thickness of the skin material. The configuration is set to be slightly smaller than the size.

According to a third aspect of the present invention, in the apparatus for producing a composite molded body according to the first or second aspect, the molding surface cooling means is constituted by a cooling water pipe formed inside the molding die. There is.

[0011]

With the above construction, the present invention provides the following actions. According to the first aspect of the invention, at the time of molding the skin material, the skin material is positioned between the pair of molding dies in a heated state, and the molding die is closed. At this time, the molding die abutting on the cushion layer of the skin material is uniformly cooled on the entire molding surface by the molding surface cooling means, whereby the entire cushion layer of the skin material is also cooled uniformly. become. Therefore, when the base material is integrally formed on the cushion layer side of the skin material, the cushion material is at a low temperature, so that the cushioning property of the cushion layer is deteriorated and the cushion layer is damaged. There is no such thing. Further, even if it is possible to obtain a sufficient mold closing force for the skin material, the entire cushion layer can be sufficiently cooled, so when a texture pattern or the like is transferred, while clearly forming the texture pattern or the like, It is possible to avoid deterioration of the cushioning property of the cushion layer and damage to the cushion layer.

According to the second aspect of the present invention, when the molding die is closed at the time of molding the skin material, the cushion layer is compressed and deformed in the thickness direction, and the surface layer and the cushion layer face each other. The surface will be pressed with high pressure. Therefore, in the case of transferring a texture pattern or the like to the surface layer, in addition to the effect according to the invention of claim 1, the texture pattern is further clearly formed, while in the cushion layer, it is a cooling surface. The cooling effect from the molding surface of the molding die is sufficiently exerted, and the entire cushion layer is cooled uniformly.

According to the third aspect of the invention, when the skin material is molded, the cooling water is circulated through the cooling water pipe formed in the molding die, whereby the entire molding surface is uniformly cooled and the skin The entire cushion layer of material will be cooled evenly.

[0014]

An embodiment of the present invention will be described below with reference to the drawings. Further, in this example, as a manufacturing apparatus for the composite molded body,
An apparatus for manufacturing a door trim 1 (composite molded article according to the present invention) formed by integrally adhering a skin material 2 and a base material 3 as shown in FIGS. 1 and 2 will be described as an example. . As shown in FIG. 3, the skin material 2 of the door trim 1 is made of a laminate of a PVC surface layer 2a and a foam cushion layer 2b, and the base material 3 is made of a resin material such as polypropylene. The base material 3 is the cushion layer 2 of the skin material 2.
It is attached to the b side.

FIG. 4 shows a state in which the upper mold 4 and the lower mold 5 as molds of the manufacturing apparatus according to this embodiment are opened.
The molds 4 and 5 will be described below. The lower surface of the upper die 4 is recessed, and the recessed portion is formed on the molding surface 4a. On this molding surface 4a, a grain pattern to be transferred to the surface layer 2a of the skin material 2 of the door trim 1 is formed. ing. A vacuum passage 6 is provided inside the upper mold 4. The vacuum passage 6 has a plurality of branch vacuum passages 6a, 6a, ... One end of which opens to the molding surface 4a, and a merged vacuum passage 6b in which the other ends of the branch vacuum passages 6a, 6a ,.
The combined vacuum passage 6b is connected via a vacuum pipe 7 to a vacuum pump (not shown). Therefore, when the vacuum pump is driven, the branch vacuum passages 6a, 6a, ... Are evacuated through the confluent vacuum passage 6b, and the branch vacuum passages 6a, 6a ,. A suction force is generated in the part. On the other hand, the upper surface of the lower mold 5 is projected, and the protruding portion is formed on the molding surface 5a having a shape corresponding to the molding surface 4a of the upper mold 4. In addition, inside the lower mold 5, a molten resin material 3 ′ (FIG.
A resin supply passage 8 for supplying the molding surface 5a to the molding surface 5a. The upstream end of the resin supply passage 8 is connected to a resin supply device (not shown) through a resin supply pipe 9, while the resin supply passage 8 is branched into a plurality of parts inside the lower mold 5, and the downstream ends of the branched parts are molding surfaces 5 a of the lower mold 5. It is open to the public. Therefore, when the resin supply device is driven, the molten resin material 3 ′ is supplied onto the molding surface 5 a of the lower mold 5 through the resin supply pipe 9 and the resin supply passage 8. Further, as a characteristic configuration of the lower mold 5, a cooling water passage 10 as a molding surface cooling means is provided inside thereof. A plurality of the cooling water passages 10 extend in the vertical direction of the paper surface of FIG. 4, and the entire lower die 5 is cooled by the supply of cooling water from a water pump (not shown). The cooling water passage 10 is arranged so that it does not interfere with the resin supply passage 8 and that the entire lower die 5, especially the molding surface 5a of the lower die 5 is uniformly cooled without unevenness. ing.

Further, in each of the molds 4 and 5, when the upper mold 4 is lowered and the mold is closed, the clearance (dimension t1 in FIG. 6) between the molds 4 and 5 is the skin to be molded. It is set to be slightly smaller than the thickness dimension of the material 2 (dimension t2 in FIG. 3). Specifically, the skin material 2
The thickness t2 of the mold is 3.6 mm, while the mold clearance t1 is set to 3.0 mm. Further, in the state where the mold is closed in this way, the clearance (dimension t3 in FIG. 8) formed between the peripheral edge of the molding surface 4a of the upper mold 4 and the peripheral edge of the molding surface 5a of the lower mold 5 is as described above. It is set to be smaller than the mold clearance t1 so that the molten resin material 3'is prevented from leaking outside between the molding surfaces 4a and 5a during the door trim molding.

Next, the molding operation of the door trim 1 by the molds 4 and 5 configured as described above will be described. The molding operation of the door trim 1 includes a molding operation of the skin material 2 and an integral molding operation of the skin material 2 and the base material 3. First, the operation of forming the skin material 2 will be described. Figure 4
As shown in FIG. 3, in the state where the upper mold 4 is lifted and the mold is opened, the skin material 2 in which the surface layer 2a and the cushion layer 2b are integrally molded in advance is placed on the upper surface, that is, the upper mold 4. The molds 4 and 5 are arranged so as to face each other. At this time, the skin material 2 is moved between the molds 4 and 5 while the edge portion of the skin material 2 is clamped by the clamp device 11. Moreover, between the skin material 2 and the upper mold 4, and the skin material 2
The heating heaters 12 and 12 are arranged between the lower mold 5 and the lower mold 5, respectively, and the heating heaters 12 and 12 heat up to a predetermined temperature. After heating the skin material 2 in this manner, the heating heater 12 is retracted, and the skin material 2 is placed between the upper and lower molds 4 and 5.
Move the mold closing operation with only the chimney placed. In this mold closing operation, the vacuum pump is driven, and a suction force is generated in the portion of the branch vacuum passages 6a, 6a, ... Opened to the upper mold forming surface 4a, so that the skin material 2 is sucked to the upper mold forming surface 4a. The upper mold 4 is abutted, and in this state, the upper mold 4 is lowered as shown in FIG. In this way, the skin material 2 is brought into contact with the upper mold molding surface 4a by the suction force, whereby the grain pattern of the upper mold molding surface 4a is transferred to the surface layer 2a. At this time, the cooling water is supplied from the water pump so that the cooling water is circulated in the cooling water passage 10 to cool the entire lower die 5 (for example, 20 to 40 ° C.). Then, with the lowering of the upper die 4 as described above, the upper die molding surface 4
Since the clearance t3 formed between the peripheral edge portion of a and the peripheral edge portion of the lower die molding surface 5a is small, the skin material 2
Is filled with air between the lower mold forming surface 5a and the lower mold forming surface 5a, and when the upper mold 4 is further lowered from this state, the pressure of the space S between the skin material 2 and the lower mold forming surface 5a. Rises. Since this pressure acts as a force that presses the skin material 2 against the upper mold molding surface 4a, the grain pattern transferred from the upper mold molding surface 4a to the surface layer 2a is more clearly formed. become. In this state, the upper mold 4
When the mold is lowered, the peripheral edge of the molding surface 4a of the upper mold 4 and the lower mold 5 are
The air gradually leaks out from a slight gap of the clearance t3 formed between the peripheral surface of the molding surface 5a and the surface layer 2a on the upper mold molding surface 4a as shown in FIG.
However, when the cushion layer 2b is in contact with the lower mold forming surface 5a, the skin material 2 is formed between the molds 4 and 5 by the forming surfaces 4a and 5a.
Will be molded into a predetermined shape. Further, as described above, the clearance t1 between the molds 4 and 5 is set to be slightly smaller than the thickness dimension t2 of the skin material 2, so that the cushion layer 2b is closed in this manner. Is compressed and deformed, and the surface layer 2a becomes the upper die molding surface 4a.
In addition, the cushion layer 2b is pressed against the lower mold molding surface 5a with high pressure. Therefore, the surface layer 2a
In the above, the grain pattern transferred from the upper mold molding surface 4a is formed more clearly, while in the cushion layer 2b, the cooling effect from the lower mold molding surface 5a is sufficiently exerted, whereby the whole is uniformly cooled. Will be done.

After the operation of forming the skin material 2 is performed in this manner, the operation of integrally forming the skin material 2 and the base material 3 is started. In the integral molding operation of the skin material 2 and the base material 3, first, as shown in FIG. 7, the upper mold 4 is lifted and the mold is opened while the vacuum suction state of the skin material 2 by the upper mold 4 is maintained. . afterwards,
The resin supply device is driven to supply the molten resin material 3'for forming the base material 3 on the lower die molding surface 5a through the resin supply pipe 9 and the resin supply passage 8. The amount of the molten resin material 3'supplied is measured in advance based on the volume and shape of the base material 3 to be molded and the opening position of the resin supply passage 8 to the lower mold surface 5a. Then, after the molten resin material 3'is supplied onto the lower mold molding surface 5a in this manner, immediately the upper mold 4 is lowered and the mold is closed. Then, when the upper mold 4 is lowered to a predetermined position, the skin material 2 and the base material 3 are integrally formed in a predetermined shape between the molds 4 and 5, as shown in FIG. Further, in this mold closed state, the cushion layer 2b is compressed and deformed. Then, in such an operation, the molten resin material 3 ′ comes into direct contact with the cushion layer 2 b, but the cushion layer 2
Since the whole b is uniformly cooled during the forming operation of the skin material 2, the cushion b of the cushion layer generated when the base material comes into contact with the cushion layer having a high temperature as in the conventional case. The deterioration of the property and the damage of the cushion layer are not caused. Therefore, it is possible to form the skin material 2 into a favorable predetermined shape, obtain good cushioning properties over the entire cushion layer 2b, and avoid damage to the cushion layer 2b. In addition, compared with the conventional type in which a cooling air passage is formed in the mold, the skin material can be cooled more quickly, which shortens the processing time and improves workability. Since the step of closing the cooling air outlet of the cooling air passage is not required at the time of integrally molding the material and the base material, it is excellent in practicality.

In this embodiment, the apparatus for manufacturing the door trim is described as an example of the apparatus for manufacturing the composite molded article, but the present invention is not limited to this, and various composite molded articles such as seat trims can be manufactured. It is applicable to manufacturing equipment.

[0020]

As described above, according to the present invention, the following effects are exhibited. According to the first aspect of the present invention, the molding surface cooling means for uniformly cooling the entire molding surface of the molding die is provided in the molding die that comes into contact with the cushion layer during molding of the skin material, of the pair of molding dies. For this reason, even when the base material comes into direct contact with the cushion layer, the entire cushion layer is uniformly cooled during the molding operation of the skin material. The deterioration of the cushioning property of the cushion layer and the breakage of the cushion layer, which have occurred when the materials come into contact with each other, will not be caused, and the entire cushion layer can be formed while allowing the skin material to be molded into a favorable predetermined shape. Good cushioning properties can be obtained over the entire length, and damage to the cushion layer can be avoided. Further, even when the mold closing force with respect to the skin material is sufficiently obtained, the entire cushion layer can be sufficiently cooled. Therefore, in the case of transferring a texture pattern or the like, the texture pattern or the like should be clearly formed. It is possible to avoid deterioration of the cushioning properties of the cushion layer and damage to the cushion layer while obtaining a good finished state of the surface material.

According to the second aspect of the present invention, the clearance between the molding dies when the molding dies are closed during molding of the skin material is set to be slightly smaller than the thickness of the skin material. While it is possible to more clearly form the embossed pattern or the like on a material that transfers the embossed pattern or the like to the surface layer, the cushion layer can sufficiently exhibit the cooling effect from the molding surface of the molding die. The whole can be cooled uniformly.

According to the third aspect of the present invention, since the molding surface cooling means is constituted by the cooling water pipe formed inside the molding die, the entire molding surface is covered by the cooling water flowing through the cooling water pipe. Since it is cooled uniformly, the entire cushion layer of the skin material can be surely cooled uniformly.

[Brief description of drawings]

FIG. 1 is a front view of a door trim.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a partially enlarged sectional view showing a structure of a door trim.

FIG. 4 is a vertical cross-sectional view showing a mold open state before forming a skin material.

FIG. 5 is a vertical cross-sectional view showing an intermediate operation of forming a skin material.

FIG. 6 is a vertical cross-sectional view showing a mold closed state at the time of forming a skin material.

FIG. 7 is a vertical cross-sectional view showing a mold open state before integral molding of a skin material and a base material.

FIG. 8 is a vertical cross-sectional view showing a mold closed state at the time of integrally molding a skin material and a base material.

[Explanation of symbols]

 1 Door Trim (Composite Molding) 2 Skin Material 2a Surface Layer 2b Cushion Layer 3 Base Material 4 Upper Mold (Molding Mold) 5 Lower Mold (Molding Mold) 4a, 5a Molding Surface 10 Cooling Water Passage (Molding Surface Cooling Means)

Continuation of front page (51) Int.Cl. ⁶ Identification number Internal reference number FI Technical indication location B29L 31:58 (72) Inventor Toshihiko Naka, 4-7-3, Miiri, Asakita-ku, Hiroshima City Nanjo Equipment Industrial Co., Ltd. Company Technology Development Department

Claims (3)

[Claims] 1. A pair of molds having a molding surface of a predetermined shape is provided, and a skin material composed of a surface layer and a cushion layer is heated and positioned between the molds to close the mold. In the apparatus for manufacturing a composite molded body, which is configured to form a composite molded body by integrally forming a base material on the cushion layer side with respect to the skin material, and then molding the skin material into a predetermined shape. Among the molding dies, a molding surface cooling means for uniformly cooling the entire molding surface of the molding die is provided inside the molding die that abuts the cushion layer during molding of the skin material. Molded body manufacturing equipment. 2. The clearance between the respective molding dies in a state where the molding dies are closed during the molding of the skin material is set to be slightly smaller than the thickness dimension of the skin material. Manufacturing equipment for composite molded products. 3. The apparatus for producing a composite molded body according to claim 1, wherein the molding surface cooling means is constituted by a cooling water pipe formed inside the molding die.