JPH07223227A - Manufacture of composite molding and manufacturing device - Google Patents

Abstract

PURPOSE:To enable the surface of a composite molding to have a cushion-like feeling with a concurrent advantage of keeping the rigidity of the composite molding, and further, eliminate a processing step by making a vacuum molding die unnecessary and avoid the production of a reject due to the positional deviation of a skin material from the bottom force of a molding die. CONSTITUTION:First, a skin material 2 consisting of a surface layer laminated to a cushion layer is heated, then the skin material 2 is deposited on the surface of a bottom force 4 and is vacuum-adsorbed onto the molding surface 4a of the bottom force to form the skin material 2 to a specified shape along a molding surface 4a and at the same time, transfer a crimp pattern to the surface layer from the molding surface 4a, in the manufacture of a door trim comprising the skin material 2 and a base material 3. After the above process, a top force 5 is closed to a bottom force 4. Then the base material is supplied into a cavity formed between the bottom force 4 and the top force 5, and consequently, the skin material 2 and the base material 3 are integrally formed in a laminated fashion.

Description

Detailed Description of the Invention

[0001]

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

[0002]

2. Description of the Related Art Conventionally, for example, Japanese Unexamined Patent Publication No. 5-16165
As disclosed in Japanese Unexamined Patent Application Publication No. 2004-242242, an automobile door trim or the like is made of a composite molded body in which different kinds of materials are laminated.
Then, as a method of manufacturing the composite molded body, a composite molded body having a predetermined shape is obtained by pressurizing different materials arranged in a stacked state in a cavity in a closed mold. A concrete example of the manufacturing process of the door trim will be described in advance.
Is formed into a predetermined shape by vacuum forming with a vacuum forming die, and at this time, the grain pattern formed on the vacuum forming die is transferred to the surface of the skin material. After that, FIG.
Further, the skin material b and the base material c are integrally formed by the trim forming die a as shown in FIG. As the operation of forming the door trim by the trim forming die a, first, as shown in FIG. 7, a skin material b formed in a predetermined shape.
Is placed on the lower mold d. Further, the upper surface of the lower mold d is formed on a molding surface d1 (same shape as the skin material b) which is an uneven surface corresponding to the door trim shape to be formed, and the skin material b is formed on the molding surface d1. Will be placed. Further, a vacuum passage d2 for vacuuming is formed in the lower die d and opens to the molding surface d1, and the skin material b is brought into contact with the molding surface d1 without a gap by the suction action from the vacuum passage d2. Will be contacted. Then, with the skin material b placed on the lower mold d in this way, as shown in FIG. 8, the upper mold e whose lower surface is formed on the molding surface e1 is lowered to close the mold. Further, in the state where the upper and lower molds d and e are closed as described above, a cavity for molding the base material c is formed between the molding surfaces d1 and e1 of the molds d and e and above the skin material b. Will be formed. Further, an injection hole e2 for injecting a base material such as urethane toward the cavity is formed through the upper mold e. Then, from this state, the base material is injected into the injection hole e2 of the upper die e to fill the cavity with the base material, and thereby the stacked state in the cavity of the closed trim forming die a. Thus, the skin material b and the base material c are arranged. Then, by opening the mold, the skin material b and the base material c
A door trim in which and are integrated will be obtained.

[0003]

However, the above-described door trim manufacturing process has the following problems. That is, since the skin material is formed in a predetermined shape by vacuum forming as a separate step in advance, a vacuum forming die is required in addition to the trim forming die,
Also, after removing the skin material from the vacuum forming die, it must be set in the lower die of the trim forming die, and if not only there are many processing steps, but there is shrinkage after forming the skin material, this Since the skin material and the lower die of the trim forming die are misaligned with each other, the skin material cannot be set at an appropriate position with respect to the lower die, which causes a defective product.

Further, when a texture pattern is transferred from the vacuum forming die to the surface of the skin material during vacuum forming of the skin material, when the skin material is transferred from the vacuum forming die to the trim forming die, Since the skin material comes into contact with and is pressed against the flat molding surface of the trim mold, there is a risk that the embossed pattern of the skin material becomes thin.

There is also a method called powder slush molding in which a skin material is formed of a powder material as a forming method capable of obtaining a high processing accuracy for the skin material, but this construction method requires high equipment cost. There were challenges.

The present invention has been made in view of this point, and eliminates the need for a vacuum forming die, reduces the number of processing steps, and causes the occurrence of defective products due to the positional deviation between the skin material and the lower die of the forming die. An object of the present invention is to provide a method for manufacturing a composite molded body that can be avoided and a manufacturing apparatus used for the manufacturing method.

[0007]

In order to achieve the above object, the present invention comprises a surface material comprising a surface layer and a cushion layer, and forming the surface material into a predetermined shape and forming a base material. And the same type. Specifically, the invention according to claim 1 is premised on a method for producing a composite molded body in which a skin material and a base material are integrally formed in a laminated state. Then, after heating the skin material formed by laminating the surface layer and the cushion layer, the skin material is brought into contact with the first molding die so that the surface layer contacts the skin material molding surface of the first molding die. And a step of forming the skin material in a predetermined shape along the surface of the skin material, and a step of closing the second molding die with respect to the first molding die after the skin material forming step. After that, the foamable base material is supplied to the cavity formed between the second mold and the cushion layer of the skin material to integrally form the skin material and the base material in a laminated state. The forming process is used.

According to a second aspect of the present invention, in the method for producing a composite molded body according to the first aspect, the surface of the first molding die for transferring the skin material transfers a pattern to the surface layer of the skin material. Therefore, the skin material is formed in a predetermined shape along the skin material molding surface, and at the same time, the pattern is transferred from the skin material molding surface to the surface layer.

According to a third aspect of the present invention, in the method for manufacturing the composite molded body according to the first or second aspect, the skin material is lowered while being held by the clamping means and placed on the upper surface of the first molding die. On the other hand, the first mold is provided with vacuum suction means, and the first mold
By sucking the skin material placed on the upper surface of the molding die toward the skin material forming surface formed on the upper surface, the skin material is formed into a predetermined shape along the skin material forming surface. Therefore, when the clamp means descends, the gripping position of the skin material by the clamp means is lowered to a position below the upper surface of the first mold.

The invention according to claim 4 relates to a manufacturing apparatus directly used in the method for manufacturing the above-mentioned composite molded body. Specifically, a skin material molding die having a molding surface of a predetermined shape on the top surface and a vacuum passage opening to the top surface is provided, and the skin material is placed on the skin material molding die, and It is premised on an apparatus for manufacturing a composite molded body in which a skin material is molded into a predetermined shape along a molding surface by a vacuuming action. Then, a groove portion in which the vacuum passage is opened and a convex portion protruding from the upper surface at a position close to the groove portion are provided on the outer edge portion of the upper surface of the skin material forming die.

[0011]

With the above construction, the present invention provides the following actions. In the invention according to claim 1, the vacuum forming mold which has been conventionally required can be eliminated. Further, since the cushion layer is interposed between the surface layer and the base material, even when a hard material is used for the base material,
A good cushioning feeling on the surface of the composite molded body can be obtained.

According to the second aspect of the invention, the skin material is formed into a predetermined shape along the skin material molding surface, and at the same time, the pattern is transferred from the skin material molding surface to the surface layer. Since the skin material is not transferred to another mold even when it is integrally molded with the base material, it is avoided that the pattern becomes unclear.

According to the third aspect of the invention, when the skin material is placed on the skin material molding surface of the first molding die, the gripping position of the skin material by the clamp means is lower than the upper end surface of the first molding die. Since it is lowered to the position, the skin material is bent along the corner of the upper surface of the first molding die, whereby sufficient airtightness between the skin material and the upper surface of the molding die is obtained. Thus, the vacuum leakage at the time of vacuum suction is surely prevented.

According to the fourth aspect of the present invention, when the skin material is placed on the skin material forming die, a part of the outer edge portion of the skin material enters the groove due to vacuum suction from the vacuum passage. At a position close to the groove, a part of the groove is curved along the protrusion. Therefore, the contact surface between the skin material and the upper surface of the skin material forming die is sufficiently secured, the airtightness between the skin material and the upper surface of the skin material forming die is sufficiently obtained, and the vacuum at the time of vacuum adsorption is obtained. Leakage will be reliably prevented.

[0015]

An embodiment of the present invention will be described below with reference to the drawings. Further, in this example, as the composite molded body, a door trim 1 formed by integrally adhering a skin material 2 and a base material 3 as shown in FIG. 4 will be described as an example. In addition, as a characteristic of this door trim 1, as shown in FIG.
It is composed of a laminate of a PVC surface layer 2a and a foam cushion layer 2b. The base material 3 is made of a material such as hard urethane, and the base material 3 is attached to the skin material 2 on the cushion layer 2b side.

FIG. 2 shows a lower mold as a mold for the molding apparatus of the manufacturing apparatus according to the present invention, which is the first mold referred to in the inventions of claims 1 to 3 and the skin material mold referred to in the invention of claim 4. 4 shows the lower mold 4 and the second mold according to the invention described in claims 1 to 3.
The upper mold 5 and the upper mold 5 are closed, respectively. The molds 4 and 5 will be described below. Lower mold 4
Has a recessed upper surface, and the recessed portion is formed on a molding surface 4a as a skin material molding surface.
The surface has a grain pattern transferred to the surface layer 2a of the skin material 2 of the door trim 1. Further, inside the lower mold 4, a vacuum passage 6 as a vacuum suction means is provided. 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 ,.
And the merging vacuum passage 6b is connected to a vacuum pump (not shown). Therefore, when the vacuum pump is driven with the skin material 2 placed on the lower mold 4, the branch vacuum passages 6a, 6 are diverged via the confluent vacuum passage 6b.
a, ... Are evacuated, and the branch vacuum passages 6a, 6a,
... Suction force is generated in the open portion to the lower die molding surface 4a,
As shown in FIG. 2, the skin material 2 is attracted to the molding surface 4 a of the lower mold 4.

On the other hand, as shown in FIG. 3, the upper mold 5 has a lower surface protruding, and the protruding portion has a molding surface 4 of the lower mold 4.
It is formed on the molding surface 5a having a shape corresponding to a.
An injection hole 7 is formed through the center of the upper mold 5. The injection hole 7 has an upper end opened to the upper surface of the upper mold 5, and a lower end opened to the molding surface 5 a of the upper mold 5. Therefore, when the foamable base material is poured into the injection hole 7 in the mold closed state as shown in FIG.
The base material is filled in the cavity formed therebetween.

Further, as a characteristic of the lower die 4, as shown in FIG. 6, the outer edge portion of the upper surface of the lower die 4 has a high adsorption force when the skin material 2 is placed on the lower die 4 and vacuum-adsorbed. To get
It has a structure that prevents vacuum leakage. Specifically, a groove portion 8 that is slightly recessed is continuously formed over the entire outer edge portion of the upper surface of the lower die 4, and the groove portion 8 is formed.
Of the branch vacuum passages 6a, 6a, ... Outermost of the branch vacuum passages 6a 'is formed with an upper end opening. As a result, on the bottom surface of the groove portion 8,
Branch vacuum passage 6 with a predetermined interval along its extension direction
Since a ', 6a', ... Are open, the inside of the groove portion 8 is set to a vacuum state when the vacuum pump is operated. Further, on the outer surface of the groove 8 on the upper surface of the lower die 4, a slightly semicircular convex section is slightly projected over the entire circumference of the lower die 4 at a position spaced apart from the groove 8. The part 9 is formed. In this way lower mold 4
Since the outer edge portion of the upper surface of the upper cover 2 is configured, when the vacuum passage 6 is evacuated in a state where the upper cover 2 is placed on the upper surface of the lower mold 4 as shown in FIG. At the outer edge portion, a part of the outer edge portion enters the groove portion 8 and is convexly curved downward, and the outer edge portion is curved upwardly along the convex portion 9 so as to be convexly curved. By this, the contact surface between the skin material 2 and the upper surface of the lower mold 4 is surely obtained, and the vacuum leakage when the skin material 2 is vacuum-sucked is prevented and a high suction force is obtained.

Further, in the manufacturing apparatus of this example, as shown in FIG. 1, a heating furnace 10 for heating the skin material 2 is installed on the side of the lower mold 4. The heating furnace 10 includes heaters 10b, 10b on the upper and lower surfaces of the inner wall of the casing 10a.
When the skin material 2 gripped by the clamps 11, 11 is introduced, the skin material 2 is heated from above and below. Further, the skin material 2 gripped by the clamping means 11, 11 is gripped in such a state that the surface layer 2a is located on the lower side and the cushion layer 2b is located on the upper side (as shown in FIG. 5). There is.

Next, the manufacturing operation of the door trim 1 by the manufacturing apparatus configured as described above will be described. One of the features of the manufacturing operation of the door trim 1 is that the skin material forming step of forming the skin material 2 and the integral forming step of integrally forming the skin material 2 and the base material 3 are paired as described above. It is to be done only with molds 4 and 5. First, the skin material forming step will be described. In this step, as shown in FIG. 1, in a state where the upper mold 4 (not shown in FIG. 1) is lifted and the mold is opened, the surface material 2a and the cushion layer 2b are previously integrated with each other. 2 is placed between the molds 4 and 5 such that the surface layer 2a faces the lower side, that is, the lower mold 4, and the cushion layer 2b faces the upper side, that is, the upper mold 5.
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 being gripped by the clamp means 11. Then, before placing the skin material 2 on the lower mold 4, the skin material 2 is introduced into the heating furnace 10 (see arrow A in FIG. 1), and the skin material 2 is, for example, 160 ° C.
Heat to 180 ° C. Then, after the skin material 2 is softened by such heating, it is taken out from the heating furnace 10 (see arrow B in FIG. 1), and is positioned above the lower mold 4 as shown in FIG. The skin material 2 is placed on the upper surface of the lower mold 4 by lowering the 11, 11. At the same time as this operation, the vacuum pump is driven,
A suction force is generated in the branch vacuum passages 6a, 6a, ... Opened to the upper die molding surface 4a, and as shown in FIG.
Is suction-contacted to the molding surface 4a of the lower mold 4, and as a result,
The skin material 2 is formed into a predetermined shape along the molding surface 4a, and at the same time, the grain pattern is transferred from the lower mold molding surface 4a to the surface layer 2a. Further, in the outer edge portion of the lower mold 4, as shown in FIG. 6, a part of the outer edge portion of the skin material 2 is the groove portion 8
It enters into the inside and is convexly curved downward, and on the outside thereof, it is convexly curved upward along the convex portion 9, whereby the upper surfaces of the skin material 2 and the lower mold 4 are curved. The contact surface with is surely obtained. Further, as shown in FIG. 6, the lowering positions of the clamping means 11, 11 are set below the upper surface of the outer edge of the lower mold 4. Therefore, in addition to the curved state of the skin material 2 as described above, the skin material 2 is bent along the corner of the upper surface of the lower die (C portion in FIG. 6), whereby the skin material 2 High air-tightness is obtained between the upper surface of the lower mold 4 and the upper surface of the lower mold 4, and vacuum leakage during vacuum suction is reliably prevented, and the skin material 2 is brought into contact with the molding surface 4a of the lower mold 4 with high suction power. Will be. Therefore, the skin material 2 can be formed in a good shape along the molding surface 4a, and the processing accuracy can be improved.

In this way, the skin material 2 is provided on the upper surface of the lower mold 4.
In the state in which the two are in contact with each other, the step of integrally forming the skin material 2 and the base material 3 is performed. The step of integrally forming the skin material 2 and the base material 3 is
First, as shown in FIG. 3, the upper mold 5 is lowered and the mold is closed while the vacuum suction state of the skin material 2 by the lower mold 4 is maintained. In addition, in the state where the upper and lower molds 4 and 5 are closed as described above, a cavity for molding the base material 3 is formed between the molding surfaces 4a and 5a of the molds 4 and 5 and above the skin material 2. Has been formed. Then, from this state, the base material is injected into the injection hole 7 of the upper mold 5 to fill the inside of the cavity with the base material. Further, this base material is a urethane material that becomes hard when cured, and the injection amount thereof is measured beforehand based on the volume of the base material 3 to be formed. As a result, the skin material 2 and the base material 3 are arranged in a laminated state in the cavity of the closed trim forming die, and after that, the respective molds 4 and 5 are cooled, and then the mold is opened to open the mold. As a result, the door trim 1 in which the skin material 2 and the base material 3 are integrated can be obtained.

Since the door trim 1 is manufactured by the above operation, the door trim 1 as a finished product has a cushion layer between the surface layer 2a and the substrate 3 while using a hard material for the substrate 3. Since 2b is interposed, the cushion feeling of the surface can be favorably obtained while maintaining the rigidity of the door trim 1. Further, in the manufacturing method of this example,
Since only the pair of upper and lower molds 4 and 5 can form the skin material 2 into a predetermined shape, transfer the texture pattern, and integrally mold the skin material 2 and the base material 3, they have been conventionally required. It is possible to eliminate the need for a vacuum forming die for forming the skin material in a predetermined shape and transferring the embossed pattern, reducing processing steps and generating defective products due to the displacement of the skin material 2 and the lower die 4. Can be avoided. Further, after the grain pattern is transferred from the molding surface 4a of the lower mold 4 to the surface layer 2a, the skin material 2 may be transferred to another molding mold even when it is integrally molded with the base material 3. Therefore, the door trim 1 as a finished product has the texture pattern clearly transferred to the surface thereof, and the appearance thereof is excellent.

In this embodiment, the door trim is taken as an example of the composite molded body for explanation, but the present invention is not limited to this, and can be applied to various other composite molded bodies. Also,
By mixing glass fiber or the like in the base material, the rigidity of the door trim as a whole can be set high. In this example, the base material is injected with the molds 4 and 5 closed, but the base material is placed in the cavity between the molds 4 and 5 with the upper mold 5 slightly opened. The material may be injected, and then the upper mold 5 may be lowered to close the mold. Further, it is also possible to set matte glass fibers or the like with the upper mold 5 opened, inject the base material, and then lower the upper mold 5 to clamp the mold.

[0024]

As described above, according to the present invention, the following effects are exhibited. According to the invention of claim 1, after heating the skin material formed by laminating the surface layer and the cushion layer, the skin material is placed so that the surface layer contacts the skin material forming surface of the first mold. A skin material forming step of bringing the skin material into contact with the first molding die to form the skin material in a predetermined shape along the skin material molding surface, and after the skin material forming step, with respect to the first molding die Laminating the skin material and the base material by closing the second mold and then supplying the foamable base material to the cavity formed between the second mold and the cushion layer of the skin material. Since the method for producing a composite molded body includes an integrally forming step of integrally forming in a state, the formation of the skin material into a predetermined shape and the integral molding of the skin material and the base material are performed by only one pair of molds. Since it can be done together, the skin material that was required in the past was formed into a predetermined shape. Vacuum forming mold to can be eliminated, it is possible to avoid occurrence of defective products due to the positional deviation between the reduction and the skin material and the lower die processing steps. Even when a hard material is used for the base material, the composite molded body as a finished product has the cushion layer interposed between the surface layer and the base material, so that the rigidity of the composite molded body is maintained. A good cushion feeling on the surface can be obtained.

According to the second aspect of the present invention, since the skin material is formed into a predetermined shape along the skin material molding surface, the pattern is transferred from the skin material molding surface to the surface layer at the same time. After the pattern is transferred from the surface material molding surface to this, the surface material will not be transferred to another mold even when it is integrally molded with the base material. The pattern of the molded product is clearly transferred to the surface of the molded product, and the appearance can be improved.

According to the third aspect of the invention, when the clamp means descends, the gripping position of the skin material by the clamp means is lowered to a position lower than the upper surface of the first molding die. Since the skin material is bent along the corners of the upper surface of the molding die of No. 1, sufficient airtightness between the skin material and the upper surface of the molding die can be obtained, and the vacuum leakage during vacuum suction can be ensured. Can be prevented, and the skin material can be brought into contact with the skin material molding surface of the molding die with a high suction force, and the skin material can be formed into a good shape along the skin material molding surface, improving the processing accuracy. Can be planned.

According to the fourth aspect of the present invention, the outer peripheral edge portion of the upper surface of the skin material forming die is provided with the groove portion in which the vacuum passage is opened, and the convex portion protruding from the upper surface at a position close to the groove portion. Therefore, in the state where the skin material is vacuum-sucked to the skin material forming die, a part of the outer edge portion of the skin material enters the groove portion, and the other part is curved along the convex portion. As a result, the contact surface between the skin material and the molding die can be reliably obtained, and the airtightness between the skin material and the molding die can be obtained. It is possible to contact, the skin material can be formed into a good shape along the skin material molding surface, and it is possible to obtain the manufacturing apparatus capable of improving the processing accuracy.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a manufacturing apparatus for explaining a skin material manufacturing operation.

FIG. 2 is a vertical cross-sectional view showing a state in which a skin material is placed on a lower mold.

FIG. 3 is a vertical cross-sectional view showing a state where the upper and lower molds are closed.

FIG. 4 is a vertical sectional view of a door trim.

FIG. 5 is a cross-sectional view showing the structure of a skin material.

FIG. 6 is a vertical cross-sectional view showing the shape of the outer edge portion of the lower mold.

FIG. 7 is a view corresponding to FIG. 2 in a conventional example.

FIG. 8 is a view corresponding to FIG. 3 in a conventional example.

[Explanation of symbols]

 1 Door Trim (Composite Molded Body) 2 Skin Material 2a Surface Layer 2b Cushion Layer 3 Base Material 4 Lower Mold (First Mold) 4a Molding Surface (Molding Surface Material) 5 Upper Mold (Second Mold) 6 Vacuum Passage (vacuum suction means) 8 Groove portion 9 Convex portion 11 Clamping means

Claims (4)

[Claims] 1. A method for producing a composite molded body in which a skin material and a base material are integrally formed in a laminated state, wherein a skin material formed by laminating a surface layer and a cushion layer is heated. A skin material is brought into contact with the first molding die so that the surface layer contacts the skin material molding surface of the first molding die, and the skin material is formed into a predetermined shape along the skin material molding surface. A skin material forming step, and after the skin material forming step, a second molding die is closed with respect to the first molding die, and then, between the second molding die and the cushion material layer of the skin material. A method for producing a composite molded article, comprising: an integral forming step of integrally forming a skin material and a base material in a laminated state by supplying a foamable base material to the formed cavity. 2. The surface molding surface of the first mold is adapted to transfer a pattern to a surface layer of the surface material, and the surface material is formed into a predetermined shape along the surface molding surface and at the same time the surface is formed. The method for producing a composite molded article according to claim 1, wherein a pattern is transferred from the surface of the skin material to the layer. 3. The skin material is lowered while being held by the clamp means and placed on the upper surface of the first mold, while the first mold has vacuum suction means. The skin material placed on the upper surface of the first molding die is sucked toward the skin material molding surface formed on the upper surface, thereby prescribing the skin material along the skin material molding surface. When the clamp means descends, the gripping position of the skin material by the clamp means is lowered to a position lower than the upper surface of the first molding die. The method for producing the composite molded body according to claim 1. 4. A skin material forming die having a forming surface of a predetermined shape on an upper surface and a vacuum passage opening to the upper surface, wherein the skin material is placed on the skin material forming die, and In a manufacturing apparatus for a composite molded body, which is formed into a predetermined shape along a molding surface by a vacuum drawing action, the outer edge portion of the upper surface of the skin material forming die, a groove portion in which the vacuum passage is opened, An apparatus for manufacturing a composite molded body, wherein a convex portion protruding from the upper surface is provided at a position close to the groove portion.