JPH0741621B2 - Manufacturing method of molded base material with bracket attached - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention uses a mat material impregnated with or mixed with a binder as a raw material, and heat-compresses the mat material between molding dies to form a molding base having a predetermined shape. The present invention relates to a method of manufacturing wood.

This mat material is specifically wood chips, paper, sugar cane,
Liquids, powders, pastes, binders, natural fibers such as bamboo, cotton, hemp, etc., fibers disintegrating used cloth, synthetic resin fibers, inorganic fibers such as glass fibers, or mixed fibers thereof as a binder. It is a material in which a thermosetting resin such as a phenol resin or a thermoplastic resin such as a propylene resin is impregnated or mixed in the form of strips or fibers.

(Prior Art) For example, a vehicle interior material such as a molded door trim board or a molded ceiling of a vehicle is manufactured by using the mat material as described above as a raw material and heating the raw material between molding dies. Or by using a hard molding base material produced by compression molding between heating molds after heating the material, and laminating a cushion layer and a decorative skin material layer on the base material. There are many.

In order to attach such an interior material to the sheet metal of the vehicle main body, as shown in FIG. 1, the engaging member attaching surface 24 having the engaging member inserting hole 22 in the center thereof and the both end edges thereof at substantially right angles to each other. The bracket 2 including the bent side wall 25 and the flange 21 bent outward from each of the side walls 25 is used to mount the bracket 2 by using the mounting hole 23 of the flange 21.
As shown in the figure, it is mechanically fixed to a predetermined position on the back surface side of the base material of the interior material 15 with a screw 27 or the like, or as shown in FIG. 2, a bracket 28 having a saw blade portion 29 at the tip edge of the side wall is internally provided. It is pressed into the base material of the material and fixed.

Then, for example, a spring seat clip 5, which is a locking tool, is mounted in the locking tool insertion hole 22 of the brackets 2, 28, and the clip 5 is strongly pressed and fitted into the clip fitting engagement hole 52 provided in the sheet metal 51. It is possible to fix the interior material 15 to the sheet metal 51 or to lock the interior material 15 in a freely colored manner.

(Problems to be Solved by the Invention) Conventionally, each of the brackets to be mounted on the molded base material has been mounted by the above method after the base material is molded. However, post-processing the brackets at desired positions on the molded base material having a complicated shape is inconvenient and inefficient in mass production, and is one of the major causes of high cost.

Also, a method of mechanically fixing to the molding substrate with the screw,
In the method of press-fitting the saw blade part of the bracket to the molded base material and fixing it, the base material is hard and somewhat difficult to toughness. There was an inferior drawback.

For this reason, as shown in FIG. 4 and FIG. 5 which is a partial detailed view thereof, a recess 33 is provided at the surface of the molding lower die 31 surface corresponding to each bracket arrangement position of the target molding substrate, and the bracket 2 is A mat material piece 11 is provided between the flange 21 and the lower molding die 31.
The main mat member 1 which is to be inserted into the concave portion 33 so as to sandwich it, and then the main mat member 1 to be the base material is heated by the lower molding die 31 and the upper molding die.
An attempt was made to introduce it between 32 and perform compression molding.

However, in this method, when the heating compression molding is performed, as shown in FIG. 6, since the upper part of the bracket attachment surface 24 of the bracket 2 is open, the main mat material portion corresponding to the surface 24 is not pressed, Also in the molded base material 13 that has been molded, as shown in the figure, the main mat material oozes out into the space with the bracket 2 as shown, and that portion is not cured and remains in a flexible pre-molding state.

Therefore, since there is the protruding portion 16, the molding substrate 13
In addition to the difficulty of inserting the locking tool into the bracket 2 mounted on the bracket 2, it was not possible to obtain a strong fixing force between the molding base material 13 and the bracket 2.

An object of the present invention is to provide a method for manufacturing a molded base material having a bracket attached thereto, which eliminates the above-mentioned conventional drawbacks.

(Means for Solving Problems) The present invention provides a mat base material containing a binder as a raw material, which is subjected to heat compression molding between molding dies to produce a molding base material having a predetermined shape. A recess is provided at a molding die surface position corresponding to each bracket mounting position, and the base is held in the molding die through the locking tool insertion hole of the bracket to be fitted, and the head is formed on the molding die surface. Equipped with an auxiliary mold that forms a part, insert the bracket into the recess by sandwiching the mat material piece between the flange and the molding die or auxiliary mold, and then mold the main mat material to be the base material. The above-mentioned problems can be solved because the gist of the method is a method of manufacturing a molding substrate having a bracket attached, which is characterized by being introduced into a mold and subjected to heat compression molding.

(Operation) Simultaneously with the compression molding of the main mat material as the molding base material, the flanges of the brackets fitted into the respective recessed positions of the mold are molded by being wrapped with the main mat material and the mat material pieces. It is embedded inside and integrated with the molding substrate.

In addition, the main mat material that could not be pressed by the mold because the upper part of the flange on the attachment surface of the fastener was open, is pressed by the auxiliary mold in the same way as other molding surfaces, so Thus, it is possible to obtain a molding substrate that is uniformly compression-molded.

Embodiment An embodiment of the present invention will be described with reference to the drawings.

The entire structure of the mounting for producing a molding base material of a predetermined shape by heat compression molding between molding dies using a mat material as a material is almost the same as that shown in FIG. An enlarged view of the improved part of the apparatus for carrying out the present invention is shown in FIG.

In FIG. 7, 31 shows a part of the lower molding die, 35 is the surface of the molding die, 33 is a predetermined surface position of the molding die surface, that is, molding corresponding to each bracket mounting position of the target molding base material. It is a recess provided at the mold surface position. In the drawings, only one place is shown as a representative.

The depth of the recess 33 is equal to the side wall 25 of the bracket 2 shown in FIG.
Is projected from the molded base material after molding, and the bottom surface thereof is matched with the size of the fitting attachment surface 24 of the bracket 2.

The recess 33 is equipped with an auxiliary mold 34. The auxiliary mold 34 is composed of a base portion 36 and a head portion 37, and the base portion 36 is detachably fitted to the lower molding die 31 by a shaft that can be inserted into the locking tool insertion hole 22 of the bracket 2 fitted in the recess 33. Have been combined,
The head portion 37 has a shape which constitutes a part of the molding die surface of the lower molding die 37 between both side walls 25 of the bracket 2 to be fitted.

In order to manufacture the molded base material to which the bracket 2 is attached, first, the bracket 2 is fitted into the recess 33 such that the mat material piece 11 is sandwiched between the flange 21 and the molding lower die 31.
Next, the base 36 of the auxiliary mold 34 is inserted into the fitting insertion hole of the bracket 2.
It is removably fixed to the lower molding die 31 through 22. Then, the main mat material 1 to be the molding base material is introduced between the lower molding die 31 and the upper molding die 32, and is heated and compressed by a compression molding mechanism (not shown). The mat material pieces 11 are integrated to form a molding base material 13. Next mold
When the molds 31 and 32 are opened, the molded product is taken out, and the auxiliary mold 34 is removed from the molded product through the notch 22a (Fig. 1) formed in the bracket attachment surface 24 of the bracket 2, as shown in Fig. 12. A molded substrate 13 having the bracket 2 attached thereto is obtained.

In this molded base material 13, the flange 21 of the bracket 2 is embedded in the inside thereof, and the portion between the side walls 25 is also pressed in the same manner as the other portions, and the entire body is uniformly compression molded, so that the flange 2 is firmly mounted. Has been done.

The main mat material 1 to be the molding base material 13 is a wood fiber mat containing 20% by weight of phenolic resin as a binder, which is compressed to 1/3 to 1/8 of the original thickness at the time of molding and the binder entangles the mat material. It is cross-linked and molded into a predetermined shape. The mat material 11 is also made of the same material or has a shorter fiber length, and its thickness is determined in consideration of the burial depth of the flange 21 of the bracket 2 and the degree of compression. It is also possible to use, as the mat material piece 11, a mat material in which a binder is semi-crosslinked in advance.

For heating the main mat material 1 and the mat material piece 11, a molding die 3 is used.
There is a method of heating 1,32 to a predetermined temperature, heating mat materials 1,11 to a molding temperature in a heating furnace in advance, or using them together. Especially when the binder contains a thermoplastic resin, if the mat material that has been heated to a predetermined temperature is compression-molded between the cooled molds,
The time required for cooling the molded substrate is shortened, and the molding cycle time can be shortened.

In the present invention, in addition to the bracket 2 provided with the mounting hole 23 shown in FIG. 1 as the bracket, other shaped brackets provided with a fastener insertion hole and a flange can be used. The locking tool insertion hole preferably has a large diameter in order to increase the thickness of the base of the auxiliary mold and to increase the buckling strength.If the mounting hole 23 is present in the flange, the mat material will enter the mounting hole 23. If the peripheral edge of the flange is processed into a saw-tooth shape, the mat member is difficult to be inserted between the blades, so that the mounted bracket can be prevented from shifting in the lateral direction.

FIG. 9 shows another embodiment in which a flange 49 is provided as the bracket 4.
FIG. 3 is a cross-sectional view showing a method of mounting the one bent inward on a molding substrate. In this case, the mat material piece 12 is placed on the head portion 37 of the auxiliary mold 34. The state after compression molding is as shown in FIG. 10, and the cross section of the obtained molding substrate 13 is shown in FIG. In this example, since the flange 49 does not extend outward, the bracket 4 can be mounted within a narrow range.

FIG. 11 is still another embodiment. In the embodiment shown in FIG. 9, when the mat material piece 12 has a large thickness and it is difficult to insert it between the flange 49 and the head 37 of the auxiliary mold 34, Adopted. The base 46 of the auxiliary die 44 is configured to be short, and the pressing plate 43 is moved to the lower die 4 at the final stage of the die clamping of the die 41, 42 during compression molding.
Since the protrusion 45 of the push plate 43 pushes up the base portion 46 of the auxiliary mold 44 and the head 47 thereof reaches the predetermined molding surface position,
Similar to the embodiment shown in FIG. 9, a molding substrate having the bracket 4 as shown in FIG. 13 attached can be obtained. The pressing plate 43 has a structure in which when the molding dies 41 and 42 are opened, they are separated from the lower molding die 41 by the repulsive force of the spring 48 and the auxiliary mold 44 descends.

(Effects of the Invention) Simultaneously with compression molding of the main mat material that is the molding base material, the flange of the bracket that is fitted into each recess of the mold is molded by being wrapped with the main mat material and the mat material piece. It is embedded in the base material and integrated with the molding base material.

In addition, the main mat material portion that could not be pressed by the molding die because the upper part of the flange on the attachment surface of the fastener is open, is pressed by the auxiliary mold in the same manner as the other molding surface.
It is possible to obtain a molding substrate that is compression-molded uniformly throughout.

Therefore, as described above, according to the present invention, the intended purpose is well achieved, and it is particularly effective and appropriate as a method for producing a molding base material for various vehicle interior materials.

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of a bracket, FIG. 2 is a perspective view showing an example of a conventionally used bracket, and FIG. 3 is a molding base material fixed to a sheet metal by a locking tool inserted in the bracket. FIG. 4 is a sectional view showing a manufacturing method by a conventional method, FIG. 5 is an enlarged sectional view of a concave portion of FIG. 4, and FIG. 6 is a sectional view of FIG. FIG. 7 and FIG. 8 are sectional views showing a state after the molding, and FIGS. 7 and 8 are sectional views before and after molding for explaining an embodiment of the method of the present invention.
FIG. 10 is a cross-sectional view before and after molding illustrating another embodiment, FIG. 11 is a cross-sectional view before molding illustrating yet another embodiment, and FIGS. 12 and 13 are manufactured by the method of the present invention. It is sectional drawing which shows the example of the shaping | molding base material which attached the bracket. 1 …… Main mat material, 2,4 …… Bracket 11,12 …… Mat material piece, 13 …… Molding base material 21,49 …… Flange, 22 …… Locking tool insertion hole 31,32,41,42 ...... Molding die 33 ...... Recess, 34,44 ...... Auxiliary dies 36,46 …… Base, 37,47 …… Head

Claims (1)

[Claims] 1. A molding die corresponding to each bracket mounting position of a target molding base material when a matting material containing a binder is used as a material to produce a molding base material of a predetermined shape by heat compression molding between molding dies. A recess is provided in the surface position, and in each recess, an auxiliary mold is formed in which the base is held by the mold through the locking tool insertion hole of the bracket to be fitted and the head constitutes a part of the mold surface. Equipped with a bracket, the mat material piece is sandwiched between the flange and the molding die or the auxiliary die, and the bracket is fitted into the recess. Then, the main mat material to be the base material is introduced between the molding dies and heated and compressed. A method of manufacturing a molded substrate having a bracket attached, the method comprising molding.