JPH08142103A - Manufacture of decorated molded body using rased skin material, and metal mold therefor - Google Patents

Abstract

PURPOSE: To prevent the falling of hair on the surface of a decorated molded body, wherein the skin material comprising various kinds of cloths forms the outermost layer, and to keep the rased hair state. CONSTITUTION: Air is made to flow out through minute holes 3 and 3, which are provided in the surface of a metal mold in contact with raised skin material during the period from the supply of fused resin to cooling solidification. The air is made to escape through a metal-mold parting plane 4. Thus, the temperature rising of a hair-rased part 9 of the skin material is suppressed, and the decorated body is molded as a unitary body. Thus, the decorated molded body having the feel and touch of cloths in the intact state can be obtained. The hair-raising process by the conventional post-processing is not required, and the production cost can be greatly decreased.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a door trim for an automobile interior, an instrument panel, a glove box lid, a console lid, pillars, a handle for furniture, and other decorative molded parts using cloth as a skin material. The present invention relates to a molding method for maintaining a raised state of surface cloths when manufacturing.

[0002]

2. Description of the Related Art Interior parts of automobiles such as door trims, instrument panels, glove box lids, pillars, furniture handles, chair backrests, and other parts that directly contact a part of the human body have a texture. Since the feeling of touch is emphasized, the surface of the thermoplastic resin molded product is often decorated with various cloths. Conventionally, in the case of producing such a decorative resin molded product, a base material portion is molded with ABS resin, an adhesive is applied to the surface thereof, and various skin materials are manually attached. However, for the purpose of increasing the production quantity and reducing the manufacturing cost, in recent years, a decorative molding method has been adopted in which the surface material and the polypropylene resin as the base material are integrally molded during injection press molding. became.

In such decorative integral molding in the injection press molding, the raised portion is brought into contact with the mold surface so that the raised portion of various skin materials becomes the outermost layer when it becomes a molded product,
A thermoplastic resin is supplied to the back side of the mold, and shaping is performed by press molding by mold clamping. Thus, in the case of integrally molding with a thermoplastic resin using a raised skin material by injection press molding, usually, a thermoplastic resin in a molten state at about 200 ° C. is injected and introduced into the back side of the skin material, and the mold is closed. The resin is evenly spread along the shape of the mold to the back side of the skin material by press molding, and is cooled and solidified. Therefore, when the high-temperature resin is spread over the back surface of the raised skin material and pressed, the raised portions of the cloth on the surface of the molded product are all in a hair-falling state due to the so-called ironing effect, and the texture and tactile feeling are significantly impaired. Thus, in order to prevent the raised portion of the decorative surface material from falling down and deteriorating the value of the product, various methods have been proposed for maintaining the raised state of the surface material even during injection press molding. There is.

For example, a method for securing raised hair by molding using a non-trimmed annular weave skin material and then trimming so as to separate the tip portion of the annular weave on the surface of the molded product skin material (JP-A-61-1247). Gazette) or a method in which the mold surface, which is in contact with the raised surface of the skin material at the time of molding, is formed as a net to maintain the raised skin material on the surface of the molded product (Japanese Patent Laid-Open No. 63-
9515), or alternatively, before raising the surface material into the mold, the raised surface is previously wetted with a volatile liquid such as water, an aqueous solution, etc. to lower the temperature of the surface material during molding, A method for maintaining the raised state of the surface (Japanese Patent Laid-Open No. 64-61)
No. 213 and Japanese Patent Laid-Open No. 64-61214) have been proposed.

However, each of the methods for raising the surface of these molded products has its own problems. That is, in the method of trimming only the tip of the surface of the molded product skin after molding using the untrimmed skin material, if the molded product has a complicated shape, it is necessary to perform the trimming manually according to the shape. An efficient post-treatment process is required separately. Therefore, the original intention to shorten the process by decoratively molding the skin material and the resin by integral molding cannot be achieved, and the cost cannot be reduced.

Further, in the method in which the surface in contact with the skin material is made into a mesh body and the raised surface of the molded product is maintained, the heat of the molten resin on the back surface of the skin material and the mold clamping pressure at the time of injection press are directly applied to the skin material surface, The nap is maintained differently between the part where the mesh is in direct contact and the part where it is not in contact, resulting in an uneven surface state. For this reason, it is necessary to further perform manual work such as brushing so as to give a texture and a tactile sensation so that the unevenness of the raised state of the surface of the molded product is made uniform after the molding.

On the other hand, in the method of spraying water on the front surface or the back surface of the skin material before molding and then integrally decorating, heat is taken away due to temperature rise and vaporization of the skin, and the surface of the skin surface of the molded product is raised. Although it can be maintained, since moisture adheres to the mold during production, rust occurs in the mold and peripheral equipment, and equipment with sliding parts requires sufficient rust prevention treatment. Also,
Since excess water is contained in the skin material on the surface of the molded product, it is necessary to carry out a post-treatment for a drying operation to remove the water from the decorative integrally molded product. If such an operation is not performed, various kinds of bacteria will propagate on the decorative integrally molded product, and it will not be possible to use it as a product.

As described above, there are problems in each of the conventional methods for maintaining the raised state of the surface material of the molded product in the decorative integral molding, and a new molding method that does not burden the molding machine and the mold is required. Was there.

[0009]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to provide a skin material composed of various cloths such as moquette, tricot and jersey as an outermost layer. To provide a method for manufacturing a decorative molded product capable of preventing hair fall of the skin material on the surface of the molded product and maintaining raised hair when integrally molding the decorative molded product, and a mold device used for the same. is there.

[0010]

Means for Solving the Problems The inventors of the present invention have made extensive studies to solve the above problems and completed the present invention. That is, in the method for producing a decorative molded product according to the present invention, in the decorative integral molding with the thermoplastic resin using the raised part of the raised skin material as the outermost layer, from the supply of the molten resin to the cooling and solidification, the raised skin material is By blowing out air from the fine holes provided on the die surface that is in contact and letting air escape through the parting surface of the die, the temperature rise of the raised part of the skin material is suppressed and the decorative integral molding is performed. Is.

It is recommended that the amount of air blown out from the fine holes be adjusted to 50 to 500 cm ³ / min per unit square centimeter.

Further, in the above-mentioned manufacturing method, a raised skin material is sandwiched between a fixed side mold and a movable side mold, and a thermoplastic resin is supplied from the resin supply port of the fixed side mold to the back surface of the raised side skin material, In a mold device for integrally forming a napped skin material and a thermoplastic resin, the movable die is provided with a large number of fine holes that are opened in a surface in contact with the napped portion on the front side of the napped skin material. It can be suitably carried out by the mold device for producing a decorative molded product according to the present invention, which is configured to blow air from.

In the present invention, as a molding method for integrally molding a skin material made of various cloths and a thermoplastic resin, the skin material is placed in a mold and then the mold is closed to plasticize it. Molded by injection-filling the backside of the skin material with the thermoplastic resin, so-called in-mold molding method, or after the skin material is installed in the mold, the plasticized thermoplastic resin is injected with the mold open, There are a so-called injection stamping molding method, an injection press molding method, and the like, in which molding is performed by closing the mold at a low pressure. Further, the present invention is not limited to such a molding method, and any means capable of performing decorative integral molding of the skin material made of various cloths and the thermoplastic resin can be used.

In the decorative integral molding with the thermoplastic resin of the present invention, as a skin material, moquette, tricot, jersey and the like, various cloths having an outermost layer called brushed on the surface are covered with urethane foam and foamed chloride. Adhesive with a reinforcing layer having elasticity such as vinyl, expanded polyethylene, expanded polypropylene, etc., directly on the back side of cloths, or on these elastic bodies, non-woven fabric, adhesive layer such as thermoplastic resin film, resin flow acceleration A skin material in which the layers are adhered is used.

Examples of the thermoplastic resin used in the decorative integral molding of the present invention include polystyrene resin, acrylonitrile butadiene resin (ABS resin), low density polyethylene resin, high density polyethylene resin, polypropylene resin, vinyl chloride resin, There are others, and polymer alloys of these resins with each other or with these resins and other engineering resins are also included. In addition, glass fibers, talc, mica, etc. may be blended with these resins, or
It also includes a thermoplastic resin composition prepared by mixing various additives such as a plasticizer, a release agent and an antistatic agent, and kneading and mixing a colorant such as a pigment and a dye.

[0016]

[Function] Conventionally, a plasticized thermoplastic resin is directly injected and filled into the back side of these skin materials so that the surface of the skin material is pressure-bonded to a mold cavity, or the resin on the surface of the skin material is spread by press diffusion. For crimping to the mold cavity,
The raising of the cloths on the surface of the molded product causes the hair to fall down like ironing, but according to the present invention,
The temperature rise of the raised part of the skin is suppressed by the cooling effect of the air blown out from the fine holes provided on the mold surface where the raised skin is in contact, so the falling of the raised hair is prevented, the surface texture and tactile feel. It is possible to efficiently manufacture a decorative integrally molded product having good quality.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below with reference to the drawings. FIG. 1 is an explanatory view schematically showing an embodiment of a mold apparatus for carrying out the manufacturing method according to the present invention, and FIG.
FIG. 3 is an enlarged cross-sectional view simulating the state of the surface layer of a decorative integrally molded product molded by the manufacturing method according to the present invention, and FIG. 3 is a decoration when molded by a conventional in-mold molding method, injection press molding method, or the like. It is an expanded sectional view which shows the state of the surface layer of an integrally molded product.

In FIG. 1, 1 is a fixed-side mold, 2 is a movable-side mold, and 3 and 3 are a plurality of fine holes provided on the surface of the movable-side mold that contacts the skin material. 4 is a mold parting surface where the fixed side mold and the movable side mold are separated, 5 is an air blower for sending adjusted air to the fine holes 3 of the movable side mold, 6 is a prepared air storage tank, and 7 is a skin Thermoplastic resin supplied to the back surface of the material, 8 is a cloth-like back reinforcing foam of the skin material, 9 is a raised portion on the cloth-like surface of the cloth material, 10 is a thermoplastic resin supply port, and 11 is a nozzle of an injection molding machine. , 12 are prepared air blown out from the mold parting surface, and FIG.
9a in the inside is a raised portion of the skin material in which the raised state is maintained, and FIG.
9b in the inside shows the raised part of the skin material in which the hair fell.

In the present invention, in order to maintain the raising of the raised skin material, fine holes 3 and 3 are provided in the movable mold 2 in contact with the surface of the outermost skin material of the molded product in the mold cavity, and prepared from these fine holes. It is characterized by blowing out the generated air. Here, the fine holes 3 and 3 provided on the surface of the mold cavity that is in contact with the skin material have a diameter of 0.005 mm or more and 0.05 mm or less, and it is desirable to install as many as possible evenly per unit area. If the diameter of the fine holes 3 and 3 is 0.05 mm or more, the plasticized thermoplastic resin may intrude and solidify into the fine holes when the resin is formed by low pressure molding, and the fine holes may also be clogged with 0.005 mm. In the following, it is not preferable because the die processing becomes difficult and the air pressure to be blown out needs to be high. Therefore, the diameter of the micropores is preferably 0.005 mm or more and 0.05 mm or less, more preferably 0.01
It is preferable that the thickness is not less than mm and not more than 0.03 mm. Also, since it is necessary to cool the surface of the skin material as uniformly as possible, it is desirable to provide a large number of fine pores at even intervals. In some cases, the material of the portion of the movable die that contacts the raised skin material is porous. It is also recommended to use metal.

In the present invention, the amount of air jetted from the fine holes 3 and 3 provided on the cavity surface of the movable mold is 50 to 500 cm ³ / min per unit square centimeter.
It is good to do. That is, if it is 50 cm ³ / min or less per unit square centimeter, the effect of cooling the surface of the skin material at the time of shaping may not be sufficient, and the surface of the molded product after molding is likely to have hair fall. Further, when the density is 500 cm ³ / min or more per unit square centimeter, the cooling effect is sufficient, but the skin material is not stably fixed in the mold, and the air supply device becomes significantly large as the shaping area increases, which is economical. Not be advantageous. Thus, suitable balloon of prepared air, 50~500cm ³ / min are preferred per unit square centimeter, and more preferably to a 100~200cm ³ / min.

The term "prepared air" as used herein refers to dry air that has been prepared at a temperature as low as possible and a humidity as low as possible in order to promote the cooling effect. Since air itself has a smaller specific heat than liquids such as water,
As described above, the mass velocity is increased to achieve the cooling effect, and the evaporation of a small amount of water contained in the skin material is promoted by the low-temperature low-humidity air to remove the heat to the surface of the skin material by the introduction of the plasticized molten resin. Must be set to. Specifically, 5
It is preferable to use the same air as the generally used instrument air having a relative humidity of 50% or less at about 10 ° C.

In the present invention, the air thus prepared is supplied to the mold with the thermoplastic resin in a plasticized state after the skin is placed in the mold, and the thermoplastic resin spreads to the back side of the skin. It is indispensable that the material is shaped into a molded product and continuously supplied until it is cooled and solidified. That is, the effect of heat and pressure on the skin material by the plasticized thermoplastic resin,
In order to reduce the amount on the surface of the skin material in contact with the mold, it is necessary to supply a fixed amount of prepared air during the resin supply, shaping and cooling and solidification. The air supplied here is sequentially released into the atmosphere along with the steam vaporized by heating and the like along the mold parting surface between the surface of the skin material of the decorative integrally molded product and the mold.

As described above, by using the method and apparatus of the present invention, a decorative integral molding of a thermoplastic resin and a skin material having a raised cloth such as moquette, tricot, jersey, etc. as the outermost layer. The raised state of the surface of the molded product can be easily maintained.

That is, as shown in FIG. 3, the raised layer of the surface layer of the decorative integrally molded product formed by the conventional in-mold molding method, injection press molding method or the like is in a hair fall state 9b. As shown in FIG. 2, the surface layer of the decorative integrally-molded product formed by the manufacturing method according to the present invention can have the raised portion in the raised state 9a.

[0025]

INDUSTRIAL APPLICABILITY In the decorative integral molding of a skin material made of various cloths and a thermoplastic resin, according to the present invention, the skin material raising portion by blowing out the prepared air from the mold surface in contact with the skin material. Due to the effect of preventing the temperature rise, the raised surface of the molded product can be maintained, and a decorative molded product excellent in texture and touch can be manufactured. As a result, unlike the past, there is no need to perform a treatment to restore the raising of cloths after molding, and it is possible to significantly reduce the cost, and the skin material and thermoplastics made of cloths such as automobile interior parts, furniture parts, etc. It can now be widely used for resin-integrated molded products.

[Brief description of drawings]

FIG. 1 is an explanatory view schematically showing an embodiment of a mold apparatus for carrying out a manufacturing method according to the present invention.

FIG. 2 is an enlarged cross-sectional view schematically showing a state of a surface layer of a decorative integrally molded product molded by the manufacturing method according to the present invention.

FIG. 3 is an enlarged cross-sectional view schematically showing a state of a surface layer of a decorative integrally molded product when molded by a conventional in-mold molding method, injection press molding method or the like.

[Explanation of symbols]

 1 Fixed Side Mold 2 Movable Side Mold 3 Micro Holes 4 Mold Parting Surface 5 Air Delivery Blower 6 Prepared Air Storage Tank 7 Thermoplastic Resin 8 Cloth Back Reinforcement Foam 9 Skin Material Raising Part 9a Raising Maintained State 9b Hair Tilted state 10 Thermoplastic resin supply port 11 Injection molding machine nozzle 12 Prepared air blown from the mold parting surface

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Claims (4)

[Claims] 1. When the napped portion (9) of the napped skin material is used as the outermost layer for decorative integral molding with a thermoplastic resin, the napped skin material is provided on the surface of the mold in contact with the napped skin material from the time of supplying the molten resin to the cooling and solidification By blowing out air from the fine holes (3, 3) and letting air escape through the mold parting surface (4), it is possible to suppress the temperature rise of the raised portion (9) of the skin material and perform decorative integral molding. A method for producing a decorated molded product characterized by the above. 2. The fine holes (3, 3) provided on the die surface.
The method for producing a decorated molded article according to claim 1, wherein the amount of air blown out is adjusted to 50 to 500 cm ³ / min per square centimeter. 3. A resin supply port (10) for the fixed side mold, wherein a raised skin material is sandwiched between the fixed side mold (1) and the movable side mold (2).
Supply the thermoplastic resin (7) to the back surface of the brushed skin material from
In a mold device for decoratively forming a raised skin material and a thermoplastic resin, the movable die (2) is provided with a large number of fine holes that are opened in a surface in contact with the raised portion (9) on the front side of the raised skin material. (3, 3) is provided, and it is comprised so that air may be blown out from the said fine hole (3, 3), The metal mold | die apparatus for a decorative molded product manufacture characterized by the above-mentioned. 4. The diameter of the fine holes (3, 3) is 0.005 m.
The mold apparatus for producing a decorative molded product according to claim 3, wherein the m is 0.05 mm or more and 0.05 mm or less.