JPH0911260A - Resin molding and production thereof - Google Patents

Abstract

PURPOSE: To achieve the improvement of the appearance quality of a product and the reduction of mold cost and to strongly and closely bond a skin material and a core material to develop a soft feeling by changing the constitution of a core member by the presence of the lamination of the skin material. CONSTITUTION: A skin material 2 is partially arranged to one mold and a molten resin 17 is supplied to the space between a female mold 7 and a male mold 1 and the female and male molds 7, 13 are closed to spread the molten resin 13 within a cavity 18 to press and shape the same to integrally mold the skin material 2 and a core member. Thereafter, the molten resin is injected into the cavity between the closed female and male molds 7, 13 from a side gate 16 other than a product corresponding part under high pressure to mold the core member to produce a resin molded object bonded to the core member 4 of low pressure compression molding.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin molding such as an instrument panel, a door rim and a console box and a method for manufacturing the resin molding. More specifically, a skin material is partially bonded to a resin core and integrally molded. And a method for manufacturing the same.

[0002]

2. Description of the Related Art As a method for producing a resin molded article such as an instrument panel, a door rim, a console box, etc., which is an interior part of an automobile, a blended resin of vinyl chloride and ABS resin is extruded into a sheet shape, and then an etching squeezing roll is used. After a pattern is placed, the skin material shaped by vacuum molding and the core material (base material) shaped by injection molding or stamping molding are placed in a urethane foam mold, and then urethane foam is injected to integrally mold the material. The method was the mainstream.

The problem with this method is that it does not give a sufficient feeling of skin drawing due to etching and that the drawing is enlarged and shallowed by stretching the sheet by vacuum forming. Further, when considering recycling of parts, there is a problem that the above-mentioned three-layer structure cannot be easily separated, and the cost of waste disposal increases. Furthermore, since the above-mentioned construction method comprises three steps, that is, skin molding, core material molding, and foam molding, it has been evaluated that the foam molding for obtaining a soft feeling of the product is too costly.

Therefore, as a method for removing urethane, a method for obtaining a molded product which is less distorted by a low pressure and is less deformed,
Injection press molding method or SP mold (Low S
What is called a "Train Molding Process" is adopted. This is a composite sheet lined with EPP on a calendered or extruded sheet by vacuum forming, set in a female die of an injection molding die, and supplying molten resin into the die during the die clamping operation. The skin material and the core material are integrally molded by pressing pressure.

On the other hand, as a method for reproducing the feeling of squeezing the genuine leather, there has been conventionally a slush skin forming using an electroforming mold, and a vinyl chloride skin, a vinyl chloride foam using this method,
The integrally foamed product of the core has been adopted as a product having an excellent squeezing feeling.

[0006]

However, one of the drawbacks of the SP molding method among the above-mentioned molding methods is that the exposed portion of the resin is large in the partially bonded portion of the skin material, or
When the product shape is complicated and there is a portion where the molten resin is difficult to rotate, it is necessary to set the gate at an appropriate position, but in that case usually there is a ring mark around the gate or defective appearance such as gloss unevenness. Occur.

Further, as the mold structure, since the resin is supplied before the mold is clamped, in order to set the through hole (opening) in the product at the time of molding, the resin flowing into the through hole is sealed before the mold is clamped. In order to do so, it is necessary to install a special insert, which is required for all openings including mounting holes. Further, even in the resin exposed portion where the skin is not adhered, a cutout shape is required on the outer periphery similarly to the skin adhered portion, which causes an increase in mold cost.

The present invention solves such problems, and by changing the structure of the core body depending on whether or not the skin material is laminated, the appearance quality of the product is improved and the die cost is reduced, and the skin material is improved. An object of the present invention is to provide a resin molded product which can give a soft feeling firmly adhered to a core material and a method for producing the same.

[0009]

That is, a feature of the present invention is that in a resin molded body in which a skin material is partially integrally molded and laminated on the surface of a resin core body, the core body is a skin. A resin molded body is formed by bonding a low pressure compression molded core body in which materials are bonded together and a high pressure injection molding core body in which no skin material is bonded together.

The above skin material may be a skin material obtained by slush molding of a pulverized product of a thermoplastic elastomer, or a skin material obtained by powder slush molding of vinyl chloride resin. Alternatively, it includes a case where the sheet material is a skin material obtained by vacuum forming a sheet material in which a vinyl chloride resin and an ABS resin are mixed.

Further, according to the present invention, in a method for producing a resin molded body in which a surface of a resin core is partially molded integrally with and laminated to a surface thereof, one of the molds is partially provided with the skin. After the molten resin is supplied between the unclosed female mold and male mold, the female mold and male mold are closed, the molten resin is expanded and pressed into the cavity, and after shaping, the skin material and the core are integrally molded. Characterized in that a molten resin is injection-molded at a high pressure into a cavity between a female mold and a male mold which is closed by a side gate other than a product-corresponding portion to mold a core, and the core is joined to the core for low-pressure compression molding. There is a method for producing a resin molded body.

The skin material may be a skin material obtained by slush molding of a pulverized product of a thermoplastic elastomer, or a skin material obtained by powder slush molding of vinyl chloride resin, or The case includes a skin material obtained by vacuum forming a sheet material in which a vinyl chloride resin and an ABS resin are mixed.

The resin molding and the method for producing the same according to the present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a perspective view for explaining the basic concept of the resin molded body according to the present invention. Reference numeral 1 is an example of a resin molded body, and this resin molded body has a skin material partially (right half in FIG. 1) attached to the surface of the core body, and the remaining portion is formed by attaching the skin material. This is a structure having an unexposed core body 3.

The cores 4 and 5 of the resin molded body 1 are the same in material but different in molding method, that is, the core body 4 on the side of covering the skin material is a low pressure compression molding method, and the core material of the skin material is The core body 5 on the exposed side of the core body, which is not bonded, is formed by a high pressure injection molding method, and a through hole 6 which is an opening of the product is provided in the center portion.

Here, the skin material 2 is a skin material obtained by slush molding of a pulverized product of a thermoplastic elastomer, a skin material obtained by powder slush molding of vinyl chloride resin, or a vinyl chloride resin and an ABS resin. It is one of the skin materials obtained by vacuum forming the mixed sheet material. The material of the cores 4 and 5 is polypropylene, ABS,
It is made of polystyrene resin.

Next, a method for manufacturing a resin molded body according to the present invention will be described with reference to FIGS. In the following description, both the male type and the female type are placed horizontally, but the present invention is not limited to this, and both the male type and the female type may be placed vertically. Figure 2
As shown in FIG. 5, the skin material 2 is laminated on the surface of the resin core body and integrally molded. First, the skin material 2 separately molded by powder slush molding or vacuum molding is mounted on the female mold 7 as shown in FIG. In this case, a passage 8 penetrating to the surface of the die is provided in the female die 7, and the skin material 2 is attached to the female die 7 by operating the suction device 9 to evacuate.

A projecting portion 10 projecting from the surface of the die is provided at approximately the center of the female die 7 and is in close contact with the end portion 11 of the skin material. This protrusion 10 forms a recess 21 in the product,
A boundary is formed between the skin-bonded side and the resin-exposed side where the skin material is not bonded. On the other hand, in the central portion of the female die 7 corresponding to the resin exposed portion side 3 where the skin material is not adhered, the protrusion 12 that is larger than the protrusion portion 10 protrudes from the die surface.
Is provided, and a cut groove 22 is provided on the die surface at the left end portion of the female die 7 corresponding to the outside of the product.

On the other hand, the male mold 13 has a recess 14 for accommodating the female protrusion 10 on the mold surface in the substantially central portion thereof, and gates 15 and 16 for injecting the molten resin on the left and right sides thereof.
Is provided. Among them, the gate 15 is located at a position corresponding to the product-corresponding part to which the skin material is attached, and the side gate 16 is provided at a position not corresponding to the product-corresponding part on the resin exposed part side. In this case, the temperature of the female die 7 and the male die 13 is 30 to 40 ° C.

Next, as shown in FIG. 3, a female die 7 and a male die 1
The molten resin 17 having a relatively high viscosity is supplied to the mold surface of the male mold 13 from the gate 15 of the male mold 7 in a state where the mold 3 is half-closed and not closed. Further, as shown in FIG. 4, the female mold 7 and the male mold 13 are closed to spread the molten resin 17 into the cavity 18 on the side where the skin material is attached, and the mold clamping surface pressure is 30 to 150 kg / cm.
Press at ² to shape. In this case, the molten resin 17 is prevented from flowing by the protrusions 10 provided on the female die 7, and does not enter between the die surface and the skin material 2.

Then, as shown in FIG. 5, the molten resin 19 is injection-molded from the other side gate 16 at a high pressure to fill the cavity 20 on the side where the skin material is not adhered.
It is desirable that this injection molding be performed as soon as possible after completion of the low pressure compression molding.

After that, the female mold 7 and the male mold 13 are opened, and the resin molding is released from the mold. The obtained resin molding 1 is in the form of a panel as shown in FIG. 1, and is formed by high pressure injection molding in which the core material 4 of the low pressure compression molding in which the skin material 2 is attached to the resin core body 4 and the skin material are not laminated. It has a configuration in which the core body 5 is connected. The end portion 11 of the skin material is accommodated in the recess 21 of the core body 4,
It has a good appearance.

[0022]

INDUSTRIAL APPLICABILITY As described above, according to the resin molded product of the present invention and the manufacturing method thereof, the core body laminated with the skin material is integrally molded by the low pressure compression molding method, and the core body on the side not laminated with the skin material is high pressure. The following effects can be expected by injection molding. . The exposed portion of the core body can be formed into a structure that does not adversely affect the product surface of the side gate by high pressure injection molding, and a skin-integrated molded product with good appearance quality can be obtained. . By injection molding after mold clamping, the through hole on the side where the skin material is not laminated can be obtained at the time of molding, the cost of post-finishing can be reduced, and the hole accuracy can be improved. . There is no need for a mold-cutting structure for exposed resin parts,
A normal injection molding structure can be adopted, and the mold cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view of a resin molded body according to the present invention.

FIG. 2 shows a step of mounting a skin material on a female mold.

FIG. 3 shows a step of supplying molten resin from the male gate to the male mold surface in a state where the female mold and the male mold are not closed.

FIG. 4 shows a step of closing the female mold and the male mold and pushing the molten resin into the cavity.

FIG. 5 shows a step of injection-molding a molten resin in the remaining cavity with the female mold and the male mold being closed.

[Explanation of reference numerals] 1 resin molded body 2 skin material 3 core exposed portion 4 core for low pressure compression molding 5 core for high pressure injection molding 7 female 8 passage 10 protrusion 12 protrusion 13 male 15 gate 16 side gate 17 Molten Resin 18 Cavity 19 Molten Resin 20 Cavity 21 Recess 22 Notch Groove

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Mitsuhiro Watanabe 4-1-21, Hamazoe-dori, Nagata-ku, Kobe Mitsuboshi Belting Co., Ltd.

Claims (8)

[Claims] 1. A resin molded body in which a surface material is partially integrally molded and laminated on a surface of a resin core body, wherein the core body is a low-pressure compression molded core body and a skin material. A resin molded body, characterized in that the resin molded body is joined to a high-pressure injection-molded core body which is not laminated. 2. The resin molding according to claim 1, wherein the skin material is a skin material obtained by slush molding a pulverized product of a thermoplastic elastomer. 3. The skin material is a skin material obtained by powder slush molding of vinyl chloride resin.
The resin molded article according to the above. 4. The skin material is vinyl chloride resin and AB.
The resin molding according to claim 1, which is a skin material obtained by vacuum forming a sheet material mixed with S resin. 5. A method for producing a resin molded body, in which a skin material is partially integrally molded and laminated on the surface of a resin core,
A skin material is partially arranged in one mold, molten resin is supplied between the unclosed female mold and male mold, the female mold and male mold are closed, and the molten resin is expanded and pressed into the cavity. After integrally molding the shaped skin material and the core body, the molten resin is injection-molded at a high pressure into the cavity between the female mold and the male mold closed by the side gate other than the product equivalent part to mold the core body. A method for producing a resin molded body, characterized in that the resin molded body is combined with a low pressure compression molded core body. 6. The method for producing a resin molded article according to claim 5, wherein the skin material is a skin material obtained by slush molding a pulverized product of a thermoplastic elastomer. 7. The skin material is a skin material obtained by powder slush molding of vinyl chloride resin.
A method for producing the resin molded body described. 8. The skin material is vinyl chloride resin and AB.
The method for producing a resin molded article according to claim 5, which is a skin material obtained by vacuum forming a sheet material mixed with S resin.