JPH09314598A - Apparatus and method for molding multilayer molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an apparatus and a method for molding a multilayer molding capable of simplifying the structure and reducing the cost of a product. SOLUTION: The apparatus for molding a multilayer molding comprises a lower mold 9 for placing a skin material 3, and an upper mold 7 for pressing to mold molten resin injected between the material 3 and the mold 9 together with the material 3. The mold 9 has a woodgrained groove 17 for woodgrain treating the peripheral edge 3a of the material 3 oppositely to the peripheral edge 3a of the material 3. The mold 7 has a protrusion 15 capable of woodgrain treating the peripheral edge 3a of the material 3 by inserting it into the groove 17 of the mold 9. When the molds 7, 9 are approached at a predetermined distance, the peripheral edge 3a of the material 3 is held by the opening edge of the groove 17 and the end of the protrusion 15.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding apparatus and a molding method for a multi-layer molded article which is suitable for use as an interior material for automobiles.

[0002]

2. Description of the Related Art For a door trim as an interior material of an automobile, a multilayer molded article 1 in which a skin material 3 covers a part of a resin molded body 2 and a parting line 5 is formed is used as shown in FIG. Has been. This multilayer molded product 1 is molded by a molding device 10 as shown in FIG.

That is, in the molding apparatus 10 shown in FIG. 14, 7 is an upper mold and 9 is a lower mold. The upper mold 7 is fixed to the upper platen 6, and the lower mold 9 is fixed to the lower platen 8. The parting line 5 of the skin material 3 is formed on the molding surface 7a of the upper mold 7.
The small projection wall 11 is provided at a position corresponding to. Also,
On the molding surface 9a of the lower mold 9, a slide mold 14 having a concave groove 12 is provided at a position corresponding to the small projection wall 11 of the upper mold 7, and the slide mold 14 is provided.
A pin 13 that can be moved up and down is provided at a position slightly away from.

When molding the multilayer molded article 1, FIG.
As shown in (a), the skin material 3 is first cut into a predetermined size.
Is placed on the molding surface 9a of the lower mold 9. In this case, the surface of the skin material 3 is arranged so as to face the upper die 7 side.

Next, the upper die 7 is lowered to move the upper die 7
And the lower mold 9 is temporarily stopped at a predetermined position where the gap between the molding surfaces 7a and 9a is larger than the product thickness. At this stop position, as shown in FIG. 14 (b), the skin material 3 is lifted while moving the pin 13 and the slide mold 14 in the upward direction to lightly contact the molding surface 7 a of the upper mold 7. next,
In this state, the molten resin 4 is injected between the lower mold 9 and the skin material 3 (the back surface side of the skin material 3) through a resin passage (not shown) provided in the lower mold 9. 0.5 seconds after the start of injection, the pin 13 is lowered to the original position shown in FIG. 14A, and the slide die 14 is also lowered to the original position after 1.0 second.

Next, as shown in FIG. 14 (c), the upper mold 7 is lowered again. As a result, the molten resin 4 becomes the skin material 3
Is spread between the molding surfaces 7a and 9a of the upper mold 7 and the lower mold 9 while being pressed by the upper mold 7 and the lower mold 9 through the skin material 3
And the resin molded body 2 are integrated to complete the shaping of the multilayer molded product 1.

After that, the upper die 7 is raised and the multilayer molded article 1 is taken out from between the upper die 7 and the lower die 9.

[0008]

However, in the conventional molding apparatus 10 described above, when the molten resin 4 is injected between the lower mold 9 and the skin material 3, the displacement of the skin material 3 is surely ensured. In order to prevent this, a mechanism is provided that lifts the skin material 3 by using the pin 13, the slide mold 14 or the like to lightly contact the molding surface 7a of the upper mold 7. Therefore, the molding apparatus 10 becomes complicated and expensive, and the price of the multilayer molded article may increase.

Further, since it takes time to raise the pin 13 and the slide mold 14 to bring the skin material 3 into contact with the molding surface 7a of the upper mold 7, the time required for molding becomes long.
Therefore, the product cost may increase.

SUMMARY OF THE INVENTION The present invention is intended to solve the above conventional problems, and provides a molding apparatus and a molding method for a multilayer molded product, which has a simple structure of the molding apparatus and can reduce the cost of the product. To aim.

[0011]

In order to achieve this object, the invention according to claim 1 arranges a skin material between two molds which are relatively movable, and one of the two molds is provided. In a molding apparatus for injecting a molten resin between a molding die and a skin material to obtain a multilayer molded article, one of the molding dies faces a peripheral edge portion of the skin material and a peripheral edge portion of the skin material. Is provided with a wood grain groove for processing

[0012] One of the other molding dies is provided with a protrusion capable of processing the peripheral edge of the skin material to be wood-grained by being inserted into the wood-grooving groove of the one molding die. When relatively approaching by a predetermined distance, the peripheral edge portion of the skin material is held by the tip portion of the protrusion and the opening edge portion of the wood grain groove.

According to a second aspect of the present invention, the protrusion height of the protrusion according to the first aspect is formed to be high at a predetermined position, and the depth of the wood-groove groove is predetermined according to the height of the protrusion. It is deeply formed at the position.

According to a third aspect of the present invention, at least one of the molding dies having the structure according to the first aspect extends toward the other molding die at a predetermined position of the opening edge portion of the wood grain groove.
The ridge is formed on the side covered with the skin material.

Further, the invention according to claim 4 is such that, on the side wall of the wood grain groove of the structure according to claim 1 on the side covered with the skin material, a ridge for holding the skin material is formed. There is.

According to a fifth aspect of the present invention, a skin material is arranged between two molds that can move relative to each other, and the skin material is melted between one of the two molds and the skin material. In a molding method of injecting a resin to obtain a multi-layer molded article, one mold having a wood grain groove facing the peripheral edge of the skin material and subjecting the peripheral edge of the skin material to a wood grain, and the one wood grain of the mold Between the other molding die having a projection capable of wood graining the peripheral edge portion of the skin material by being inserted into the groove, a disposing step of disposing the skin material, and after the disposing step,
The two molds are brought relatively close to each other by a predetermined distance, and the protrusion of the other mold is inserted into the wood grain groove of the one mold, and the tip of the protrusion and the opening edge of the wood grain groove form the skin. A holding step of holding the peripheral edge of the material, an injection step of injecting a molten resin between the one mold and the skin material after the holding step, and a step of performing the injection step simultaneously with or after the injection step. A molding step of bringing the two molds closer to each other and pressing the skin material and the molten resin.

In the present invention, a cloth, a PVC sheet, a foamed PVC sheet, a polyethylene foamed PVC sheet or the like is used as the skin material.

Specifically, the cloth is a cloth laminated with urethane or compressed urethane having a density of 0.04 to 0.3 g / m ³ , and the PVC sheet has a knitted fabric. Thickness is 0.5 to 1.0
mm, the knitted portion is 70 to 200 g / m ³ , and the foamed PVC sheet has a PVC layer thickness of 0.4 to
The thickness of the foam layer is 0.8 mm, the thickness of the foam layer is 1 to 4 mm, and the expansion ratio is 2 to 8 times. The PVC sheet with polyethylene foam has a PVC layer thickness of 0.4 to 0.8 m.
m, the polyethylene foam layer has a thickness of 2 to 5 mm with a foaming ratio of 15 to 25 times.

Further, the size of the wood grain groove formed on the one mold and the size of the projection formed on the other mold and insertable into the wood groove are such that when these two molds approach each other by a predetermined distance. A size capable of holding the peripheral edge portion of the skin material is selected by the peripheral edge portion of the opening of the wood grain groove and the tip portion of the protrusion.

Here, holding the peripheral edge of the skin member means that the inner peripheral edge of the outer peripheral material is slightly in contact with the opening peripheral edge of the wood grain groove, and the outer peripheral edge of the outer peripheral material is slightly protruding. It is in a state of being inserted into the wood grain groove by the tip. That is, the peripheral edge portion of the skin material is bent from a portion in contact with the opening peripheral edge portion of the wood grain groove, the outer peripheral edge is inserted in the wood grain groove, the skin material of the wood grain groove by its own elastic restoring force. It is held by contacting the peripheral edge of the opening and the tip of the protrusion.

Thereafter, while the peripheral edge of the skin material is held by the two molding dies by the peripheral edge of the opening of the wood grooving groove and the tip of the projection, a molten resin is injected between one of the molding dies and the skin material. To do.

Simultaneously with or after the injection of the molten resin, it is pressure-molded by a molding die to obtain a multilayer molded article.

Therefore, when injecting the molten resin,
Since the skin material is held by the two molds, the skin material is advantageously prevented from being displaced with respect to the mold. In this case, since a slide mold or the like is not required to hold the skin material, the structure of the molding apparatus is simplified and the time for operating the slide mold or the like is not required, and the number of manufacturing steps is shortened. Because you can
Product cost reduction can be advantageously achieved.

Further, by increasing the height of the protrusion at a predetermined position, the peripheral edge portion of the skin material can be held at a position where the relative distance between the two molding dies is large. It is possible to prevent the skin material from being deteriorated by the high-temperature molten resin when the molten resin is injected by increasing the interval between them.

Further, by providing a protrusion on the opening edge of the wood grain groove, it is possible to shorten the length of the peripheral edge portion of the skin material inserted into the wood grain groove, and to reduce the depth of the wood grain groove. Therefore, it is possible to shorten the dimension of the protruding portion generated on the back surface of the multilayer molded article by the wood grain groove and advantageously prevent interference with other members.

Further, by forming a ridge for holding the skin material on the side surface of the wood grain groove, the dimension between the protrusion and the side surface of the wood grain groove can be made substantially smaller (narrower). It is convenient to apply different skin materials.

[0027]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will now be described with reference to the drawings as an embodiment in which the present invention is applied to a molding apparatus and a molding method for a multilayer molded product of a door trim of an automobile.

FIG. 13 is a perspective view of a vehicle door trim. This door trim is a multi-layer molded product 1 composed of a resin molded body 2 and a skin material 3. The skin material 3 covers the resin molded body 2 to form a parting line 5 on the surface of the door trim. On the line 5, the skin material 3 is subjected to the graining treatment on the thermoplastic resin molded body 2.

FIG. 1 is a sectional view of a molding apparatus 10 for molding the multi-layer molded product 1, and FIG. 2 is an enlarged sectional view showing a main part of FIG. As shown in the figure, the molding apparatus 10 has two molds which are relatively movable, namely, an upper mold 7 and a lower mold 9, and molding surfaces are provided on the respective facing surfaces of the upper mold 7 and the lower mold 9. 7a and a molding surface 9a are formed. The skin material 3 can be arranged between the upper mold 7 and the lower mold 9, and in this embodiment, the skin material 3 is arranged on the lower mold 9.

The lower mold 9 is formed with a wood grain groove 17 which faces the peripheral edge portion 3a of the skin material 3 and performs a wood graining treatment on the peripheral edge portion 3a of the skin material 3. The wood grain groove 17 has a rectangular cross section. Then, it is formed with a uniform groove width and a uniform depth. Forming surface 9 of the portion where the wood grain groove 17 is formed
A step S for facilitating the positioning of the skin material 3 is formed in a. Further, a passage 6 for injecting the molten resin is opened at a substantially central portion of the molding surface 9a of the lower mold 9.

On the molding surface 7a of the upper mold 7, the lower mold 9 is formed.
The skin material 3 is inserted into the groove 17 of the wood.
The peripheral edge portion 3a is provided with a projection 15 capable of grain processing. The protrusion 15 is formed with a substantially uniform protrusion height at a position corresponding to the parting line 5 shown in FIG.

Here, the protrusion height h of the projection 15 formed on the upper die 7 is such that when the upper die 7 descends and the upper die 7 and the lower die 9 relatively approach each other by a predetermined distance (the molten resin is injected). 2 (a), the peripheral edge portion 3a of the skin material 3 is formed by the tip end portion 16 of the protrusion 15 of the upper die 7 and the opening edge portion 18 of the wood grain groove 17 of the lower die 9, as shown in FIG. 2 (a). Is set to a height that can hold. The depth dimension and width dimension of the wood grain groove 17 formed in the lower mold 9 is such that the molten resin is injected on the back surface side of the skin material 3, that is, between the skin material 3 and the lower mold 9, After being pressed and molded by the mold 7 and the lower mold 9, as shown in FIG. 2B, the skin material 3 is set to a size such that the resin molding 2 is subjected to wood grain processing.

Specifically, when the plate thickness of the multilayer molded product 1 is t and the gap (mold clearance) between the upper mold 7 and the lower mold 9 at the molten resin injection position is c, this mold clearance c is the skin. Depending on the type of material, it is adjusted within the range of 0 <c ≦ 15 mm, preferably when t = 2.5 mm, c = 2.5 m
A dimension of m is selected. The dimension h'from the molding surface 7a of the upper mold 7 after the molten resin is press-molded to the bottom of the wood grain groove 17 has a relationship of h '> h≥t + c.

Next, a method of molding the multi-layer molded article 1 using the molding apparatus 10 having the above-mentioned structure will be described. As shown in the time chart of the molding process shown in FIG. 3, the multi-layer molded product 1 is molded by opening the mold, starting the lowering of the upper mold, temporarily stopping the upper mold, injecting molten resin, starting the lowering of the upper mold, and molding. It is executed according to the steps of closing, cooling / solidifying, starting to lift the upper mold, and completion of lifting the upper mold.

First, at the open mold position, the skin material 3 cut into a predetermined size is placed on the molding surface 9a of the lower mold 9.
In this case, the skin material 3 is arranged so that its surface side faces the upper die 7 side, and the step S provided on the molding surface 9a of the lower die 9 is arranged.
Thus, the peripheral edge portion 3a is arranged so as to face the wood grain groove 17 (arrangement step).

Next, the upper mold 7 is lowered from the upper mold lowering start position, and the upper mold 7 is temporarily stopped at a predetermined position, that is, an upper mold temporary stop position where the mold clearance is C dimension.

At the upper die temporary stop position, the projection 15 formed on the upper die 7 is inserted into the wood grain groove 17 formed on the lower die 9, and the end 16 of the projection 15 and the opening peripheral edge 18 of the wood grain groove 17 are formed. Thus, the peripheral edge portion 3a of the skin material 3 is held (holding step, see FIG. 2A).

After the peripheral portion 3a of the skin material 3 is held, the molten resin is injected between the skin material 3 and the lower mold 9 through the passage 6 (injection step).

After the injection step, the upper mold 7 is lowered again from the upper mold re-lowering start position to the closed mold position where the mold clearance becomes zero, and the skin material 3 and the molten resin are pressed (molding process, figure 2 (b)). The state in which the mold clearance is zero is maintained until the upper mold starts to rise, and the injected molten resin is solidified and cooled.

After a lapse of a predetermined time from the closed mold position, the upper mold 7 starts to rise from the upper mold rising start position and returns to the open mold state at the upper mold lifting completion position. In this open mold state, the multilayer molded product 1 is taken out from the upper mold 7 and the lower mold 9.

It should be noted that the injection of the molten resin does not always take place in the upper mold 7.
It is not necessary to temporarily stop the lowering operation of the upper mold 7, and as shown in FIG. 4, the lowering speed of the upper mold 7 is reduced from immediately before the upper mold 7 approaches the lower mold 9 to a predetermined distance (mold clearance C).
The molten resin may be injected and pressure-molded in the decelerated state.

Therefore, when injecting the molten resin,
Since the skin material 3 is held by the two molding dies, the upper die 7 and the lower die 9, the skin material 3 is advantageously prevented from being displaced from the molding dies 7 and 9. In this case, since a slide mold or the like is not required to hold the skin material 3, the structure of the molding device 10 is simplified and
Since it is possible to shorten the number of manufacturing steps without requiring time for operating the slide mold or the like, it is possible to advantageously reduce the product cost.

According to the present invention, the skin material 3 is not limited to a multi-layer molded product having a straight grain groove, as shown in FIG.
Can be also applied to a product in which the resin molding 2 is arranged in an approximately central portion in an island shape and the wood grain groove has a continuous curve.

FIGS. 6 and 7 are views showing another embodiment of the present invention. The difference between this embodiment and the above embodiment is that the protrusion height of the projection 15 formed on the upper die 7 is different. That is, the height projection 19 is formed high at a predetermined position, and the depth of the wood grain groove 17 is formed deep at a predetermined position corresponding to the height projection 19 to form a deep groove 21.

With this structure, the tall protrusions 19 can hold the peripheral edge portion 3a of the skin material 3 at a position where the relative distance between the upper mold 7 and the lower mold 9, that is, the mold clearance is wide. As a result, the same effect as that described in the above-described embodiment is obtained, and in addition, the distance between the skin material 3 and the lower mold 9 is sufficiently increased, that is, the molten resin passage 6 is formed.
It is possible to increase the gap between the skin material 3 and the skin material 3. Therefore, since it takes time for the molten resin to reach the skin material 3 to be cooled, it is possible to prevent the skin material 3 from being deteriorated by the high temperature molten resin when the molten resin is injected. it can.

In this case, since the deep groove 21 is formed in a part of the grained groove 17, a protruding portion due to the deep groove 21 is formed on the back side of the product after the molding process, and this protruding portion is formed. Interference with a mating member, such as an inner panel, can be considered, but this can be easily solved by forming the tall protrusion 19 and the deep groove 21 at predetermined positions where interference can be avoided.

Although it is possible to hold the peripheral edge portion 3a of the skin material 3 at the position where the mold clearance is large by the tall protrusions 19, the upper mold 7 is further lowered while the skin material 3 is held. Since it is arbitrary to inject the molten resin, after all, with a single molding die having the tall protrusions 19, not only the skin material having low heat resistance but also various skin materials are used for the molding work. It is possible.

8 and 9 are views showing still another embodiment of the present invention. The difference between this embodiment and the above embodiment is that a wood grain groove 17 formed in the lower mold 9 is shown.
This is the point at which a ridge 22 extending toward the upper mold 7 side is formed at a predetermined position of the opening edge portion 18. That is, this ridge 22
Is formed in the opening edge portion 18 of the wood grain groove 17 on the side covered with the skin material 3.

With this construction, the wood grain groove 17
Since it is possible to shorten the length of the peripheral edge portion 3a of the skin material 3 inserted therein, it is possible to make the depth of the wood grain groove 17 shallow. Therefore, the size of the projection formed on the back side surface of the multilayer molded article 1 can be shortened by the wood grain groove 17, and the projection can be advantageously prevented from interfering with other members such as the inner panel.

The protrusion 22 may be formed not only in a part of the opening edge portion 18 of the wood grain groove 17 as shown in FIG. 8 but also in the entire area of the opening edge portion 18.

10 and 11 are views showing still another embodiment of the present invention. The difference between this embodiment and the embodiment is that the skin of the wood grain groove 17 formed in the lower mold 9 is shown. The point is that a ridge 23 for holding the skin material 3 is formed on the side wall covered with the material 3.

With this structure, the dimension between the projection 15 and the side surface of the wood grain groove 17 can be substantially reduced. Therefore, when applying the skin material 3 having a particularly small thickness, a predetermined holding force is applied. Can be held.

When a thin skin material is applied, as shown in FIG. 12, the protrusion 15 formed on the upper die 7
May be biased in the width direction of the wood grain groove 17 so that the dimension a from the side surface of the wood grain groove on which the skin material 3 is arranged to the protrusion is narrower than the dimension b on the opposite side.

[0054]

As described in detail above, according to the present invention, when the molten resin is injected, the skin material is held by the two molds, so that the skin material is displaced from the mold. Is advantageously prevented. In this case,
Since a slide mold or the like is not required to hold the skin material, the structure of the molding device is simplified, and the time for operating the slide mold or the like is not required, and the number of manufacturing steps can be shortened. Therefore, the product cost can be advantageously reduced.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a molding device for a multilayer molded product according to an embodiment of the present invention.

2 is an enlarged cross-sectional view showing a main part of FIG. 1, and is a cross-sectional view (a) of a holding step of holding a peripheral edge portion of a skin material and a cross-sectional view (b) of a molding step.

FIG. 3 is a time chart of a molding process.

FIG. 4 is a time chart of a molding process showing another embodiment.

FIG. 5 is a perspective view of a door trim.

FIG. 6 is a perspective view of a protrusion showing another embodiment of the present invention.

7A and 7B are enlarged cross-sectional views showing a grain-groove portion of a molding device to which the protrusion shown in FIG. 6 is applied, in which FIG. 7A is a sectional view taken along the longitudinal direction of the protrusion, and FIG. a) XX
It is a line sectional view.

FIG. 8 is a perspective view showing the vicinity of a lower wood grain groove showing still another embodiment of the present invention.

9 is a sectional view of the embodiment shown in FIG. 8 and is similar to FIG.

FIG. 10 is a perspective view showing the vicinity of a lower-grained groove, showing still another embodiment of the present invention.

11 is a sectional view of the embodiment shown in FIG.
It is a drawing similar to (a).

FIG. 12 is a cross-sectional view showing still another embodiment of the present invention, which is similar to FIG. 2 (a).

FIG. 13 is a perspective view of a door trim including a multilayer molded product.

FIG. 14 is a cross-sectional view of a conventional molding apparatus for a multilayer molded article, showing a state in which a skin material is arranged on a lower die (a), a state in which a molten resin is injected (b), and a molten resin. It is drawing (c) which shows the state pressed.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Multilayer molded product 2 Resin molded body 3 Skin material 3a Peripheral part 7 Upper mold (molding mold) 9 Lower mold (molding mold) 15 Protrusion 16 Tip part 17 Wood grain groove 18 Opening edge part

Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical display location B29C 43/36 B29C 43/36 B60J 5/00 501 B60J 5/00 501C B60R 13/02 B60R 13/02 B

Claims (5)

[Claims] 1. A multi-layer molded article in which a skin material is arranged between two molds that are relatively movable, and a molten resin is injected between one of the two molding dies and the skin material. In the molding apparatus for obtaining, in any one of the molding dies, facing the peripheral portion of the skin material, a wood grain groove for graining the peripheral portion of the skin material is provided, the other molding die,
When the two molds are relatively close to each other by a predetermined distance, the peripheral edge portion of the skin material is provided with a projection capable of being wood-grained by being inserted into the one of the molds. A molding apparatus for a multilayer molded article, characterized in that the peripheral edge of the skin material is held by the opening edge and the tip of the protrusion. 2. The protrusion height of the protrusion is formed to be high at a predetermined position, and the depth of the wood grain groove is formed to be deep at a predetermined position corresponding to the height of the protrusion. Molding equipment for multi-layer molded products. 3. A ridge is formed at a predetermined position of an opening edge portion of a wood grain groove formed in the one molding die, the ridge extending toward the other molding die and on the side covered with the skin material. The apparatus for molding a multilayer molded article according to claim 1. 4. The molding device for a multilayer molded article according to claim 1, wherein a protrusion for holding the skin material is formed on a side wall of the side surface of the wood grain groove that is covered with the skin material. 5. A multi-layer molded article in which a skin material is arranged between two molds that can move relative to each other, and a molten resin is injected between one of the two molds and the skin material. In the molding method for obtaining, one molding die facing the peripheral portion of the skin material and having a wood grain groove for graining the peripheral portion of the skin material, and by being inserted into the one wood grain groove of the molding die. An arranging step of arranging the skin material between the other peripheral edge of the skin material and the other molding die having a projection capable of graining, and after the arranging step, the two molding dies are brought relatively close to each other by a predetermined distance. A holding step of inserting the protrusion of the other molding die into the grain-groove of one molding die and holding the peripheral edge portion of the skin material by the opening edge of the grain-groove groove and the tip of the protrusion; After the process, melt between the one mold and the skin material A multi-layer comprising: an injection step of injecting a resin, and a molding step of pressing the skin material and the molten resin by bringing the two molds closer to each other simultaneously with or after the injection step. Molding method for molded products.