JPH10156865A - Manufacture of monolithic molding with skin material and base - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a refinedly designed monolithic molding with a skin material which has sharply angled ridge parts and is free from creases. SOLUTION: A molding fixture 17 of almost the same shape as an instrument panel is ranged on a male mold 12 and a skin material 2 is preformed between the molding fixture 17 and a female die 11. Next, the ridge parts 2a, 2a of a projecting cross section of the skin material 2 is vacuum-sucked into the female die 11. As the skin material 2 is preformed into a shape following the contour of the female die 11, the skin material 2 is brought into tight contact with the female die 11 without being creased. In addition, the skin material 2 is gradually stretched through discrete performing and vacuum suction processes, so that there is no fear that a break may be generated in the ridge parts 2a, 2a.

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 forming an integrally molded product of a skin material and a base material, for example, an instrument panel of a vehicle.

[0002]

2. Description of the Related Art An instrument panel of an automobile is an integrally molded product of a skin material and a base material in which a base material is joined to the back surface of the skin material. It is a member including a cross section. Since this instrument panel is always seen by the occupants in the cabin, it is preferable that the ridge of the convex cross section is sharp and angular, so that the design is excellent. Japanese Patent Application Laid-Open No. 3-26 discloses a method for manufacturing an integrally molded product of a skin material and a base material.
No. 2615, “Method for Manufacturing Interior Parts for Automobile” is known. This manufacturing method will be described with reference to the flowchart of FIG.

FIG. 10 is a flow chart for explaining a conventional method of manufacturing an integrally molded product of a skin material and a base material.
Txx indicates a step number. ST100: Prepare a skin material made of polyvinyl chloride having a sheet thickness of 0.6 mm, and heat the skin material to a softening temperature. ST101: The skin material is vacuum-adsorbed to the molding surface of the female mold and vacuum-formed into a convex cross section. ST102: Supply molten resin to the molding surface of the male mold. ST103: Clamp the mold, spin the molten resin on the back surface of the skin material, press-mold the molten resin on the base material, and integrally join the base material and the skin material. An instrument panel of an integrally molded product of the skin material and the base material is obtained.

[0004]

In the above ST101, in order to make the ridge of the convex section of the skin material sharp and angular, it is necessary to sufficiently extend the ridge of the convex section during vacuum suction. is there. For that purpose, it is necessary to strongly suction the ridge of the skin material. However, in the conventional manufacturing method, since the suction port for vacuum suction is separated from the ridge portion of the skin material, the ridge portion of the skin material cannot be sufficiently drawn by strong suction. Therefore, it is not possible to make the ridge line portion of the skin material sharp and sharp.

Further, when the skin material is heated to the softening temperature before vacuum suction as in the conventional manufacturing method, the tensile strength of the skin material decreases. Therefore, after the skin material is heated to the softening temperature, when the flat skin material is vacuum-formed into a convex cross section, the ridge portion of the skin surface having reduced tensile strength is rapidly elongated, and the ridge portion is broken. There is a fear.

Further, since the skin material is heated to the softening temperature before vacuum forming, the heated skin material is vacuum-adsorbed during vacuum forming and is adsorbed on the molding surface of the female mold. Therefore, since the heated skin material is rapidly cooled while adsorbed on the female mold surface, the skin material cannot slide and move on the mold surface during cooling. For this reason, the entire skin material cannot be uniformly shrunk, and a part of the skin material may shrink and be wrinkled.

Accordingly, an object of the present invention is to form an integral molded product of a skin material such as an instrument panel and a base material by shaping the ridge portion of the skin material into a sharp shape and without wrinkling the skin material. It is an object of the present invention to provide a technology that makes the design excellent.

[0008]

In order to solve the above-mentioned problems, a first aspect of the present invention is to open a mold composed of one mold and the other mold, and attach the one-piece mold to the integrally molded article. A forming jig arranging step of arranging a forming jig having substantially the same shape, and a skin material arranging step of arranging a skin material sandwiched between clamp members on both sides of a mold between the forming jig and the other mold. Preliminary molding step of moving the clamp member, disposing the skin material at the press molding position, clamping the mold and preliminary press molding the skin material with the molding jig and the other mold, Thereafter, a vacuum suction step of vacuum-adsorbing the ridge portion of the convex cross section of the preliminary press-molded skin material to the other mold, an intermediate mold opening step of opening the mold, and A molding jig removing step of removing the molding jig from one of the molds; A mold setting step of returning to a larger clearance, a resin injecting step of injecting a molten resin from one mold side to the clearance, and turning the molten resin on the back surface of the skin material by clamping the mold to the thickness of the molded product, This is a method for producing a skin integral molded product, which comprises an integrating step of obtaining an integral molded product.

In the mold prepared for the final integration process,
It is characterized by forming a mold for preforming only the skin material only by combining the molding jig, and preforming the skin material into a good shape without using a dedicated mold for the skin material Can be done. Next, the ridge portion of the convex cross section of the preformed skin material is vacuum-sucked to the other mold. At this time, since the skin material is in close contact with the other mold, it is possible to prevent wrinkles from being generated in the skin material, and to reliably discharge air between the skin material and the other mold. In addition, since the ridge portion of the convex cross section is vacuum-sucked to the other mold, the ridge portion can be sharply formed with a square shape. Furthermore, since the skin material is gradually elongated in two stages of preforming and vacuum suction molding, the ridge portion of the skin material can be gradually elongated, and there is no possibility that the ridge portion of the skin material will be broken. . In addition, before clamping the mold, it is possible to cover the skin material on the forming jig while moving the clamp members on both sides of the mold at a speed lower than the mold clamping speed, so that the length between the clamp members is large. It is also possible to stretch the skin material slowly.

[0010]

Embodiments of the present invention will be described below with reference to the accompanying drawings. The drawings should be viewed in the direction of reference numerals. FIG. 1 is a perspective view of an instrument panel of an automobile. The instrument panel 1 as an integrally molded product of the skin material and the base material is a member that incorporates various meters and various warning lights (not shown) into the openings 1a and 1b, and melts the base material 3 on the back surface of the skin material 2. It is a two-layer integrally molded product joined.

FIG. 2 is a sectional view taken along line 2-2 of FIG. The skin material 2 of the instrument panel 1 is, for example, polypropylene or polyvinyl chloride having a sheet thickness t ₁ of about 0.3 to 0.6 mm, and the base material 3 has, for example, a thickness t ₂ of 2.0.
It is obtained by adding a filler (talc) to polypropylene of about mm.

FIG. 3 is a simplified sectional view of the instrument panel shown in FIG. 2, showing a state where the instrument panel is rotated clockwise by 90 ° from the position shown in FIG. Hereinafter, the present invention will be described using the simplified cross section of the instrument panel 1. The same members as those in FIG. 2 are denoted by the same reference numerals. The instrument panel 1 has a molded product thickness t and includes a convex cross section, and the convex cross section has ridges 2a, 2a.
Is provided.

FIG. 4 is a front view of the molding stand according to the present invention. The molding stand 5 includes a mold opening / mold assembly mechanism 6,
It comprises a device 7 for manufacturing an integrally molded product of the skin material and the base material.
The mold opening / mold assembling mechanism 6 includes a base 6a, columns 6b standing up from the base 6a (... denotes a plurality, the same applies hereinafter), and a top plate 6c spanning over the columns 6b. An elevating plate 6d attached to the columns 6b so as to be able to move up and down, a small-diameter cylinder 6e for elevating and lowering the elevating plate 6d, and a large-diameter cylinder 6f for pushing the small-diameter cylinder 6e strongly downward if necessary. . The mold 13 (see FIG. 5) is divided and attached to the upper surface of the base 6a and the lower surface of the lifting plate 6d. This mold 13
When the mold is opened and assembled, the elevating plate 6d is raised or lowered at high speed by the small-diameter cylinder 6e. Also, mold 1
When the mold 3 is clamped, the clamp claw 6h attached to the piston rod 6j of the large-diameter cylinder 6f is closed, the small-diameter cylinder 6e and the piston rod 6j are integrated, and the large-diameter cylinder 6f is actuated. The mold can be clamped.

Apparatus 7 for manufacturing integrally molded product of skin material and base material
Comprises a clamp mechanism 8 for sandwiching the skin material 2 and a mold part 10 (see also FIG. 5) for molding the skin material 2 and the like. The clamp mechanism 8 includes a clamp elevating cylinder 8a attached to the left and right ends of the top plate 6c, and a slider connected to the distal end of the piston rod 8b of the clamp elevating cylinder 8a and attached to the left and right columns 6b so as to be able to move up and down. 8c
, And a lower clamp 8d fixed to the slider 8c,
An upper clamp 8e supported vertically above and below a lower clamp 8d, and a holding cylinder 8 attached to a slider 8c and connecting a piston rod 8f to the upper clamp 8e.
g ... The clamping mechanism 8 includes a clamping cylinder 8.
The piston rod 8f of g ... is extended and the upper clamp 8e is extended.
, And the skin material 2 is sandwiched between the upper clamps 8e and the lower clamps 8d. The clamp mechanism 8 expands and contracts the clamp elevating cylinders 8a to elevate the sliders 8c, and elevates the upper clamps 8e and the lower clamps 8d. 8h are guide pins for guiding the upper clamps 8e.

FIG. 5 is a perspective view of an apparatus (first embodiment) for producing an integrally molded product of a skin material and a base material according to the present invention. still,
The description of the clamp mechanism 8 is omitted since it is shown in FIG. The mold part 10 of the apparatus 7 for manufacturing the integrally molded product of the skin material and the base material
Is a female mold 11 as one of the molds 13 and a female mold 11
, A vacuum pump 15 as a vacuuming mechanism connected to the suction ports 14, and a male mold 12 as the other mold of the mold 13. A molten resin injection port 19a opened on the molding surface 12a of the male mold 12, a molten resin supply mechanism 20 connected to the injection port 19a, and a molding jig that can be arranged to cover the molding surface 12a of the male mold 12. 17, a sealing member 21 surrounding the cavity 16 (see FIG. 7 (b)) slidably mounted on the male mold 12, and a compression spring 22 as a pressing mechanism for pressing the sealing member 21 against the female mold 11. Consists of

The male mold 12 has a groove 28 around the molding surface 12a, and a seal member 21 is provided in the groove 28 so as to be movable up and down.
The vacuum pump 15 is a device for evacuating via a pipe 26 connected to the suction ports 14. 24 is a stop valve and 25 is a flexible hose. The seal member 21 is a member whose tip 21a contacts the female mold 11 during mold clamping to seal the cavity.

The forming tool 17, the instrument panel 1 (see FIG. 3) substantially the same shape made of metal, with a non-metallic member, the convex cross-sectional thickness t ₁ is the instrument panel 1
Substantially the same as the thickness t (see FIG. 3), the height H ₁ is the male 12
The width W ₁ is slightly larger than the height H of the male mold 12.
Slightly larger. This molding jig 17 is
Is located at the press molding position (position covering the molding surface 12a of the male mold 12), the inner corners 11b, 11b of the female mold 11
And ridge lines 17a, 17a facing each other.

That is, by disposing the forming jig 17 at the press forming position, the forming jig 17 becomes a temporary forming surface that is one size larger than the forming surface 12 a of the male mold 12, and moves to the female mold 11 when press-forming the skin material 2. It acts to increase the pressing force of. The molding jig 17 is moved between the press molding position and a standby position outside the mold 13 by a moving mechanism (not shown).

Next, a method for manufacturing an integrally molded product of the skin material and the base material according to the present invention will be described. FIG. 6 is a flowchart of a method for manufacturing an integrally molded article of a skin material and a base material according to the present invention,
7 (a) to 7 (c) are explanatory views of a method for producing an integrally molded product of a skin material and a substrate according to the present invention, and FIGS. 8 (a) to 8 (b) are skin materials and a substrate according to the present invention. FIGS. 9 (a) to 9 (c) are explanatory diagrams of a method of manufacturing an integrally molded article of a skin material and a base material according to the present invention.

ST01 (molding jig arrangement step); FIG.
In (a), the mold 13 is opened and the molding jig 17 is opened.
Is placed at the press forming position of the opened mold 13. ST02 (skin material arranging step);
b and the lower clamps 8a, and are supported. The skin material 2 is disposed between the forming jig 17 and the female die 11. In this case, since the span between the left and right clamps can be set large, the length of the skin material 2 can be increased. The seal member 21 projects upward by the elastic force of the compression springs 22.

ST02 (first preforming step); FIG.
In (b), upper clamps 8b and lower clamps 8a.
To the position shown in the figure (press forming position), and slowly lower than the clamping speed to cover the forming jig 17 in a state where the skin material 2 is pulled. Therefore, the skin material 2 extends slowly. Next, the female mold 11 is lowered, and the skin material 2 is preliminarily press-molded by the forming jig 17 and the female mold 11. At this time, since the surface of the molding jig 17 is one size larger than the molding surface 12a, the skin material 2 can be preformed into a good shape.

ST04 (vacuum suction step); In FIG. 7 (c), the vacuum pump 15 is driven to suck air above the skin material 2 of the cavity 16 from the suction ports 14.
The skin material 2 is vacuum-adsorbed to the first molding surface 11a at a vacuum pressure of 60 Torr. The suction ports 14 are provided with ridges 2a of the skin material 2,
Since it is located at 2a, the ridge lines 2a are strongly sucked. Since the skin material 2 is in close contact with the female mold 11, the skin material 2
Can be prevented, and the air between the skin material 2 and the female mold 11 can be reliably discharged.

ST05 (intermediate opening step); FIG. 8 (a)
In, the female mold 11 is raised and the mold 13 is opened while continuing the vacuum suction in the previous step. ST06 (molding jig removing step); in FIG.
The molding jig 17 is moved from the press molding position to the outside standby position while continuing the vacuum suction in the previous step.

ST07 (mold setting step); FIG. 9 (a)
In, the female mold 11 is lowered while the vacuum suction in the previous step is continued, and the clearance between the male mold 12 and the female mold 11 is set to c ₂ . This is to a suitable clearance c ₂ in resin injection in the next step. ST08 (resin injection step); in FIG. 9B, the molten resin supply mechanism 20 is driven while continuing the vacuum suction in the previous step, and the molten resin is placed between the molding surface 12a of the male mold 12 and the skin material 2. Inject 4. The injection pressure of the molten resin 4 by the molten resin supply mechanism 20 is 50 kg / cm ² G.

ST09 (integration step); In FIG. 9 (c), the female mold 11 is lowered and clamped to the molded product thickness t.
The base material 3 is formed by turning the molten resin on the back surface of the skin material 2.
The skin material 2 and the base material 3 are joined to obtain an instrument panel 1 (integrally molded product of the skin material and the base material) shown in FIG.

In the above embodiment, the case where one type is a male type 12 and the other type is a female type 11 has been described. However, one type may be a female type and the other type may be a male type. Although the case where the vacuum pump 15 is used as the evacuation mechanism has been described, a blower or a fan may be used instead of the vacuum pump 15. Although the case where the compression spring 22 is used as the pressing mechanism has been described,
The compression spring 22 may be replaced with a cylinder or the like. In the above embodiment, the case where the forming jig 17 has substantially the same shape as that of the instrument panel 1 has been described.

[0027]

According to the present invention, the following effects are exhibited by the above configuration. Claim 1 is characterized in that a mold for preforming only the skin material is constituted only by combining a molding jig with the mold prepared for the final integration step, and is exclusive to the skin material. The skin material can be preformed into a good shape without using the above mold. Then, since the ridge of the preformed skin material is vacuum-sucked to the other mold, sharp ridges can be formed with the ridge. At this time, since the skin material is preliminarily formed into a shape following the other mold, it can be closely attached to the other mold without wrinkling. Furthermore, since the skin material is gradually elongated in two stages of preforming and vacuum suction molding, the ridge portion of the skin material can be gradually elongated, and there is no possibility that the ridge portion of the skin material will be broken. . Therefore, according to the present invention, there is no wrinkle,
It is possible to obtain a high-quality integral molded product with sharp ridges, and it is possible to reduce equipment costs since a mold and a press for preforming are not required.

[Brief description of the drawings]

FIG. 1 is a perspective view of an instrument panel of an automobile.

FIG. 2 is a sectional view taken along line 2-2 of FIG.

FIG. 3 is a simplified sectional view of the instrument panel shown in FIG. 2;

FIG. 4 is a front view of a molding stand according to the present invention.

FIG. 5 is a perspective view of an apparatus for manufacturing an integrally molded product of a skin material and a base material according to the present invention.

FIG. 6 is a flowchart of a method for manufacturing an integrally molded product of a skin material and a base material according to the present invention.

FIG. 7 is an explanatory view of a method for producing an integrally molded product of a skin material and a base material according to the present invention.

FIG. 8 is an explanatory view of a method for producing an integrally molded product of a skin material and a base material according to the present invention.

FIG. 9 is an explanatory view of a method for producing an integrally molded product of a skin material and a base material according to the present invention.

FIG. 10 is a flowchart illustrating a conventional method for manufacturing an integrally molded product of a skin material and a base material.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1: Integral molded article of a skin material and a base material (instrument panel), 2 ... Skin material, 2a ... Ridge part, 3 ... Base material, 4 ... Molten resin, 7 ... Integral molded product of a skin material and a base material Manufacturing equipment,
8 ... clamp mechanism, 8a ... clamp lifting / lowering cylinder, 8
d: lower clamp, 8e: upper clamp, 10: mold part, 1
1 ... the other mold (female mold), 11a ... molding surface, 12 ... one mold (male mold), 12a ... molding surface, 13 ... mold, 14 ... suction port, 15 ... vacuum evacuation mechanism (vacuum pump), 16: cavity, 17: molding jig, 20: molten resin supply mechanism, 21
... sealing member, 21a ... front end, 22 ... pressing mechanism (compression spring), 31 ... air heater, c ₂ ... clearance, t ... moldings thickness.

Claims (1)

[Claims] 1. A manufacturing method for manufacturing an integrally molded article of a skin material including a convex cross section and a base material, wherein a mold comprising one mold and the other mold is opened, and one mold is opened. A molding jig arranging step of arranging a molding jig having substantially the same shape as the integrally molded article in a mold; and disposing a skin material sandwiched between clamp members on both sides of the mold between the molding jig and the other mold. A skin material arranging step to move the clamp member to dispose the skin material at a press molding position, clamp the mold, and preliminarily press the skin material with the molding jig and the other mold. A pre-forming step of forming; a vacuum suction step of vacuum-suctioning the ridge of the convex cross section of the pre-pressed skin material to the other mold; and a half-opening step of opening the mold. A molding jig removing step of removing the molding jig from one of the opened molds; A mold setting step of returning the mold to a clearance larger than the thickness of the molded article; a resin injecting step of injecting a molten resin into the clearance from one mold side; A method for producing an integral skin product, comprising: an integral step of turning a molten resin on the back surface to obtain an integral molded product.