JPH10225957A - Method and apparatus for manufacture of resin molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To give shaping of high quality precision according to a shape of a cavity die by a method wherein pinching force of softened resin with a skin clamp mechanism is released, and then the softened skin material is integrated with a core material by press force between the cavity die and a core die. SOLUTION: A metal frame 3 on a metal frame transfer means 5 is transferred to a specific position. When the metal frame 3 and the metal frame transfer means 5 are removed from an under part of the cavity die 15, the core die approaches the cavity die 15. When a softened skin material 10 pinched to the cavity die 15 with a skin clamp mechanism 19 is sucked onto a cavity surface by negative pressure of a vacuum suction opening 16, the pinch force of the softened skin material 10 with a partial skin clamp mechanism 19 is released, the softened skin material 10 is effectively shaped onto the cavity surface with suction force caused by a vacuum. Then, resin 12 being the core material is injected from the core die 9 approaching the cavity die 15. The core die 9 further rises, the resin 12 is pressed, and the integrated core material 12 is formed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin molded product, such as an instrument panel, used as an interior component of an automobile, and more particularly to a resin molded product having a multilayer structure comprising a core material and a softened skin material. The present invention relates to a method and an apparatus for manufacturing a resin molded product molded by an injection press.

[0002]

2. Description of the Related Art For example, a resin molded product such as an instrument panel installed in an automobile includes a core material made of a resin such as polypropylene, a skin layer made of, for example, polyvinyl chloride or thermoplastic elastomer, and a polypropylene foam layer. And has a multilayer structure with a softened skin material layered on the surface of the core material. A conventional method of manufacturing a resin molded product having such a multilayer structure is shown in FIGS. 14 to 23. First, as shown in FIG. 14 and FIG. 15, a skin supporting needle 1 is implanted in a frame shape, and at appropriate places around the frame.
Further, a metal frame 3 for supporting the skin, which is provided with a positioning hole 2 to be positioned in the metal frame conveying means and a long hole 4 for locking the cylinder rod, is prepared in advance, and the metal frame 3 has a desired shape. The edge of the cut skin 10 is pierced into the cut skin support needle 1 to be stretched and supported.

[0003] The metal frame 3 thus supporting the softened skin material 10
The frame transfer means 5 is provided in the positioning hole 2 provided in the
The metal frame 3 is set on the metal frame transporting means 5 by using the positioning pins 6 provided on the frame (see FIG. 16). Next, the metal frame 3 supporting the softened skin material is sent into the heating furnace 7 by the metal frame transfer means 5 (see FIG. 17), and the softened skin material 10 supported by the metal frame 3 is heated and softened.

[0004] The heat-softened softened skin material 10 is
At the same time, it is transported between the cavity mold 8 and the core mold 9, that is, directly below the cavity mold 8 by the metal frame transfer means 5 (see FIG. 18). Next, the cylinder rod 11 descends from the cavity mold 8 and is inserted into the elongated hole 4 provided in the metal frame 3. Then, the cylinder rod 11 is rotated by about 90 degrees, so that the cylinder rod 11 is rotated. And the metal frame 3 are locked (see FIG. 19).

Next, the softened skin material 10 that has been heated and softened together with the metal frame 3 by the rise of the cylinder rod 11 is placed near the cavity mold 8. At the same time, the frame transporting means 5 retreats (see FIG. 20). At this time, cavity mold 8
Then, a vacuum force acts, and the softened skin material 10 which has been softened by this is shaped by the suction force of being sucked to the cavity surface, and at the same time, the core mold 9 rises and approaches the cavity mold, and the core mold 9 Resin 1 serving as core material between softened skin materials 10
2 is injected (see FIG. 21).

Next, the core mold 9 is further raised, and the resin 12 is pressed to form the core material 12 integral with the softened skin material 10 (see FIG. 22). Thereafter, the cylinder rod 11 provided in the cavity mold 8 is
When the core frame 9 is disengaged by disengaging the metal frame 3 and the cylinder rod 11 by lowering by 0 degree and then the core mold 9 is lowered, the softened skin material 1
The multilayer resin molded product 13 integral with the core material 9 and the core material 12 descends together with the core mold 9 and the metal frame 3, and the multilayer resin molded product 13 can be released (see FIG. 23).

[0007]

At the time of forming the conventional multilayer resin molded product formed as described above, the edge of the softened skin material 10 is pierced into the skin support needle 1 to form the metal frame 3.
In this state, the heating and softening is performed in the state of being stretched and supported, and then the shaping is performed by the suction force to the cavity surface by the vacuum force while maintaining the stretched support by the skin supporting needle 1. The edge of the softened skin material 10 supported by 3 is pierced and held by the skin support needle 1, and the displacement of the softened skin material 10 is regulated. However, it is difficult to form along the cavity mold surface due to the tensioning force of the skin support needles 1, and as a result, there is a problem that it is not possible to perform good-quality molding corresponding to the cavity mold.

In the conventional molding method, before releasing the multilayer resin molded product 13 molded by the pair of cavity mold 8 and the core mold, as shown in FIG. Since the metal frame 3 remains fixed to the edge (periphery of the softened skin material) by piercing the skin supporting needle 1, the multilayer resin molded product 13 is released after the release of the multilayer resin molded product 13. The work of removing the metal frame 3 is necessary, and there is also a lack in productivity.

The present invention has been made in view of the above, and a skin clamp mechanism capable of sandwiching an edge of a softened skin material is provided on a peripheral portion of a cavity mold so as to be heated and softened. When the skin material is conveyed to the lower portion of the cavity mold together with the metal frame, the softened skin material clamps the peripheral portion of the softened skin material together with the cavity mold by the softened skin material clamping mechanism so that the vacuum suction force of the cavity mold is obtained. Resin molded product that can be shaped with high quality according to the shape of the cavity mold by holding the softened skin material with a clamping force that is not excessively stretched when it is adsorbed on the cavity surface due to It is an object of the present invention to provide a manufacturing method and a manufacturing apparatus.

[0010]

In order to achieve the above object, according to the present invention, the softened skin material held by the metal frame is divided into a plurality of skin clamps arranged on the periphery of the cavity mold. By the clamping force of the mechanism, it is transferred from the above-mentioned metal frame to the clamping by the cavity mold, and then, while maintaining the clamping by the cavity mold, the softened skin material is formed on the cavity mold surface by the suction action of the cavity mold, and then by the core mold. When closing the mold, the material to be the core material is injected and pressurized between the core mold and the softened skin material, while releasing the clamping force of the softened resin by the skin clamp mechanism, and then the cavity mold and the core mold are released. The method is characterized by a method for producing a resin molded product having a multilayer structure in which the softened skin material and the core material are integrated by the pressing force of the above.

According to a second aspect of the present invention, there is provided a cavity mold having vacuum suction means for adsorbing the softened skin material heated and softened to the cavity surface, and a back side of the softened skin material combined with the cavity mold. In a multilayer injection press molding apparatus having a core mold for press-molding a core material injected into a cavity mold, a peripheral portion of the cavity mold, a peripheral edge of the softened skin material that is heat-softened, and a peripheral surface of the cavity mold. The present invention is characterized in that it is a resin molded product manufacturing apparatus in which a plurality of skin clamp mechanisms for clamping in cooperation are arranged.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to FIGS.
Although described in detail based on the embodiment shown in, in this embodiment, the characteristic structure is a cavity type,
Since other structures are the same as the above-described conventional example, the same structural parts as those of the conventional example are denoted by the same reference numerals as used in the conventional example, and the description of the structure is omitted.

In FIG. 3, reference numeral 15 denotes a cavity mold. The cavity mold 15 has a plurality of vacuum suction ports 16 formed on a cavity surface thereof, which communicate with an intake device (not shown). A plurality of (four corners in this embodiment) cylinders 17 are arranged on the outer surface of the cavity mold 15, and the cylinders 17 are provided with the cylinder rods 11 that operate in the vertical direction. In addition, a metal frame hook 1 is provided at the tip of the cylinder rod 11.
8 are formed.

Further, at an appropriate position on the outer surface of the cavity mold 15, a skin clamp mechanism 19 is disposed.
The detailed structure of the skin clamp mechanism 19 is described in, for example, FIG.
Alternatively, it has the structure shown in FIG.

The skin clamp mechanism 19 shown in FIG.
Is a bearing 20 fixed to the outer surface of the cavity mold 15 and a first support shaft 2 provided on the bearing 20.
1 and a clamper 24 which is supported by a second support shaft 23 provided on the bearing 20.
And the rod 25 of the air cylinder 22 are connected by a third support shaft 26. When the rod 25 moves in the axial direction, the clamp claw 27 screwed to the tip end of the clamper 24 has a cavity. It can contact the lower surface 28 of the mold 15. Therefore, air cylinder 2
The lower surface 28 of the cavity mold 15 is moved by the operation of the rod 25
The softened skin material 10 located at the position (1) can be clamped between the clamp claw 27 and the lower surface 28 of the cavity mold.

A skin clamp mechanism 19 shown in FIG.
Is a swing air cylinder 29 fixed to the outer surface of the cavity mold 15;
And a clamper 31 having a clamp claw 27 fixed to the tip of the rod 30 and abutting against the lower surface 28 of the cavity mold. The softened skin material 10 located on the lower surface 28 of the cavity mold 15 can be clamped between the clamp claw 27 and the cavity mold lower surface 28 by the operation of the rod 30 of the swing air cylinder 29.

The skin clamp mechanism 19 configured as described above.
Is provided in the cavity mold 15, it has the following operation. Similarly to the description of the conventional example, the softened skin material 10 stretched and held by the large number of skin support needles 1 provided on the metal frame 3 is conveyed by the metal frame conveying means 5, and in the conveying process, the heating means is used. First, as shown in FIG. 4, the softened skin material 10 softened by heating is
Is transported directly below. At this time, the relationship between the outer dimensions of the metal frame 3 and the outer dimensions of the softened skin material 10 is such that the peripheral edge of the softened skin material 10 is more outward than the outer edge of the metal frame 3 as shown in FIG. The shape of the softened skin material 10 is set so as to protrude.

Then, when the softened skin material 10 is positioned directly below the cavity mold 15, the cylinder rod 11 provided in the cavity mold 15 descends and enters into the elongated hole 4 provided in the metal frame 3. The cylinder rod 11 is inserted and then rotated by about 90 degrees, so that the metal frame hooking hook 18 of the cylinder rod 11 is locked to the metal frame 3. Next, the cylinder 17 is operated by the cylinder 17.
Rises along with the operation, the metal frame 3 moves up together with the softened skin material 10 and approaches the cavity mold 15 (FIG. 5).
reference).

Next, the skin clamp mechanism 19 operates,
The periphery of the softened skin material 10 is sandwiched between the clamper 24 or 31 of the skin clamp mechanism 19 and the lower surface of the cavity mold 15. Thereafter, the cylinder 17 is re-operated, and the cylinder rod 11 is extended downward.
It descends out of 0 and is returned to the metal frame transporting means 5 (see FIG. 6).

The metal frame 3 placed on the metal frame transporting means 5 is
When the metal frame 3 and the metal frame transfer means 5 are removed from the lower portion of the cavity mold 15 by being moved to a predetermined position by the operation of the metal frame transfer means 5, the core mold 9 approaches the cavity mold 15 (FIG. 8). reference).

The skin mold clamping mechanism 1 is mounted on the cavity mold 15.
When the softened skin material 10 held by 9 is about to be attracted to the cavity surface by the negative pressure of the vacuum suction port 16, the holding force of the softened skin material 10 by a part of the skin clamp mechanism 19 is released, The softened skin material 10 is effectively formed on the cavity surface by the suction force of the vacuum. Next, a resin 12 serving as a core material is injected from the core mold 9 approaching the cavity mold 15 (see FIG. 8).

Next, the core mold 9 is further raised, and the resin 12 is pressed to form the core material 12 integral with the softened skin material 10 (see FIG. 9). Thereafter, when the clamping of the softened skin peripheral edge by the clamp mechanism 19 is released and the core mold 9 is lowered, the multilayer resin molded article 13 is lowered on the core mold 9 (see FIG. 10). When the multilayer resin molded product 13 is released from the core mold 9, the above operation is repeated, and the multilayer resin molded product 13 is sequentially produced.

As described above, according to the above-described cavity mold 15 structure, the cavity mold 15 itself is provided with the skin clamp mechanism 19 for holding the periphery of the softened skin material 10,
When the periphery of the heated softened skin material before being shaped by the cavity mold is clamped by the clamp mechanism 19, and the softened skin material starts shaping operation by the cavity mold, the softened skin by the partial skin clamp mechanism is used. Since the material holding force is released so that the softened skin material can easily come into contact with the cavity surface, when the softened skin material is shaped by vacuum suction of the cavity mold, the clamp claw and the softening member are clamped by the clamp mechanism 19. The unreasonable tension (locking force) between the skin materials 10 is relaxed, so that the softened skin material can be easily transferred to the cavity surface (fitting) at the time of suction, so that the softened skin corresponding to the cavity shape can be obtained. It is easy to shape the material, and it is possible to manufacture a high-quality multilayer resin molded product that does not cause unnecessary elongation or undesired wrinkles.

The metal frame 3 holding the softened skin material 10 stretched and held is removed from the softened skin material 10 immediately after the softened skin material 10 is clamped to the cavity mold 15. As described above, the metal frame 3 is not attached to the multilayer resin molded product, so that the operation of removing the metal frame 3 from the multilayer resin molded product is not required, which is advantageous in productivity.

In the above embodiment, the outer dimensions of the softened skin material 10 are set to be larger than the outer dimensions of the metal frame 3 so that the periphery of the softened skin material 10 can be easily clamped by the clampers 24 and 31. For example, the outer shape of the metal frame 3 is changed as shown in FIG.
If the notches 32 into which the tips of the clampers 24 and 31 (the mounting portions of the clamp claws 27) are inserted are provided between the respective skin supporting needles 1 arranged on the periphery of the soft skin material 10, the outer dimensions of the softened skin material 10 can be reduced. Even if the outer dimensions of the metal frame 3 are not set to be larger than the outer dimensions of the metal frame 3, the edges of the softened skin material 10 can be reliably clamped by the clamper, so that useless use of the softened skin material 10 is suppressed, and the economy is enhanced.

[0026]

As described above, according to the present invention, the clamping force of any one of the plurality of skin clamp mechanisms among the plurality of skin clamp mechanisms for clamping the heat-softened skin material before being shaped by the cavity mold 15 is obtained. It can be released as appropriate, and as compared with the conventional piercing and holding means using a fixed needle, the tensile force (pinching force) of the softened skin material during the shaping operation can be appropriately moderated and adjusted. , The softened skin material does not wrinkle or elongate, and a high quality multilayer resin molded product can be obtained.

A metal frame 3 for supporting the heat-softened skin material 10
Can be detached from the softened skin material 10 at the same time as the lowering operation of the cylinder rod 11, so that there is no need to artificially remove the metal frame 3 from the softened skin material 10, and for this reason, the multilayer resin molded product Productivity and economy are improved.

[Brief description of the drawings]

FIG. 1 is a plan view of a metal frame according to an embodiment of the present invention.

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

FIG. 3 is an explanatory side view of a cavity mold according to the embodiment of the present invention.

FIG. 4 is an explanatory diagram at the time of initial lifting of the epidermis according to the embodiment of the present invention.

FIG. 5 is an explanatory diagram at the time of finishing lifting of the epidermis according to the embodiment of the present invention.

FIG. 6 is an explanatory view at the time of epidermal clamping according to the embodiment of the present invention.

FIG. 7 is an explanatory view when the metal frame and the metal frame transporting means according to the embodiment of the present invention are withdrawn.

FIG. 8 is an explanatory view at the time of core material injection according to the embodiment of the present invention.

FIG. 9 is an explanatory view at the time of press molding using a cavity mold and a core mold according to an embodiment of the present invention.

FIG. 10 is an explanatory view at the time of completion of molding of a multilayer resin molded product according to an embodiment of the present invention.

FIG. 11 is an explanatory view of a skin clamp mechanism according to an embodiment of the present invention.

FIG. 12 is an explanatory view of a skin clamp mechanism according to another embodiment of the present invention.

FIG. 13 is a perspective view of a metal frame according to another embodiment of the present invention.

FIG. 14 is a plan view of a conventional metal frame.

FIG. 15 is a sectional view taken along line BB in FIG. 14;

FIG. 16 is an explanatory diagram showing the relationship between a metal frame, a metal frame transporting means, and a skin of a conventional example.

FIG. 17 is an explanatory diagram of a conventional example at the time of heating and softening the skin.

FIG. 18 is an explanatory view when the epidermis is moved directly below a cavity mold of the conventional example.

FIG. 19 is an explanatory view of a conventional example at the initial stage of lifting the skin.

FIG. 20 is an explanatory view of a conventional example at the end of lifting the skin.

FIG. 21 is an explanatory view of a conventional example when a core material is injected.

FIG. 22 is an explanatory view at the time of press molding using a conventional cavity mold and core mold.

FIG. 23 is an explanatory view at the time of completion of molding of a conventional multilayer resin molded product.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Skin support needle 2 ... Positioning hole 3 ... Metal frame 4 ... Long hole 5 ... Metal frame conveying means 6 ... Positioning pin 7 ... Heating furnace 9 ... Core type 10 ... Softened skin material 11 ... Cylinder rod 12 ... Core material 13 ... Multi-layer resin molded product 15 ... Cavity mold 16 ... Vacuum suction port 17 ... Cylinder 18 ... Hook hook 19 ... Skin clamp mechanism 20 ... Bearing 21 ... First spindle 22 ... Air cylinder 23 ... Second spindle 24 ... Clamper 25 ... Rod 26 ... Third support shaft 27 ... Clamp claw 28 ... Cavity type lower surface 29 ... Swing air cylinder 30 ... Rod 31 ... Clamper 32 ... Notch

Continued on the front page (51) Int.Cl. ⁶ Identification code FI B29L 31:58

Claims (2)

[Claims] 1. A softened skin material (10) held by a metal frame (3) is clamped by a plurality of skin clamping mechanisms (19) disposed on a peripheral portion of a cavity mold (15). , A cavity mold (15) from the metal frame (3)
Then, while maintaining the holding by the cavity mold (15), the softened skin material (10) is formed on the cavity mold surface by the suction action of the cavity mold (15), and then the core mold (9). When the mold is closed, the core mold (9) and the softened skin material (10) are injected and pressurized with the material to be the core material, while releasing the clamping force of the softened resin by the skin clamp mechanism (19). Then, a method of manufacturing a resin molded product having a multilayer structure in which the skin and the core material are integrated by the pressing force of the cavity mold (15) and the core mold (9). 2. A cavity mold (15) having vacuum suction means for adsorbing a softened skin material (10) heated and softened to a cavity surface, and the softened skin material is combined with the cavity mold (15). In the multilayer injection press molding apparatus having a core mold (9) for press-molding the core material injected on the back side of (10), the cavity mold (1) is provided.
On the periphery of 5), the softened skin material (1)
An apparatus for manufacturing a resin molded product, comprising a plurality of skin clamping mechanisms (19) for clamping the edge of (0) in cooperation with the peripheral surface of the cavity mold.