JPH11277559A - Method for molding composite molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for molding a quality composite molded product in which part of a base material is coated with a skin material surely and economically. SOLUTION: In this method for molding a composite molded product, a skin material S, after being set a pair of upper and lower molds 1, 2, is cut into prescribed shapes in prescribed positions in the upper and lower molds, the unnecessary parts of the cut skin material S are removed, and a thermoplastic resin P to be a base material is supplied to the back part of the skin material S and the space between the molding surfaces of the residual upper and lower molds 1, 2 thoroughly to stick the skin material S integrally.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for molding a composite molded product in which a part of the surface of a substrate made of a synthetic resin is covered with a skin material, using a pair of upper and lower dies opposed to each other.

[0002]

2. Description of the Related Art Conventionally, a composite molded product in which a part of the surface of a base material made of a synthetic resin is covered with a skin material is used for automobile interior parts,
It is widely used for home appliances, indoor furniture, etc. As a method of molding it, 1) a method of covering a surface of a preformed base material with a skin material and bonding it with an adhesive, 2) pressing a base material in a mold press A method is adopted in which a skin material is set in a mold in advance at the time of molding, and the skin material is integrally attached to the base material simultaneously with the formation of the base material. However, in the above method 1), the molding of the base material and the molding and sticking of the skin material are performed in separate steps, so that many facilities are required and it takes time to complete the molding. In recent years, these methods have not been implemented except in special circumstances. On the other hand, the above-mentioned method 2) is widely practiced because there is no such problem.

[0003]

When a composite molded article is to be obtained by the above method 2), there are the following problems.
It is difficult to always keep the boundary line between the exposed part of the base material and the part covered with the skin material, and it is troublesome to accurately set the pre-cut skin material terminal to the predetermined position of the mold. It was a task that required nerves and required skill.
For this reason, there has been an economical problem that many defective products occur due to the inability to accurately set the skin material. The present invention has been made in view of the above-described problems, and provides a molding method that forms a composite molded product in which a part of a base material is covered with a skin material with high quality and reliability, and is economically advantageous. With the goal.

[0004]

Means for Solving the Problems In order to achieve the above object, a method for molding a composite molded article according to the present invention comprises the steps of: forming a composite molded article in which a part of the surface of a substrate is covered with a skin material;
A method of molding using opposed upper and lower molds, and a step of setting a skin material between molding surfaces of the upper and lower molds,
A step of cutting the skin material into a desired shape by skin material cutting means provided inside the mold by bringing the upper and lower molds closer to each other, and after removing unnecessary portions of the cut skin material,
A step of supplying the thermoplastic resin between the molding surface of the lower mold and the rear surface of the skin material left between the molding surfaces of the lower mold and the molding surface of the remaining upper and lower molds, and bonding the skin material integrally with the whole, Characterized by the following.

According to the present invention, by employing the above-described solution, the skin material is cut along a predetermined line in a state of being set in a mold, and the skin material is bonded to the base material simultaneously with the molding of the base material. As a result, the quality of the composite molded article to be molded is always stable, the number of working facilities is reduced, and it is economically advantageous.

[0006]

Embodiments of the present invention will be described below in detail with reference to the drawings. First, a basic method for molding a composite molded product will be described with reference to FIGS. Molding surface 1
The molding surface 1 is provided below the upper mold 1 in which A is formed in a convex shape.
A lower mold 2 in which a molding surface 2A corresponding to A is formed in a concave shape is arranged, and a skin material S is placed on the upper part of the lower mold 2 between the molding surfaces 1A and 2A of the upper and lower molds 1 and 2. And set (FIG. 1). Next, the upper mold 1 is lowered to approach the lower mold 2 and is stopped immediately before the molding surface 1A of the upper mold 1 comes into contact with the skin material S, and thereafter, the skin material inside the lower mold 2 is cut. The cylinder 4 of the means 3 extends to raise the cutting blade 5 to raise the upper mold 1.
2 is cut into the state shown in FIG.

Next, the cut material of the skin material S is manually removed to bring it into the state shown in FIG. 3, and then the cylinder 4 is brought into a free state, and the upper mold 1 is further lowered to form a molding surface. The skin material S in a state where the interval between 1A and 2A is narrowed
The thermoplastic resin P, P is pushed and injected through the internal passage 2B of the lower mold 2 by an extruder (not shown) to form the state shown in FIG. 4 between the rear surface of the lower mold 2 and the molding surfaces 1A, 2A of the remaining upper and lower molds. You.

Next, the upper mold 1 is further lowered to spread out the thermoplastic resin P, P which has been pushed and injected, so that the thermoplastic resin P, P is completely spread over the back surface of the skin material S and the entire remaining molding surfaces 1A, 2A. Immediately before the mold is closed, the cylinder 4 is reversely operated to forcibly return the cutting blade 5 to the original position, and the skin material S is integrally attached to the base material made of the thermoplastic resins P and P as shown in FIG. Then, the composite molded article is molded. In the above embodiment, the cutting blade 5 rises after the upper mold 1 approaches the skin material S, but the cutting blade 5 is protruded upward in advance, and the skin material S is lowered by lowering the upper mold 1. The operation may be changed so as to cut off.

Further, another example of molding a composite molded article will be described with reference to FIGS. In the above-mentioned molding example, the same process is performed until the skin material S is cut, the scraps are manually removed, and the upper mold 1 is further lowered. Next, the lower mold 2 is moved by an extruder (not shown) only at the rear position of the skin material S.
The thermoplastic resin P is pushed and discharged through the internal passage 2B of FIG. Next, the upper mold 1 is further lowered, the final mold is clamped, and the thermoplastic resin P which has been pushed and discharged is spread and spread over the entire back surface of the skin material S, and the cutting blade 5 is brought into the state shown in FIG. The thermoplastic resin P is injected and press-fitted between the remaining molding surfaces 1A and 2A through the injection passage 2C of the lower mold 2 by an injection molding machine (not shown), and the thermoplastic resin P is spread over the entire area between the remaining molding surfaces 1A and 2A. A skin material S is integrally adhered to a base material made of resin P to form a composite molded product.

The tip of the skin material cutting means 3 is shown in FIGS.
As shown in FIG. 8 in addition to the one shown in FIG.
And a flat skin material holding portion 3A and a projecting skin material cutting blade portion 3B along the boundary line between
As shown in the figure, the skin material holding portion 3A of the skin material cutting means 3 is formed in a concave groove-shaped concave surface, and the corresponding convex skin material holding portion 3C is provided on the corresponding upper mold 1 side. If the cutting blade portion 3D is provided at the end of the skin material holding portion 3A that is a concave surface or the end portion of the skin material holding portion 3C that is a convex surface on the upper mold 1 side so that the cutting blade portion 3D can be cut off, the end portion of the skin material S Can be held in a groove receiving shape, and can be attached in a wood-grained state at the time of molding and sticking with resin. The cutting of the skin material S may be performed by the shear-cutting blade 3E as shown in FIG. Further, the skin material cutting means 3 is provided with a skin material cutting blade on the molding surface 1A of the upper mold 1 in FIG. You may make it do.

When the skin material S is set between the molding surfaces 1A and 2A of the upper and lower molds 1 and 2, the molding surface 1A of the upper mold 1 is made concave as shown in FIG. If the molding surface 2A is convex, one of the sides left in the upper and lower molds 1 and 2 after cutting is locked and supported by a spring 11 and a mounting pin 12, and the upper and lower molds are cut after cutting. One of the sides to be removed from 1 and 2 is locked and supported by a cylinder 13 and a mounting pin 14, and as shown in FIG. 13, the skin material cutting means 3 (shown in FIG. After the cutting, the cylinder 13 is contracted to release the engagement between the skin material S and the mounting pin 14, and the surplus skin material S is removed. Further, when the protruding skin material cutting means 3 is returned into the mold during molding of the composite molded product and the skin material sags and becomes wrinkled, FIG.
4. As shown in FIG. 15, tensioning devices 17 and 18 which can be moved inward while tension is applied to one side of the lower mold 2 to the skin S through the cylinder 15 or the spring 16 in the outward direction. May be provided.

[0012]

As is apparent from the above description, the present invention sets the skin material between the molding surfaces of the upper and lower dies, cuts and holds the same at a predetermined position in the mold, and holds the back surface of the skin material. Since the thermoplastic resin is supplied between the position and the molding surface of the remaining upper and lower molds to spread the entire surface, the process from cutting molding of the skin material to molding of the base material and sticking of the skin material is performed. It can be completed in the lower mold, minimizing the molding equipment, and stably applying the skin material at the boundary line accurately and reliably. There is a great thing.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view showing a skin material setting state of a mold apparatus for carrying out a method of the present invention.

FIG. 2 is a longitudinal sectional view showing a cut state of a skin material.

FIG. 3 is a longitudinal sectional view showing a state in which a skin material is removed.

FIG. 4 is a longitudinal sectional view showing a supply state of a thermoplastic resin.

FIG. 5 is a vertical cross-sectional view showing a spread state of a thermoplastic resin.

FIG. 6 is a longitudinal sectional view showing another supply state of the thermoplastic resin.

FIG. 7 is a vertical cross-sectional view showing another expanded state of the thermoplastic resin.

FIG. 8 is an enlarged detailed view showing a skin material cutting means in which a slashing blade is formed.

FIG. 9 is an enlarged detail view showing another cut portion of the skin material.

FIG. 10 is an enlarged detail view showing still another cut portion of the skin material.

FIG. 11 is an enlarged detail view showing a skin material cutting means portion on which a shear cutting blade is formed.

FIG. 12 is a longitudinal sectional view showing a skin material setting state using another mold apparatus.

FIG. 13 is a longitudinal sectional view showing a cut state of the skin material.

FIG. 14 is a longitudinal sectional view showing another skin material setting state.

FIG. 15 is a longitudinal sectional view showing still another skin material setting state.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Upper mold 2 Lower mold 1A 2A Molding surface 3 Skin material cutting means 3A 3C Skin material holding part 3B 3D Skin material cutting blade part 3E Shear-cutting blade 4 Cylinder 5 Cutting blade 11 14 Mounting pin 17 18 Tension device P Heat Plastic resin S Skin material

Claims (8)

[Claims] 1. A method of molding a composite molded article having a part of the surface of a base material covered with a skin material using opposed upper and lower dies, wherein a molding surface of the upper and lower dies is provided. A step of setting a skin material in between, a step of bringing the upper and lower molds closer to each other, and a step of cutting the skin material into a desired shape by means of a skin material cutting means provided inside the mold, and eliminating the need for the cut skin material. After removing the portion, the thermoplastic resin is supplied between the molding surface of the upper and lower molds and the rear surface of the skin material left between the molding surfaces of the upper and lower molds, and the thermoplastic resin is supplied between the molding surfaces of the remaining upper and lower molds. And a step of integrally attaching a material. 2. The step of supplying the thermoplastic resin and spreading the entirety includes pushing and discharging the thermoplastic resin into both the back surface of the skin material and the space between the molding surfaces of the remaining upper and lower molds. 2. The method for molding a composite molded article according to claim 1, wherein the lower mold is clamped to spread the thermoplastic resin and spread the whole. 3. The step of supplying the thermoplastic resin and spreading the whole resin is performed by pushing the thermoplastic resin into the back surface of the skin material, discharging the thermoplastic resin, clamping the upper and lower molds, and expanding the thermoplastic resin. The thermoplastic resin is injected by injection between the molding surfaces of the remaining upper and lower molds after injection to spread over the entire back surface of the skin material, and then is spread over the entire remaining molding surface. Item 7. A method for molding a composite molded article according to Item 1. 4. The method according to claim 1, wherein the step of setting a skin material between the molding surfaces of the upper and lower molds comprises placing a skin material on the upper part of the lower mold. Or the molding method of the composite molded article of 3. 5. The step of setting a skin material between the molding surfaces of the upper and lower molds after elastically supporting a peripheral portion of the skin material above and below the lower mold via an elastic support. ,
4. The method according to claim 1, wherein the upper and lower molds are brought closer to each other and the lower surface of the upper mold is pressed against the elastic support via a skin material. 6. The step of setting a skin material between the molding surfaces of the upper and lower molds, wherein at least a part of a peripheral edge of the skin material is tensioned outwardly above the lower mold. 4. The method of molding a composite molded product according to claim 1, wherein the composite molded product is movable inward and elastically supported in a vertical direction via an elastic support. 7. The method for forming a composite molded product according to claim 1, wherein the cutting of the skin material is performed by hitting. 8. The method according to claim 1, wherein the cutting of the skin material is performed by shear cutting.