JPS5828115B2 - Manufacturing equipment for synthetic resin foam moldings with uneven surfaces - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an apparatus for producing a synthetic resin foam molded product having an uneven shape covered with a skin material, such as a vehicle interior decoration panel or a door panel.

BACKGROUND OF THE INVENTION Products having an uneven surface made by pasting a decorative skin material on the surface of a synthetic resin foam are widely used in various fields including vehicle interior decorative panels and door panels.

Conventionally, in order to integrally mold a skin material onto a synthetic resin foam, the skin material was attached to the inner surface of the mold in advance, and the stock solution for foam molding was injected into the mold, and the stock solution foamed and overflowed from the mold. Before exiting, the mold is closed, and the pressure of the polymerization reaction of the foaming stock solution inside the sealed mold is used to shape the product into a certain shape that follows the shape of the mold, and also to bond the skin material to the foam layer. It was something.

Therefore, the molding apparatus including the mold and the mold moving device needs to have a structure that can withstand the polymerization pressure of the foaming stock solution, resulting in a problem that the equipment becomes large and the equipment cost becomes high.

In order to solve this problem, a synthetic resin foam stock solution is applied to a stretchable knitted fabric and foamed, and while the polymerization reaction of the foam is not yet completed, a predetermined uneven shape is formed on the mold surface. A method has been developed in which a molded product having a predetermined uneven shape is obtained by carrying the molded product into a mold having a surface and press-forming it.

The above method includes a step of foaming a stock solution and combining the foam with a skin material, a step of carrying the synthetic resin foam into a predetermined mold while the polymerization is incomplete, and performing pressure molding. A maturing process for a certain period of time is required, so when mass production is carried out, a number of molds are used to transport the foam and skin material one after another into the molds, and after the molds are closed, It is necessary to continue the process of aging the molded product for a certain period of time and then removing it from the mold.

The present invention provides an apparatus for continuously manufacturing the above-mentioned molded products, which includes a rotating table with a large number of molds installed, and a loading station for a material combining a foam and a skin material;
A pressurization and mold clamping station, a ripening zone, and an unloading station are set along the rotational feed direction, and the material carried into the mold is shaped in relation to the rotational movement of the rotary table, and after one rotation, the molded product is The invention is characterized in that continuous molding is performed in preparation for transporting the mold from within the mold.

Embodiments of the present invention will be described below with reference to the drawings.

1 to 3 show a first embodiment of the present invention.

That is, a large number of molds 2, 2, . Consists of a combination mold with mold 2B, upper mold 2A is lower mold 2B
It is held movably up and down on a pair of posts 3, 3 fixed to
Moreover, it is urged upward by a spring 4 mounted on the post 3, and the mold is always kept in an open state.

Further, each mold 2 is provided with a manual (or automatic) clamp 5 for tightening the upper mold 2A and the lower mold 2B.

As shown in FIG. 2, the rotary table 1 is supported horizontally by a rotary shaft 6 provided at its center of rotation, and the rotary shaft 6 is connected to a reducer 8 directly connected to a motor 7 with a brake via a gear mechanism 9. The rotation feed is provided at each fixed rotation angle.

A-
4 (8 stations) are set up, the A position is the material loading station, the adjacent B position is the mold pressurization and mold clamping station, and the range from C to G position is the ripening zone ( cure zone), and the H position is the unloading station.

As shown in FIG. 2, in the mold pressurization and mold clamping station B, a cylinder device 11 is installed above the transfer line of the mold 2 as a mold pressurization device, and is connected to a rod 11A of the cylinder device 11. A press plate 12 is provided above the mold 2 so as to be movable up and down.

Further, an oven 13 having a built-in heating device is disposed along the conveyance line of the mold 2 over the range of the cure zone CG.

A mold 14 as a material forming device is installed in front of the loading station A on the rotary table 1, and a nozzle 15 of a foaming machine is placed above the mold 14.

In the embodiment, as shown in FIG. 3A, a lining member or a mold release material is laid in a mold 14 with an open top, and a stock solution a for forming a synthetic resin foam is poured from above through a nozzle 15.
is injected and allowed to foam naturally.

Next, a skin material 16 such as a stretchable textile fabric or a stretchable textile fabric laminated with a synthetic resin is placed on the surface of the foam layer, and the material is obtained while the stock solution a is not completely polymerized. The prepared material C is taken out from the formwork 14 as shown at the opening in the same figure, and is carried between the upper and lower molds 2A and 2B of the mold 2 from the carry-in position A on the front as shown in the figure.

Next, the rotary table 1 is intermittently rotated by a constant angle by the rotation of the motor 7.

First, move the mold 2 to position B, push down the press plate 12 by driving the cylinder device 11 as shown in FIG. 2, press down the upper mold 2A against the pressing force of the spring 4, and then As shown in figure E, two people operate the upper and lower types.
Tighten 2B.

In this state, the rotary table 1 is further rotated by a certain angle one after another, and carried into the open 13 from the C position, and from the D position to
Heat aging is performed with the mold clamped until the G position is reached.

After the polymerization reaction of the foam layer is completed, the clamp 5 is removed as shown in the figure at position 11, the upper mold 2A is opened, and the molded product M with the uneven surface formed from the inside of the upper and lower molds 2A and 2B. Take out.

FIGS. 4 and 5 show other embodiments of the material forming apparatus in the apparatus of the present invention.

That is, in this embodiment, a belt conveyor 17 is installed in front of the carry-in station A of the rotary table 1, and the backing material d (or mold release material) is continuously fed out along the conveyance of the belt conveyor 17, and the foaming material above the backing material d is fed out continuously. machine nozzle 1
From step 5, supply the foam forming stock solution a and apply it to the backing material d.
Alternatively, foaming is performed on the mold release material, and then the skin material 16 is sent out from above, and the foam layer is bonded to the backing material d and the skin material 16.
The material is sandwiched between the
After the foam layer and the skin material 16 are bonded together by applying pressure using the cutter 19, the laminated material C is cut into a desired size and taken out onto a table 20.

A roller conveyor 21 is installed on this table 20, and the material C is transferred along this roller conveyor 21, carried into the mold 2 from the carry-in station A, and processed by the intermittent feeding of the rotary table 1 in the same manner as described above. After passing through the pressing, mold clamping, and ripening steps, the mold is opened at an unloading station H, and the molded product M is similarly taken out.

In this embodiment, the structures of the rotary table 1 and the mold 2 installed on the rotary table 1 are the same as those of the previous embodiment, so the same numbers are given and the explanation thereof will be omitted.

In addition, regarding the mold clamping mechanism of the mold, the upper mold 2A and the lower mold 2
It is also possible to synchronize the mold clamp 5 with the upper mold 2A with the vertical movement of the pressurizing cylinder device 11*1 to automatically clamp the mold. A support arm may be made to protrude, a guide rail may be provided on the table 1 on which the mold 2 rotates, and the rotation of the table causes the upper mold 2A to move up and down along the guide rail for mold clamping and demolding.

When cutting a material after forming it into a continuous strip, the number of molds on the rotary table and the production speed of the material have the following relationship.

1) Rotation speed of the rotary table... 25" stop + 5" moving time in each process (rotates intermittently) 2) Rotating speed of the rotary table... 15' stop + 5" moving time in each process ※※ (Rotates intermittently) Therefore, the number of molds varies depending on the production speed of the material, aging time, and rotation speed of the rotary table, but it is advantageous to determine the production speed of the material according to the rotation speed of the rotary table.

Further, the materials used and molding conditions in the present invention are as follows.

(1) Skin material...■ When using a stretchable knitted or woven fabric For example, knitted or woven fabrics made from cotton, cotton, nylon, acrylic, polyester, or the like can be used.

■ When using a synthetic resin sheet with a synthetic resin foam transferred to a stretchable knitted fabric, for example, foamed polyvinyl chloride, polyethylene, polyurethane, etc., or a urethane film as a synthetic resin sheet. There are thin flexible resin films such as polyolefin films, butadiene films, and vinyl chloride films.

(2) Backing material or mold release material: Used to prevent adhesion between the foamed synthetic resin and the press mold during pressing or to reinforce the molded product. For example, as a backing material, a knitted fabric that has been impregnated to prevent hardening, For example, a release material such as a release paper or a polyethylene film may be used as a nonwoven fabric.

(3) Synthetic resin foam: Rigid or semi-rigid foams are used for interior decoration panels for vehicles, door panels, etc., and soft or semi-rigid foams are used for vehicle or furniture cushions. do.

For example, synthetic resin foams such as polyvinyl chloride, polyethylene, and polyurethane are used, but in the case of cushions, soft or semi-rigid polyurethane with open cells is preferred.

In the case of interior decorative panels for vehicles, rigid or semi-rigid polyurethane is preferred.

(4) Oven temperature 40° to 220°C (5) Gold
Type: Female and male type, female type and plate type, or female type and male type.

A small through hole may be made in the design surface of the female mold to improve air release during pressure molding.

Varies depending on the composition.

(7) Molding pressure 0.1 to 1 kg/ff1 In the present invention, the material C in which the foam layer and the skin material 16 are laminated as described above is carried one after another into the mold 2 on the rotary table 1. The mold 2 is pressurized and clamped by the rotary feed, and the ripening process is completed. After one revolution of the rotary table, the mold 2 is opened and the molded product M is taken out. Since the foaming solution is fed into the mold 2 in the same state, no polymerization pressure of the foaming stock solution is applied to the mold, and the uneven surface according to the shape of the mold 2 can be accurately formed on the molded product M. The skin material 16 and the foam layer are tightly bonded to each other, so that a molded article M having a uniformly shaped uneven surface can be continuously obtained.

Further, since the polymerization reaction is incompletely bonded, the resin penetrates into a part of the skin material 16, so that the two can be inseparably bonded, and a molded article M without peeling can be obtained.

Further, according to the present invention, in order to use a rotary table, after one rotation of the rotary table, the demolded molds 2 return to the loading station A one after another, and the material C is loaded into each mold 2. This enables continuous molding, and the time necessary for ripening can be secured during one rotation of the rotary table 1 from the beginning.

In addition, in the example, a case was explained in which the mold was heated to a constant temperature during the aging process using the oven 13.
Depending on the type of synthetic resin used, it may be possible to ripen without heating.

The present invention has a great effect in that molded products having uneven surfaces can be manufactured continuously and with high efficiency from a material that combines a foam and a skin material.

[Brief explanation of the drawing]

1 to 3 show a first embodiment of the present invention,
Fig. 1 is a plan view, Fig. 2 is a sectional view taken along line 1 in Fig. 1, Fig. 3 is a process explanatory diagram, and Figs.
FIG. 4 is a plan view, and FIG. 5 is a cross-sectional side view. 1...Rotary table, 2...Mold, 5
... Clamp, 11 ... Cylinder device, 12 ... Pressing plate, 13 ... Oven, 14 ... Formwork, 15 ... ...Nozzle, 1
6...Skin material, C...Material, A...-
... Loading station, B ... Pressure and mold clamping station, C-G ... Ripening zone, H
・・・・・・Transportation station.

Claims (1)

[Claims] 1. A large number of molds are installed on a rotary table that is given rotational feed in one direction, and along the feed direction of the rotary table, there is a material loading station consisting of a foam and a skin material overlaid on its surface, and a mold transfer station. Set up the pressurization and mold clamping station, ripening zone, and unloading station in order,
A molding device for combining foam and skin material is installed in front of the material loading station, a mold pressurizing device is placed above the pressurizing and mold clamping station, and each of the molds is rotated. The surface is composed of a lower mold set on a table and an upper mold that is always biased upward, has a predetermined unevenness on the mold surface, and is further equipped with a clamp that connects the upper and lower molds. A manufacturing device for synthetic resin foam molded products with irregularities.