JPS5915072B2 - Manufacturing method and device for composite molded products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a composite molded product and an apparatus for manufacturing the same. The skin material and base material that make up the material are supplied, and these materials are molded and bonded (laminated) using warm or hot press, and then finishing processing such as trimming and drilling is performed. It provides a series of manufacturing systems for producing products.

30 Conventionally, a relatively rigid base material such as a plate-shaped polystyrene foam or resin-impregnated cardboard and a flexible skin material such as a PVC sheet or fabric are bonded and laminated, and then formed into a predetermined shape. In the manufacturing of composite molded products such as interior materials for automobiles, there is no method to manufacture them as a series of systems from the supply of 35 materials to the finishing process of the product, and each process is only partially combined. Things are proposed and adopted.

For example, (1) forming the base material, adhering the skin material, punching out the outside, and making holes are provided separately, and a worker is assigned between each process; and (2) this forming process. (3) A method that combines the steps from 1 to 1 and the adhesion of the skin material, and (3) a method that combines the steps of forming, punching, and drilling holes by making a plate-shaped laminate of the skin material and base material in advance and stocking it. One method is to create a series of lines in which the stocked laminate is supplied, but all of these require a large amount of space, investment, personnel, etc. when viewed from the manufacturing equipment as a whole. It was hot. Furthermore, among such composite molded products, in the case of large interior parts, it has been considered and adopted to mainly transport only the material, but in this case, the material is transported between each process. There were problems such as deformation, and since the material was processed in each process, it was necessary to accept large variations in dimensional accuracy. In addition, these problems tend to be further aggravated as interior materials become lighter. Therefore, as a countermeasure to these problems, it is recommended to use a chain or the like to transport the material or the interior material formed from it, and chain-clamp both ends of the material in the width direction, so that the material is transported across each process. There were many. However, this method has the following problems. In other words, since the chain spans each process, it may impede maintainability in the event of a problem, and in processes such as the molding process where molds need to be replaced depending on the type of molded product, the chain may be placed inside the equipment. Because the material passes through a When transporting products, it is necessary to remove excess material to account for shrinkage in the forward and backward directions relative to the direction of travel, which leads to a decrease in material yield for the product. Since the material is not retained in the front-to-back direction even when the material is crushed, defects such as molding defects and wrinkles are likely to occur, leading to problems such as unstable molded product quality. It is against this background that the present invention was developed, and it combines each process from supplying materials to punching out the product and drilling into a series of systems, and integrates the entire equipment into a series of systems. In addition to reducing investment costs and requiring fewer workers in a small space, this also reduces troubles during material transportation and improves dimensional accuracy, thereby stabilizing quality and increasing yield. In addition to this, the purpose is to improve maintainability and setup efficiency.

In order to achieve such an objective, the present invention provides a base material,
A series of manufacturing processes, from the material introduction process in which materials such as skin materials are introduced, through the heating process, lamination/forming process, to the finishing process such as outer punching and drilling, are carried out, and the finishing process is combined with the material introduction process. A pair of jigs that can be separated and connected to each other to clamp and set the base material and the skin material are used to construct a manufacturing circuit by connecting them, and the base material is attached to each of the pair of jigs. Then, the skin material is clamped and set and moved (transported) within the manufacturing circuit, and in each of the above steps, the pair of jigs are separated and combined as necessary, and then set in the respective jigs. The object of the present invention is that a predetermined treatment or processing is performed on the material. That is, according to the present invention,
The materials to be processed, such as the base material and the skin material, are clamped and set as a single plate (usually rectangular) in the transport jig for each material, and then moved to each process as a pair of jigs, so that each It is possible to securely hold the material, thereby effectively stabilizing the quality and improving the yield. As a pair of jigs are moved and circulated, and the pair of jigs are separated and combined in a series of processes to perform the necessary treatment or processing on each material, the equipment is made more compact. In addition to reducing the space required to return the jigs from the end of the process to the beginning, the number of workers can also be reduced. ), it is possible to transport the jig using roller drive or cylinder drive for each process, which improves maintainability and setup efficiency, and also eliminates the need for equipment that spans between processes. Because the system facilitates separation and connection between processes, it has become possible to flexibly respond to changes in the load on manufacturing equipment.

In addition, since the transport device can be placed on the floor, maintainability can be further improved. Hereinafter, the present invention will be explained in more detail based on embodiments shown in the drawings.

In FIGS. 1 and 2, which are a plan view and a front view schematically showing a process layout of a manufacturing apparatus according to an embodiment of the present invention, steps A to 1 are sequentially connected, and further steps 1 and A are connected in sequence. By connecting these, the series of manufacturing processes for the composite molded product constitutes a manufacturing circuit.

In each process, a known transfer mechanism such as a roller 1 drive or a cylinder drive is provided to convey the pair of jigs 1 or one of the jigs a or b brought into the process to the next process. (not shown). Also,
A pair of jigs 1 that can be moved and circulated through such a manufacturing circuit
As shown in FIG. 3, it consists of a jig a and a jig b, and these jigs A and b both have rectangular fixed outer frames 11a,
11b, and a rectangular movable inner frame 12 for holding materials (base material, skin material) inside the fixed outer frames 11a, 11b.
a, 12b. These movable inner frames 12a, 1
Each side of pin 13a is movable in the direction shown by the arrow in the figure and can be fixed at a predetermined position.
, 13b or a suitable clamper can adjust the width and length of the material held. Furthermore, the jig a and the jig b are arranged so that they can be easily separated and connected by fitting the legs 14 provided at the four corners of the jig a, and can be attached at a predetermined interval. It's getting old. The pairing jig 1 consisting of these jig a and jig b starts from process A in FIG. 1, process B...I
While the manufacturing circuit is sequentially moved through the process and returns to process A, each jig A,
A predetermined treatment or processing is performed on the material set in b. That is, in step A, which is the step of taking out the product P and setting the base material S, as shown in FIG. Ru.

Immediately after being carried out, the pair of jigs 1 are separated, and the jig a is moved horizontally to step B, which is the step of setting the skin material w. On the other hand, the jig b is lowered in the same position, and when it is lowered to the working level, it is temporarily stopped, and the worker takes out the product P and sets the base material S on the jig b. That is, each end of a veneer of a predetermined size of the relatively rigid base material S is inserted into the pin 13b and set in the jig b. After completing this work, the jig b is further lowered and horizontally moved from the lowered end to step B by the first drive roller 8. As shown in FIG. 5, in step B, the skin material is set by inserting the ends of a flexible skin material W of a predetermined size into the pins 13a on all sides of the jig a. After that, the jig a is lowered, and the jig a is temporarily held at an intermediate position.

Then, when the aforementioned jig b is carried into the process B, the jig a is released and integrated with the jig b by means of leg portions 14 (not shown). This pair of jigs 1 are moved to the left (rightward in FIG. 5) as shown in FIG. 1 and transported to process C. Unfortunately, here, a considerable amount of idle space is set aside between process B and process C. Further, a transfer passage from this process B to process C is provided so as to pass under the overhanging bolsters and the like of the pressing process G and finishing process 1, which will be described later. In process C, as shown in FIG. 6, the pair of jigs 1 are raised by the lipter 2, only the jig a is held at the rising end, and then the lipter 2 is lowered by a certain amount. By doing this, jig a and jig b are separated, and further, the lipta 2 is separated from jig b.
are separated. After the jig b is separated, it is further moved in the horizontal direction and carried to process D, where the direction is changed, and then carried to heating process E where the upper and lower heaters 7A,
The base material S set in the jig b is subjected to heat treatment for a certain period of time by 7b, and then sent to the next heating step F. Also in this heating step F, the base material S is heated for a certain period of time.

After the jig b is heated for a certain period of time in this process F, the jig a held in the previous process C is put into the process F, and the jig b and Reunify (combine)
This results in a pair of jigs 1. At this time, jig a (12a)
The skin material W set on the surface is preheated for a certain period of time by the upper and lower heaters 7A and 7b. Such heating has a positive effect on the molding conditions in subsequent steps. Naturally, for skin materials that do not require preheating, this can be done by adding the jig a in the time that eliminates the heating time. Then, the pair of jigs 1 that have come out of step F are then put into the molding and bonding press step of step G shown in FIG.
descends. The jig 1 supported from the lower die 4 via an air cylinder 9 or the like is lowered by electrical timing with the upper die 3 and stops at the parting surface. At this time, the skin material W and the base material S between the upper mold 3 and the lower mold 4 are molded along the shape of the mold, and at the same time, both are bonded and integrated (laminated body).
becomes. An adhesive material such as an adhesive or an adhesive film is applied in advance to one of the mating surfaces of the skin material w and the base material S, and the two are bonded together by this adhesive material. In addition, the upper mold 3 is temporarily held at the bottom dead center,
Then it rises. At the same time, the pair of jigs 1 are also returned to their original level by the air cylinder 9. During this molding, the jigs A and b are held at a predetermined distance by the legs 14, so the distance between the skin material W and the base material S is set constant, so that the surface material W Since the material is press-molded in a stretched state, wrinkles and the like on the appearance of the molded product are effectively prevented. The molded product P molded in this molding and bonding step G is attached to a pair of jigs 1 and transported to the next step H. In step H, the molded product P is cooled to room temperature, and the shrinkage of the materials S and W is completed.

Then, the upper die 5 is lowered at the same time as it is carried from process H to the trimming and hole punching process 1, which is a finishing process shown in FIG. Air cylinder 1 from lower mold 6
The jig 1, which is supported via the upper die 5 and the like, is lowered by electrical timing and stops at the parting surface. At the lower end of the upper die 5, a hole is punched in the outer punching and press direction, and a hole in the direction perpendicular to the plane is drilled with a Q cylinder or the like while remaining at the bottom dead center. At this time, the trimming process is completed without cutting the entire circumference of the product, leaving some unprocessed (uncut) areas. This is because when the product P is cut all around and separated from the remaining material held in the pair of jigs 1, the product P must be taken out in step 11fC}, but there are bolsters etc. on both sides of step 1. This is because the removal work there is difficult. Thereafter, the upper die 5 is raised, and the pair of jigs 1 are also returned to that level by the air cylinder 10 or the like. Since the product P has unprocessed parts as described above, it is transported to the process A while attached to the pair of jigs 1. Note that the skin material W clamped to jig a in the outer punching step 1 is unclamped and transported to step A (see Fig. 4, 1), but even if unclamped in this way, the skin material Since the W portion is held by the base material S, there is no problem. In addition, such unclamping is for immediately transferring jig a from process A to process B by horizontal movement, and therefore, the unclamping must be performed before the horizontal movement starts. However, there are no restrictions on the period. Then, the pair of jigs 1 thus carried into process A are separated immediately after being carried out, and materials (i.e., skin material W and base material S) are set on jigs a and jigs b again, and the above-mentioned steps are carried out. By repeating this process, product P is manufactured.

In particular, by sequentially moving a plurality of the pair of jigs A and b to the manufacturing circuit and performing each process or processing in sequence, the purpose of The composite molded article will be continuously taken out from step A. }, The flow of such a jig is,
It is also indicated by an arrow in FIG.

In the figure, mark Q means lowering of the jig, and mark 8 means rising of the jig. Further, the present invention is not limited to the above-mentioned system; for example, the material S,
Various process changes are possible depending on the heating conditions required for W.

FIG. 10 is a partial schematic diagram showing one of its application examples,
There, the jig a separated in step C is conveyed in the same direction as the jig b described in the previous example, that is, via steps D and E, where appropriate heating is performed.
The degree of heating of the base material S and the skin material W is controlled by the difference in transportation time until the process F is reached and the jigs A and b are joined there, and in particular the difference in residence time in the heating processes E and F. It is. In addition, the first
What is the number in one diagram? The jig 1 is separated in step σ, and the jig a is lifted up by the lipter 2 and transported to step H. On the other hand, jig b is transported to steps C, D, E, and F and heat-treated in the same manner as in the first embodiment. Then, jig b carried out from process F and jig a carried in from process H to process G are combined in process G, molded and bonded at the same time, and carried out to process H as a pair of jig 1. It is. This system does not require heating the skin material W at all, in other words, the skin material W is not required to be heated at all.
It is preferably used when heating should not be done.
Furthermore, the jigs A and b used in the present invention must be able to be easily combined and separated, and each material must be securely held without sagging (
It goes without saying that the present invention is not limited to the example shown in FIG. 3 as long as it can be set (preferably from four directions).

According to the manufacturing system for composite molded products as described above, the materials are first set in respective jigs and then transported as a pair of jigs to each process that constitutes the circuit. The quality is significantly more stable than the conventional method, and the defect rate is 10-15% compared to the conventional method.
The defective rate can be significantly reduced to about 3 to 5%. In addition, since it is possible to clamp the material in four directions (four sides) using a jig as shown in Fig. 3, there is no shrinkage of the unclamped end compared to the conventional method.
The material yield can be improved from the conventional 60 to 70% to 80 to 85%. In addition, by using the material as a veneer, compared to using the material in a roll, there is less material loss in the event of a defect, or in other words, the material yield can be improved. . Furthermore, since tension during maple molding is ensured by setting the material on the jig, appearance defects such as wrinkles hardly occur. On the other hand, since a jig is used in terms of equipment, it is possible to separate each process, which is extremely advantageous in terms of maintainability and the like. For example, maintenance man-hours are significantly reduced to 10 hours/month compared to the conventional 200 hours/month. In addition, during setup in the press process, it is possible to use the same number of setup steps as with conventional workpiece conveyance types. Furthermore, since each process in the system of the present invention is a series of circuits, fewer workers are required. Furthermore, in the case of the existing chain drive, the conveyor rail of the chain is a fixed object, so it is necessary to add an extra stroke to the lower die 4 of the press.
This has led to an increase in setup man-hours and equipment investment, but in the system of the present invention, the lower mold 4 can be of a fixed type as illustrated, making it possible to use a type that does not require such an extra stroke. As described above, the system of the present invention has many excellent features and has great industrial significance.

[Brief explanation of the drawing]

1 and 2 are a plan view and a front view, respectively, showing a schematic process layout of a manufacturing apparatus according to an embodiment of the present invention, and FIG. 3 shows →1 of a jig used in the present invention. FIG. 4 to FIG. 9 are perspective views, and FIGS. 11
Figures A and b are Figure 1 according to another embodiment of the present invention, respectively;
FIG. 3 is a partial schematic diagram corresponding to FIG. 2; 1: Jig, 2: Lifter, 3, 5: Upper die, 4, 6: Lower die, 7a, 7b: Heater, 8: Drive roller, 9, 10:
Air cylinder, 11a, 11b: Fixed outer frame, 12a, 1
2b: Movable inner frame, 13a, 13b: Pin, 14: Leg.

Claims (1)

[Claims] 1. In manufacturing a composite molded product such as an interior material by laminating a base material and a skin material and molding them into a predetermined shape, such a base material and skin material are introduced. By connecting the finishing process to the material introduction process, a series of manufacturing processes from the material introduction process through the heating process, lamination/forming process, and finishing processes such as punching and drilling are configured as a manufacturing circuit. , using a pair of jigs that can be separated and combined to set the base material and the skin material, respectively, and move the base material and the skin material on the pair of jigs in the manufacturing circuit; A composite device characterized in that in each of the steps, the pair of jigs are separated or combined as necessary so that a predetermined treatment or processing is performed on the material set in each of the jigs. Method of manufacturing molded products. 2. A manufacturing device that manufactures composite molded products such as interior materials by laminating base materials and skin materials and molding them into a predetermined shape, introducing such base materials and skin materials, and manufacturing them. a material introduction part that is set in each jig to form a pair; a heating part that is separated from the pair of jigs and that performs a predetermined heat treatment on at least the jig in which the base material is set; The jig in which the heat-treated base material is set and the jig in which the heat-treated skin material is set as necessary are combined, and the set base material and skin material are combined. A press part that simultaneously laminates and shapes the base material and skin material by performing a press molding operation on the material; and a press part that performs finishing processes such as punching and drilling on the laminated and molded materials in the press part. and a finishing part, and a manufacturing circuit is formed by connecting the finishing part to the material introducing part, and the base material and the skin material are respectively set within the manufacturing circuit, allowing for separation and combination. A plurality of pairs of jigs are arranged,
1. An apparatus for manufacturing a composite molded product, characterized in that composite molded products of a predetermined shape are continuously manufactured by sequentially moving and circulating the parts.