JPS59165620A - Manufacturing device for composite shape - Google Patents

Abstract

PURPOSE:To mass-produce complicated rugged shape products efficiently under the state of which the loss of a material is small according to the shape of a design by a series of continuous processes jointly using a vacuum forming method and an injection molding method, a compression molding method or a resin bead foaming method. CONSTITUTION:A base body layer 1 is molded through an injection molding method for a resin, and a material layer, on a back thereof a synthetic resin foamed quality cushion sheet 3 is pasted together previously as an intermediate material layer, is used as a skin material layer 2. The molded base body layer 1 and the molded skin material layer 2 combined with the cushion material layer 3 are fast stuck and joined in a fitting manner through vacuum forming, thus obtaining a composite shape A. Each layer may be molded through a compression molding method, a resin bead foaming method or a vacuum forming method besides the injection molding method.

Description

DETAILED DESCRIPTION OF THE INVENTION As shown in FIG. The present invention relates to an apparatus for manufacturing a composite molded body A consisting of a three-layer laminated skin material layer 2.

The base layer 1 is made of hard or semi-hard synthetic resin, resin bead foam, or the like. The skin material layer 2 is made of a soft solid or foamed sheet, synthetic leather, woven fabric, knitted fabric, non-woven fabric, or the like. The intermediate material layer 3 is made of synthetic resin foam, felt, or the like.

The composite molded product A having the layered structure described above can be used, for example, for vehicle interior parts such as door trim boards, front seat back panels, ceiling lining boards, instrument panels, etc., as well as various interior materials for architecture, furniture, and exteriors of electrical appliances. It is widely used for parts, etc.

Conventional methods for producing the composite molded body A can be roughly divided into a board molding method in which each layer is laminated in one piece, and a method in which each layer is laminated sequentially.

The former method uses a laminated flat plate in which each of the constituent layers 1112 or 1, 3, and 2 are bonded together as a material, and then heat-forms this (
It is molded into the desired shape by vacuum forming, pressure forming, plug forming, etc.), press forming, etc.

In the latter method, the material of the base layer 1 is molded into a desired shape by an appropriate means, the surface shape of the molded base layer 1 is shaped, and the surface material layer 2 or the intermediate material layer 3 is manually formed. Next, the skin material layer 2 is sequentially formed, or the intermediate material layer 3 and the skin material layer 2 are
are laminated together in advance. Alternatively, the product is obtained by covering the surface of the molded base layer 1 with material 2 or 3.2 in a sewing-wrapping manner.

However, in the former method, each layer is integrally laminated to form a plate.Since the constituent layers 1, 2, or 1, 3, and 2 of the material plate have different properties, the chain plate is formed by thermoforming. In some cases, it takes a high degree of skill, skill, and time to heat-soften the board uniformly and well throughout the board.Whether forming is done by thermoforming or press forming, the thickness of the material board may vary. As the thickness increases, the overall shape of the molded product inevitably becomes vague.The amount of material removed by trimming is large, and the material removed by trimming is composed of layers of materials of different materials.
2 or 1.3.2, so in most cases it is impossible to remelt it and recycle it as a raw material, resulting in a low material utilization rate and high product cost. In many cases, the final product is obtained by trimming the outer periphery, but if only the trimming is performed, the laminated cross section of each layer is exposed on the cut surface, that is, the outer periphery of the composite molded body A, and the appearance is poor. It is easy to peel off from the cross section.

Therefore, in cases where the cut surface needs to be hidden, it is common practice to attach separately produced molding material around the line of the trimmed molded body to hide the cut surface and make the final product, but the process for attaching the molding material This requires materials and labor, resulting in high costs. Furthermore, the edges of the molded body are often framed with molding material, which is not preferred as a form.

There are drawbacks such as.

On the other hand, the latter method of laminating each layer sequentially requires manual labor and has low productivity, and moreover, the intermediate material layer 3
・There is a drawback that it becomes difficult or impossible to adhere the skin material layer 2 to each part of the base layer 1, which has a complicated uneven surface shape, and to bond them beautifully. This is an inefficient method that is limited to small-volume production.

The present invention was proposed in view of the above, and although it is classified as a method of laminating each layer sequentially, it combines a vacuum forming method, an injection molding method, a pressure molding method, or a resin bead foam molding method. Through a series of continuous processes, composite molded products A, such as the one shown in the first example, can be efficiently mass-produced even with complex uneven shapes according to the designed shape with less material loss.
This type of composite has other major features, such as the ability to easily obtain a composite molded product in which the outer peripheral end surface of the material is neatly concealed by the skin material layer 2 and the continuous thin covering layer 4, and the edges are finished. The purpose of the present invention is to provide an automatic manufacturing device for molded bodies.

A detailed explanation will be given below based on an embodiment of the apparatus shown in the figure.

In this example device, the base layer 1 is molded by resin injection molding, and the skin layer 2 is vacuum-formed using a synthetic resin foam fleshy cushion sheet 3 pasted as an intermediate layer on the back surface of the skin layer 2. , the composite molded body A is obtained by closely joining the molded base layer 1 and the molded skin material M2+cushion material layer 3 in a fitting manner.

Fig. 2 is an overall plan view of the device, Fig. 3 is a partially vertical front view of the injection molding mechanism with the third mold inserted;
FIG. 4 is a partially cutaway side view of the rotating mechanism for advancing and retracting the third mold, and FIG. 5 is a front view of the material sheet heating and conveying mechanism.

The equipment in this example can be broadly divided into an injection molding mechanism (horizontal type) and a third
It consists of three mechanical parts: a mold advancing/retracting rotation mechanism and a material sheet heating/conveying mechanism.

■ Injection molding mechanism (Figures 2 and 3) 5 and 6 are a pair of first and second molds for resin injection molding to form the base layer l of the composite molded object A. When the molds are clamped together, the inside A cavity having a spatial shape corresponding to the base layer l is constructed. In this example, the first mold 5 is used to mold the front side of the base layer 1, and this is placed on a fixed Goi plate 8.
．． Make sure to hold it firmly in place. The second mold 6 is a mold for molding the back side of the base layer 1, and is firmly attached to and held by a movable goo plate 9. The movable goo plate 9 is supported by four horizontal tie bars 10 (up, down, left and right), and the tie bars 10 move forward and backward as the ram 12 of the hydraulic system 11 moves forward and backward.
It is driven forward or backward with respect to the fixed guide plate 8 along.

That is, the vacuum molding mold 7 as a third molding mold, which will be described later, is the first molding mold.
When the movable gouly plate 9 is driven forward in a state where it is released laterally from between the second molds 5 and 6, the second mold is moved against the first mold 5 on the fixed gouy plate 8 side. 6 are butted against each other, and the remolding molds 5 and 6 are brought into a clamped state. Conversely, when the movable goo plate 9 is driven backward, the mold is opened.

Reference numeral 13 denotes a nozzle part of a resin injection (or pressure feeding) device, which is not shown in the figure, and is fitted into the fitting hole of the fixed guide plate 8 from the back side of the plate, and the resin injection hole at the tip is connected to the sprue 52 of the first mold 5. Connection is communicating.

51 is a molding surface of the first mold 5, 53 is a mold mating surface (butting surface) with the second mold, 54 is a cooling water pipe buried within the thickness of the first mold 5, and 61 is a second mold The molding surface of the mold, 62 is a mold mating surface with the first molding mold 5 or the third molding mold 7 described later;
63 is an ejector pin built into the second mold 6; 64
numeral 65 is a hydraulic unit for advancing and retracting the pin (disposed inside the ram 12 for advancing and retracting the movable guide plate), and 65 is a cooling water pipe buried within the wall thickness of the second r&form type 6.

The hydraulic device 11 drives the movable guide plate 9 forward based on a mold clamping signal from a control circuit (not shown), so that the second mold 6 is in a clamped state with the first mold 5 or a third mold 7 to be described later. When this happens, further forward movement of the movable goo plate 9 is stopped by a signal from a sensor (not shown, microswitch, photoelectric sensor, timer circuit, etc., the same applies hereinafter) that detects this.

In addition, the movable gouly plate 9 is driven backward by the mold opening signal from the control circuit, and when the second mold 6 has retreated to a predetermined retreat position, a signal from a sensor (not shown) that detects this causes the movable gouly plate 9 to move further. Stop the backward drive.

II Third mold advance/retreat/rotation mechanism (Figures 2, 3, and 4) 7 is a vacuum forming mold as the third mold for molding the laminated sheet material 2 of the skin material layer + cushion material layer 3 The third mold 7 is disposed laterally at the upper and lower portions between the opened first and second molds 5 and 6 of the injection molding mechanism so as to be perpendicular to the advancing and retreating direction of the second mold 6. The molding surface 71 is held on the second mold 6 side between the upper and lower pair of guide rails 14 in a vertical position so as to be freely slidable. The rod 16 of the advancing/retracting rod device 15 is driven forward and pushed, and moves along the guide rails 14 and 14 between the first and second forming molds 5 and 6 in an open state.

Conversely, when the rod 16 is driven backward, it is pulled and moves backward laterally from between the first and second molds 5 and 6 in the opened state.

The reciprocating rod device 15 supports a rod 16 having rack teeth 17 formed on its longitudinal side so as to be slidable in the longitudinal direction by a bearing support 18, and a pinion 19 driven by a forward/reverse motor Ml is engaged with the rack teeth 17 of the rod 16. It is set.

Reference numerals 20 and 21 denote outwardly protruding shafts that are integrally provided at the center portions of the front end side surface and the rear end side surface of the third mold 7 with their axes aligned with each other;
The front end shaft 20 is rotatably connected to the center of the sliding column 22 which is engaged and held between the upper and lower guide rails 14, and the rear end shaft 21 is rotatably connected to the front end of the reciprocating rod 16. It can be freely connected and held. 23 is a friction wheel fixed to the rear end side shaft 21, and 24 is a friction wheel driven by a forward/reverse rotation motor M2.

The motor M1 is driven to rotate in the forward direction based on the third mold advance signal from the control circuit, thereby moving the rod 16 forward. As a result, the third mold 7 is inserted into the guide rails 14
The mold moves along the path between the first and second molds 5 and 6 in the open state. When the third mold 7 moves forward to a position exactly facing the second mold 6, a signal from a sensor (not shown) that detects this causes the motor Ml to rotate forward, that is, the third mold 7 is driven forward. will be stopped.

Further, this motor Ml is driven in the reverse direction based on the third mold retraction signal from the control circuit to move the rod 16 backward. As a result, the third mold 7 moves backward from between the first and second molds 5 and 6 along the guide rails 14 and 14 to the side. The third mold 7 is eventually removed from the guide rails 14 (shown by two-dot chain lines in Figures 2 and 4), and the friction wheel 23 fixed to the rear end shaft 21 of the mold 7 is moved to the motor M2. It comes into pressure contact with the friction wheel 24 on the side. When the third molding die 7 reaches this state, a sensor (not shown) that detects this causes the motor Ml to be driven in reverse, that is, the third molding die 7
The reverse drive is stopped.

After the third mold 7 stops working backward, the motor M2 drives the third mold 7 in the control circuit in forward rotation based on a rotation signal to drive the friction wheel 23, that is, the shaft 21 on the third mold 7 side, to the third mold 7. Rotate clockwise in Figure 5. This causes the third mold 7 to rotate clockwise around the shafts 20 and 21. 90
When the third mold 7 rotates and is received by the stopper member 25, the forward rotation of the motor M2 is stopped by a signal from a sensor (not shown) that detects this. This third mold 7
By rotating 90', the mold 7 is converted and held in a substantially horizontal position with the molding surface 71 facing upward (the position shown by the solid line in Figures 2, 4, and 5).

In addition, when the motor M2 is driven in the reverse direction based on the third mold raising rotation signal from the control circuit in this posture state, the third mold 7 is reversely rotated by 90° counterclockwise, and the stopper member 2
A sensor (not shown) that detects when it is received by 6
The reverse drive of motor M2 is stopped by the signal. This 90' reverse rotation of the third mold 7 returns the mold 7 to its initial vertical position.

72 is a mold matching surface of the third mold 7 with the second mold 6; 73
(Fig. 3) shows the molding surface 71 and molding surface 7 of the third mold 7.
Numerous vacuum holes are opened at 2, and 74 are cooling water pipes buried within the thickness of the mold.

■ Material sheet heating and transport mechanism (Figure 2, middle 5) 27.2
Reference numeral 7 indicates a pair of parallel horizontal rails disposed in the left-right direction above the 90° rotating portion of the third mold 7, and reference numeral 28 indicates that rollers 29 disposed at the four corners of the upper surface are engaged with the rails 27. The material sheet heating plate, which is arranged and supported almost horizontally on the underside of the rails 27 and 27 and can be moved left and right along the rails 27 and 27, is attached to the heating plate. 30 is the center of the rear side of the plate 28. A rack bar 131 whose tip end is integrally connected to the rack bar is a pinion meshed with the rack bar, and the pinion is rotationally driven by a forward/reverse rotation motor M3.

When the pinion 31 is driven forward, the plate 28 moves to the rack bar 3.
It is pushed by the forward movement of 0 and moves forward to the left in FIG. 2 along the rails 27. Conversely, when the pinion 31 is driven in the reverse direction, the board 28 is pulled by the backward movement of the rack bar 30 and moves backward to the right along the rail 27φ27.

Reference numeral 32 indicates a hydraulic rod device in which a reciprocating rod 33 is disposed in a substantially central portion of the upper surface of the panel 28 so as to protrude downward from the lower surface of the panel 28, and numeral 34 connects an approximately central portion of the upper surface to the lower end of the retracting rod 33. Material sheet heating plate supported substantially horizontally, 35
are erected at the four corners of the upper surface of the material sheet heating plate, and the material sheet heating plate vertical movement guide rods are respectively fitted into through holes drilled at the four corners of the plate 28. When the advancing/retracting rod 33 of the hydraulic rod device 32 is moved in a protrusive manner, the material sheet heating m34 descends downward in a substantially horizontal position without rotating, and conversely, when the rod 33 is moved backward, the board 3
4 moves upward. The material sheet heating plate 34 has a planar shape that is approximately the same size and shape as the material sheet, and has an electric heating element 36 within its wall thickness.
A heat source such as a steam pipe is provided, and a number of small vacuum suction holes 37 are formed on the lower surface.

Reference numeral 38 denotes a material sheet mounting table disposed to the right of the 90° rotating portion of the third mold 7, on which the material sheet, that is, the skin material layer 2 and the cushioning material layer 3 are laminated in advance. A large number of sheets are stacked and set with the cushioning material layer 3 side facing upward.

The material sheet heating plate 34 is always in a standby position with a home position directly above the material sheet mounting table 38. When a sheet material holding signal is issued from the control circuit in this state, each vacuum hole 37 on the bottom surface of the board 34 enters an air suction state, and the hydraulic rod device 32 is driven in the downward direction of the rod protrusion, causing the board 34 to move downward. Then, its lower surface is completely pressed into close contact with the upper surface of the loaded material sheet on the table 38. When this pressed contact is detected by a sensor (not shown), the signal causes the hydraulic rod device 32 to be switched and driven in the rod retraction direction, and the board 34 moves upward. At this time, only one of the stacked material sheets 2-3 on the table 38 is held in close contact with the entire bottom surface of the board by the vacuum suction force of the vacuum hole 37 on the bottom surface of the board and lifted.

When the board 34 rises to the initial position and returns, this is detected by a sensor (not shown), and the rod retraction drive of the hydraulic rod device 32 is stopped in response to the signal. Then motor M
The normal rotation drive of No. 3 is started, and the I6 rack par 30 moves forward. As a result, the board 34 moves forward to the left along the rails 27. That board 34
When the third mold 7 reaches a position directly above the third mold 7, which is held in a horizontal position by the 90° rotation movement part of the third mold, it is detected by a sensor (not shown), and the signal causes the motor M to move.
3, that is, the forward drive of the plate 34 is stopped.

Next, the hydraulic rod device 32 was driven in the downward direction of the rod protrusion, the plate 34 was moved downward, and the material sheets 2 and 3 held by vacuum suction on the lower surface of the plate were pressed and covered with the third mold 7 in the horizontal position. (shown by the two-dot chain line in Figure 5)
At this point, the downward movement of the rod of the hydraulic rod device 32, that is, the downward movement of the plate 34, is stopped.

The material sheets 2 and 3 were held in close contact with the lower surface of the plate 34 by vacuum suction on the table 38, and were heated by the plate 34 until they were covered with the third mold 7, so that each part was uniformly heated and softened. state.

When the above-mentioned downward movement of the board 34 stops, the signal causes the m3
The vacuum suction and holding of the material sheet by each vacuum hole 37 of 4 is released, or conversely, air is blown out from each vacuum hole 37. Further, each vacuum hole 73 of the third mold 7 is brought into a vacuum suction state. As a result, the material sheets 2 and 3 are vacuum-formed and pressure-formed using the third mold 7.

Next, the hydraulic rod device 32 is driven in the rod backward direction, and the board 34 is raised to the initial position.Then, the motor M3 is driven in the reverse direction, and the rack par 30 is moved backward to be returned to the initial home position on the right end side of the rail.

■ Manufacturing process (a) Equipment state before manufacturing starts The first and second molds 5 and 6 are held in an open state with the movable guide plate 9 in the retracted position (Fig. 2). The mold 5 has a molding surface 71 in the 90° rotation part.
is held in an upward horizontal position (2nd, 4th,
Figure 5 shows the state shown by the solid line).

The material sheet heating plate 34 has retreated to its home position directly above the material sheet mounting table 38 and is on standby (FIG. 5).

(b) Based on the mold clamping signal of the molding control circuit of the base layer 1, the movable guide plate 9 is driven forward, and the second molding mold 6 advances against the fixed first molding mold 5, and the two molds are brought into abutting state. 5 and 6 are clamped.

Next, in response to a mold clamping end signal, molten resin is injected from the resin injection device through the nozzle 13 and sprue 52 into the molding cavities in the clamped molds 5 and 6, and the base layer 1 is formed.

After resin injection, when a predetermined cooling time has elapsed, the movable guide plate 9 is driven backward based on the mold opening signal from the control circuit, and the molding base layer l is held on the movable second mold 6 side (Fig. 3).
Then both molds 5 and 6 are opened.

(C) Vacuum forming of the material sheet In parallel with the forming step of the base layer 1 described in (b) above, the operation of the material sheet heating and conveying mechanism is started by a sheet material holding signal from the control circuit. That is, as explained in the above section (2), the material sheet heating plate 34 is lowered to the upper surface of the loaded material sheet → vacuum suction and holding of the uppermost sheet material 9 2 and 3 → the vacuum forming mold 7 side which is the third molding mold in a horizontal position Transfer to→A material sheet is applied to the chain acid type mold, and the applied material sheet is vacuum formed or vacuum/pressure formed by the third mold 7. The molded material sheet is maintained as it is on the surface of the third mold 7 under suction.

The board 34 then returns to its home position and moves.

(d) When the laminated material sheet heating plate 34 of the molding base layer l and the molding material sheets 2 and 3 moves back to a position where it does not interfere with the third mold 7, the operation of the third mold advance/retreat/rotation mechanism starts. be done. That is, as explained in the above section 11, the motor M2 is driven in reverse by the third mold raising rotation signal from the control circuit, and the third mold is rotated 90 degrees counterclockwise to take the vertical position (first position). 2, 4, and 5 (the posture shown by the two-dot chain line in Figures 2, 4, and 5). Next, the normal rotation of the motor M1 is started, and the third mold 7 in the vertical position moves forward to move the upper and lower guide rails 14.
・The rod 16 enters and engages between the rails 14 and is subsequently driven forward by the forward rotation of the motor Ml to form the base layer l along the rails 14. The first and second molds 5 and 5 are opened after completion of the process.
Enter between 6 and 6. When the third mold 7 moves forward to a position exactly facing the second mold 6, the motor M
It stops when the normal rotation drive of No. 1 is stopped (Fig. 3).

After the third mold 7 is stopped, the movable goo plate 9, that is, the second
The mold 6 is driven forward and is clamped against the third mold 7. This advancement of the second mold 6 causes the mold base layer l held on the mold 6 side to fit with the cushion material layer 3 of the molding material sheets 2 and 3 held on the third mold 7 side. It is applied to the extent that it is pressed appropriately and becomes in close contact.

As a result, the molded base layer 1 and the molding material sheets 2 and 3 are integrated to form a composite molded body A. The base layer 1 and the cushioning material layer 3 are well integrated by forming a hot-melt or solvent-based adhesive layer on the free surface of the cushioning material layer 3 of the material sheets 2 and 3 in advance. Ru. Furthermore, since both the base layer 1 and the material sheets 2 and 3 have a considerable amount of retained heat, it is also possible to integrate them by heat-pressure bonding without using an adhesive.

Next, the movable guide plate 9 is moved backward, and the second mold 6 is moved backward from the third mold 7.

At this time, the ejector pin 63 is driven forward by the drive of the hydraulic unit 64, so that the tip of the pin 63 projects forward from the molding surface 61 of the second mold 6, and the molding base layer l is separated from the molding surface 61. .

Therefore, the composite molded body A is held on the third mold 7 side. The ejector pin 63 is then driven backwards so that its tip end surface is in the second position.
The molding surface 61 of the mold 6 and the road surface return to the initial retracted state.

(e) Removal of the composite molded product A After the second mold 6 is retracted, the motor M1 is driven in the reverse direction and the rod 16 is moved backward, as explained in Section 11 above, thereby holding the composite molded product A. 3 mold 7 is the first
Then, it moves backward from between the second molds 5 and 6 along the rails 14 and 14, and eventually comes out from between the rails 14Φ14, and the friction wheel 23 on the mold 7 side becomes the friction wheel 24 on the motor M2 side. The backward movement of the third mold 7 is stopped in a pressed contact state. Next, the third mold 7 is rotated 90° clockwise by the forward rotation of the motor M2, and the molding surface holding the composite molded body A is converted and held in an upward substantially horizontal position. Then, the composite molded body held by vacuum suction in the third mold 7 is released from vacuum suction and held and taken out. This extraction can also be automated using a robotic mechanism.

Thereafter, the steps (b) to (e) described above as one cycle are repeatedly executed to automatically and continuously manufacture the composite molded body A.

(f) Edge finishing of the composite molded body A The composite molded body A taken out above is shaped like a molded body A as shown in FIG.
An extra extension material portion 4a of the laminated sheet material of the skin material layer 2 and the cushion material layer 3 remains on the outer peripheral edge. Therefore, this extra extension portion 4a is trimmed along the outer periphery of the base layer l.

and product A. Alternatively, this extra extension material portion 4a may be
Since the abutting surfaces 62 and 72 of the two molds are compressed by the clamping of the third mold 6117 and the thickness is considerably thinned, the trimming process C2-C2L is performed to be larger than the outer periphery of the base layer 1. It is rolled up on the back side of the base layer 1 as shown in the dotted chain line, and the edges are finished with an adhesive or a fastener (4).

The above trimming process ct-ct or C2-C2 is performed in advance on the mold clamping abutment surfaces 62 and 7 of the second and third molds 6 and 7.
By forming a trimming cutting blade and a concave portion facing each other in the mold 2, the mold clamping of both molds 6 and 7 can be automatically performed at the same time.

(g) Modifications etc. In the above example, the base layer 1 is molded by resin injection molding, but by using the first mold 5 as a resin bead foam mold, the base layer 1 can be made into a resin bead foam molded product. It is also possible to make a composite molded product. FIG. 7 shows an example of the first mold 5, with reference numeral 55 a foamable resin bead introduction tube opened in the molding surface 51 of the first mold 5, and 56 a plurality of openings in the molding surface 51. This is a small hole for blowing out hot air such as steam and hot air. That is, after the second mold 6 is clamped to the first mold 5, foamed resin beads are introduced and filled into the cavity through the introduction pipe 55, and then hot air is blown into the cavity from the small hole 56. By doing so, the heat causes the foamable resin beads in the cavity to thermally foam and form a mass.

The skin material layer 2 and the cushion material layer 3 explained in the above section (f)
In order to more effectively reduce the thickness of the extra-extended material portion 4a by the clamping force of the second and third molds 6 and 7, the mold abutment surface 62 of the second mold 6 and/or It is preferable to dispose a heater H (FIG. 3) on the mold abutting surface 72 of the third mold 7 for heating and softening the material portion 4a to promote elongation due to compression.

Further, by forming a considerably deep annular groove 75 on the mold abutting surface 72 of the third mold 7 as shown in FIG. 8, and opening a small vacuum hole 73 at the bottom of the groove 75, During vacuum forming of the bonded material sheet of the skin material layer 2 and cushion material layer 3 using the third mold 7, the excess material portion 4a of the material is drawn into the groove 75 and vacuum formed to be stretched thin. You can also do this.

In the case of a composite molded body A having a two-layer structure of a base layer 1 and a skin material layer 2 as shown in FIG. Just follow.

In the case of a composite molded body A having a three-layer structure consisting of a base layer 1, an intermediate material layer 3, and a skin material layer 2 as shown in Figure 1, an intermediate material is preliminarily applied to the back surface as the skin material layer 2 as in the above example. Even if the skin material layer 2 is not bonded together, the skin material layer 2 can be formed by vacuum forming in the third mold 7, and the skin material layer 2 can be formed into a third mold that holds the skin material layer 2 as shown in FIG.
Before clamping the second mold 6 holding the molding base layer 1 to the mold 7, an adhesive layer such as a hot-melt type adhesive is applied to both the front and back surfaces between the two molds 6 and 7, and By introducing the heat-softened sheet material 3 for the intermediate material layer and then clamping the mold, the sheet material for the intermediate material layer is pressed into a sandwich between the base layer 1 and the skin material layer 2. Three layers of 1φ3.2 may be laminated together. Alternatively, as shown in FIG. 9, the first and second molds 5
・A protrusion consisting of a protruding pipe pin 66, an advancing/retracting plate 67, a hydraulic unit 68, 68 for advancing and retracting the plate, etc., which penetrates the thickness of the molded base layer 1 to form a small vacuum hole 1 during molding of the base layer 1 according to 6. The tube pin mechanism is built into the second mold 6 and the ram 12, and the base layer 1 is formed with vacuum holes 1 and 1 formed on its outer surface. Then, as shown in FIG. 9, the thermally softened intermediate layer sheet material 3 introduced between the second and third molds 6 and 7 is inserted into the base layer 1 through the small vacuum holes 1 and 1 formed in the base layer 1. Vacuum forming layer 1 to make it adhere,
Next, the second mold 6 is clamped and moved relative to the third mold 7, and the intermediate material layer 3 and the skin material layer 2 on the third mold 7 side are brought into close contact with each other, thereby forming the three layers 1 and 3. It may be possible to integrate the whole.

As described above, the present invention provides: (1) The base layer 1 and the skin layer 2 (or the skin layer 2 + the intermediate material layer 3), which are the constituent layers of the composite molded article A, or the base layer 1,
Since the intermediate material layer 3 and the skin material layer 2 are separately molded into the desired shape and then laminated and integrated in a fitting manner to obtain the desired molded product, even products with complex uneven shapes can be shaped into the overall molded shape. It is possible to produce a molded article having a sharp highlight portion without so-called obscurity and having a predetermined design.

(2) The base layer l has no so-called trimming loss;
In the case of a molded product with a two-layer laminated structure of a skin material layer 2 and a skin material layer 2, the skin material layer 2 removed by trimming is a single material, and therefore, if it is a thermoplastic resin, it can be remelted and reused. There is no waste and resources can be saved. Also, in the case of a laminated sheet of the skin material layer 2 and the intermediate material layer 3, by making both of them thermoplastic resins of the same type, they can be remelted and reused.

(3) It is also possible to easily produce a good-looking molded body A in which the thick end face around the molded body is hidden by the skin layer 2 and a series of thin extension material pieces 4a and the edges are finished 4.

(4) The opening/closing movements or positional movements of the first, second, and third molds are sequentially controlled in a relational manner as described above, and the above (b)
Since the step (e) is continuously automated as one cycle, this type of composite molded article can be mass-produced efficiently.

8

[Brief explanation of drawings]

Figures 1a and b are cross-sectional views showing the layer structure of the composite molded body, Figure 2 is an overall plan view of an apparatus according to an embodiment of the present invention, and Figure 3 is a state in which the third mold is inserted. Fig. 4 is a partially cutaway side view of the forward/backward movement Φ rotation mechanism of the third mold, and Fig. 5 is a front view of the material sheet heating and conveying mechanism. , FIG. 6 is a cross-sectional view of the manufactured composite molded body before edge treatment, FIG. 7 is a cross-sectional view of the first mold example in which the base layer is made of resin bead foam, and FIG. 8 is a cross-sectional view of the molding material sheet. FIG. 9 is a cross-sectional view of a part of the third mold in which the extra extension material portion is thinned by vacuum forming, and FIG. 9 is a cross-sectional view of the main part of the modified device. Reference numeral 8 denotes a fixed gouly plate, 9 a movable gouly plate, 13 a nozzle portion of a resin injection machine, and 14 a guide rail of a third mold.

Claims (2)

[Claims] (1) The base layer (1) is formed by resin injection molding or resin pumping acid forming by resin bead foam molding.A split mold consisting of a fixed first mold (5) and a movable second mold (6) ,
Clamping the second mold (8) against the first mold (5)
A second mold drive device (11) that moves the mold opening, and a skin that can be freely moved in and out by an advance/retreat drive device (15) between the first and second molds (5) and (6) in the opened state. It consists of a third forming mold (7) for vacuum forming a material sheet formed by laminating the sheet for material layer (2) or the sheet for intermediate material layer (3) on the back side of the sheet (2), and After molding the base layer (1) using the second molds (5) and (8), the molded base layer (1) is held on the second mold (6) side, the mold is opened, and the remolding mold (5) is opened. )/(6) Insert the third mold (7) in which the material sheet (2) or the material sheet (2)/(3) is vacuum-formed and held, and face the second mold (6). position, and move the second mold (6) forward again to form the third mold.
The molding die (7) is clamped or brought close to the molding base layer (1) on the second molding mold (8) side and the molding sheet material (2) or the same (2) on the third molding mold (7) side. 3) A device for manufacturing a composite molded body, characterized in that the movement of the mold is sequentially controlled in a relational manner so as to join and integrate the molds. (2) Base layer (1)/intermediate material layer (3)-skin material layer (2)
In the case of a composite molded body consisting of a laminate of the molded base layer (
1) and a second mold (6) holding the molded skin material layer (2).
) is inserted between the sheet for the intermediate material layer (3) and the third mold (7) holding the mold, and the second mold (6) is moved forward to form the sheet for the intermediate material layer (3). The above three layers (1), (3) and (2) are laminated together by sandwiching and pressing between the base layer (1) and the molded skin material layer (2), or The introduced intermediate material layer sheet (
3) is vacuum-formed onto the surface of the molding base layer (1) of the second mold (6) and moved forward to clamp or approach the third mold (7). Then, the above three layers (1)・(
2) and (3) are joined and integrated (
1) The apparatus for manufacturing a composite molded body according to item 1).