JPS60262610A - Manufacture of resin molded product - Google Patents

Abstract

PURPOSE:To obtain effectively the product without the occurrence of wrinkles on its surface by a method in which the skin of the product is molded in a heated mold, feeding powder resin stock thereinto, and then the mold with said skin is filled with the foaming resin stock. CONSTITUTION:A heating part 1, a powder resin feeding part 2 and a foam molding part 3 are provided, and a mold 4 is enabled to be transported among these parts, while providing a transporting rail, etc. among these parts. Powder resin is caused to adhere to the mold surface of the heated mold and is fused, and then cooled, whereby a skin is molded. Further, while injecting foaming resin stock into the mold, said resin stock is foamed and molded. The skin is caused to adhere integrally to the surface of a foamed molded product. A plurality of molds are provided, and the molds are heated with time lag for each mold, whereby the process from skin molding to foaming molding is achieved.

Description

[Detailed Description of the Invention] (Industrial Application Field) The present invention is applicable to automobiles, motorcycles, etc., for example.
The present invention relates to a method for manufacturing a resin molded product in which the surface of a foamed resin is covered with a resin skin.

(Prior Art) 1. There are dual-use sheets, etc., in which the surface of a resilient foamed resin molded product is covered with a resin skin.

To manufacture such a molded product, conventionally the skin and the foamed resin molded product are manufactured separately, the skin is trimmed to match the shape of the foamed resin molded product, and the trimmed skin is then foamed. It is either placed over the resin molded product and glued, or the edges of the skin are sewn.

As another molding method, there is a method in which a skin is prepared in advance and set in a mold, and a foamed resin material containing a foaming agent is injected into the second mold to carry out foam molding.

(Problems with the prior art) However, when trimming a separately manufactured skin and placing it on a foamed molded product, wrinkles may occur at the edges of the skin, or overlapping parts may occur, resulting in poor integration. It becomes a product. Another problem is that since the skin and the foamed molded product are manufactured in separate processes, it takes time and effort. On the other hand, even with the method of setting the skin in the mold, wrinkles are likely to occur in the deep-drawn portion, and a mold separate from that for molding the skin must be prepared, which is troublesome.

(Objective of the invention) The invention was made in view of the problems mentioned above, and the first object is that the process from forming the skin to foaming the foamed resin can be carried out in a series of steps, It is an object of the present invention to provide a method for producing a resin molded article, which does not cause wrinkles on the surface of the obtained product and can increase the production efficiency to a greater extent than in the past.

(Structure of the Invention) In order to achieve the object 1-, the present invention is based on the premise that everything from skin molding to foam molding is performed with one mold, and a plurality of such molds are prepared, and each mold is The mold is heated at different times, the powdered resin is melted on the molding surface of the heated mold, and then the molten resin layer formed on the molding surface is cooled to carve the skin. Further, a structural feature is that a foamed resin raw material is injected into a mold and foam molded, and a skin is integrally formed on the surface of the foamed molded product.

(Example) Embodiments of the present invention will be described below based on the accompanying drawings.

Figure 1 shows the overall plane [4] of the manufacturing apparatus used to carry out the method of the present invention, and the main parts of this manufacturing apparatus are a heating section (1), a powder resin supply section (2), and a foam molding section (3). The structure of each part of the manufacturing apparatus is shown in FIGS.
explain about.

Figure 2 is a top view of the heating section (1) and the section integrated with the heating section (1). A heating furnace (7) is installed below the frame (6) and near the column (5). This heating furnace (7) has a holding plate (8) for the mold (4) attached to the upper opening, and a filter (9) is installed horizontally inside the heating furnace (7). is divided into an upper chamber (Sl) and a lower chamber (S2), the upper chamber (St) is filled with a heating medium such as alumina particles (lo) and a heater (II) is provided, and the lower chamber (s9 ) is supplied with compressed air. Then, the alumina particles (1o) are heated by the heater (11), and the alumina particles (1o) are heated from the lower chamber (St) through the filter (8). ″% room (S
By supplying air to 1), a heated fluidized bed is formed in the -1 partial chamber (Sl).

Further, the traveling frame (6) is provided with a conveying device (12). The structure of this conveyance device (12) is such that a traveling body (13) mounted on a traveling frame (6) is moved by a motor (14) (
(see FIG. 3), it is possible to move n1 along the traveling frame (6). A cabonox (15) is provided in a part of the running body (13), and this cabonox (1
5) is made to pass through the long end (16) in the vertical direction, and the vertical end (16) is lowered 4 times by the drive of the motor (17) previously installed in the cabonx (15), and the opening,
A cover unit (18) is attached to the lower end of the door (16) via a support plate (18), and a mold (4) is attached to this cover unit [19].
A chuck mechanism (20) for attaching and detaching is provided.

A base (21) is installed on the side of the heating furnace (7) and in front of the powder resin supply section (2), and a mold reversing device (22) is installed on this base (21). There is. This reversing device (2
The structure of 2) consists of a pair of supports (23) on a base (21) l-.
.

(23) is erected, and a support (24) is placed between these supports (23) and (23) so as to be parallel to the traveling frame (6).
and secure this shaft (24) to one of the pillars (23).
Furthermore, the shaft (24) is provided with a pair of arms (2B) which are perpendicular to the traveling frame (6) and have a mechanism for clamping the mold (4) at the tip. ) and (28) are tied together. Then,
Arno (2ft) driven by reversible motor (25),
(2B) rotates forward and backward (left and right in FIG. 3) in the normal and reverse directions within a range of approximately taOo, as shown by the imaginary lines in FIG.

Also, behind the reversing device (22) (right side in Figure 3)
A powder resin supply section (2) is arranged at.

This powder resin supply section (2) has rails (27), (2
7) is fixed, a moving platform (28) is mounted on these rails (27), (27), and this moving platform (28) is mounted on rails (27), (27) using a shilling unit h (28). The movable table (28) has a link (30
) and the cylinder unit [・(31) to connect the rail (32) that can be lowered by y1 to the i! 1! Tie this rail (32)
An elevating body (34) that moves vertically along the kite cup (33) fixed to the movable table (28) is mounted, and the frame body (35) is placed on this ν1 descent (34N-). !, and the powder resin filling tank (36) is held by this frame (35).

In addition, stoppers (37) and (38) are provided on the moving platform (28) and the A lowering body (34), respectively, and these stoppers (3
7).

(38) regulates the travel limit and 1-movement limit of the rail (32).

On the other hand, a stand (39) is placed in front of the first base (21) as shown in FIG. ) has been established. A rail (4
0) and (40), and from the center of the stand (39) to the right foam molded part (3).

Rails (41) and (41) are laid down to (3), and the cooling box (42) of the mold (4) is mounted on these rails (40) and (41) so that it can run. . That is, the rail (
Movement along the rails (40) and (40) is carried out by a chain driven by a motor (not shown) and by a rail (40).
The movement along lines 1) and (41) is performed by the cylinder unit 1-(43) as shown in FIG.

The structure of the foam molding part (3) is shown in Figures 4 and 5.
44) A part of the hem (46) which can be rotated by the cylinder unit (45) is pivotally attached to a part of (7)1, and a rond (47) is attached to the tip of this head part (46).・ is slidably inserted into this lower 1" (47)...a holding plate (4) equipped with a chuck mechanism for the foam mold (48) at the tip.
9), and attach the top part (4) to the holding plate (49).
A rod (51) of a silling unit (50) fixedly attached to the tip of the rod (6) is tied. By operating the cylinder unit (50) with the head (46) tilted forward as shown by the solid line in FIG. 5, the holding plate (48) is moved up and down. In addition, by operating the cylinder unit (45), the holding plate (49) is moved as shown by the imaginary line in FIG.
moves toward the rear E while holding the foaming mold (48).

Further, an injection device (53) which is created by a cylinder unit (52) and moves downwardly and backwards is attached to the side of the support base (44), and this Q4 injection device (53) is advanced and its tip is moved forward. It is inserted into the through hole provided in the foam molding mold (48), and the space (
For example, 11 liquid foamable resin raw materials are placed in S).

Further, a foaming mold changing device (54) is arranged on the side of the foaming molding section (3). This exchange device (54) has a support rod (55) erected on the floor 1-, and this support rod (55)
Multiple frames (56) in the space divided by...
1- by storing ... with wire (57) etc.
A cylinder unit (5) is provided with equal spacing in the direction of the lower blade, and this wire (57) is fixed to the side of the branch (55).
8) through a pulley (58).

Further, each frame body (56) accommodates a foaming mold (48) having a different shape.

Then, by operating the shilling unit I (58), the foaming mold (48) having a predetermined shape is positioned at the exchange position.

A molding method using a molding apparatus having the configuration described in 1- will be described below.

First, a mold (
4) Soak. In this case, in order to prevent the alumina particles (10) from adhering to the molding surface of the mold (4),
The molding surface of the mold (4) is set to 1-, and the mold (4) is immersed in a fluidized bed made of alumina particles (1O) with the flange portion of one end hung on the holding plate (8).

Simultaneously with the heating of the mold (4), the conveying device (12) is moved along the traveling frame (6).
) is placed on standby in one side of the heating furnace (7)I. And the mold (4
), the motor (17) of the conveying device (12) is driven to lower the cover (19) together with the support plate (18), and the cover (18) is heated to a predetermined temperature.
)-knee rI'I) opening is cold and the cover is integrated (1
The mold (4) is held by a chuck mechanism (20) provided in 9). Then, by rotating the motor (17) in the reverse direction, the mold (4) together with the cover assembly (19) is pulled out of the heating furnace (7) towards one side. This state is shown by the solid line in FIG.

Thereafter, the conveying device (12) is moved along the traveling frame (6) by driving the motor (14), and the mold (
4) of the reversing device (22) as shown by the imaginary line in FIG. transport to the destination. Then, the motor (17) of the transfer device (12) is operated again to lower the mold (4), clamp the mold (4) at the tips of the arms (2Ei) and (28), and chuck the mold (4). The mechanism (20) is released to release the engagement between the cover unit (19) and the mold (4).

After this, the motor (25) is driven to move the motor (26).

(26) is turned backward approximately 180° while holding the mold (4). In this case, the powder resin filling tank (36) is the third
As shown in 14, the robot is waiting at the front position (left side in the figure) at the position lifted at 1y1 (34). Therefore, by reversing the arms (26) and (2B), the mold (4) is opened. . In this state, the mold (4) and the powder resin filling tank (36)
is held by the frame (35).

In addition, on the left and right sides of the frame (35), as shown in Fig. 1, pressure contact plates (
130), (60) are arranged, and this pressure contact plate (8o
), (so) are connected to the motor (8) via the gear (61).
2).

After closing the opening of the powder resin filling tank (36) with the mold (4), the frame (
35) is held, and then the cylinder unit (31) is retracted to lower the elevating body (34). In this case, the frame (35) is connected to the pressure contact plates (80), (80
), the frame body (35) and the elevating body (34) move between each other without descending. In addition, in this state, the mold (4
) are unclamped by arms (26), (28).

When the motor (62) is driven from this state, the mold (4)
and the powder resin filling tank (36) are held in the frame (35) with their openings abutting each other, and the frame (35)
5) and the 1lvlit' body (34) are separated, so the frame body (35) rotates without interfering with the elevating body (34), and the mold (4) and the powder resin filling tank (36) The top and bottom are reversed. Incidentally, the rotation angle of the frame (35) is, for example, 27 degrees.
0, and once it has rotated 270 degrees, it should be rotated in the opposite direction to return to its original position.

Then, along with the 1-th rotation, the powder resin filling tank (36)
The powdered resin inside moves into the mold (4), and the powdered resin that comes into contact with the molding surface of the mold (4) is melted by the heat of the mold (4), forming a molten resin tank on the molding surface. Here, the molten resin tank is
Since the molten resin tank is formed so that it gradually dries up starting from the part closest to 'ii, no air is trapped in the molten resin tank.

Note that air may be blown into the powder resin filling tank (36) in order to bring the powder resin into even contact with the molding surface of the mold (4).

Here, in order to supply powdered resin into the powdered resin filling tank (36), as shown in FIG.
The frame body (36) holding the powder resin filling tank (36) is activated.
35) is placed on the y lowering body (34) i, and pull it out to the position indicated by the imaginary line in the figure.
) Replenish powdered resin into the chamber.

After forming the molten resin on the molding surface of the mold (4) as described above, the mold (4) is clamped by art, (2e), (2B), and the arms (2B), Rotate (2B) forward (to the left in Figure 3). Then, at this time, the cooling box (42) placed on the traveling base (63) via the rails (40), (40) moves to the arms (26), (2B).
It is located in between. Therefore, arm (2B), (26
) is housed in the cooling box (42), and at this point the arms (2G) and (2G)
Release the clamp state.

Next, the carriage (63) is moved along the rails (40) and (40) toward the base (39), and the mold (4) with the molten resin tank formed on the molding surface is placed in the cooling box (42). ) is transported to the base (39) t::. Here, the cooling box (42) is filled with cooling water (64), and by storing the mold (4) in the cooling box (42), the mold (4) is cooled. The molten resin bath formed on the molding surface of the mold (4) hardens to form a skin on the molding surface.

Then, the mold (4) transferred to the nol stand (38) J: remains housed in the cooling box body (42) until the cylinder unit).
- It is transported to the foam molding section (3) by the operation of (43).

Here, in the molding section (3), when the mold (4) is conveyed, the head (
46) is in the standby position rotated in the L direction, and the holding plate (49
) The foam mold (4th) attached to the cooling box (42)
It is designed not to interfere with the transportation of Also, Norudai (3
9)-1-, the cold JJL box body (42) runs along the rails (4], ), (41) at cylinder unit 7.
A connecting member (65) provided at the tip of the rod (43)
This is done by engaging the cooling box body (42).

In this way, the cooling box body (4) containing the mold (4)
2) is located in the foam molding section (3), the cylinder unit (45) is operated to form the foam molding section 7.
1" (46) forward and attach it to the tip of the head (46) via the front (47) and retaining plate (48).
Fit the cut foam mold (48) into the metal mold (4). Next, the cylinder unit (50) is operated to clamp the metal plate (4) and the foaming mold (48), and this and (Jf
By activating the cylinder 227 (52), the tip of the injection device (53) is inserted into the injection through-hole formed in the foaming mold (48), and the tip of the injection device (53) is inserted into the injection through-hole formed in the foaming mold (48). A urethane resin liquid or the like containing a foaming agent is injected into the space (S) formed between the molding surface and the foaming mold (48), and is foamed after a predetermined period of time to integrate the skin and the foamed resin. .

As a result, a resin molded product is obtained in the mold (4) in which the surface of the foamed resin is covered with a resin skin.

Further, the operation of the exchanging device (54) for the foam mold (48), which was previously installed on the side of the foam mold section (3), is as follows.

It is assumed that the foaming mold (48) matched with the mold (4) in FIG. 4 is to be exchanged with the mold (48a) waiting in the exchanging device (54).

In this case, first, the empty frame body (56) that does not contain a foaming mold is moved to the exchange position (two steps ['' from the bottom in the figure) by operating the cylinder unit (58). At the same time, the cylinder unit l-(45) of the foam molding section (3) is operated.

The head (46) is rotated upward to separate the mold (4) and the foam mold (4 days).

Next, the empty frame body (56) is connected by the connecting member (65), and in this state, the cylinder unit (43) is retracted, and the cooling box body (42) and the empty frame body (5
6) to the left in FIG. 4 to position the empty frame (56) in the foam molding section (3).

After that, the old cylinder unit (45) is activated, the head (46) is tilted forward, the foam mold (48) is housed in the empty frame (56), and the holding plate (49) and the foam mold (
48). And the head (46
) is rotated upward again and the cylinder unit (43) is moved to protrude, and the frame (56) containing the cooling box (42) and the foam mold (48) is opened as shown in Fig. 4. Move it to the right, position the frame body (56) between the supports (55), and engage it again with the chain (57).

Then, the cylinder unit 1-(57) is operated to move the frame (56) holding the foaming mold (48a) to be replaced by 7A to the replacement position, and the connecting member (85) and the frame (56) are moved 7A to the replacement position.
6), the cylinder unit (43) is operated to position the foaming mold (48a) in the foaming molding section (3).

After this, the cylinder unit (45) is operated and the Hen F
(4Ei) is rotated forward and downward, and the foam molding part (48a) is held by the holding plate (49) attached to the head (46), thereby completing the replacement of the mold.

Figure 6 is a time chart 1 showing an example of a molding system according to the method of the present invention. In this example, a total of four molds are used, and the same molding process is performed on each mold at different times. I have to.

That is, the second mold is heated when the first mold is subjected to skin molding, that is, a molten resin bath is formed on the molding surface of the mold, and the cooling of the first mold is completed. The third mold is heated, and the fourth mold is heated when the first mold is being subjected to foam molding (foaming and curing).

Here, for example, the first mold and the second mold undergo a part of the foam molding process, but the molding device described above has foam molding parts (3) and (3) on the left and right, respectively. There is no problem because it is set up. In particular, by performing foam molding, which requires the most time, using two foam molding sections, the efficiency of the entire molding operation is improved.

(Effects of the Invention) As is clear from the following explanation, according to the present invention, powdered resin is supplied into a heated mold to form a skin, and the mold in which the skin has been formed is filled with foamed resin raw material. As a result, wrinkles etc. do not occur on the epidermis, trimming work can be omitted compared to conventional methods, and resin molded products with excellent product characteristics can be effectively produced. Further, since only one mold is used from the formation of the skin to the foaming process, the number of molds to be prepared can be reduced, and the molding apparatus as a whole can be made more compact. Furthermore, since the same molding apparatus is used and the same molding process is performed on a plurality of molds at the same time at different times, there are many advantages such as being able to manufacture resin molded products extremely efficiently.

[Brief explanation of drawings]

Fig. 1 is an overall plan view of a molding apparatus for carrying out the method of the present invention, Fig. 2 is a front view of the heating section of the apparatus, Fig. 3 is a side view of the powder resin supply section of the apparatus, and Fig. 4 is a FIG. 5 is a front view of the foam molding section of the same apparatus, FIG. 5 is a side view of the same foam molding section, and FIG. 6 is a time chart showing an example of the method of the present invention. In addition, (1) in the drawing is a heating section, (2) is a powder resin supply section,
(3) is the foam molding section, (4) is the mold, (6) is the traveling frame, (7) is the heating furnace, (12) is the conveyor device, (2+)
, (39) is the base, (22) is the reversing device, (26) is the arm, (36) is the powder resin filling tank, (42) is the cooling box, (48) is the molding mold, (53) is an injection device, (54
) is a foam mold changing device. Patent applicant: Kida Giken T-gyo Co., Ltd. Agent Patent attorney: 1) Department: Patent attorney Kuni Ohashi Department: Yu Koyama, patent attorney

Claims (1)

[Claims] In a method for manufacturing a resin molded product in which the same molding process is performed on multiple molds at different times, the molding process includes a step of heating the molds in a heating section, and a step of heating the molds in a heating section, and converting the heated molds into powdered resin. The powder resin is transported to the supply section, and in this powder resin supply section, the powder resin is adhered to and melted on the molding surface of the mold, and the molten resin layer formed on the molding surface of the mold is cooled to form a skin. and transporting the mold with the skin formed thereto to a foamable resin raw material injection section, and injecting the foamable resin raw material into the mold at this injection section to cause foaming. manufacturing method.