JPS61220812A - Method and device for manufacturing composite skin of synthetic resin - Google Patents

Abstract

PURPOSE:To make interchange of material reserving tanks unnecessary by a method wherein the inside of a reservoir tank is partitioned in the vertical direction thereof and blockading plates, attached to each reserving chambers accommodating a plural kind of materials, are opened and closed under providing them with time differences. CONSTITUTION:Heating oil is flowed into a pipe 3 to heat a mold 1. A mold box 2 and the reservoir tank 4 are connected integrally. When they are tilted to open the blockading plate 9 and solid layer forming powder material S is thrown into the mold 1, the thrown material S is gelled at the surface of cavity and becomes viscous. When they are returned to the initial positions, the material S, remaining in the mold 1 under a condition that it is not gelled yet, flows down into the first reserving chamber 6. The gelled material, adhered to the surface of cavity of the mold 1, is molten perfectly by the temperature increase of the mold 1 and a solid layer 31 is formed. The blockading plate 9 is closed and the same process is effected with respect to the powder material F in the second reserving chamber 7 to form the composite skin 33, in which an expanded layer 32 is adhered to the inside of the solid layer 31. Cooling oil is flowed into the pipe 3 to cool the mold 1 and, thereafter, the composite skin 33 is released from the mold 1.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing a synthetic resin composite skin and an apparatus for manufacturing the same. Synthetic resin composite skin refers to the skin that is a part of automobile interior parts such as console boxes, instrument panel pads, and glove boxes. The present invention relates to a method for manufacturing a composite skin for automobile interior parts, which is a skin body consisting of a composite layer of layers, and a backing layer such as a hard polyurethane as a final product, and an apparatus for carrying out this manufacturing method. The present invention relates to an invention centered on a reservoir tank proposed with the intention of efficiently supplying a synthetic resin powder material for molding and forming a foam layer to a mold with a time lag.

(Prior Art) Various methods have been proposed for manufacturing the skin of automobile interior parts, such as instrument panel pads. After inputting the material, the mold is heated to the melting temperature of the material to melt and adhere the film to the cavity surface of the mold.
Next, there is a slush molding method in which this is formed into a cooling surface 4a.
Further, a manufacturing method in which a mold is alternately rotated upward and downward in order to form a film having a uniform thickness is disclosed in, for example, Japanese Patent Laid-Open No. 59-204511.

The above-mentioned slush molding method was described for a single-layered skin, but a method for manufacturing a composite skin consisting of a solid layer and a foam layer, which is a further development of this method, is aimed at further reinforcing and retaining the shape of this composite skin. A manufacturing method for automobile interior parts that is constructed with multiple layers of backing layers and emphasizes a soft feel has been proposed, and due to its light weight, it has attracted attention in the industry.

(Problems to be Solved by the Invention) When manufacturing a composite skin using the manufacturing method described above, a plurality of reservoir tanks containing powder materials for forming a solid layer and for forming a foam layer are required, and the manufacturing process is complicated. When replacing the tank, it is necessary to attach and detach the reservoir tank and the mold box with the mold attached, which inevitably increases the molding time as well as the labor involved.
Furthermore, arranging a plurality of reservoir tanks requires a large space, and these problems ultimately lead to higher product costs.

(Means for Solving the Problems) The first invention according to the present invention, that is, the method for manufacturing a composite skin made of synthetic resin, divides the interior in the vertical direction with partition walls, and forms a solid layer and a foam layer in each. A reservoir tank with a storage chamber containing materials for use in a mold is equipped with a temperature control mechanism, and the mold and tank are connected in a closed state with the opening facing the tank, and the mold is connected in a connected state. By alternately reversing the vertical positions of the mold and the tank, the materials for forming the solid layer and the foam layer are heated in the mold, and are sequentially supplied from the tank to the mold with a time difference. During the subsequent return of surplus material from the mold to the tank, the blocking plate attached to each storage chamber is opened and closed to suppress the movement of the material and the mixing of the two materials. In this case, the inside of the reservoir tank is vertically divided into a plurality of storage chambers, and the movement of materials is made possible by alternating the time difference and vertical position by opening and closing a closing plate attached to each storage chamber. This integration of the reservoir tank can greatly contribute to speeding up and simplifying the work, as the time-consuming work of attaching and detaching the reservoir tank and mold is only done once in each manufacturing process. It is.

In addition, the second invention according to the present invention, that is, an apparatus for manufacturing a synthetic resin composite skin, connects a mold equipped with a temperature control mechanism to a reservoir tank with the opening of the mold facing toward the reservoir tank. This device combines a reservoir tank and a mold, which maintains the closed state and allows the position to be reversed in the vertical direction. A structure in which a partition wall divides the storage chambers into a pair of storage chambers that accommodate the materials for forming the solid layer and the foam layer, respectively, and each storage chamber is equipped with a closing plate so that it can be opened and closed in an inverted manner by its own operating mechanism. With efficient use of one reservoir tank,
This enables smooth movement of materials from the tank to the mold, and from the mold to the tank, and accurate timed supply without mixing of painting materials.

(Example) Next, specific embodiments of the present invention will be described using the drawings.

Figures 1 to 5 show the manufacturing process of a composite skin step by step. The mold and reservoir tank are connected in a closed state, or more precisely, the mold box with the mold attached and the reservoir tank are connected. A schematic longitudinal cross-sectional view shown in diagrammatic form,
FIG. 6 is a perspective view of the reservoir tank, and FIG. 7 is a partially cutaway side view of the tank.

In the figure, (1) is a slush molding die, with a thickness of 3.0~
5.01811 nickel electroforming mold, copper electroforming mold, aluminum electroforming mold, metal spraying mold, etc., a pipe (3) is attached to the mold (1) so as to cover almost the entire outside surface of the mold (1). 3) Alkylbenzene-based heating oil and cooling oil alternately flow into the interior during a predetermined time period,
The temperature of the mold (1) is controlled, and the mold (1) is set in a mold box (2) with the opening of the mold (1) open.

On the other hand, the inside of the reservoir tank (4) is divided by a partition wall (5) vertically erected approximately at the center, and the inside of the tank (4) forms the surface side of the target composite skin. A first storage chamber (6) that accommodates the powder material for forming a solid layer (8) and a second storage chamber (7) that accommodates the powder material for forming a foam layer (F') that forms the inner surface of the composite skin. It is sectioned.

It extends along the top of the partition wall (5) at the top position, and both ends thereof are connected to a pair of side walls of the reservoir tank (4).
(to) A pivot (8) supported between both storage chambers (6)
) (7), respectively, are hinged, and the pair of blocking plates (9) aO are configured to be able to rotate around the pivot (8), and each blocking plate (9) A backing material made of a band-shaped silicone foam material or the like is attached to the peripheral edge that contacts the inner wall surface of the tank (4) of α1.

and each storage chamber (6) by a pair of blocking plates (9) QO (
The end view shape of the pair of blocking plates (9) α1 which are opened when the block 7) is in the closed state is an open V-shape with the pivot (8) part as the trough. When opened, the closing plate (9) QO rotates to the position of the other closing plate maintaining the closed state, and the pair of closing plates (9) QO turn to the overlapping position. Next, we will talk about the turning operation of both opening plates (9) QO. Studs αυαυ are installed at both ends of the blocking plate (9) QO, and when the blocking plate is turned, the studs I11υ are Arc-shaped guide grooves (to) are formed on both side walls of the reservoir tank (4) in accordance with the arc-shaped locus, and the reservoir tank (4) is fitted into the guide grooves so that its tip protrudes outward. The ends of the piston rods (to) of a pair of actuating cylinders disposed on both sides of the tank (4) (Q side) are connected to the studs αυαυ. The lower end of → is connected to the short axis αη installed on the side wall (6) of the tank (4) through the connecting rod α・, and the cylinder σ◆ freely rotates in that direction using the short axis aη as a fulcrum. It has a structure that can be changed.

The inner or outer part of the arc-shaped guide groove (1313) formed on both side walls (2) of the reservoir tank (4) covers the entire length of the guide groove to prevent leakage of powder material made of a rubber-like elastic sheet or the like. This shielder 00 is covered with an arcuate notch (A) and the stud α implanted in the side end of the closing plate (9) α1.
υ protrudes in such a way as to push and expand the notch portion.

The reservoir tank (4) contains the powder material for solid layer formation (8) in the first storage chamber (6) and the powder material for foam layer formation (F') in the second storage chamber (7). (1
) with its opening facing the tank (4),
A gasket D is interposed between the facing flanges of the tank (4) and the mold (1), while the mold box (2) to which the mold (1) is attached is connected to the reservoir tank (4).
) are connected and connected in a tightly closed manner by means such as a clamp (a).

The manufacturing process of a composite skin using the manufacturing apparatus having the above configuration will be described. In Figure 1, there are 2 in Nosip (3).
80'-270°C heated oil flows in, the mold (1) is heated to 120'-180°C, and the mold box (
2) and reservoir tank (4) are clamp devices (a)
are combined and connected.

In Figure 2, the combined molded box (2) and reservoir tank (4) are rotated 180' and their vertical positions are reversed, and the closing plate (9) of the first storage chamber (6) is The solid layer forming powder material (8) is opened into the mold (1) by opening to a position where it overlaps the closing plate αQ, and at the same time, a louver (not shown) installed in the first storage chamber is also opened. On the cavity surface of the mold (1) that has been preheated or heated after the material has been introduced, gelation of the official material progresses, and the powder material gradually becomes sticky, and in order to increase the thickness of the solid layer 6p. There is a residence time of material (81) in the mold (1) for 5 seconds.

In Figure 3, the combination of tank (4) and box (2) rotates 180', returns to its original position, and opens the closing plate (9) in the tank (4) located below. The first one in
In the storage chamber (6), the ungelled material ls) left in the mold (1) is refluxed into the first storage chamber (6) using the inclined obstructing plate (9) as a guide. do. Under this situation, the gelled material adhering to the cavity surface of the mold (1) is removed by increasing the temperature of the mold (1) to 200°C.
The semi-molten thin film is completely melted, and the mold (1) has a thickness of 0.3
A solid layer I3υ of ~1.511 is formed. Then, the closing plate (9) is closed and the powder material (81) is stored in the first storage chamber (6). After this state is completed, the process moves to the heating process.

In Fig. 4, the combining device is rotated 180° again, and this time the blocking plate αQ of the second storage chamber (7) of the tank (4) located above is replaced by the other blocking plate in the closed state. (9), and at the same time open the louver (not shown) of the second storage chamber (7) to open the mold (1), more specifically, the inside of the solid layer 0υ in the mold (1). Powder material (F'
) is added, and after heating for about 2 to 10 seconds, proceed to the next step.

In Fig. 5, the combined object (2) C4) has been rotated 180° and is located below, and the second storage chamber (7) with the blocking plate aQ open has surplus material (D is an inclined The liquid is refluxed to the second storage chamber (7) using the current state of the closed plate as a guide.

After this, the mold (1) is heated to about 50 to 90°C at 200° to 280°C.
Heat for 0 seconds to create a thickness of 2 on the inner surface of the existing solid layer (b).
〜4) is formed on the thick foam layer of the seagull, and a composite skin (to) is formed with a foam layer □□□ on the inside of the solid layer (b).
is formed.

Next, insert the 20° inside the pipe (3) attached to the mold (1).
~70' of cooling oil was introduced, and the mold (1) was heated to 5.
After being cooled to 0° to 90°C, the composite skin (2) is completed, consisting of a solid layer (2) on the cavity surface of the mold (1) and a foam layer (2) on the inside thereof. ) and mold box (2) with mold (1) attached
By opening the clamp, the composite skin (2) is removed from the cavity surface of the mold (1).

The synthetic resin powder material forming the solid layer 0p is made of vinyl chloride resin powder to which a plasticizer, stabilizer, and lubricant are added, and more specifically, vinyl chloride having a porous particle shape. In the resin, plasticizer, stabilizer,
A powder compound with a particle size of 50 to 350μ is created by kneading and adsorbing lubricants, or by kneading plasticizers, stabilizers, lubricants, etc. with vinyl chloride ill, gelling it, cooling it, and pulverizing it into powder. It is composed of a powder compound.

On the other hand, the constituent material of the synthetic resin powder material forming the foam layer is the same as the synthetic resin powder material forming the solid layer described above, and A foaming agent is added to this powder material.
, D, C, A (azodicarbonamide), D, Ps T
(Di-nitrosopentamethylene
te-mine) S urea compound, etc., and the amount added is 1 to 20 parts by weight, preferably 5 to 15 parts by weight, per 100 parts by weight of the powder compound. (Effects of the Invention) The present invention The interior of the reservoir tank is divided vertically to form storage chambers that contain visible materials, and by installing a closing plate in each storage chamber, a series of operations can be performed by opening and closing these closing plates at different times. It is possible to input and discharge multiple materials with different properties into and out of the mold accurately and at the same time without mixing, and there is no need to replace the material storage tank, making it easier to use than traditional manufacturing methods. This results in a reduction in the number of molding cycles and a reduction in work time, increasing the work efficiency by approximately 12% in a series of molding cycles.
A reduction in work time was confirmed. In addition, by using a single reservoir tank, the work space can be halved to approximately 1/2, and it has been confirmed that the equipment cost has been reduced by more than 5%.These effects contribute to lower product costs. It is directly linked to.

Furthermore, the present invention makes it possible to efficiently utilize a single tank by dividing a single reservoir tank into storage chambers that store multiple types of materials in the vertical direction. A pair of closing plates that share the opening and closing of each storage chamber in the storage room exhibit an open V-shape when viewed from the end, and each closing plate overlaps the other closing plate that is in the closed state. By making it possible to swivel to the desired position, when returning excess material to the tank, the slanted obstructing plate when opened can be used efficiently as a guide, allowing material to be returned without any residue. This can reliably and effectively prevent mixing of different materials, resulting in the production of high quality composite displays.

[Brief explanation of the drawing]

FIGS. 1 to 5 are schematic vertical cross-sectional views of a reservoir tank and a mold box equipped with a mold connected in a closed state, showing step-by-step the manufacturing process of a composite skin according to the present invention; Figure 6 is a perspective view of the reservoir tank, Figure 7
The figure is a side view of the tank, also shown with a portion cut away. In the figure, (1) is a slush mold, (2) is a mold box, (3) is a pipe, (4) is a reservoir tank, (5) is a partition wall, (6) is a first storage chamber, ( 7) is the second storage chamber, (8) is the pivot, (9) αQ is the closing plate, αυ is the stud, Q3 is the arcuate guide groove, (141 is the operating cylinder, the handle is the clamp, and ca'D is the solid layer. , (to)
1) indicates a foamed layer, 2) indicates a composite skin, 2) indicates a powder material for forming a solid layer, and 2) indicates a powder material for forming a foamed layer.

Claims (6)

[Claims] (1) In a mold equipped with a temperature control mechanism, the reservoir tank is vertically divided by a partition wall and has storage chambers containing materials for forming a solid layer and a foam layer, respectively. The mold and tank are connected in a closed state with the opening facing the tank, and the materials for forming the solid layer and foam layer are respectively placed in the mold by reversing the vertical positions of the mold and tank in the connected state. During the heating process in the mold, the supply from the tank to the mold is carried out sequentially with a time difference, and when the surplus material is subsequently returned from the mold to the tank, the closing plate attached to each storage chamber is opened and closed. A method for producing a composite skin made of synthetic resin by controlling the movement of the materials and the mixing of both materials. (2) The method for manufacturing a synthetic resin composite skin according to claim 1, characterized in that, when the closing plate is opened, it moves to a position where it overlaps the other closing plate that is in the closed state. (3) A mold equipped with a temperature control mechanism is connected to the reservoir tank with the opening of the mold facing toward the reservoir tank, making it possible to reverse the position vertically while maintaining the closed state. In a device that combines a reservoir tank and a mold, the inside of the reservoir tank is divided into a pair of partition walls arranged vertically at approximately the center of the reservoir tank, each of which accommodates a solid layer and a foam layer forming material, respectively. 1. An apparatus for manufacturing a composite skin made of synthetic resin, characterized in that the storage chambers are divided into two storage chambers, and both storage chambers are each equipped with a closing plate that can be opened and closed in an inverted manner by its own operating mechanism. (4) The apparatus for manufacturing a synthetic resin composite skin according to claim 3, wherein the closing plate attached to each storage chamber is pivotably hinged around the upper end of the partition wall of the reservoir tank as a fulcrum. . (5) 1 hinged to the upper end of the partition wall in each storage room;
5. The apparatus for manufacturing a synthetic resin composite skin according to claim 4, wherein the pair of closing plates have a V-shape that opens when viewed from the end when closed. (6) When the closing plate hinged on the partition wall is opened,
The apparatus for manufacturing a synthetic resin composite skin according to claim 4 or 5, which is configured to be able to turn over to a position where it overlaps the other occlusion plate that maintains the occlusion state.