JPS61246056A - Resin molded shape having soft skin and manufacture thereof - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION Object of the Invention (Field of Industrial Application) The present invention relates to a resin molded product having a soft skin used for automobile interior parts, indoor equipment products, etc., and a method for manufacturing the same.

(Prior art) Resin molded products used for automobile interior parts, indoor equipment products, etc. have an excellent appearance, and the surface of the molded products is abraded in order to hide defects such as scratches and uneven coloring on the resin surface. It is useful to decorate with wood.

Further, in addition to the appearance problem, in order to make the product soft to the touch, it is desirable to use a skin having a foam layer, for example, as the skin.

Conventionally, the following method has been used to mold this molded product.

■Covering the surface of a base material formed by injection molding or the like with a skin by vacuum forming.

(2) A foamed urethane resin is formed on the surface of the base material by RIM molding to form a skin.

■A base material is formed by injection molding resin on the back side of the skin that has been shaped by vacuum forming or the like.

(Problems to be Solved by the Invention) However, the molded product formed by the above method and its manufacturing method have the following problems.

That is, according to the method (2), a male mold is often used as the mold, and if this is done, there will be a portion that is partially stretched during vacuum forming, and there is a risk that grain flow will occur at that portion.

Therefore, it becomes difficult to provide stitches, grain patterns, etc. to the surface of the epidermis.

Additionally, an adhesive is required between the base material and the skin.

Furthermore, the substrate must be formed in a separate process, and vacuum holes must be provided in the substrate.

According to method (2), an adhesive is required between the base material and the skin. Furthermore, since the skin is formed from a foamed urethane resin, a mold coat layer must be provided on the mold that forms the surface of the skin. Therefore, if this mold coat layer is not formed reliably, small pinholes will appear on the surface. Additionally, the substrate must be formed in a separate process.

Furthermore, the molded product as a finished product is likely to have flakes.

According to method (2), the epidermis must be formed in a separate process. Additionally, a reinforcing press product is required to protect the skin. Furthermore, the molded product as a finished product is likely to have flakes.

Structure of the Invention (Means for Solving the Problems) In order to solve the above-mentioned problems, the present invention provides a foamed skin layer comprising a skin layer made of vinyl chloride resin and a foam layer made of vinyl chloride resin. On the layer side, a means is adopted in which a base material made of hard or semi-hard urethane resin is integrally formed, and the second invention includes a step of heating and softening a skin made of vinyl chloride resin, and a step of heating and softening the skin made of vinyl chloride resin. a step of shaping the
A method is adopted which includes a step of integrally molding a hard or semi-hard urethane resin on the foam layer side of the shaped skin.

(Function) Therefore, according to the present invention, since the semi-rigid or hard urethane resin is integrally joined to the foam layer on the back side of the vinyl chloride resin skin, the resins are mutually bonded to each other at the boundary. Penetrates into the foam. Therefore, even though no adhesive is used, the two are firmly joined by a mechanical anchor effect or the like. In addition, the foam layer on the skin retains its soft touch.

Further, according to the second invention, the skin whose surface has been softened by the heating process is shaped into a predetermined shape using a vacuum molding die. An upper mold is placed on top of the mold in which the skin has been shaped, and a semi-hard or hard urethane resin is injected to form a base material.

(Example) Next, an example in which the present invention is embodied in a console upper of an automobile will be described with reference to FIGS. 1 to 5.

This console upper has a skin 1 whose cross section is approximately trapezoidal.
and a base material 4 integrally formed on the back surface thereof.

The skin 1 is made of vinyl chloride resin and includes a solid skin layer 2 on the front surface and a soft foam layer 3 on the back surface. Further, although not shown, patterns such as stitches and grain patterns are formed on the surface of the skin layer 2.

In this embodiment, the foam layer 3 has a foaming rate of 2 to 10 times and a thickness of 1.0 to 2.5 mm, and the skin layer 2 has a thickness of 0.5 mm.
It is formed to have a thickness of 3 to 1.0 mm.

In addition, since the base material 4 is integrally joined to the foam layer 3 on the back surface of the skin 1 by RIM molding of semi-rigid urethane resin, the resins of each other penetrate into the foam at this boundary part. . Therefore, the two are firmly joined by mechanical anchoring effect or fusion. In particular, urethane resin has high adhesiveness and is firmly bonded to the vinyl chloride skin 1.

In addition, in this example, the base material 4 has a density of 10,000
It has a bending elastic modulus of 4 kg/c4 or more and a foaming rate of 5 times or more.

Next, a method for manufacturing the console upper constructed as described above will be explained with reference to FIGS. 2 to 4.

First, the apparatus used in this manufacturing method will be explained. As shown in FIG. 4, the upper surface of the upper mold 11 of the RIM molding die, which consists of a pair of upper and lower molds 11 and lower molds 12, is provided with a nozzle contacting part 13 on which an injection nozzle (not shown) comes into contact. There is. A molding groove 14 for molding a molded product is provided on the mold splitting surface of the upper mold 11, and a part of the molding groove 14 has an opening of a sprue 15 communicating with the nozzle contact portion 13. is formed.

A molding groove 17 corresponding to the molding groove 14 is recessed in the lower mold 12, and a plurality of vacuum holes 18 are formed through the molding groove 17, and are connected to a pressure reducing device (not shown). Therefore,
When used alone, this lower mold 12 serves as a female mold for vacuum forming.

Further, a square frame-shaped clamp 21 for clamping the skin 1 is provided on the side of the mold so as to be movable vertically and horizontally. Furthermore, a heater 22 for heating the epidermis is provided on the side of the clamp 21, and slides to enclose the clamp 21 during heating.

Next, a manufacturing method using this device will be explained.

First, the mold is opened, and the skin layer 1 is cut to be slightly larger than the lower mold 12, and the clamp 21 is moved and clamped so that the skin layer 2 faces the mold cutting surface of the lower mold 12. Thereafter, as shown in FIG. 2, the heater 22 is slid so as to enclose the clamp 21, and the skin 1 is heated and softened to bring it into a drawdown state.

When this state is reached, the heater 21 is returned to its original position, the clamp 21 is lowered to the lower mold 12 side, the skin 1 is brought into contact with the mold splitting surface, and a pressure reducing device (not shown) is activated to perform vacuum forming. Then, as shown in FIG. 3, the skin 1 is pulled by the suction force within the mold and pressed into the molding groove 17.

Subsequently, as shown in FIG. 4, the clamp 21 is released and moved to the side of the mold to align the upper mold 11 and the lower mold 12. An injection nozzle (not shown) is brought into contact with the nozzle contact part 13, and molten urethane resin is injected to increase the pressure inside the cavity to 5 to 30 kg/cffI.
Then, RIM molding is performed.

The mold is opened and a molded product in which a semi-rigid urethane resin is integrally molded as a base material 4 on the back side of the skin 1 is taken out. Then,
As shown in FIG. 5, by trimming the excess skin portion using a trimming cutter 23 or the like, a contoured collar molded product is formed.

As described above, the console upper of this embodiment has the foam layer 3 of the skin 1.
This allows for a softer feel to the touch, and
Since semi-rigid urethane resin is used as the base material 4, it can be reliably bonded to the vinyl chloride skin 1 without using an adhesive.

In addition, since the foam layer 3 of the skin 1 is used to create a soft feel for the resin molded product itself, by adjusting the foaming ratio and thickness of the foam layer 3, it can be made soft without being affected by the material of the base material 4. You can control your anger freely.

Further, since the skin 1 is provided on the surface of the base material 4, it is possible to provide the external shape of the base material 4, that is, a surface shape that is not affected by uneven flow, pinholes, etc.

Furthermore, in this example, since a semi-rigid urethane resin having a foaming rate of 5 times or more is used for the base material 4, the weight of the molded product itself can be reduced, and the material cost can also be reduced.

Furthermore, according to the manufacturing method of this embodiment, the vacuum hole 18 was provided in the lower mold 12 of the RIM molding die and used as the female mold of the vacuum molding mold, so there is no need to form the skin 1 in a separate process. It can be manufactured in a single process. Therefore, not only the number of manufacturing steps can be reduced, but also manufacturing costs can be reduced. Furthermore, since all the molding is completed in one step, it is possible to eliminate joining errors between the two, compared to a method in which only the outer skin 1 is formed in a separate step and then the base material 4 is joined to the back surface thereof.

In addition, since the skin 1 is formed by vacuum forming with a scalpel, stitches, grain patterns, etc. can be reliably transferred, and
It is also possible to prevent the grain from flowing due to partial stretching. Therefore, a good-looking skin appearance can be formed.

In addition, because RIM molding, which is low temperature and low pressure molding, was used, the pressure inside the cavity was 5 to 30 kg/co! Therefore, the foam layer 3 of the skin 1 will not collapse and cause a poor appearance.

Note that the present invention is not limited to the above embodiments,
For example, it may be implemented as shown below.

(1) Applying a decorative layer such as flocking to the surface of the epidermis 1 of the above embodiment. In this way, the appearance can be made even more attractive.

(2) Use injection molding instead of RIM molding.

(3) The present invention is not limited to the console upper of the above embodiment, but can also be embodied in the finish, cluster, center pillar, front pillar, etc. of an instrument panel, and can also be applied to other household appliances. ,
It can also be applied to outdoor equipment and the like.

Effects of the Invention As described in detail above, according to the present invention, the foamed layer of the vinyl chloride skin can be made soft to the touch, and the semi-hard or hard urethane resin is used as the base material. It can be reliably bonded to a vinyl chloride skin without using an adhesive.

Further, according to the second invention, since the step of shaping the skin and the step of bonding the base material to the back side of the skin can be performed in one process, manufacturing costs can be reduced, and Since molding can be performed using the same mold, it is possible to improve the transferability of the skin and also eliminate bonding errors between the skin and the base material.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of the present invention in an automobile console upper, and FIGS. 2 to 5 are cross-sectional views showing the method of the second invention. A cross-sectional view showing when the skin is placed above the mold and the skin is heated and softened;
Fig. 3 is a cross-sectional view showing the state in which the skin is crimped onto the lower mold by vacuum forming, Fig. 4 is a cross-sectional view showing the state in which the molds are matched and semi-rigid urethane resin is RIM-molded, and Fig. 5 is the mold opened. FIG. 3 is a cross-sectional view showing the molded product taken out from the molded article is trimmed into a predetermined shape. Epidermis; l Skin layer; 2 Foam layer; 3 Base material; 4 Patent applicant Toyoda Gosei Co., Ltd. Agent
Patent Attorney On 1) Hironobu Figure 4

Claims (1)

[Claims] 1. The skin layer (2) made of vinyl chloride resin and the foamed layer (3) side of the skin layer (1), which is made of a skin layer (2) made of vinyl chloride resin, have a hard or A resin molded product having a soft skin, characterized in that a base material (4) made of a semi-hard urethane resin is integrally formed. 2. A process of heating and softening the skin (1) made of vinyl chloride resin, a process of shaping the heat-softened skin (1), and a foam layer (3) side of the skin (1) that has been shaped. 1. A method for producing a resin molded product having a soft skin, comprising the step of integrally molding a hard or semi-hard urethane resin onto a resin molded product. 3. The resin molded product having a soft skin according to claim 2, wherein the hard or semi-hard urethane resin is integrally joined to the skin (1) by RIM molding. Production method.