JPS6143524A - Manufacture of monolithic-molded article of lining material - Google Patents

Abstract

PURPOSE:To manufacture a monolithic-molded article of a lining material on a continuous manufacturing line, by a method wherein a resin-molded component is formed by making fusion molding of a resin material on the top of a continuous lining component by a first press part and blank processing of the lining material is performed by a second press part so that the lining material having a predetermined width exists on the circumference of the resin-molded component. CONSTITUTION:A manufacturing line is constituted with a resin material supply device 20, a resin molding press 30 of a first press part, a secondary processing machine 40, a blanking press 50 of a second press part, a taking-out device 60 of a product and a product stand 70. A resin material 5 and a lining material 2 are molded into a predetermined shape by a bottom force 34 and a top force 35 of the resin molding press 30, and the fringe part 5A of the resin material 5 is cut off by actions of a fringe part cutter 38 and the fringe 35A. Predetermined printing is performed on the surface of the lining material 2 by a cylinder 42 and a plate cylinder 45. Then when the lining material 2 is cut off, a bending piece 2B of the lining material 2 is bent upward and a top force 55 arrives at the stroke end, a product 10 lifted up by a knockout 57 is transferred to a product stand 70.

Description

[Detailed Description of the Invention] [Industrial Application Field J] The present invention is an integrated lining material used for suitcases, cosmetic cases, home appliances, furniture, automobile instrument panels, automobile door inner materials, etc. The present invention relates to a method for manufacturing a resin molded article.

[Background technology and its problems] In recent years, in order to improve the appearance of products, so-called lining products, in which raised cloth materials, various leather products, artificial leather, etc. are stretched over the surface of resin molded parts, have been widely used. ing.

A conventional manufacturing method for such a lining product is to adhere a lining material to the surface of a resin product that has been pressure-molded into a predetermined shape by adhesion, pressure bonding, or the like. At this time, when using a material that has been integrally molded with a lining material on the surface of a resin sheet and deforming it by heating in a press, the edges of the finished molded product may be partially covered with the lining material. This method may not be applicable at all depending on the shape of the product, as this may cause the edges where no lining material was originally placed to be exposed on the surface of the molded product, significantly damaging the appearance. .

In order to improve such conventional drawbacks, Japanese Patent Application Laid-Open No. 55-5
The invention described in Japanese Patent No. 900 has been proposed. According to this publication, the edge of the resin material is cut off during press molding using a special mold, and the lining material is cut off by a predetermined size larger than this edge, thereby forming the edge of the resin molded member. This method eliminates the uncovered portion of the lining material by making it possible to wrap the lining material with a lining material cut larger than the end shape. Although this method can provide a molded product with a good appearance, there is a problem in that productivity is not necessarily good. That is, since both the resin material and the lining material use sheet materials cut to a predetermined size, a continuous molding line cannot be constructed, and mass productivity is not so high.

[Object of the Invention] An object of the present invention is to provide a method for producing an integrally molded product with a lining material, which has a good appearance as a finished product, can be continuously produced, and is excellent in mass productivity.

[Means and effects for solving the problems] The present invention has the following features:
Using a continuous lining material, a resin material is integrally fused and molded on the upper surface of this continuous lining member by a first press section to form a resin molded member, and a resin material is integrally molded on the upper surface of this lining material. The lining material is punched out in the second press section so that the lining material of a predetermined width is present around the molded part to produce a molded product with the lining material, and the scraps of the lining material are discharged as is in a continuous state. The purpose of this invention is to achieve the above object by making it possible to manufacture integrally molded products of lining material one after another in a series of continuous production lines.

[Example 1] An apparatus for carrying out the method of the present invention will be described below with reference to the drawings.

In the schematic diagram showing the overall configuration of Figure i1, the production line includes a resin material supply device 20, a resin molding press 30 as a first press section located on the lining material supply side,
A secondary processing machine 40 as a secondary processing stage that performs secondary processing such as printing, a punching press 50 as a second press section, and a lining provided near the punching press 50 from the punching press 50. A product unloading device fi60 that takes out the product IO as an integrally molded product, and a product placement table 7 on which the product 10 taken out by the product unloading device 60 is placed.
The lining material 2 whose one end is wound around a lining material roll l is continuously supplied to this production line, and the other end of this lining material 2 is pulled out after passing through the line. It is adapted to be wound up on a winding roll 3. As the lining material 2, polyvinyl chloride seed, a thermoplastic resin sheet such as polypropylene or polyethylene, human varnished material, artificial leather, leather, raised woven fabric, nonwoven fabric, etc. are used, and any suitable material that improves the appearance of the product 10 is used. has been done. ″ On the arm portion 21 of the resin material supplying device 20, a polyolefin such as polypropylene or a polyolefin containing wood flour as a filler is placed, which is heated to an extent that it can be plastically deformed but does not exhibit excessive fluidity. A resin material supply device 2 is supplied with a resin material 5 made of thermoplastic resin.
The resin material 5 can be supplied to the resin molding press 30 at a position above the lining material 2 by the rotation of the arm portion 21 of the resin molding member 2.

The resin molding press 30 includes a bolster 31 installed on the floor, a gate-shaped column 32 erected on the bolster 31, and a drive (not shown) that is slidably supported by the column 32. Slide 3 moved up and down by the source
3, a lower mold 34 is mounted on the bolster 31, and an upper mold 35 is mounted on the lower surface of the slide 33. When the resin molding press 30 is driven by these lower mold 34 and upper mold 35, the resin material 5 and the lining material 2 are fused together and formed into a predetermined shape, and the resin material 5 is a resin molded member 6 having a predetermined shape as shown on the right side of the resin molding press 30 in FIG.

The secondary processing machine 40 is used for printing, for example, and includes a frame 41 installed on the floor, a cylinder 42 supported by this frame 41, and rotatably supported by the tip of a piston rod 43 of this frame 41. A press roll 44 as an impression cylinder, a plate cylinder 45 that faces the press roll 44 via the lining material 2 and the resin molded member 6 and is rotatably supported by the frame 41, and an ink reservoir on the plate cylinder. 46 and an ink roll 48 that supplies ink 47 in the piston rod 4 of the cylinder 42.
3 to advance and support the edge of the resin molded member 6 with the press roll 44, and at the same time, by driving the plate cylinder 45,
It is possible to perform predetermined printing on the surface of the molded part of the lining material 2.

The punching press 50 is the same as the resin molding press 30.
Similarly, the bolster 51. A column 52 and a slide 53 are provided, and a lower mold 54 is mounted on the bolster 51 and an upper mold 55 is mounted on the lower surface of the slide 53.
Unlike the upper mold 35, a cutter 56 is fixed over the entire circumference of the upper mold 55. Further, the product delivery device 60 is provided on the left and right sides of the punching press 50, and the product delivery device 60 has a pair of product delivery devices 60 on the left and right sides of the punching press 50, that is, on the front end and the rear end in the feeding direction of the lining material 2. A pair of feed bars 62 are provided between the gripping and feeding mechanisms 61 to grip the portion of the lining material 2 integrally molded with the resin molded member 6 and feed it forward. The product 10 punched by the punching press 50 is conveyed by the bar 62 and placed on the product placement table 70.

Further, the other end side of the lining material 2, that is, the part to be punched out of the product 10 by the punching press 50, is wound up by the punching roll 3 located at the outer end of the product placement table 70. .

The detailed structure of the lower die 34 and the upper die 35 of the resin molding press 30 is shown in FIG. That is, the lower mold 34 has a female shape with a recess 36 formed in the center, and
Inside this lower mold 34 is a resin molded member 6 formed by press molding the resin material 5 on the upper surface of the recess 36 of the lower mold 34.
A knockout 37 is provided to release the lining material 2 from the lower mold 34 together with the lining material 2. This knockout 37 has a flange 37A at its upper end, and this flange 37
The upper surface of A is connected to the lower mold 3 from the position where the bottom surface of the recess 36 is formed.
It can be moved to a position that substantially coincides with the top surface of 4. Further, the upper mold 35 is a male mold that protrudes downward. Furthermore, a cutter 38 in the shape of a cutter is disposed at a position below the upper die 35 and above the lining material 2 supplied between the lower die 34 and the upper die 35. The cutter 38 has a stepped portion 38A on the inner periphery of its upper surface, onto which the resin material 5 is supplied. At this time, an edge 5A of the resin material 5 is formed to be larger than a peripheral edge 35A of the protrusion of the upper mold 35, and is supported by the step 38A by this edge 5A. In addition, since the resin material 5 is heated and softened, its central part sag to some extent, but this central part is supported by the lining material 2, and in some cases, the lower mold 34 located below the lining material 2 hangs down. It will be supported on the top surface. Furthermore, the inner edge of the edge cutter 38 and the upper
The peripheral edge 35A allows the edge 5A of the resin material 5 to be cut when the upper mold 35 is lowered (see FIG. 2).

The detailed structure of the lower mold 54 and upper mold 55 of the punching press 50 is shown in FIG. That is, the lower mold 54
A product 1 is formed by cutting out a resin molded member 6 together with a part of the lining material 2 from the lining material 2.
0 and is formed in the lower die 54.
A knockout 57 is provided which can move up and down. This knockout 57 has a support block 57A at its upper end that can support the resin molded member 6 without deforming it.
and is biased by a spring 58 so that the upper surface of the lower mold 54 and the upper surface of the support block 57A are always on the same plane. Further, the size of the recess 54A of the lower mold 54 is larger than the outer shape of the resin molded member 6, that is, the thickness of the lining material 2 when the entire outer edge of the resin molded member 6 is covered with the lining material 2. The inner edge of the upper end of the concave portion 54A has a size slightly larger than that of the recess 54A.
A tapered surface 54B is formed for bending a part of the lining material 2 of a predetermined width inward, which is cut out from the lining material 2 together with the resin molded member 6.

A convex portion 55A matching the upper surface shape of the resin molded member 6 is formed on the lower surface of the upper mold 55, and this convex portion 55A is formed on the lower surface of the upper mold 55.
The cutter 56 is attached to the support block 56 along the outer peripheral edge of A.
The ivy 56 and the support block 56A are supported by the upper die 55 so as to be able to slide vertically, and are always urged by a spring 59 in the protruding direction. At this time, the positional relationship between the upper mold 55 and the cutter 56 is such that the cutter 56 is in a protruding state, and the convex part 55A of the upper mold 55 is at a position one step lower, that is, the surface that presses the upper flat part of the resin molded member 6. and the lower surface of the support block 56A are substantially on the same plane, and the tip of the cutter 56 protrudes from this surface, and this protrusion amount is slightly larger than the total plate thickness dimension of the resin molded member 6 and the lining material 2. It is made to be the same length.

As shown in FIG. 4, the lining material 2 transported along the production line shown in FIG. The lining material 2 is fed in the longitudinal direction under some tension to prevent the lining material 2 from sagging on the way. In addition, in FIG. 4, an imaginary line drawn around the resin molded member 6 indicates a punching line 2A of the lining material 2 punched from the lining material 2 wider by a predetermined width than the outer periphery of the resin molded member 6. The lining material 2 punched around the resin molded member 6 is hereinafter referred to as a bent piece 2B.

Next, the operation of this embodiment will be explained.

The lining material 2 is arranged along the production line shown in FIG. A resin material 5 heated to a predetermined temperature is supplied. This state is shown in FIG. 2(A). In this state, the resin material 5 is in a predetermined heated state, so its center part sag slightly, but this is caused by the lining material 2 and the lower mold 34. Supported.

Next, when the bolster 31 of the resin molding press 30 is lowered and the upper mold 35 is moved to the lower mold 34 side, as shown in FIG.
), the lining material 2 is held between the lower mold 34 and the upper mold 35 together with the resin material 5, and the resin material 5 and the lining material 2 are molded into a predetermined shape, and the upper mold 35 The edge cutter 38 and upper mold 35
The edge 5A of the resin material 5 is cut off by the action of the edge 35A of the resin material 5, and becomes a cutting scrap.

In the state shown in FIG. 2(B), the lower mold 34 and the upper mold 35 are cooled by a water cooling jacket (not shown), so the resin material 5 is cooled and hardened to the extent that its shape does not change. After curing, the upper mold 35 is moved in the upward direction together with the slide 33. After the upper die 35 is raised, the knockout 37 disposed in the lower die 34 is driven in the upward direction, and the edge cutter 38 is also driven in the upward direction by a link mechanism (not shown) connected to the slide 33. As a result, the resin molded member 6 integrally formed with the lining material 2 is raised to a position slightly above the transfer line of the lining material 2 as shown in FIG. 2(C) by the action of the knocker I.37. It is assumed that the lower die 34 has been completely removed. At this time, the upper surface of the knockout 37 is flush with the upper surface of the lower die 34,
In this state, the resin molded member 6 formed into a predetermined shape is intermittently transported to the next process together with the lining material 2 by a transport means (not shown).

This intermittently transferred resin molded member 6 is transferred to a cylinder 42 and a plate cylinder 45 in the secondary processing machine 40 shown in FIG.
By this operation, predetermined printing is performed on the surface of the lining material 2. Furthermore, with the intermittent transfer of the resin molded member 6,
The printed portions of the resin molded member 6 are sequentially transferred to the position of the punching press 50.
The product 10 will be pulled out from the lining material 2 at the position.

FIG. 3 (
Shown in A). In FIG. 3(A), the resin molded member 6 that has been conveyed is stopped on the support flange 57A of the knockout 57 whose upper surface is flush with the upper surface of the lower die 54. This stopping position is such that the inner edge of the recess 54A of the lower mold 54 and the outer edge of the resin molded member 6 substantially coincide with each other with a substantially equal gap around the entire circumference.

Next, as shown in FIG. 3(B), as the slide 53 of the punching press 50 descends, the upper die 55 is also lowered, and the cutter 56 provided on the periphery of the upper die 55 cuts into the lining material 2. The lining material 2 is then cut along the punch line 2A shown in FIG. 4. The tip of the ivy 56 cuts the lining material 2 and comes into contact with the upper surface of the lower die 54, and as the upper die 55 descends, the cutter 56 is pushed up against the spring 59. In this pressing down step, the convex portion 55A of the upper mold 55 bends the bent piece 2B of the lining material 2 that protrudes from the resin molded member 6 cut off from the main body of the lining material 2 with the cutter 56 as shown in FIG. 3(C). As shown in FIG. 2, the resin molded member 6 is bent upward along the edge thereof in cooperation with the inner periphery of the recess 54A of the lower mold 54.

In this way, slide 53. That is, when the upper mold 55 reaches the stroke end, the upper mold 55 moves in the upward direction, but as the upper mold 55 moves upward, the upper mold 55 presses the resin molded member 6 and the cut lining material 2 through the resin molded member 6 and the cut lining material 2. The support flange 57A of the knockout 57, which had been raised, also rises at the same time due to the action of the spring 58. As the support flange 57A rises, the product IO consisting of the resin molded member 6 and the cut lining material 2 also rises, resulting in the state shown in FIG. 3CD). The state shown in FIG. 3(D) shows a state in which the lower surface of the upper mold 55 has separated from the upper surface of the support flange 57A and has further risen. Product 1 lifted by the support flange 57A of this knockout 57
0 is clamped by the feed bar 62 of the product unloading device 60 shown in FIG. At this time, the bent piece 2B of the lining material 2 bent around the resin molded member 6 is removed from the lower die 54 by the knockout 5.
After being raised by 7, it is fixed to the resin molded member 6 by appropriate means until it is placed on the product placement table 70, or after being placed on the product placement table 70. As this appropriate fixing means, for example, a tacker driving device capable of driving a member (tough force) such as a stapler (trade name), an adhesive application device, or the like is used.

In the product placing stand 70, the stand supporting the product IO is the product IO.
Alternatively, after the product 10 is transferred, the product 10 is immediately moved to a position where it is removed from the transfer line of the lining material 2 by a conveying means (not shown).
The structure is such that it is possible to transfer the next product 10 by transferring the product 10.

According to this embodiment as described above, the lining material 2 is continuously fed, and the resin material 5 is integrally formed into a predetermined shape on the upper surface of the lining material 2 in the resin molding press 3° serving as the first press section. This is because the molded resin member 6 is transported as it is.

It becomes possible to fully automate the production line and significantly improve production efficiency. Furthermore, when transporting the lining material 2, both side edges of the lining material 2 are guided by a plurality of pairs of guide rolls 75, and the lining material 2 is transported while being stretched to some extent in the width direction. It can be done extremely smoothly. Furthermore, since the molding of the resin material 5 and the cutting of the lining material 2 are performed by the resin molding press 3o and the punching press 5o located at separate locations, the resin molding press 30 and the punching press 50 are A secondary processing machine 40 that performs processing such as printing can be placed in between, and the commercial value of the product 10 can be improved. In addition, the punching process of the lining material 2 in the punching press 50 is not only a simple punching process, but also the bending piece 2B of the lining material 2 is formed into a resin molded member by forming the convex part 55A of the upper die 55 and the concave part 54A of the lower die 54. Since I bent it along the edge of lining material 2
When adhering the bent piece 2B to the back surface of the resin molded member 6, the bent piece 2B can be easily adhered, and workability can be improved from this point as well. can. Furthermore, since the resin material 5, that is, the resin molded member 6, is arranged on the upper surface of the lining material 2, there is a risk that the resin molded member 6, which has not yet been sufficiently cured, may peel off from the lining material 2 and fall when the lining material 2 is transported. Therefore, the resin molded member 6 can be sufficiently transported without being completely cured in the molding press 30, and the processing cycle time can be shortened.

In the above embodiments, the secondary processing machine 40 was described as one that performs printing, but the present invention is not limited to this, and may also perform other secondary processing such as grain pattern processing, engraving, etc. Alternatively, it is not necessary to provide this secondary processing stage, and in this case, the resin molding press 30 and the punching press 50 may be constructed using an integrated press machine having a plurality of stages. In the punching process using the press 50, it is not necessarily necessary to perform the bending process as well as the punching process of the lining material 2 as in the above embodiments, but only the punching process is performed and the bending process is performed separately. However, as in the present embodiment, after punching, the punching press 50
．． If the bending pieces 2B of the lining material 2 are simultaneously bent using the press stroke, the above-mentioned advantages can be obtained. Further, in the above embodiment, the lower die 34 of the resin molding press 30 was a female die and the upper die 35 was a male die, but the present invention is not limited to this. 35 may be a female die, and this relationship is the same for the punching press 50.

[Effects of the Invention] As described above, according to the present invention, when manufacturing a product in which a lining material is integrally molded, it is possible to manufacture a product with a finished appearance that is better than that obtained with a conventional injection product, and also This method enables continuous molding, which is not possible with cut sheet molding methods, and has the advantage of providing a manufacturing method with excellent mass productivity.

[Brief explanation of drawings]

FIG. 1 is a schematic configuration diagram showing an example of an apparatus for carrying out the manufacturing method of the present invention, and FIGS. 2 (A) to (C) are explanations showing the operating states of the upper mold and lower mold in the first press section. Figure, Figure 3 (A
) to (D) are explanatory diagrams showing the operating state of the upper die and the lower die in the second press section, and FIG. 4 is a perspective view seen from below showing the continuous conveyance state of the lining material. 2... Lining material, 5... Resin material, 6... Resin molded member, 10... Product as lining material integrally molded product, 20... Resin material supply device, 30... First
Press for resin molding as a press part of 34.54...
- Lower die, 35.55... Upper die, 40... Secondary processing machine as a secondary processing stage, 50... Punching press as a second press section, 56... Cutter, 60・・・
・Product unloading device.

Claims (2)

[Claims] (1) Supplying a continuous lining material to a production line having at least two stages of press sections, a first and a second stage,
A resin material that can be thermoplastically processed is supplied to a first press section located on the supply side of the lining material so as to be above the lining material, and the resin material and the lining material are transferred to the first press section. A resin molded member is formed by integrally fusion-molding the upper surface of the lining material, and the lining material is lined in the second press section so that a predetermined width of the lining material exists around the resin molded member integrally molded on the upper surface of the lining material. A method for manufacturing an integrally molded lining material product, the method comprising manufacturing a molded product integrally with a lining material by punching a material. (2) In claim 1, the first,
A method for manufacturing an integrally molded product of lining material, characterized in that a secondary processing stage such as printing, stamping, and embossing is arranged in the middle of the second press section.