JPS62108039A - Simultaneous molding method for skin material - Google Patents

Abstract

PURPOSE:To obtain beautiful finish by performing fold back work of a skin material efficiently, by a method wherein turning-back molding of the external circumferential part of the skin material in its vacuum molding is performed from the vicinity of the external circumference of a mold cavity to the backside along a turning-back mold thrusted out to the backside of the mold cavity from the external circumference of a female mold. CONSTITUTION:A skin material S is kept heated and softened beforehand so that vacuum molding of the same is possible, the skin material S is arranged on the center between a male mold 1 and female mold 2, the skin material S is brought into contact with a mold 20 side by clamping the molds, vacuum suction is performed through vacuum piping 23 and deformed thermally so that the skin material S adheres closely to a mold 20. The skin material S is turned back to the backside along the surface of a turning-back mold 24 which is in a protruded boardlike state by moving the turning-back mold 24 of a female mold 2 side to the backside of a mold cavity 5 through protrusion, through which turning-back part S' is formed, which is folded back toward the external circumference and molded into a state that the same is bent into an S-shaped form. Both the molding tools 1, 2 are clamped completely, raw material particles are supplied and fill the mold cavity 5 formed between mold 10 and the skin material S through a raw material filling device 3, heating steam is supplied and simultaneously with molding of a foamed article F the same and the skin material S are joined unitarily.

Description

[Detailed Description of the Invention] Technical Field> The present invention relates to a method for simultaneously molding a skin material, in which a skin material such as a vinyl chloride sheet is simultaneously molded along the surface of a foam molded product such as expanded polystyrene. It concerns a method of integrally joining.

<Prior art> A foam molded product with a skin material, in which the skin material and the foam molded product described above are integrally joined, has a high thermal insulation property and Ifi of the foam molded product.
Demand has been increasing in recent years for applications such as automobile ceiling materials and architectural interior materials, as it can take advantage of the beauty and strength of the surface material.

As a method for simultaneously molding the skin material and the foam molded product, as shown in Fig. 5, a pair of male and female molds (1) (II
After placing the heat-softened skin material (h) on the mold (1') and vacuum forming the skin material (h) along one mold (m), (h) is filled with expandable thermoplastic resin particles and foam-molded to form a foam-molded product (f), and at the same time integrally joined with the skin material (h). A method has been developed, and specific prior art includes Japanese Utility Model Publication No. 58-15156, Japanese Unexamined Patent Application Publication No. 54-24975, and Japanese Patent Application Publication No. 54-73.
It is disclosed in Publication No. 532 and the like.

The methods of the prior art described above use only a pair of molds, which are almost the same as those for ordinary foam molding, and there is no need to prepare a separate mold or molding device for vacuum forming.
This method not only simplifies the manufacturing equipment, but also has good manufacturing efficiency because vacuum forming and foam molding are performed continuously, and provides excellent integrity between the skin material and the foam molded product.

When the foamed molded product (f) with skin material (h) manufactured by the above method is used as a ceiling material for an automobile, etc., the outer periphery of the foamed molded product ([) as shown in FIG. At the edge, fold the skin material (h) back to the back side and make the foam molded product (
f), so that the foamed molded product (f) is not exposed on the front side and outer peripheral edge, which becomes the outer surface during use.

However, the work of folding and joining the skin material (h) is very troublesome and time-consuming, which hinders the improvement of manufacturing efficiency and also increases the manufacturing cost.

In addition, in the mold having the structure shown in Fig. 5, after vacuum forming the skin material (h) with the female mold (-) concave inward, the skin material (h) and the flat male mold (m' ), when foam molding occurs on the mating surfaces of both molds (m) (m'), the skin material Th
) along the outer periphery back surface of the foam molded product (f)
) will be attached. Then, when folding the skin material (h), the gap (f') gets in the way, making it difficult to perform the folding process smoothly, and the finished part of the folding part becomes dirty.

<Purpose> Therefore, the purpose of the present invention is to solve the problems of the prior art described above, to efficiently fold back the skin material at the outer peripheral edge of a foam molded product, and to obtain a beautiful finish in terms of appearance. The objective is to develop a method for simultaneously molding skin materials.

<Structure> And, as a method for achieving the above purpose, after performing vacuum forming of the skin material along the female mold of a pair of male and female molds, In the simultaneous molding method for skin materials, in which foam molding is performed in a mold cavity, and the foam molded product and skin material are integrally joined, the outer peripheral portion of the skin material is Along the folded mold that protrudes from the outer periphery to the back side of the mold cavity, the folded part of the skin material is folded from the outer peripheral edge of the mold cavity to the back side, and during foam molding, the folded part of the skin material is placed on the outer periphery back of the foam molded product. It is characterized by being integrally joined.

<Example> Next, an example of the present invention will be described below with reference to the drawings.

FIG. 1 shows the entire molding apparatus used for carrying out the method of this invention. (1) (In the center of 21, there is a mold cavity (51 (Fig. 172 and
). A female mold (10) with a trapezoidal center protruding in the center is attached to the male mold (1) to form one side of the foam molded product. A chamber (11) is provided so that heated steam for foam molding can be introduced.

(3) is a raw material filler, which is installed so as to open from the back of the male mold (1) to the inner surface of the mold (10), and supplies expandable thermoplastic resin particles that will be the raw material for foam molding. It can be filled.

Although not shown, the mold (10) is provided with appropriate steam holes so that heated steam can be supplied from the steam chamber (11) through the mold (10) into the mold cavity (5). It has become. The basic structure of the above male type (1) is as follows:
It is the same as conventional molding equipment.

Next, a vacuum forming mold (20) is attached to the female mold (2), which has a female shape that is shallowly concave at a constant depth. The mold (20) has vacuum suction holes (2) at appropriate positions.
1) is formed through the mold (20), and a vacuum chamber (22) is provided on the back side of the mold (20), and the vacuum chamber (22) is connected to a vacuum source as appropriate via a vacuum piping (23). The vacuum chamber (22) is formed to be capable of vacuum suction, and the mold (22)
A skin material, which will be described later, can be vacuum-suctioned from the surface of the mold (20) through the vacuum suction hole (21) of No. 0).

In the mold (20), at the end corresponding to the outer periphery of the mold cavity (5), (24) is a folded type and has a thin plate shape. It is provided so as to be able to protrude and move in the horizontal direction from inside the mold (20) to the central inner side of the mold cavity (S). It is formed so as to be placed on the outer circumferential surface of the foamed molded product.As a moving mechanism for the folded mold (24), although not shown, a cylinder line drawing or the like can be adopted as appropriate.

In addition, the mold (10) of the male mold (1) is clamped with the female mold (2) so that the folded mold (24) can be accommodated when the folded mold (24) protrudes and moves. , mold (10)
The outer periphery of the mold is slightly recessed in the portion corresponding to the folded mold (24).

In addition to the above-mentioned explanation, each mold has various structures similar to conventional molding equipment, such as cooling piping and a molded product ejection mechanism, but they are not shown in the drawings and are not detailed here. I'll omit the explanation.

Next, the molding method of the present invention using the above-described molding apparatus will be explained in order of steps with reference to FIGS. 1 to 4.

First, as shown in Figure 1, a skin material (S) such as a vinyl chloride sheet is placed in the center of the molded male mold (1) and female mold (2).At this time, the skin material (S) is Heat and soften in advance so that vacuum forming is possible.

Next, as shown in Figure 2, the left and right molds, the female mold (1)
Clamp the male mold (a) with the male mold (a). However, at this time, it is not necessary to completely clamp the molds, and there may be some gap between them.Then, insert the skin material (S) into the male mold (2).
While in contact with the mold (20) side, apply vacuum from the vacuum piping (23) of the male mold ('2J), and remove the skin material (S) from the vacuum suction hole (21) of the mold (20). Vacuum suction is applied to thermally deform the heated and softened skin material (S) so that it tightly adheres to the mold (20), thereby performing so-called vacuum forming.

At this time, place I (the folded mold (24) on the 2nd side and the mold hole (5)
) by moving it protruding to the back side of the mold (
At the outer peripheral end of the mold cavity (5), the skin material (S) is folded back from the outer peripheral end of the mold cavity (5) to the back side along the surface of the protruding plate-shaped folded mold (24), and the folded part ( After forming S'), it is further folded back toward the outer periphery, and the entire outer periphery is formed into an S-shape.

Note that if the mold (20) is configured to be freely heated and the skin material (S) in contact with the mold (20) can be heated, thermal deformation of the skin material (S) can be prevented. It can be done smoothly and is more suitable.

After that, as shown in Figure 3, the drawing molds (1) (2)
Completely clamp the mold, and from the raw material filling device (3) on the female mold (1) side, the mold formed between the mold (10) of the female mold (1) and the vacuum-formed skin material (S) After supplying and filling the raw material particles into the mold cavity (S), heated steam introduced into the steam chamber (11) from the steam pipe (12) is supplied into the mold cavity (S) to heat and foam the raw material particles. At the same time as the foam molded product (F) is molded, the foam molded product (F) and the skin material (S) are integrally joined to produce a foam molded product with a skin material.

In addition, when heating and foaming the raw material particles, the male mold (second mold) is used.
If 20) is heated with a heater or the like, foam molding can be carried out efficiently.

If a foam molded product with a skin material can be molded as described above, the molded product is taken out after going through the usual cooling process, etc. At this time, as shown in Figure 4, the folded mold (24) is inserted into the mold. (20) and move it out to the inside of the skin material (S).
This allows the S-shaped bent portion to be removed from the mold.

After that, if the foam molded product (F) and the skin material (S) are separated from the surrounding skin material (S) at the inner end of the folded part (S'), where the foam molded product (F) and the skin material (S) are integrally joined, the foamed product with skin material The manufacturing process of the molded article is completed.

In the above-described molding method of the present invention, among the coloring devices used for molding, a male mold (1) and a female mold (2) are used.
The overall structure of the mold (10) and the shape of the mold (20) can be changed as appropriate depending on the shape of the foam molded product with skin material to be manufactured, and are not limited to the illustrated embodiment. do not have. In addition, the structure of the molding mechanism and filler (3) of the male mold (1) and female mold (a) can be implemented using the structure adopted in ordinary foam molding or vacuum molding molds. It is.

As a folded mold (24) provided in the female mold ('2J mold (20)), a skin material (S) is placed at a position corresponding to a part of the inner surface from the outer peripheral edge of the foam molded product (F). It only needs to be able to be folded back, and shapes other than those shown can be used depending on the shape of the mold cavity and the foamed molded product.Furthermore, the movement mechanism for the folded die (24) may be a hydraulic pneumatic or electromagnetic type. cylinder mechanism, rack and pinion mechanism, cam mechanism, etc.
Various types of operating n-tubs that are used in ordinary mechanical devices can be used as appropriate.

Next, the skin material (S) used for molding is made of various thermoplastic resins as long as it is a sheet-like material that can be molded into a shape that follows the surface shape of the mold (20) by vacuum forming. Foamed or non-foamed sheets, stretchable paper, cloth,
A nonwoven fabric or the like can be used, and a laminated sheet obtained by laminating a plurality of the above sheet-like bodies can also be used. Furthermore, even if the sheet material is difficult to mold alone, it may be possible to use it by laminating it on the above-mentioned sheet material that is easy to mold.

In addition, as raw material particles for forming foam molded products ("),
It is possible to use expandable thermoplastic resin particles made of various thermoplastic resins such as polystyrene, polyethylene, polypropylene, etc., singly or copolymers, or mixed resins.

The foamed molded product with a skin material manufactured using the mold of this invention can be freely applied to automobile ceiling materials, architectural interior materials, and other products.

Effect> According to the simultaneous molding method of the present invention configured as described above, a pair of molds, namely a male mold (1) and a 1ffi mold (2
1, in the mold (20) of the female mold (2) for vacuum forming, a part of the outer periphery is made into a folded mold (24), and the mold cavity (5), that is, the back side of the foamed molded product (F) make it stand out,
By vacuum forming the skin material (S) along the surface of the folded mold (24), a folded part (S') is formed on the outer periphery of the skin material (S), so that the foam molded product can be formed by foam molding. When (F) and skin material (S) are integrally joined,
The folded portion (S') of the skin material (S) can be integrally joined to the outer peripheral back surface of the foam molded product ([).

Therefore, as in the conventional simultaneous molding method, after the skin material is extended and formed around the outer periphery of the foam molded product, a part of the skin material is folded back and joined to the outer periphery back of the foam molded product in a separate process. This eliminates the need for this process, making it possible to greatly streamline the manufacturing process for foam molded products with skin materials.

Furthermore, in the past, there was a problem in which it was difficult to fold back the skin material due to the flakes generated around the outer periphery of the foam molded product.
With this invention method, the folded part (S') is attached to the skin material (S).
) is formed, then foam molding is performed, so the foam molded product (
The folding work is not obstructed at all by the flaps in F), and the shape of the folded portion (S') is very accurate and a beautiful finish can be obtained.

As described above, the foamed molded product with a skin material can be manufactured extremely efficiently, and the molded product has a good finish, making it possible to manufacture a product that is very suitable for automobile ceiling materials, etc.
This is an excellent molding method.

[Brief explanation of drawings]

The figures show examples and comparative examples of the invention,
Fig. 1 is a cross-sectional view of the entire device, Figs. 2 to 4 are structural cross-sectional views of main parts showing the sequential molding process, Fig. 5 is a schematic cross-sectional view of main parts of a conventional molding device, and Fig. 6 is FIG. 7 is a sectional view showing an example of a foam molded product with a skin material. FIG. 7 is a sectional view showing an example of a foam molded product with a skin material immediately after molding. (1)...Male mold, (10)...Mold,
(2)...Female mold, (20)...Mold,
(24)...Folded type, (3)...Filler, (S)...Skin material, (S')...
- Folded part, (F)...Foam molded product. Patent applicant Sekisui Plastics Co., Ltd. Toyota Motor Corporation

Claims (1)

[Claims] 1. Along the female mold of a pair of male and female molds. After vacuum forming the skin material, the male mold and Foaming occurs within the mold cavity formed between the skin material After molding, the foam molded product and the table Simultaneous formation of skin material to integrally join skin material In the shape method, when vacuum forming the skin material, The outer periphery of the skin material is molded from the outer periphery of the female mold. Along the folded pattern that protrudes from the back side of the fossa. Then, fold it back from the outer edge of the mold cavity to the back side. Form it in advance, and then use it during foam molding. The folded part of the skin material is integrated on the back of the outer periphery of the product. Simultaneous skin material characterized by joining Molding method.