JPS62108040A - Simultaneous molding method for skin material - Google Patents

Abstract

PURPOSE:To constitute the titled method so that filling of resin particles are made reliable and a molding form of a skin material of the external circumferential part can be performed precisely, by a method wherein the resin particles are packed in a mold cavity under a state that capacity of the external circumferential part of the mold cavity is expanded and the capacity of the external circumferential part of the mold cavity is reduced by pressing in the resin particles of the part, whose capacity has been expanded, into an adjoining part by a movable mold. CONSTITUTION:A skin material S which has been heated and softened beforehand 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 performing mold clamping, vacuum suction is performed through vacuum piping 23 and deformed thermally so that the skin material S adheres closely to the mold 20. Both the molding tools 1, 2 are clamped completely, resin particles B are supplied and fill a mold cavity 5 to be formed between a mold 10 and the skin material S through a raw material filling device 3. In an expanded space 12, a movable mold 13 is moved and arranged on an interior side and capacity of the external circumferential part of the mold cavity 5 is kept expanded. Then the capacity of the expanded space 12 is reduced by moving the movable mold 13 from the interior and the resin particles B are packed out under a compressed state. Heating steam is supplied within the mold cavity 5, a foamed molded article F is molded and the foamed molded article F and skin material S are joined together 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> The foam molded product with a skin material, in which the skin material and the foam molded product described above are integrally joined, has excellent heat insulation properties of the foam molded product, and! !
Demand has been increasing in recent years for applications such as automobile ceiling materials and architectural interior materials, as it can take advantage of its impact resistance and 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. 6, a pair of male and female molds (m) (II
After placing the heat-softened skin material (h) on the mold (l') and vacuum forming the skin material (h) along one mold (III), A method is to perform foam molding by filling the foamable thermoplastic resin particles (b) into the mold cavity formed between the material (h), molding the foam molded product, and simultaneously joining it integrally with the skin material. Specific prior art includes Japanese Utility Model Publication No. 58-15156, Japanese Unexamined Patent Publication No. 54-24975, and Japanese Unexamined Patent Publication No. 54-735.
yfl is shown in Publication No. 32 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 high manufacturing efficiency because vacuum forming and foam molding are performed continuously, and provides excellent integrity between the skin material and the foam molded product.

However, in the above molding method, when trying to mold a relatively thin molded product with a large area, the resin particles (b) are transferred to the outer periphery of the mold cavity away from the filler during foam molding. It becomes difficult to reliably fill the mold by passing it through the narrow mold cavity, leading to problems such as partial filling failures and insufficient filling density at the outer periphery.

In addition, during vacuum forming, the skin material (h) is molded only by vacuum suction from one mold (m) side, so the skin material (h) is completely adhered to the mold (Ill). It is difficult to mold, especially in the vicinity of the outer periphery of the mold (m), where the skin U (h) remains lifted from the surface of the mold (m), resulting in the problem that accurate molding may not be possible.

Therefore, it is an object of the present invention to solve the problems of the prior art described above, to ensure the filling of resin particles at the outer peripheral end of a foam molded product, and to improve the molded shape of the skin material in the outer peripheral part. The objective is to develop a method for simultaneously molding skin materials that can be done accurately.

The method for achieving the above purpose is as follows:
After performing vacuum forming of the skin material along the female mold of a pair of molds, foam molding is performed in the mold cavity formed between the male mold and the skin material, and the formed foam molded product and In the simultaneous molding method of the skin material, in which the skin material is integrally joined with the skin material, a part of the outer periphery of the male mold is formed to be movable, and the volume of the outer periphery of the mold cavity is configured to be variable. In the filling process of resin particles, with the volume of the outer periphery of the mold cavity expanded,
After filling the resin particles, the movable mold formed in the male mold described above pushes the resin particles in the volume-expanding part of the mold cavity into the adjacent part to reduce the volume of the outer peripheral part of the mold cavity. It is a feature.

<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 to carry out the method of the present invention. Among a pair of molds, (1) is a male mold, ('2J is a female mold, and a drawing mold (1) In the center of [21, a mold cavity (9 (see Fig. 2 onwards)) which becomes a molding space can be formed. Flat mold for (10)
is installed, and a steam chamber (11) is installed on the back of the mold (10).
The structure is such that heated steam for foam molding can be introduced. (3) is a raw material filling device, which is installed so as to open from the back of the male mold (1) to the inner surface of the mold (10);
Expandable thermoplastic resin particles, which are raw materials for foam molding, can be supplied and filled.

Further, although not shown, the mold (10) is appropriately formed with steam holes so that heated steam can be supplied from the steam chamber (11) through the mold (10) into the mold cavity (S). Note that the basic structure of the male mold (1) described above is the same as that of a conventional molding device.

In the outer periphery of the mold (10), (12) is an expanded space, and the part corresponding to the outer periphery of the mold 8 (51) is
An old man is formed on the back side of the flat mold surface, creating an expanded space (
A movable mold (13) is provided inside the mold (12), which is movable from the inner part to the surface of the mold (10).
By moving the mold cavity (3), the volume of the expansion space (12), which constitutes a part of the mold cavity (S), can be freely varied.The movable mold (13) has a cylinder mechanism (
14) or the like as appropriate.

Next, a vacuum forming mold (20), which has a female shape with a shallow recess at a constant depth, is attached to the female mold (2), and the front surface of this mold (20) is fixed. Place the skin material and perform vacuum forming. The mold (20) has vacuum suction holes (
21) 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 vacuum piping (23). There it is,
A vacuum chamber (22) is formed to allow vacuum suction, and the mold (
The skin material can be vacuum-suctioned from the surface of the mold (20) through the vacuum suction hole (21) of the mold (20).

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 5.

First, as shown in FIG. 1, a skin material (S) such as a vinyl chloride sheet is placed in the center of the opened male mold (1) and female mold (2). At this time, the skin material (S) is heated and softened in advance so that it can be vacuum formed.

Next, as shown in Figure 2, the left and right molds, the female mold (1)
and the male mold (2) are clamped together. However, at this time, the molds do not necessarily need to be completely clamped, and a certain amount of gap may be left. Then, the skin material (S) is attached to the male mold (2
) in contact with the mold (20) side, apply vacuum from the vacuum pipe (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.The mold (20) is configured to be able to be heated freely. Set the mold (
If the skin material (S) in contact with 20) can be heated, the skin material (S) can be thermally deformed smoothly, which is more suitable.

However, in the above vacuum forming, the skin material (S) does not completely adhere to the female mold (2J mold (20)) at the outer peripheral part of the mold cavity (5), and the outer peripheral corner of the mold (20) There is no problem even if there is a slight gap between the parts.

Thereafter, as shown in Fig. 3, the drawing mold (11 (2)) is completely clamped, and the mold (10 ) and vacuum-formed skin material (
Resin particles (B) as a raw material are supplied and filled into the mold cavity (S) formed between the movable mold (13) and the mold (10). is moved to the back side and the volume of the outer periphery of the mold cavity (9) is expanded.

Therefore, type! (The resin particles (B) filled in 51 are filled up to the inside of the enlarged space (12).

Next, as shown in FIG.
3) from the deep part of the expansion space (12) to the surface, the volume of the expansion space (12) is reduced, so the resin particles (8) in the expansion space (12) are moved from the deep part of the expansion space (12) to the surface of the mold cavity (9). It is pushed into the outer peripheral part adjacent to the expanded space (12) and filled in a compressed state.Also, by moving the resin particles (8), the skin material (S) is shaped into a female mold (2). It is pressed against the mold surface of the female mold (2) to firmly adhere, and even if there is a gap between the skin material (S) and the mold surface of the female mold (2) during vacuum forming, the gap disappears during this process.

Thereafter, as shown in FIG. 5, heated steam introduced from the natural air pipe (12) into the steam chamber (11) is supplied into the mold cavity (5) to heat and foam the resin particles (8). Foam molded products (
At the same time, the foam molded product (") and the skin material (") are molded.
S) are integrally joined to produce a foam molded product with a skin material. In addition, when heating and foaming the resin particles (B), the male mold (
If the 2J mold (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 can be taken out through the usual cooling process, ejection process, trimming of the outer periphery of the skin material, etc., and then the manufacturing process of a foam molded product with a skin material can be completed. is completed.

In addition, in the method explained above, after pushing the resin particles (B) in the enlarged space (12) into the adjacent part of the mold 'm (9), heated steam is supplied into the mold cavity (5), Resin particles (B
) with a heating and foaming spoon, but if the resin particles (8) are not completely heated and foamed, during the heating and foaming stage, the resin particles CB) are expanded from the expanded air flSI (12) to the mold cavity (5). It may be pushed into the adjacent part.

In the molding method of the present invention explained above, among the molding devices used for molding, the male mold (1) and the old mold (2)
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 (2) are the same as those used in regular foam molding or vacuum molding molds. It is possible.

Then, an expanded space (
The shape and size of 12) are such that it can replenish the insufficient amount of resin particles (B) in the outer peripheral part of the mold cavity (5).
It is sufficient that there is a space for accommodating the resin particles (B), and this may be changed as appropriate depending on the overall shape of the mold cavity (S) and the particle size and type of the resin particles (B).

As for the movable mold (13), if the resin particles (B) filled in the expansion space (12) can be pushed into the mold cavity (5) side and the ffj (12) can be closed during expansion, the resin particles (B) filled in the expansion space (12) can be closed during expansion.
Corresponding to the shape of 2), it can be carried out in an appropriate shape, and it can be carried out in a mobile type (
In addition to the illustrated cylinder mechanism, a cam mechanism, a gear mechanism, or any other normal operating mechanism may be appropriately employed as the shift 1iII mechanism in 13).

Furthermore, in the illustrated embodiment, the female mold (2) side is used for vacuum forming, the male mold (1) side is used for foam molding, and the mold (10) of the male mold (1) has an expanded space (12). However, on the contrary, vacuum forming is performed on the male mold side, an expanded space is formed on the female mold side, and between the skin material vacuum formed on the female mold side and the male mold, It is also possible to carry out foam molding.

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 the resin particles (B) for molding the foamed molded product ([), expandable thermoplastic resin particles made of a single or copolymer of various thermoplastic resins such as polystyrene, polyethylene, polypropylene, or a mixed resin are used. Available for use.

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.

<Effects> 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 female mold (of the two, the male mold (1) on the side where foam molding is performed) In the mold (10), an expansion space (12) is formed at the outer periphery of the mold cavity (5), and from the deep part of the expansion space (12) to the surface,
A movable mold (13) is provided, and the resin particles (B
), first move the movable mold (13) to the expanding space (1
2) to increase the volume of the expanded space (12), and the resin particles (8)
), the movable mold (13) is moved to reduce the volume of the expansion space (12) before or during the heating and foaming of the resin particles (B), and the volume of the expansion space (12) is reduced. )
By pressing and compressing the resin particles (B) inside the mold cavity (5) into the adjacent outer circumferential portion of the mold cavity (5), the mold cavity (5), which is prone to poor filling or insufficient filling in the conventional raw material filling process, is removed. 5) The packing density of the resin particles (B) in the outer peripheral portion can be increased.

That is, in the outer circumferential part of the mold cavity (51), it is 1 m (12
) The resin particles (B) contained in the mold cavity (5) near the filling device (3) will be compressed and filled in excess.
) is farther from the filling device (3) than the central part of the
Even the outer peripheral part, where resin particles (B) were not sufficiently supplied, is now filled with sufficient ordinary resin particles (B), and the foamed molded product (F) is expanded from the center to the outer peripheral part. A product having good expansion ratio, foamed particle density, particle fusion degree, etc. can be manufactured throughout.

In addition, in the outer peripheral portion of the mold cavity (5) described above, as the resin particles (B) are pushed by the movable mold (13),
Since the skin material (S) will be pressed against the mold (20) surface of the female mold (2), there will be some space between the skin material (S) and the mold (20) during vacuum forming. Even if there is a gap, the above pressing action ensures that the skin material (S) is firmly attached to the mold (20).
This enables accurate molding of the skin material (S), which was insufficient with vacuum forming alone, and improves the accuracy of the finished shape of the foam molded product with the skin material, which improves quality. This can greatly contribute to improvement.

The outer periphery of the above-mentioned foamed molded product (") is the part that is attached to the base material during use, and is likely to receive direct vibrations and shocks from external forces. Therefore, the foaming ratio and strength of this outer periphery should be determined. It is extremely important to improve the shape of the foam and accurately form the end shape, and the method of this invention eliminates filling defects in the outer peripheral part and adjusts the expansion ratio of the outer peripheral part of the foam molded product (F). This makes it possible to increase the strength and improve the finish quality, which has a very large practical effect.

In addition, by accurately forming the shape of the skin material (S) on the outer periphery, the appearance can be made aesthetically pleasing, and at the same time, the shape of the part when attached to the base material is accurate, improving usability. It also has the effect of

Therefore, according to the method of the present invention, it is possible to extremely reliably and efficiently manufacture thin, large-area products such as automotive ceiling materials by simultaneously molding the skin material, which has been difficult in the past. This will greatly contribute to the popularization and expansion of demand for the above-mentioned simultaneous molded products.

[Brief explanation of drawings]

The figure shows an embodiment of the present invention and a conventional example,
FIG. 1 is a cross-sectional view of the entire apparatus, FIGS. 2 to 5 are structural cross-sectional views of main parts showing sequential molding steps, and FIG. 6 is a schematic cross-sectional view of main parts of a conventional molding apparatus. (1)...Male mold, (10)...Mold,
(12)...°...expanded space, (13)...
・Mobile type, ('2J...Female type, (20)...
... Mold, (3) ... Filler, (S) ...
...Skin material, [B)...Resin particles, (F)...
...Foam molded product. Figure 1 Figure 2 Figure 3

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 molding method, a part of the outer circumference of the male mold is transferred. The volume of the outer periphery of the mold cavity is for foam molding. In the filling process of resin particles, the mold cavity is With the volume of the outer periphery expanded, the resin After filling the particles, it is formed into the male shape described above. Of the mold fossa, depending on the moved mold, Transfer the resin particles in the expanded volume area to the adjacent area. Indentation reduces the volume of the outer periphery of the mold cavity. Simultaneous molding of skin material characterized by Method. 2. Pushing of resin particles by a moving mold, The above patent application is carried out before heating and foaming the resin particles. Simultaneous molding of the skin material described in item 1 of the scope of request. Method. 3. Pushing of resin particles by a moving mold, The above patent is carried out during heating and foaming of resin particles. Simultaneous production of the skin material according to claim 1 shape method.