US20020058081A1 - Process and mold for producing a multilayer molded article - Google Patents

Process and mold for producing a multilayer molded article Download PDF

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Publication number
US20020058081A1
US20020058081A1 US10/036,425 US3642502A US2002058081A1 US 20020058081 A1 US20020058081 A1 US 20020058081A1 US 3642502 A US3642502 A US 3642502A US 2002058081 A1 US2002058081 A1 US 2002058081A1
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US
United States
Prior art keywords
mold
skin material
resin body
molded article
multilayer molded
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/036,425
Inventor
Shohei Masui
Masahito Matsumoto
Nobuhiro Usui
Toshihiro Hosokawa
Ryuichi Ishitsubo
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Sumitomo Chemical Co Ltd
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Sumitomo Chemical Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sumitomo Chemical Co Ltd filed Critical Sumitomo Chemical Co Ltd
Priority to US10/036,425 priority Critical patent/US20020058081A1/en
Publication of US20020058081A1 publication Critical patent/US20020058081A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/20—Making multilayered or multicoloured articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/12—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/78—Moulding material on one side only of the preformed part

Definitions

  • the present invention relates to a process and a mold for producing a multilayer molded article comprising a resin body and at least one sheet of a skin material which covers a part of a surface area of the resin body.
  • a multilayer molded article comprising a resin body and a skin material laminated on the resin body has good appearance due to its high quality and warm feeling.
  • the multilayer molded article greatly improves the textures of a resin molded article, such as providing for a cool feeling and provides an article with high value and beauty.
  • multilayer molded articles are widely used as automobile interior materials or furnishing materials.
  • One object of the present invention is to provide a process for producing a multilayer molded article comprising a resin body and a skin material which covers a part of the surface of the resin body.
  • Another object of the present invention is to provide a mold suitable for producing a multilayer molded article comprising a resin body and a skin material which covers a part of the surface of the resin body.
  • a process for producing a multilayer molded article comprising a resin body and a skin material which covers a part of the surface of the resin body so that an edge part of the skin material present on the surface of the resin body is placed in a groove formed on the surface of the resin body, which process comprising steps of:
  • an unclosed mold comprising a lower mold having at least one pin for fixing the edge part of the skin material at a position where the edge part of the skin material is placed and an upper mold having a kick for forming the groove
  • a mold for producing a multilayer molded article comprising a resin body and a skin material which covers a part of the surface of the resin body so that an edge part of the skin material present on the surface of the resin body is placed in a groove formed on the surface of the resin body, which mold comprises a lower mold having at least one pin for fixing the edge part of the skin material at a position where the edge part of the skin material is placed and an upper mold having a kick for forming the groove on the surface of the resin body.
  • FIG. 1 is a cross section of the multilayer molded article having the skin material which covers a part of the surface of the resin body
  • FIG. 2 is a perspective view of the multilayer molded article of FIG. 1,
  • FIGS. 3 and 4 schematically show the process for producing the multilayer molded article according to the present invention, with FIG. 3 being a cross section of the mold of FIG. 5B along the line A- 4 at the start of molding and FIG. 4 having a cross section of the mold of FIG. 5B along with the line A- 4 at the end of molding,
  • FIGS. 5A, 5B and 5 C are a cross section of the upper mold, a plane view of the lower mold and a cross section of the lower mold, respectively, of a first embodiment of the mold of the present invention
  • FIG. 6 is a cross section along the line corresponding to line B-B of FIG. 5B of the multilayer molded article produced by means of the mold shown in FIGS. 5A, 5B and 5 C,
  • FIGS. 7A, 7B and 7 C are a cross section of the upper mold, a plane view of the lower mold and a cross section of the lower mold, respectively, of a second embodiment of the mold of the present invention
  • FIG. 8 is a cross section of the multilayer molded article produced by means of the mold shown in FIGS. 7A, 7B and 7 C.
  • the skin material may be any of conventionally used materials.
  • the skin material are woven or non-woven fabric, nets made of metals, fibers or thermoplastic resins, paper, metal foils, and a sheet or a film of a thermoplastic resin or elastomer.
  • the skin material may be decorated with uneven patterns such as grain patters, printing, dying and the like.
  • the skin material may be made of foamed materials of thermoplastic resins or rubbers.
  • a laminate comprising at least two layers each made of the same material or different materials which are bonded to each other with an adhesive can be used as the skin material. Before the skin material is supplied in the mold, a part or whole of the skin material may be preheated to adjust tensile stress and elongation.
  • the resin to be molded by the process of the present invention any of the conventional resins used in compression molding, injection molding and extrusion molding can be used.
  • the resin are non-expandable or expandable resins of thermoplastic resins (e.g. polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, nylon, etc.), and thermoplastic elastomers (e.g. ethylene-propylene copolymer, styrene-butadiene copolymer, etc.).
  • the resin may contain at least one additive such as fillers (e.g. inorganic fillers and glass fibers), pigments, lubricants, antistatic agents and the like.
  • FIGS. 1 and 2 show a cross section and a perspective view, respectively, of the multilayer molded article 6 produced in one embodiment of the present invention, which has a skin material 1 covering a part 5 of a surface of a resin body 2 with leaving a surface area 4 uncovered. An edge part 1 a is placed in a groove 3 which is formed on the surface of the resin body 2 .
  • the groove 3 has a width and a depth sufficient for receiving the edge part 1 a of the skin material 1 , and the sizes of the groove 3 depend on the type of material, and the thickness and width of the edge part of the skin material.
  • FIG. 3 One example of the mold to be used in the process according to the present invention is shown in FIG. 3.
  • the mold comprises an upper mold 7 and a lower mold 8 .
  • the lower mold 8 has means for fixing the edge part 1 a of the skin material 1 .
  • one or more pins are retained on one or more discretely formed protrusions as shown in FIG. 3.
  • the number of pins depends on the length of the edge part 1 a to be fixed. Further, the protrusions and the pins may be moveable in a direction in which the molds are closed, although they may be fixed to the lower mold 8 .
  • the article produced by using the mold of FIG. 4 has small holes corresponding to the protrusions 10 located on an inner surface of the lower mold. If the protrusions are lowered by, for example, hydraulic action after the resin melt is filled in the cavity of the mold and before the resin melt is solidified, such holes disappear and only the pin holes remain in the article.
  • the pin When the pin is vertically movable, it is lifted up to a level at which the edge portion 1 a is easily fixed with the pin 13 , and it is lowered to a desired level during molding.
  • the upper mold 7 has a kick 11 at a position which the edge part 1 a contacts.
  • the kick may be movable in a direction in which the molds are closed.
  • Edge parts other than the edge part 1 a can be fixed with a clamping frame 9 surrounding the mold.
  • the multilayer molded article can be produced by using the mold of FIG. 3 as follows:
  • edge part 1 a of the skin material 1 is fixed to the fixing section 10 with the pin 13 . Then, other edge is fixed to the clamping frame with other pin 13 .
  • a mass of resin melt 12 is supplied between the skin material 1 and the lower mold 8 . Since the edge part 1 a is fixed with the pin to the fixing section 10 , there are free gaps between the protrusions as shown in FIG. 5B, so that the resin melt can flow through such gaps and spread all over the inner surface of the lower mold 8 when the molds 7 and 8 are closed and the resin melt is compressed.
  • the pins 13 are directly attached to the bottom of groove 14 . Then, the edge part 1 a of the skin material is fixed at the upper part of each pin 13 , so that a gap is formed between the skin material and the groove bottom.
  • the multilayer molded article 6 shown in FIG. 8 can be produced by substantially the same procedures as described above.
  • the kick 11 forms a groove which receives the edge of the skin material to beautifully finish the edge of the skin material.
  • the boundary is clearly formed between the covered surface area 5 and the uncovered surface area 4 .

Abstract

A multilayer molded article constitutes a resin body and a skin material which covers a part of the surface of the resin body so that an edge part of the skin material present on the surface of the resin body is placed in a groove formed on the surface of the resin body. The article is produced by providing an unclosed mold having a lower mold having at least one pin for fixing the edge part of the skin material at a position where the edge part of the skin material is placed and an upper mold having a kick for forming the groove, placing the skin material on the lower mold and fixing the edge part of the skin material with the pin, supplying a mass of resin melt between the skin material and the lower mold, and closing the upper and lower molds to form the multilayer molded article.

Description

    BACKGROUND OF THE INVENTION
  • 1. Field of the Invention [0001]
  • The present invention relates to a process and a mold for producing a multilayer molded article comprising a resin body and at least one sheet of a skin material which covers a part of a surface area of the resin body. [0002]
  • 2. Description of the Related Art [0003]
  • A multilayer molded article comprising a resin body and a skin material laminated on the resin body has good appearance due to its high quality and warm feeling. The multilayer molded article greatly improves the textures of a resin molded article, such as providing for a cool feeling and provides an article with high value and beauty. [0004]
  • In fact, multilayer molded articles are widely used as automobile interior materials or furnishing materials. [0005]
  • To improve the ornamental effect of the skin of a multilayer molded article, it is desired to laminate the skin material on a part of the surface of the resin body. However, the conventional processes or molds for producing the multilayer molded article cannot produce such an improved multilayer molded article. The free edge of the skin material covering a part of the surface of the resin body cannot be beautifully finished. [0006]
    • SUMMARY OF THE INVENTION
  • One object of the present invention is to provide a process for producing a multilayer molded article comprising a resin body and a skin material which covers a part of the surface of the resin body. [0007]
  • Another object of the present invention is to provide a mold suitable for producing a multilayer molded article comprising a resin body and a skin material which covers a part of the surface of the resin body. [0008]
  • According to a first aspect of the present invention, there is provided a process for producing a multilayer molded article comprising a resin body and a skin material which covers a part of the surface of the resin body so that an edge part of the skin material present on the surface of the resin body is placed in a groove formed on the surface of the resin body, which process comprising steps of: [0009]
  • providing an unclosed mold comprising a lower mold having at least one pin for fixing the edge part of the skin material at a position where the edge part of the skin material is placed and an upper mold having a kick for forming the groove, [0010]
  • placing the skin material on the lower mold with fixing the edge part of the skin material and the pin, [0011]
  • supplying a mass of resin melt between the skin material and the lower mold, and [0012]
  • closing the upper and lower molds to form the multilayer molded article. [0013]
  • According to a second aspect of the present invention, there is provided a mold for producing a multilayer molded article comprising a resin body and a skin material which covers a part of the surface of the resin body so that an edge part of the skin material present on the surface of the resin body is placed in a groove formed on the surface of the resin body, which mold comprises a lower mold having at least one pin for fixing the edge part of the skin material at a position where the edge part of the skin material is placed and an upper mold having a kick for forming the groove on the surface of the resin body.[0014]
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a cross section of the multilayer molded article having the skin material which covers a part of the surface of the resin body, [0015]
  • FIG. 2 is a perspective view of the multilayer molded article of FIG. 1, [0016]
  • FIGS. 3 and 4 schematically show the process for producing the multilayer molded article according to the present invention, with FIG. 3 being a cross section of the mold of FIG. 5B along the line A-[0017] 4 at the start of molding and FIG. 4 having a cross section of the mold of FIG. 5B along with the line A-4 at the end of molding,
  • FIGS. 5A, 5B and [0018] 5C are a cross section of the upper mold, a plane view of the lower mold and a cross section of the lower mold, respectively, of a first embodiment of the mold of the present invention,
  • FIG. 6 is a cross section along the line corresponding to line B-B of FIG. 5B of the multilayer molded article produced by means of the mold shown in FIGS. 5A, 5B and [0019] 5C,
  • FIGS. 7A, 7B and [0020] 7C are a cross section of the upper mold, a plane view of the lower mold and a cross section of the lower mold, respectively, of a second embodiment of the mold of the present invention,
  • FIG. 8 is a cross section of the multilayer molded article produced by means of the mold shown in FIGS. 7A, 7B and [0021] 7C.
    • DETAILED DESCRIPTION OF THE DRAWINGS
  • In the present invention, the skin material may be any of conventionally used materials. Specific examples of the skin material are woven or non-woven fabric, nets made of metals, fibers or thermoplastic resins, paper, metal foils, and a sheet or a film of a thermoplastic resin or elastomer. The skin material may be decorated with uneven patterns such as grain patters, printing, dying and the like. In addition, the skin material may be made of foamed materials of thermoplastic resins or rubbers. Also, a laminate comprising at least two layers each made of the same material or different materials which are bonded to each other with an adhesive can be used as the skin material. Before the skin material is supplied in the mold, a part or whole of the skin material may be preheated to adjust tensile stress and elongation. [0022]
  • As the resin to be molded by the process of the present invention, any of the conventional resins used in compression molding, injection molding and extrusion molding can be used. Specific examples of the resin are non-expandable or expandable resins of thermoplastic resins (e.g. polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, nylon, etc.), and thermoplastic elastomers (e.g. ethylene-propylene copolymer, styrene-butadiene copolymer, etc.). The resin may contain at least one additive such as fillers (e.g. inorganic fillers and glass fibers), pigments, lubricants, antistatic agents and the like. [0023]
  • FIGS. 1 and 2 show a cross section and a perspective view, respectively, of the multilayer molded [0024] article 6 produced in one embodiment of the present invention, which has a skin material 1 covering a part 5 of a surface of a resin body 2 with leaving a surface area 4 uncovered. An edge part 1 a is placed in a groove 3 which is formed on the surface of the resin body 2.
  • The [0025] groove 3 has a width and a depth sufficient for receiving the edge part 1 a of the skin material 1, and the sizes of the groove 3 depend on the type of material, and the thickness and width of the edge part of the skin material.
  • One example of the mold to be used in the process according to the present invention is shown in FIG. 3. [0026]
  • The mold comprises an upper mold [0027] 7 and a lower mold 8. The lower mold 8 has means for fixing the edge part 1 a of the skin material 1. In one embodiment, one or more pins are retained on one or more discretely formed protrusions as shown in FIG. 3.
  • The number of pins depends on the length of the [0028] edge part 1 a to be fixed. Further, the protrusions and the pins may be moveable in a direction in which the molds are closed, although they may be fixed to the lower mold 8.
  • The article produced by using the mold of FIG. 4 has small holes corresponding to the [0029] protrusions 10 located on an inner surface of the lower mold. If the protrusions are lowered by, for example, hydraulic action after the resin melt is filled in the cavity of the mold and before the resin melt is solidified, such holes disappear and only the pin holes remain in the article.
  • When the pin is vertically movable, it is lifted up to a level at which the [0030] edge portion 1 a is easily fixed with the pin 13, and it is lowered to a desired level during molding.
  • The upper mold [0031] 7 has a kick 11 at a position which the edge part 1 a contacts. The kick may be movable in a direction in which the molds are closed.
  • Edge parts other than the [0032] edge part 1 a can be fixed with a clamping frame 9 surrounding the mold.
  • The multilayer molded article can be produced by using the mold of FIG. 3 as follows: [0033]
  • The [0034] edge part 1 a of the skin material 1 is fixed to the fixing section 10 with the pin 13. Then, other edge is fixed to the clamping frame with other pin 13.
  • A mass of [0035] resin melt 12 is supplied between the skin material 1 and the lower mold 8. Since the edge part 1 a is fixed with the pin to the fixing section 10, there are free gaps between the protrusions as shown in FIG. 5B, so that the resin melt can flow through such gaps and spread all over the inner surface of the lower mold 8 when the molds 7 and 8 are closed and the resin melt is compressed.
  • By the above process, the multilayer molded [0036] article 6 shown in FIG. 6 is produced.
  • In the embodiment of FIGS. 7A, 7B and [0037] 7C, the pins 13 are directly attached to the bottom of groove 14. Then, the edge part 1 a of the skin material is fixed at the upper part of each pin 13, so that a gap is formed between the skin material and the groove bottom.
  • With using such a mold, the multilayer molded [0038] article 6 shown in FIG. 8 can be produced by substantially the same procedures as described above. The kick 11 forms a groove which receives the edge of the skin material to beautifully finish the edge of the skin material.
  • In the multilayer molded article produced by the process of the present invention, the boundary is clearly formed between the covered [0039] surface area 5 and the uncovered surface area 4.

Claims (4)

What is claimed is:
1. A mold for producing a multilayer molded article comprising a resin body and a skin material which covers a part of the surface of the resin body and an edge part of which present on the surface of the resin mold is placed in a groove formed on the surface of the resin body, which mold comprises a lower mold having at least one pin for fixing the edge part of the skin material at a position where the edge part of the skin material is placed and an upper mold having a kick for forming the groove on the surface of the resin body.
2. The mold according to claim 1, wherein the fixing pin is retained on a protrusion on the lower mold.
3. The mold according to claim 2 , wherein the protrusions are movable in a direction in which the upper and lower molds are closed.
4. The mold according to claim 2, wherein the pins are formed in a groove which is formed in the lower mold.
US10/036,425 1988-12-27 2002-01-07 Process and mold for producing a multilayer molded article Abandoned US20020058081A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US10/036,425 US20020058081A1 (en) 1988-12-27 2002-01-07 Process and mold for producing a multilayer molded article

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
JP63334089A JP2696374B2 (en) 1988-12-27 1988-12-27 Manufacturing equipment for synthetic resin molded products with skin material partially adhered
JP334089/1988 1988-12-27
US45500989A 1989-12-22 1989-12-22
US86630792A 1992-04-13 1992-04-13
US08/173,930 US6348170B1 (en) 1988-12-27 1993-12-28 Process for producing a multilayer molded article
US10/036,425 US20020058081A1 (en) 1988-12-27 2002-01-07 Process and mold for producing a multilayer molded article

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US08/173,930 Division US6348170B1 (en) 1988-12-27 1993-12-28 Process for producing a multilayer molded article

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US20020058081A1 true US20020058081A1 (en) 2002-05-16

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US08/173,930 Expired - Fee Related US6348170B1 (en) 1988-12-27 1993-12-28 Process for producing a multilayer molded article
US10/036,425 Abandoned US20020058081A1 (en) 1988-12-27 2002-01-07 Process and mold for producing a multilayer molded article

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US08/173,930 Expired - Fee Related US6348170B1 (en) 1988-12-27 1993-12-28 Process for producing a multilayer molded article

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US (2) US6348170B1 (en)
EP (1) EP0376264B1 (en)
JP (1) JP2696374B2 (en)
KR (1) KR900009246A (en)
CA (1) CA2006677C (en)
DE (1) DE68925108T2 (en)

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US11325328B2 (en) 2014-04-04 2022-05-10 Bayerische Motoren Werke Aktiengesellschaft Mould for producing a fibre composite component

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JP3465388B2 (en) * 1994-12-22 2003-11-10 住友化学工業株式会社 Mold for forming multilayer molded article and method for producing multilayer molded article using the same
JP3050366B2 (en) * 1995-03-29 2000-06-12 河西工業株式会社 Molding method and molding apparatus for laminated molded article
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US6471276B1 (en) * 2000-02-04 2002-10-29 Universal Trim, Inc. Molded insert netted map pocket
KR100419265B1 (en) * 2001-08-13 2004-02-18 강지수 Structure of a can lid
JP3743401B2 (en) 2002-06-28 2006-02-08 ブラザー工業株式会社 Image reading device
US7749182B2 (en) * 2005-12-13 2010-07-06 3M Innovative Properties Company Stay hinge for orthopedic supports and method of using same
US7862527B2 (en) * 2005-12-13 2011-01-04 3M Innovative Properties Company Edge binding for orthopedic supports and method of using same
US7976487B2 (en) 2005-12-13 2011-07-12 3M Innovative Properties Company Fastener tabs and strapping system for orthopedic supports and method of using same
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US6348170B1 (en) 2002-02-19
DE68925108T2 (en) 1996-05-02
KR900009246A (en) 1990-07-02
CA2006677A1 (en) 1990-06-27
CA2006677C (en) 2000-01-25
JP2696374B2 (en) 1998-01-14
DE68925108D1 (en) 1996-01-25
EP0376264B1 (en) 1995-12-13
EP0376264A3 (en) 1991-08-28
EP0376264A2 (en) 1990-07-04
JPH0327910A (en) 1991-02-06

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