JP3019292B2 - Molding method and molding apparatus for laminated molded articles - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for forming a laminated molded product suitable for an automobile interior part such as an automobile door trim. The present invention relates to a molding method and a molding apparatus for a laminated molded article capable of molding a laminated molded article having excellent dimensional accuracy.

[0002]

2. Description of the Related Art FIG. 11 is a sectional view showing an automobile door trim which is one of interior parts for automobiles. The automobile door trim 1 is a resin core material having shape retention and rigidity for mounting to a vehicle body panel. 2 and a skin molding 3 that is integrated with the surface and imparts decorativeness and cushioning properties.

As a method of manufacturing the door trim 1 for automobiles, there is a tendency to frequently use a mold press molding method having excellent moldability. In this method, as shown in FIG. The skin material 3 is set on the mold surface of the upper mold 4 for mold press molding. Usually, a holding mechanism such as a set pin or a vacuum suction mechanism is provided, and an injection molding machine 6 is attached to the lower mold 5 for mold press molding. Are connected, and a semi-molten resin M, which is a material of the resin core material 2, is injected from the injection molding machine 6 to the gate 5 a formed in the lower mold 5.
As shown in FIG. 13, the upper and lower dies 4 and 5 are clamped to form the resin core material 2 into a required shape along the cavity by dispensing and supplying to a predetermined location on the mold surface of the lower mold 5. At the same time, the surface material of the resin core material 2 is covered and integrated with the skin material 3 to complete the molding of the automobile door trim 1 shown in FIG.

[0004]

As described above, the mold press molding method has various advantages such as a small number of steps and a complicated curved surface shape. At this time, the front side 2a of the resin core material is in contact with the skin material 3 having a heat insulating effect, while the back side 2b of the resin core material 2 is in contact with the mold surface of the lower mold 5 at room temperature or lower. I have.

For example, when a polypropylene resin mixed with talc is used as a material of the resin core material 2, the temperature difference between the front side 2a and the back side 2b of the resin core material 2 is 80 to 90 ° C. , The back side 2b is 30 to 40 ° C, and there is an opening around 50 ° C.

Therefore, this temperature difference affects the crystallization speed, and the resin core 2 is liable to be deformed and deformed as indicated by a dotted line in FIG.
There was a drawback that reliable attachment to the door panel could not be guaranteed.

[0007] As a countermeasure, a step of correcting the deformation after the molding is required for the expected deformation, so that a lot of trouble and time are required, and there is a disadvantage that productivity is reduced.

Further, an attempt has been made to raise the mold temperature of the lower mold 5 for mold press molding so as to basically prevent distortion deformation, and to keep the temperature of the front and back surfaces of the resin core material 2 substantially constant. However, in such a case, there is a problem that the lower mold 5 expands and the mold opening operation cannot be performed smoothly when the upper mold 4 is raised.

The present invention has been made in view of such circumstances, and a method and apparatus for forming a laminated molded article in which a resin core material and a skin material are integrated by a mold press molding method are provided. An object of the present invention is to provide a molding method and a molding apparatus for a laminated molded body capable of obtaining a laminated molded body with excellent dimensional accuracy by reliably preventing distortion deformation of a resin core material.

[0010]

In order to achieve the above object, the present invention provides a resin core formed by molding a semi-molten resin into a required shape in a mold press molding die, and a mold for molding the resin core. In the press molding, in a method of forming a laminated molded body composed of a skin material covering the surface of a resin core material, the upper mold on which the skin material is set is lowered by a predetermined stroke, and a predetermined portion on the mold surface of the lower mold is formed. Distribute and supply the semi-solid resin to the upper mold, and then lower the upper mold to the bottom dead center, perform the mold clamping of the upper and lower molds for a predetermined time, mold the resin core material, and then release the press pressure of the upper mold. In addition, the temperature of the front and back surfaces of the resin core material is controlled substantially uniformly by blowing hot air from the hot air supply mechanism installed on the lower mold over the entire back surface of the resin core material.

Further, in the molding apparatus according to the present invention, the skin material is set on the mold surface, and connected to an upper mold for mold press molding capable of moving up and down by a predetermined stroke and an injection molding machine to become a material for the resin core material. Consisting of a lower mold for mold press molding with a gate for supplying a semi-molten resin and a hot air supply mechanism provided on the lower mold to control the temperature of the back surface of the resin core material It is characterized by.

[0012]

As is apparent from the above configuration, according to the method of the present invention, after the mold is clamped, the press pressure is applied for a predetermined time, the press pressure is released, and the resin core material is discharged from the outlet of the hot air supply mechanism. If hot air is blown on the back side, the skin material will be compressed, and warm air will be supplied over the entire back surface of the resin core material. The surface temperatures of the front and back surfaces of the core material are substantially equal, and the crystallization speed of the front and back surfaces of the resin core material is also uniform.

Therefore, there is no occurrence of distortion deformation of the resin core material after the mold press molding.

Further, the molding apparatus according to the present invention comprises an upper mold for mold press molding capable of moving up and down, a lower mold for mold press molding connected to an injection molding machine, and a resin core material from a predetermined surface of the lower mold. It is composed of a hot air supply mechanism that blows out hot air to the back side, and in particular, the hot air outlet is designed to prevent resin intrusion and allow only hot air to be blown out. Can be maintained well,
Also, there is no problem with the mold opening operation.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of a method and an apparatus for forming a laminate according to the present invention will be described in detail below with reference to the accompanying drawings.

In the following examples, a laminated molded product applied to an automobile door trim will be described.

FIG. 1 is a front view showing a vehicle door trim to which the present invention is applied, FIG. 2 is a sectional view showing the structure of the vehicle door trim, FIG. 3 is a sectional view showing the entire structure of a molding apparatus according to the present invention, FIG. 4 is a perspective view showing a hot air outlet in a hot air supply mechanism used in the present invention, FIG. 5 is a process chart of the method of the present invention, FIG. 6 is a press mode diagram of an upper die in the method of the present invention, and FIGS. 10 is a sectional view showing each step of the method of the present invention.

First, the structure of an automobile door trim manufactured by the method of the present invention will be briefly described with reference to FIGS.

An automobile door trim 10 is generally constituted by a resin core material 11 formed into a desired curved surface shape and a skin material 12 adhered and integrated on the surface side of the resin core material 11. The core material 11 is formed into a complicated curved shape by mold press molding, which will be described later, using a polypropylene resin mixed with a filler such as talc. When the resin core material 11 is subjected to mold press molding, the skin material 12 ,
The resin core 11 is integrally attached to the front surface side.

Further, as the skin material 12, in this embodiment, a vinyl chloride resin sheet is used as the top layer 12a, and polyethylene foam is used as the foam layer 12b lining the back surface.

The door trim 10 for an automobile is
Even after mold press molding, distortion deformation does not occur,
The initial shape can be maintained for a long period of time, and there is no problem such as hindrance to the workability of mounting on the vehicle body side and interference with a mating part due to deformation after mounting.

Before describing the molding method for molding the automotive door trim 10 which is excellent in dimensional accuracy without distortion and deformation, the configuration of a molding apparatus used for the same will be described with reference to FIG.

That is, the apparatus 20 for forming a laminated molded article used in the method of the present invention comprises a lower mold 30 for mold press molding having a desired mold surface, and a vertically movable The upper mold 40 for mold press molding, which is capable of engaging and clamping to the lower mold 30, and the resin core material 1
Injection molding machine 5 connected to lower mold 30 in order to supply semi-solid resin M serving as material 1 to a predetermined location on the mold surface of lower mold 30.
And a hot air supply mechanism 60 installed in the lower mold 30 to eliminate the temperature difference between the front and back surfaces of the resin core material 11 and to control the crystallization speed on the front and back surfaces equally. I have.

More specifically, the mold surfaces of the upper and lower dies 30 and 40 are set to be substantially equal to the product shape of the door trim 10 for an automobile, and the lower die 30 has an internal shape for supplying material from the injection molding machine 50. Is equipped with a hot runner 31
A gate 32 for distributing and supplying the resin material from the hot runner 31 to a predetermined portion of the lower mold 30 is formed.
Opening and closing valve 33 for controlling the supply timing of the material to the nozzle 2
Is installed.

On the other hand, the upper mold 40 is configured to be able to move up and down by a predetermined stroke by an elevating cylinder 41, and the mold surface of the upper mold 40 is held so as to hold the skin material 12 in close contact with the mold surface of the upper mold 40. A vacuum suction hole 42 is opened at a predetermined location, and this vacuum suction hole 42 is connected to a vacuum pump 44 via a vacuum suction pipe 43.

The vacuum suction tube 43 is provided with an opening / closing valve 45.

Next, the hot air supply mechanism 60 has a hot air outlet 61 provided with a large number of hot air outlets 61a embedded in the lower mold 30. The hot air outlet 61 is connected via a hot air supply pipe 62. It is connected to a blower 63 installed outside the lower mold.

Further, a heater 64 for heating the air from the blower 63 is also provided outside the lower mold 30, and an opening / closing valve 65 for controlling the supply of hot air is provided.

A heat insulating material 66 such as felt or urethane is provided on the outer peripheral surface of the hot air supply pipe 62 so as to prevent the temperature of the hot air from lowering.

The hot air blowing section 61 of the hot air supply mechanism 60
As shown in FIG. 4, in this embodiment, a fine lattice-shaped hot air outlet 61 a is provided, and the hot air
It is sufficient if it is installed in at least one place of the lower mold 30. However, if it is installed in a plurality of places, it becomes easier to heat the back side of the resin core material 11 accordingly.

Next, the outline of the manufacturing process of the door trim 10 for an automobile using the molding apparatus 20 will be briefly described with reference to the flow chart of FIG.
The resin core material 11 and the skin material 12 are integrally formed by mold press molding by setting the upper and lower dies 40 and 50 together.

Thereafter, hot air is blown to the back side of the resin core 11 through the hot air outlet 61 a of the hot air supply mechanism 60 installed in the lower mold 30, and the temperature difference between the front and back surfaces of the resin core 11 is eliminated. After raising the upper mold 40 and taking out the semi-finished product subjected to the mold press molding, the terminal treatment of the skin material 12 may be performed.

Further, the press mode of the upper mold 40 at the time of mold press molding is controlled as shown in FIG. 6, so that the function of the hot air supply mechanism 60 of the present invention is effectively exhibited.

That is, the upper mold 40 descends from the uppermost position to (a), and the semi-molten resin M is supplied between (a) and (b).

Thereafter, the upper die 40 is further lowered from (b) to (c), and the upper and lower dies 30, 40 are clamped.

Thereafter, a press pressure of 80 kg / cm ^{2 is applied} for about 10 seconds from (c) to (d), and the semi-molten resin M
From the resin core material 11.

Then, from (d) to (e), the press pressure of the upper mold 40 is released, and from (e) to (f), 20 to It is blown out for 30 seconds.

Thereafter, the supply of warm air was stopped and the upper mold 40 was maintained in a depressurized state from (f) to (g).
The upper mold 40 starts to rise, and rises to the uppermost position.

The press mode of the upper die 40 is as described above, and the steps (c) to (g) are a shape keeping step for about 40 seconds. Type 4
Release the press pressure of 0, and from (e) to (f)
A characteristic feature is that a warm air blowing step is performed for 30 seconds to uniformly heat the entire back surface of the resin core material 11.

This will be described in detail for each of the steps shown in FIGS.

First, FIG. 7 shows a setting process of the skin material 12, in which the upper mold 40 is located at the uppermost position with respect to the lower mold 30, and the present embodiment is arranged along the mold surface of the upper mold 40. In this case, the preformed skin material 12 is used, but a sheet material that is not preformed may be used as the skin material 12.

When the skin material 12 is set on the mold surface of the upper mold 40, the upper mold 40 is
Vacuum suction acts on the mold surface of the upper mold 40, and the skin material 12 is held in close contact with the mold surface of the upper mold 40.

Thereafter, the operation of the lifting cylinder 41 causes the upper mold 40 on which the skin material 12 has been set to move downward by a predetermined stroke, and the clearance between the upper mold 40 and the lower mold 30 to a predetermined value of 10 to 50 mm (see FIG. 6 (a position indicated by (a)), as shown in FIG.
The semi-solid resin M is distributed and supplied to a predetermined portion of the mold surface of the lower mold 30 through the hot runner 31 and the gate 32.

Thereafter, as shown in FIG. 9, the upper mold 40 descends to the bottom dead center and descends to the position (c) shown in FIG. 6, and the resin core material 11 is press-molded into a required shape. Then, the skin material 12 is integrated with the surface side of the resin core material 11.

At this moment, a temperature difference exists between the surface sides 11a and 11b of the resin core material 11.

Thereafter, the mold clamping state shown in FIG.
After maintaining the pressure for about second, the press pressure of the upper mold 40 is released, and at the same time, the hot air is supplied through the hot air supply mechanism 60 and the hot air outlet 61 a of the hot air outlet 61 a, and the back side 11 b of the resin core material 11 is released.
Spray.

Therefore, since the press pressure from the upper mold 40 is released, the resin core 11 is moved between the lower mold 30 and the lower mold 30 by the warm air pressure from the warm air blowing unit 61 as shown in FIG. A slight clearance is generated, and warm air spreads along the clearance, and the back side 11b of the resin core material 11 is formed.
The whole is heated to a predetermined temperature.

The temperature of the hot air at this time is 80 to 90 ° C.
In the press mode shown in FIG. 6, this hot air supply step is performed for 20 to 30 seconds between (e) to (f).

Thereafter, the supply of warm air is stopped, and after a certain period of time, the upper mold 40 is lifted to open the mold, and a semi-finished product comprising the resin core material 11 and the skin material 12 integrated into a required shape by mold press. Is taken out of the molding device 20 and the skin material 12
Is wound around the back side of the resin core material 11 to complete the manufacture of the automobile door trim 10 shown in FIGS.

As described above, according to the method of the present invention, when the resin core material 11 and the skin material 12 are subjected to mold press molding, hot air is supplied over the entire back surface 11b of the resin core material 11 The surface temperature of the front surface 11a and the back surface 11b of the resin 11 can be controlled substantially uniformly, the crystallization speed of the resin core material 11 can be made the same on both the front and back surfaces, and the cause of distortion after molding can be reliably eliminated. Door trim with excellent dimensional accuracy 1
There is an advantage that mass production of 0 is possible.

When the hot air outlet 61a of the hot air blowing section 61 in the hot air supply mechanism 60 is set in the range of 0.1 to 0.5 mm, the semi-molten resin M does not flow backward, and only the hot air flows. Can be effectively blown out, does not cause any hindrance to press molding, and has no problems such as the mold opening cannot be performed smoothly as in the conventional measures to raise the mold temperature. By disposing the hot air supply mechanism 60 in the mold 30 and effectively controlling the press mode of the upper mold 40, distortion deformation of the resin core material 11 can be prevented as much as possible.

When a plurality of hot air blowing portions 61 in the hot air blowing mechanism 60 are provided, the blowing time of the hot air can be reduced, and the hot air can reach every corner of the back surface 11b of the resin core material 11. No variation occurs throughout.

[0053]

As described above, according to the method of the present invention, when the resin core material and the skin material are integrally formed by the mold press molding die, the press pressure is released once after the upper and lower dies are clamped. By blowing hot air from the hot air supply mechanism provided on the mold to the back side of the resin core, the back side of the resin core can be heated to the same temperature as the front side within almost the same molding time as before, Since it is possible to surely prevent the occurrence of distortion deformation after molding on the core material, it is possible to mass-produce a laminated molded body having excellent dimensional accuracy without the need for a conventional deformation correction step and the like. At the time of mounting work on the vehicle body side, it is possible to effectively solve problems such as distorting deformation, which hinders mounting work, and after mounting work, deformation and interference with a mating part or the like due to deformation.

Further, according to the molding apparatus of the present invention, a hot air supply mechanism is added to the conventional mold press molding apparatus, and the hot air supply mechanism includes a hot air supply means such as a blower and a heater. And to provide a hot air blowing portion having a hot air outlet of a predetermined size installed in the lower mold,
It can be easily applied, and it can be easily applied to conventional molding dies, such as being able to effectively blow only hot air without resin backflow.It does not affect molding accuracy or press operation, so it is practical. It has the effect of being excellent.

[Brief description of the drawings]

FIG. 1 is a front view showing an automobile door trim which is an example of a laminated molded article formed by the method of the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a cross-sectional view showing the overall configuration of a molding device for a laminated molded product according to the present invention.

FIG. 4 is a perspective view showing a configuration of a hot air blowing section in the molding apparatus shown in FIG. 3;

FIG. 5 is a process chart in which the method of the present invention is applied to a method of manufacturing an automobile door trim.

FIG. 6 is a press mode diagram of an upper die in the method of the present invention.

FIG. 7 is a cross-sectional view showing a step of setting a skin material in an embodiment in which the method of the present invention is applied to a door trim molding method.

FIG. 8 is a cross-sectional view showing a process of supplying a semi-molten resin in an embodiment in which the method of the present invention is applied to a door trim molding method.

FIG. 9 is a sectional view showing a step of clamping the upper and lower dies in an embodiment in which the method of the present invention is applied to a method of forming a door trim.

FIG. 10 is a cross-sectional view showing a hot air blowing step in an embodiment in which the method of the present invention is applied to a door trim molding method.

FIG. 11 is a sectional view showing a configuration of a conventional automobile door trim.

FIG. 12 is a sectional view showing a step of setting a skin material in a conventional door trim mold press molding method.

FIG. 13 is a sectional view showing a mold press molding step in a conventional mold press molding method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Automobile door trim 11 Resin core material 11a Front side 11b Back side 12 Skin material 20 Molding device 30 Lower mold for mold press molding 32 Gate 40 Upper mold for mold press molding 41 Cylinder for raising and lowering 50 Injection molding machine 60 Hot air supply mechanism 61 Hot air outlet 61a Hot air outlet 62 Hot air supply pipe 63 Blower 64 Heater 65 Open / close valve 66 Insulation material

Claims (3)

(57) [Claims] 1. A mold for mold press molding (30, 40).
A resin core material (11) formed by molding a semi-molten resin (M) into a required shape in the inside, and a skin material that covers the surface of the resin core material (11) during mold press molding of the resin core material (11) (1
2) In the method of forming a laminated molded body, the upper mold (40) on which the skin material (12) is set is lowered by a predetermined stroke, and semi-fused at a predetermined position on the mold surface of the lower mold (30). The resin (M) is distributed and supplied, and then the upper mold (40) is lowered to the bottom dead center, the upper and lower molds (30, 40) are clamped for a predetermined time, and a resin core material (11) is formed. Then, the press pressure of the upper mold (40) is released, and the lower mold (30) is released.
By blowing hot air from the hot air supply mechanism (60) installed on the entire surface of the resin core material (11), the temperature of the front and rear surfaces of the resin core material (11) is controlled substantially uniformly. A method for forming a laminate. 2. A mold for mold press molding (30, 40).
A resin core material (11) formed by molding a semi-molten resin (M) into a required shape in the inside thereof, and a skin covering the surface side of the resin core material (11) during mold press molding of the resin core material (11). In a molding apparatus of a laminated molded body composed of a material (12), the molding apparatus (20) sets a skin material (12) on a mold surface, and is capable of moving up and down by a predetermined stroke. 40) and a lower die (30) for mold press molding, which is connected to an injection molding machine (50) and is provided with a gate (32) for supplying a semi-molten resin (M) as a material of a resin core material (11). ) And a hot air supply mechanism (6) provided on the lower mold (30) to control the temperature of the back surface of the resin core material (11).
0). An apparatus for forming a laminated molded article, comprising: 3. A hot air supply mechanism (60) serves as a blower (63) for supplying air, a heater (64) for heating the air to a predetermined temperature, and a passage for hot air supplied from the blower (63). The hot air supply pipe (62) and the lower mold (30) are installed at predetermined locations and blow hot air on the back surface of the resin core material (11).
Hot air blow-out part (61) for preventing backflow of semi-solid resin (M)
The molding apparatus for a laminated molded article according to claim 2, comprising: