JP3148064B2 - Composite skin integral molding method and apparatus therefor - 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 for forming a multilayer molded product in which a composite skin material is bonded to the surface of a core layer made of a thermoplastic resin, and more particularly to a composite material which can be suitably applied to interior materials for automobiles. The present invention relates to a method and an apparatus for integrally forming a skin.

[0002]

2. Description of the Related Art In general, for automobile interior parts, multilayer molded articles in which various skin materials are bonded to a surface of a base material made of a thermoplastic resin are frequently used. This multilayer molded product is formed by placing a skin material between opposed molds, clamping the mold, injecting a molten synthetic resin between the skin material and one of the molds, and performing compression molding or the like. I have. In order to provide a sense of quality in the interior of the automobile, a multi-layer molded product using a composite skin is used in which a skin material is joined to the entire surface of the base material, and another skin material is partially joined from above the skin material. Sometimes.

[0003]

Conventionally, in order to integrally join the above-mentioned composite skin material and the base material integrally, first, the base material and the whole surface skin material are integrally joined by compression molding or the like, and then the base material is integrally joined. 2. Description of the Related Art There are known techniques for joining a partial skin material with an adhesive from above a full surface skin material integrated with a material and attaching a separate molded product.

[0004] However, the joining of the partial skin material from the entire surface skin material integrated with the base material in a separate step is not possible because the partial skin material or the separate skin material is a separate skin material from the already formed predetermined shape. The joining of the molded products has a disadvantage that the joining process is complicated and troublesome, and the processing cost is increased.

An object of the present invention is to simultaneously and integrally mold a plurality of skin materials such as PVC and cloth on interior molded products such as door trims to reduce the number of processes and reduce costs.
An object of the present invention is to provide a composite skin integral molding method and an apparatus for integrally molding a composite skin and a base material that have improved bonding strength and do not affect the environment by eliminating an adhesive.

[0006]

According to a first aspect of the present invention, there is provided a composite skin integral molding method, wherein an end of a skin material and an end of a skin material different from the skin material are joined to each other at a groove of a base material. In a composite skin integral molding method for integrally joining two or more kinds of skin materials to a material, a movable mold facing a fixed mold for injecting a molten resin as a base material and a movable mold adjacent to the movable mold, respectively. Is disposed, and a step of setting a skin material on each of the movable molds, and injecting a molten resin into a cavity in which a groove corresponding to the skin material terminal is formed, press-clamping the skin material and the base material. And a first molding step in which one surface side of the terminal of the skin material is joined by a groove of the cavity with resin, and a skin material different from the skin material joined in the first molding step after the first molding step. Inject molten resin to the place where it is placed and press the mold Wherein while molding the skin material different surface material and the base material, it is bonded to one side of the terminal of the different skin material by resin groove cavity Te, further wherein the first
A resin positioned in the groove by the molding step, and a second molding step in which the skin material portion on the side opposite to the base material is brought into contact with each other and joined to the injected resin. I do.

According to a second aspect of the present invention, there is provided a composite skin-integral molding apparatus, wherein two or more kinds of terminals of the skin material and ends of the skin material different from the skin material are joined to each other at the groove of the base material. In a composite skin integral molding apparatus for integrally joining skin materials, a fixed mold for injecting a molten resin as a base material, a plurality of movable molds respectively opposed to the fixed mold, and a movable mold corresponding to each movable mold. A plurality of gates, a protrusion formed at a boundary between the movable molds, and a groove formed in a fixed mold corresponding to the protrusion, and a skin material to be formed first. In order to mold the molten resin, the movable mold is moved and clamped, and at the same time, the molten resin is injected from the fixed mold facing the movable mold, and the mold is pressed to form the skin material and the base material. In the groove on the mold side, join one side of the skin material terminal with resin,
To move the movable mold to mold the next skin material and the molten resin, clamp the mold and inject the molten resin from the fixed mold facing the movable mold, press the mold and apply a different skin material to the skin material. The method is characterized in that a base material is molded, one end of a terminal of the skin material different from the above is joined with a resin in a groove of a fixed mold, and a molten resin located in the groove is joined.

[0008]

An embodiment of the present invention will be described below with reference to the drawings. The members, arrangements, and the like described below do not limit the present invention, and can be variously modified within the scope of the present invention.

[0009] FIGS. 1-4 are intended to show an embodiment according to claims 1 and 2 of the present invention, FIGS. 1-3 apparatus and a cross-sectional view and a partially enlarged view of a step, Fig. 4 is the skin material It is a top view showing an example. The composite skin integral molding apparatus is an apparatus for joining two or more kinds of skin materials integrally to the base material by joining the ends of the skin material and the ends of the skin material different from the skin material in the grooves of the base material. is there. The composite skin-integrated molding apparatus S of the present embodiment includes a fixed mold 10, a plurality of movable molds (core movable mold 20, main movable mold 30), a plurality of gates 11, and a protrusion 2
1 and the groove 12 are main components.

In this example, for the sake of simplicity of description, a door trim is taken as an example of a molded product.
As shown in FIG. 4, a description will be given using an example in which a partial skin material 42 is arranged near a substantially central position of the entire skin material 41. For this reason, the movable mold for holding the partial skin material 42 and integrally molding the partial skin material 42 and the base material is referred to as the core movable mold 20, and the core movable mold 20 is held, and the entire surface skin material 41 is held. The movable mold for integrally molding the entire skin material 41 and the base material while holding the main body will be described as the main movable mold 30.

[0011] As the material of the skin material 41 and 42 used in the present invention, woven fabric, non-woven, polyolefin, polyvinyl chloride, thermoplastic resin and a polyolefin such as nylon,
Examples include sheets and films of thermoplastic elastomers such as polyester, urethane, and vinyl chloride. Further, the above materials may be used alone or as a laminate of two or more kinds as the skin material.

In order to give a softer touch, a foamed sheet of polypropylene, polyethylene, urethane or the like is bonded to the back surface of the skin material to protect it from the heat of the molten resin during molding, or to cover the skin material with the core material layer. For the purpose of enhancing the adhesive strength, a laminate in which a cloth or a sheet or the like is stuck on the back surface can also be used. In using these skin materials, preheating may be performed prior to supply in order to adjust the tensile stress and elongation of the skin material.

The resin J used as a base material in the present invention is:
For example, polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, thermoplastic resin such as nylon, ethylene-propylene block copolymer, thermoplastic elastomer such as styrene-butadiene block copolymer, compression molding, injection, etc. Any of those usually used for molding and extrusion can be used. In addition, those containing additives such as an inorganic filler, a filler pigment such as glass fiber, a lubricant, and an antistatic agent can be appropriately used.

[0014] stationary die 10 of this embodiment is for injecting a molten resin J serving as a base material, a plurality of gates 11 are formed. These gates 11 are provided with a movable core mold 20 described below.
The main movable mold 30 is adjusted by a valve gate so that the molten synthetic resin J is injected with a time difference. In this fixed mold 10, a groove 12 into which a projection 21 of the core movable mold 20 described below can be inserted is formed at a boundary between the movable core mold 20 and the main movable mold 30 during mold clamping. Have been.

The stationary mold 10 of the present embodiment is provided with a desired mold shape, on the outer periphery of this type shape, the skin material-holding frame that holds the entire skin material 41 (not shown) is arranged . The entire skin material 41 is held by the skin material holding frame.
An extruder or an injection molding machine (not shown) is attached to the stationary mold 10 of the present embodiment, and the synthetic resin J in a molten state is supplied from the extruder or the injection molding machine to the stationary mold 10.
Is supplied on the mold surface. In addition, the attachment of the full-surface skin material 41 can be constituted by vacuum suction or the like instead of the frame.

A core movable mold 20 and a main movable mold 30 are disposed opposite to the fixed mold 10. The outer periphery of the movable core mold 20 is formed as a projection 21 so that it can be inserted into the groove 12 of the fixed mold 10. This projection 21
A needle or the like for holding the partial skin material 42 is formed at the tip of the. A partial skin material 42 is attached to the core movable mold 20, and the core movable mold 20 is configured to be movable on the main movable mold 30 by a driving mechanism (not shown) or the like. As the driving mechanism, known means such as a hydraulic device, a pneumatic device, and a spring type can be used. For example, when using a spring system, 20 to 80 kgf / cm ²
Adjust so that Further, the main movable mold 30 is also configured to be movable by a drive mechanism (not shown) or the like, and performs the mold clamping movement at a later timing than the core movable mold 20.

Next, the composite skin integral molding method will be described using a composite integral skin molding apparatus S having the above structure. First, the partial skin material 42 is attached to the core movable mold 20 which is disposed to face the fixed mold 10, and further, the entire skin material 41 is attached to the main movable mold 30. In order to attach the entire surface material 41 to the main movable mold 30, the entire surface material 41 is attached to the above-described surface material attachment frame or the like. The mounting order of the partial skin material 42 and the entire skin material 41 is not particularly limited.

[0018] Then conduct a first molding step for molding of the partial surface material 42 and the substrate. This first molding step is shown in FIG.
As such, core movable mold fitted with a partial skin material 42 20
Is moved toward the fixed mold 10 facing the movable mold 20, and the molten resin J is injected into the cavity from the gate 11 facing the core movable mold 20, and the mold is pressurized and pressed to form the base material 42 and the base material 42. The material is molded. At this time, partial skin material 4
The end of the terminal 2 is attached to the protrusion 21 of the core movable mold 20, so that one surface side of the partial skin material 42 is made of resin J.
Is pushed into the groove 12 while being abutted.

In the course of the first molding step, a second molding step is performed. That is, as shown in FIG. 2 , the entire skin material 4 which is a skin material different from the partial skin material 42 joined in the first molding step.
The main movable mold 30 to which 1 is attached is moved. Also at this time, the molten resin J is injected from the gate 11 of the fixed mold 10 facing the main movable mold 30, and the entire surface skin material 41 and the base material are molded by clamping and pressing.

At this time , as shown in FIG. 3, one surface side of the entire surface material 41 of the groove portion 12 is joined with the resin J, and at the same time, the end portion of the entire surface material 41 is projected by the projection 21 of the core movable mold 20. The portion is pushed into the groove portion 12, and the tip portion of the portion comes into contact with the resin J injected in the first molding step and is held at the position of the groove portion 12. The gate 11 of the fixed mold 10 facing the entire surface material 41 in a state where the resin J located in the groove 12 and the surface material portion on the opposite side to the base material are brought into contact with each other by the first molding step. Is joined to the resin J injected from the substrate.

With the above construction, it is possible to simultaneously and integrally mold two or more kinds of skin materials and a base material on an interior molded product such as a door trim. By performing the two-stage molding process, it is possible to prevent cloth displacement and improve the quality of the product.

5 to 8 are process sectional views showing a composite skin integral molding method different from the method of the present invention . FIG. 5 shows a state in which the molten resin J is injected into the fixed mold 10 together with the start of mold clamping. FIG. 6 shows a state in which the molten resin J has leached from the entire skin material 41 toward the partial skin material 42 just before the movable mold and the fixed mold 10 come into contact with each other, and FIG. 7 shows a state in which mold clamping is completed. 8 shows a state where the mold is opened. Note that the same reference numerals are given to the same arrangements and members as in the embodiment according to the present invention, and description thereof will be omitted.

In the method for integrally forming a composite skin in this embodiment, a skin material (entire skin material) 41 and a skin material (partial skin material) 42 different from the skin material 41 are joined together with the same base material to form a base material. This is a method for forming a composite skin integrated molded article in which two or more skin materials are integrally joined. In the above-described embodiment, an example in which the movable core mold 20 is used is shown. However, in this example, the portion of the movable core mold 20 is not used as the position where the partial skin material 42 is disposed. It is to be molded.

[0024] That is, to set the entire skin material 41 between the movable mold 30 arranged to face the stationary mold 10 for injecting a molten resin J serving as a base material. This full-surface skin material 41 has a number of small holes 4 at a position corresponding to the position where the partial skin material 42 is disposed.
3 is formed. A known means such as a skin material holding frame or the like can be used for disposing the entire skin material 41. Next, the partial skin material 42 is doubly arranged in the movable mold 30 at the position where the small holes 43 of the entire skin material 41 are formed. The set of the partial skin material 42 corresponds to the partial skin material 42 of the movable mold 30.
A projection can be formed on the outer periphery of the arrangement position of, and can be attached to this projection.

[0025] Then, as shown in FIGS. 5 to 8, pressure injection and mold clamping pressure to the molten resin J into the cavity while moving the movable mold 30. By doing so, the molten resin J injected into the mold surface of the fixed mold 10 due to mold clamping pressure or the like.
Oozes out from the small hole 43 of the entire skin material 41 toward the partial skin material 42 side. Then, the partial skin material 42 and the entire skin material 41 are joined via the leached molten resin J, and the base material and the full skin material 41 are joined and integrally formed.

[0026]

As described above, according to the present invention, for an interior molded product such as a door trim including a composite skin material and a base material, a plurality of skin materials such as PVC and cloth are simultaneously integrally laminated and formed. It is possible to provide a composite skin integral molding method and an apparatus for integrally molding a composite skin and a base material, in which the number of steps is reduced to reduce the cost, the adhesive is eliminated, and the environment is not affected, and the bonding strength is improved without increasing the bonding strength.

[Brief description of the drawings]

FIG. 1 is a sectional view and a partially enlarged view of an apparatus and a process according to claims 1 and 2;

FIG. 2 is a sectional view and a partially enlarged view of an apparatus and a process according to claims 1 and 2;

FIG. 3 is a sectional view and a partially enlarged view of an apparatus and a process according to claims 1 and 2;

FIG. 4 is a plan view showing an example of a skin material.

FIG. 5 is a process sectional view showing another composite skin integral molding method.

FIG. 6 is a process sectional view showing another composite skin integral molding method.

FIG. 7 is a process sectional view showing another composite skin integral molding method.

FIG. 8 is a process sectional view showing another composite skin integral molding method.

[Explanation of symbols]

 Reference Signs List 10 Fixed mold 11 Gate 20 Movable mold (moveable core mold) 41 Full skin material 42 Partial skin material 43 Small hole J Synthetic resin

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification code FI // B29L 9:00 31:58

Claims (2)

(57) [Claims] 1. A composite skin integral molding in which an end of a skin material and an end of a skin material different from the skin material are joined to each other at a groove of the base material to integrally join two or more types of skin materials to the base material. In the method, a movable mold facing a fixed mold for injecting a molten resin serving as a base material and a movable mold adjacent to the movable mold are disposed, and a skin material is set on each of the movable molds. Injecting the molten resin into the cavity in which the groove corresponding to the skin material terminal is formed, molding and pressing the mold to form the skin material and the base material, and forming one surface side of the skin material terminal with the resin. A first molding step of joining at the groove portion, and after the first molding step, a molten resin is injected into an arrangement position of a skin material different from the skin material joined at the first molding step, and a mold clamping pressure is applied to the skin material. While molding different skin materials and base materials, One surface side of the terminal of the skin material is joined to the groove portion of the cavity by the resin, and further, the resin positioned in the groove portion by the first molding step and the skin material portion on the opposite side to the base material are brought into contact with each other, A second molding step of joining with the injected resin. 2. A composite skin integral molding in which an end of the skin material and an end of the skin material different from the skin material are joined to each other at a groove of the base material to integrally join two or more kinds of skin materials to the base material. In the apparatus, a fixed mold for injecting a molten resin serving as a base material, a plurality of movable molds respectively opposed to the fixed mold, a plurality of gates disposed corresponding to each movable mold, A projection formed at the boundary of the movable mold and a groove formed in the fixed mold corresponding to the projection are provided, and the movable mold is used to mold the skin material to be molded first and the molten resin. The mold is movable and clamped, and molten resin is injected from a fixed mold facing the mold, and the mold is pressed to form a skin material and a base material, and one surface of the end of the skin material is formed in the groove on the fixed mold side. The sides are joined with resin, and the movable mold is moved and clamped to mold the next skin material and molten resin Along with this, a molten resin is injected from a fixed mold facing the mold, a mold material is pressed to form a skin material and a base material different from the skin material, and the terminal of the skin material different from the above is formed in the groove of the fixed mold. A composite skin integral molding apparatus characterized in that one surface side is joined with a resin and the molten resin located in the groove is joined.