JP3280271B2 - Molding method of laminated molded body - 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 laminate suitable for an automobile interior part such as an automobile door trim.

[0002]

2. Description of the Related Art FIG. 10 is a longitudinal sectional view showing a molded product formed by a conventional method for forming a laminated body. The resin core material 1 is formed into a substantially U-shape and the surface of the core material 1. Is composed of a skin material 2 covering the entire surface.

When such a molded article is an automobile door trim, which is one of the interior parts for automobiles, the resin core material 1 is configured to have shape retention and rigidity for attachment to a vehicle body panel. The skin material 2 is configured to provide decorativeness and cushioning properties.

As a method of manufacturing such a molded article, there is a tendency that a mold press molding method excellent in moldability is frequently used. In this method, as shown in FIG. And a molding device having one lower mold 5. Of the pair of upper molds 3 and 4, the first upper mold 3 is used for molding the resin core material 1 and the second upper mold 3
The upper mold 4 is used for molding the skin material 2.

First, the first mold 3 and the lower mold 5 are used, and when the upper and lower molds 3 and 5 are opened, the mold surface of the lower mold 5 is moved from the first resin injection machine installed on the lower mold 5. A first semi-molten resin serving as a material of the resin core material 1 is supplied to a predetermined location. At this time,
The gate 7a of the second resin injection machine 7 that supplies the second semi-molten resin forming the skin material 2 protrudes from the mold surface of the lower mold 5 by a predetermined height. Then, while lowering the first upper mold 3 to the bottom dead center, the first semi-molten resin is molded with a predetermined press pressure to form the resin core material 1 having a required shape (FIG. 11 ( 1)).

Thereafter, the first upper mold is moved by opening the mold, and the second upper mold 4 is used next (FIG. 11).
(2)) First, after lowering the gate 7a of the second resin injection machine 7 to the mold surface of the lower mold 5, the second resin is placed on the resin core material 1 formed in the resin core material forming step. A second semi-molten resin serving as a material of the skin material is supplied from an injection machine, and then the second upper mold 4 is lowered to propagate the second semi-molten resin by applying a predetermined press pressure. The skin material 2 is molded (FIG. 11 (3)).

[0007]

However, in such a conventional method of forming a laminate, the upper die is
Since two upper dies, that is, a first upper die 3 for molding the resin core material 1 and a second upper die 4 for molding the skin material 2 are used, the size of the equipment itself increases and the mold cost increases. But not
It requires a slide mechanism to move the two upper dies 3, 4,
The equipment is further increased in size, and the moving time of the two upper dies 3 and 4 required for the transition between the resin core material forming step and the skin material forming step is required, and the molding time is increased accordingly.

Accordingly, the present invention has been made by focusing on such a conventional technique, and a method of forming a laminated body which aims at miniaturization of equipment, reduction of mold cost, and shortening of molding time has been achieved. It is intended to provide.

[0009]

According to a first aspect of the present invention, a laminate formed by covering the entire surface or a part of the surface of a resin core material with a skin material is formed by mold press molding. In the method of forming a laminated molded body, at the time of opening the pair of upper and lower molds for mold press molding, after installing a thin plate jig that is preformed approximately in the same shape as the skin material, on the skin material forming portion of the upper mold. Supplying a first semi-molten resin serving as a material of the resin core material from a first resin injection machine to a predetermined surface of the lower mold, and lowering the upper mold to a bottom dead center, The semi-molten resin is molded at a predetermined press pressure, and a resin core material forming step of forming a resin core material of a required shape, and thereafter, the upper mold is opened, and the thin plate jig is removed from the upper mold. Then, a second resin injection machine is used to form the skin material. The semi-solid resin is supplied, the upper mold is lowered, and the second semi-solid resin is removed from the thin plate jig and a predetermined press pressure is applied to a skin material molding cavity formed between the upper and lower molds. And a skin material forming step of molding the skin material.

According to a second aspect of the present invention, there is provided a laminated molded article formed by covering the whole or a part of the surface of a resin core material with a skin material formed so as to surround the insulated material. In the method of molding a laminated molded article molded by press molding, when opening a pair of upper and lower molds for a pair of mold press moldings, the skin material forming portion of the one mold has substantially the same shape as the skin material. After installing the preformed thin plate jig and installing the preformed intermediate material at the intermediate material installation site in the resin core material, the first resin injection machine sends a predetermined mold surface of the other mold. A first semi-molten resin serving as a material of the resin core material is supplied to a location, and the first semi-molten resin is molded at a predetermined press pressure while lowering one mold to a bottom dead center. A resin core forming step of forming a resin core of a required shape; Then, one of the molds is opened, the thin jig is removed from one of the molds, and a second resin injection machine is used to remove the thin plate jig from the second resin injection machine to the second surface. The semi-solid resin is supplied, and one mold is lowered, and the second semi-solid resin is removed from the pair of upper and lower molds after removing the thin plate jig in the skin material forming cavity. A skin material forming step of molding the skin material by applying a predetermined press pressure to the periphery of the insulated material to propagate the material.

As a result, in the resin core material forming step, a thin plate jig that is preliminarily formed in substantially the same shape as the skin material is set and placed in the skin material forming portion of one of the molds. Even if the mold clamping stroke of the pair of upper and lower molds is the same as the mold clamping stroke in the resin core material molding step, a molding cavity for the skin material is formed between the pair of upper and lower molds, and together with the other mold, One mold is used for both the resin core material forming step and the skin material forming step.

Here, as a target to which the laminated molded article is applied, interior parts for automobiles such as door trims and rear corner trims for automobiles are suitable.

As the resin core material, a hard general-purpose synthetic resin,
For example, a PP resin mixed with an inorganic filler such as a PP resin, talc, and an ABS resin may be used.

As the skin material, soft thermoplastic synthetic resin, synthetic rubber such as T
Moldable soft materials such as PO (thermoplastic olefin), TPU (thermoplastic urethane), and TPS (thermoplastic styrene) can be used.

[0015]

Embodiments of the present invention will be described below in detail with reference to the drawings.

(Embodiment 1) FIG. 1 is a perspective view showing an automobile door trim which is a laminated body formed by a method according to an embodiment of the present invention, and FIG.
It is -A sectional drawing.

In FIG. 1 and FIG. 2, a door trim 10 for an automobile has a resin core material 11 formed into a desired curved shape.
And a skin material 12 integrally adhered to a part of the surface of the resin core material 11 (there may be the entire surface).

More specifically, the resin core material 11 is made of a polypropylene resin mixed with a filler such as talc or the like, and is formed into a complicated curved shape by mold press molding, which will be described later. Press molding is performed using a relatively elastic material such as a soft resin such as TPO (thermoplastic olefin) or a thermoplastic material such as synthetic rubber.

Next, a case where the above-described door trim 10 for an automobile is formed by the method according to the embodiment of the present invention will be described with reference to FIGS.

This mold press molding apparatus comprises: an upper mold 14 for mold press molding having a desired mold surface shape; a lower mold 15 for mold press having substantially the same mold surface;
A first resin injection machine 19 that supplies a first semi-molten resin 17 as a material of the resin core material 11 and a second resin injection machine that supplies a second semi-molten resin 18 as a material of the skin material 12 20.

The present method is carried out by using the mold press forming apparatus configured as described above. In this method, a pair of upper mold 14 and lower mold 15 are used as mold press molding dies. With the upper mold 14 and the lower mold 1
5, when the resin core material 11 is molded,
It is characterized in that a thin plate jig 13 which is formed in substantially the same shape as the shape 2 is used.

The thin plate jig 13 is formed by molding a metal plate such as aluminum or brass or a resin plate, and when a clearance between upper and lower dies described later is about 5 mm,
A thin plate having a thickness of about 2.5 mm is used.

In this embodiment, first,
The resin core material 11 is formed. First, a pair of upper and lower molds 14 and 15 for mold press molding are opened, and the skin material 1 is formed on the skin material forming portion 16 of the upper mold 14.
A thin plate jig which is preliminarily formed to have the same shape as that of No. 2 is installed (FIG. 3).

Thereafter, the lower mold 1 is moved from the first resin injection machine 19.
The first semi-molten resin 17 serving as the material of the resin core material 12 is supplied to a predetermined portion of the mold surface 5 to lower the upper mold 14 to the bottom dead center. As a result, the first semi-molten resin 17 is molded at a predetermined press pressure, and the resin core material 11 having a required shape is formed.
(FIG. 4 (resin core material forming step)).
Thereafter, the upper mold 14 is opened, and the thin plate jig 13 is removed from the upper mold 14 (FIG. 5).

Next, the second resin injection machine 20 sends the skin material 1
The second semi-solid resin 18 serving as the second material is supplied. In this case, when molding the resin core 11, the gate 20 a of the second resin injection machine 20 protrudes from the mold surface of the lower mold 15 by the thickness of the resin core 11, and as a result, the resin core 11 Since the through-hole 21 is formed at a position corresponding to the gate 20 a, the second semi-molten resin 18 is supplied onto the resin core 11 through the through-hole 21.

Thereafter, the upper mold 14 is again lowered, and the second
After removing the semi-solid resin 18 from the thin plate jig 13, a predetermined press pressure is applied to the skin material forming cavity formed between the upper and lower dies 14 and 15, and the skin material 12 is molded. Thereafter, the upper mold 14 is lifted to open the mold, and after a predetermined solidification time has elapsed, the automobile door trim 10 is completed (FIG. 6 (skin material forming step)).

As a result, in the resin core material forming step, a thin plate jig 13 which is preliminarily formed in the same shape as the skin material 12 is set and placed in the skin material forming portion of the upper mold 14. Even when the mold clamping stroke of the upper and lower molds 14 and 15 is the same as the mold clamping stroke in the resin core material molding step, a molding cavity for the skin material 12 is formed between the upper and lower molds 14 and 15 during the molding. That means
One upper mold 14 together with the lower mold 15 can be used for both the resin core material forming step and the skin material forming step.

(Embodiment 2) FIG. 7 is a perspective view of an automobile door trim according to Embodiment 2 of the present invention, and FIG.
FIG.

The door trim 30 for an automobile is different from the door trim 10 of the first embodiment in that an intermediate member 33 is provided so as to surround a skin material 32.

However, when molding the door trim 10 for an automobile, first, the resin core material forming step of forming the resin core material 11 is the same as in the first embodiment.

Thereafter, the skin material molding step is started. When the upper mold 14 is opened, the insulative material 33 is placed on the lower mold 15 in advance with the resin core material placed thereon. 11 in that they are placed at predetermined locations.

After the intermediate material 33 is placed, the gate 20a of the second resin injection machine 20 is lowered to the mold surface of the lower mold 15 as shown in FIG. The second embodiment is the same as the first embodiment in that the second semi-molten resin 18 serving as the material of the skin material is supplied from 20 to the already formed resin core material 11 to form the skin material 32.

However, in the skin material forming step, since the insulative material 33 is previously present at a predetermined location of the molding cavity of the skin material 12 formed by the thin plate jig 13, the second material is provided at this portion. The semi-solid resin 18 does not propagate, and the door trim 30 having the skin material 32 surrounding the intermediate material 33 is formed.

In the skin material forming step, the molding cavity of the skin material 12 is formed by the resin core material 11 and the upper mold 14.
The lower mold 15 is configured to be sealed by contact with the lower mold 15.

As the inlay material 33, a leather material, a cloth material, a soft synthetic leather material, or the like is usually used.

[0036]

According to the present invention, in the resin core material forming step, a thin plate jig that is preliminarily formed in substantially the same shape as the skin material is installed and placed on the skin material forming portion of one of the molds.
At the time of molding the skin material, even if the mold clamping stroke of the pair of upper and lower molds is the same as the mold clamping stroke in the resin core material molding step, a cavity for molding the skin material is formed between the pair of upper and lower molds. One mold can be used together with the other mold for both the resin core material forming step and the skin material forming step.

As a result, according to the present invention, since two types of upper dies are not used unlike the conventional case, the equipment can be reduced in size and the mold cost can be reduced, and the conventional upper die can be moved. By omitting, the molding time can be shortened.

[Brief description of the drawings]

FIG. 1 is a perspective view of an automobile door trim formed by a forming method according to a first embodiment of the present invention.

FIG. 2 is a sectional view taken along the line AA in FIG.

FIG. 3 is a vertical cross-sectional view of a molding apparatus when a thin jig is installed on an upper mold when the mold is opened in the molding method according to the first embodiment of the present invention.

FIG. 4 is a longitudinal sectional view of a molding apparatus showing a molding step of the resin core material in the molding method according to the first embodiment of the present invention.

FIG. 5 is a longitudinal sectional view of the molding apparatus when a thin jig is removed when the mold is opened after molding the resin core material in the molding method according to the first embodiment of the present invention.

FIG. 6 is a longitudinal sectional view of a molding apparatus showing a molding step of the skin material in the molding method according to the first embodiment of the present invention.

FIG. 7 is a perspective view of an automobile door trim formed by a forming method according to a second embodiment of the present invention.

FIG. 8 is a sectional view taken along the line AA in FIG.

FIG. 9 is a longitudinal sectional view of a molding apparatus showing a molding step of a skin material in a molding method according to a second embodiment of the present invention.

FIG. 10 is a longitudinal sectional view of a laminated molded product formed by a conventional forming method.

11 is a longitudinal sectional view of a molding apparatus used in a conventional molding method, wherein (1) is a resin core material forming step, (2) is a process of shifting from the resin core material forming step to a skin material forming step, and (3). ) Indicate the skin material forming step.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Door trim (laminated molded body) 11 Resin core material 12 Skin material 13 Thin plate jig 14 Upper mold (one mold) 15 Lower mold (the other mold) 16 Skin material forming part 17 First semi-molten resin 18 2 semi-solid resin 19 1st resin injection machine 20 2nd resin injection machine

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-3-247423 (JP, A) JP-A-5-131474 (JP, A) JP-A-9-300389 (JP, A) 61322 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 43/14-43/20 B29C 43/32-43/44 B29C 45/14-45/16 B29C 45/37 , 33/42 B32B 31/20

Claims (3)

(57) [Claims] 1. A method of forming a laminated molded product by molding a laminated molded product formed by covering the entire surface or a part of the surface of a resin core material with a skin material using mold press molding. At the time of opening the pair of upper and lower molds for press molding, a thin plate jig which is preliminarily formed in substantially the same shape as the skin material is placed on the skin material forming portion of one of the molds.
A first semi-molten resin as a material of the resin core material is supplied from a resin injection machine to a predetermined portion of a mold surface of the other mold, and the first mold is lowered while one mold is lowered to a bottom dead center. A resin core material forming step of molding the molten resin under a predetermined press pressure to form a resin core material of a required shape, and then opening the other mold, and removing the thin plate jig from this one mold. Thereafter, a second semi-molten resin serving as a material of the skin material was supplied from a second resin injection machine, and one of the molds was lowered to remove the second semi-molten resin from the thin plate jig. Forming a skin material by applying a predetermined press pressure into a skin material molding cavity formed between a pair of upper and lower molds later, and molding the skin material. . 2. A laminated molded body formed by covering all or a part of the surface of a resin core material with a skin material formed so as to surround the periphery of an insulated material by using mold press molding. In the method of forming a laminated molded article to be molded, when the pair of upper and lower molds for mold press molding is opened, a thin plate preformed approximately in the same shape as the skin material is formed on the skin material forming portion of the one mold. After the jig is installed and the preformed inlay material is installed in the inlay material installation site in the resin core material, the resin core is transferred from the first resin injection machine to a predetermined location on the mold surface of the other mold. The first material
A resin core material for molding the first semi-molten resin under a predetermined press pressure while supplying one half-molten resin and lowering one of the molds to the bottom dead center. A molding step, and then one mold opening operation is performed, the thin plate jig is removed from the one mold, and a skin material forming portion of the resin core is provided with a material of the skin material from a second resin injection machine. A second semi-solid resin is supplied, and one of the molds is moved downward to remove the second semi-solid resin from the thin plate jig, and then a skin material forming cavity formed between a pair of upper and lower molds. Forming a skin material by applying a predetermined press pressure to the periphery of the insulated material in the inside thereof to mold the skin material. 3. The method of molding a laminated molded article according to claim 2, wherein in the skin material molding step, the skin material molding cavity is sealed by the resin core material and a pair of upper and lower molds. .