JP4042576B2 - Manufacturing method and molding die for skin integral molded product - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing an integrally molded skin and a mold for use in automobile interiors and the like.
[0002]
[Prior art]
[Patent Document 1]
Japanese Patent Laid-Open No. 3-138114 [Patent Document 2]
JP-A-5-301243
For example, as automobile interior materials such as door trims, instrument panels, and the like, skin-integrated synthetic resin molded products in which a base material is integrally formed on the back surface of a skin material are used. As a method for molding such a skin-integrated synthetic resin molded product, as shown in JP-A-3-138114, the skin material is molded by vacuum suction with a vacuum mold, and then the skin is removed from the vacuum mold. Set the upper mold in the compression molding machine, then supply the molten resin onto the lower mold of the compression molding machine, clamp both molds and compress the molten resin to expand it into the cavity, and mold the substrate At the same time, a method is known in which the skin and the substrate are integrated.
[0004]
However, such a method requires a troublesome desorption process in which the skin material is removed from the vacuum mold and set again on the upper mold of the compression molding machine, and between the upper mold and the skin material of the compression molding machine. There was a problem that the shape accuracy of the molded product was lowered due to air entering. Furthermore, it is necessary to prepare both a vacuum mold and an upper mold for compression molding. Moreover, since the skin material that has been molded shrinks before being placed in the compression molding mold after vacuum molding, it is for vacuum molding. It was necessary to make the mold of this type considering it. As a solution to these problems, the vacuum molding of the skin material and the compression molding of the base material are continuously carried out with a common mold, and detachment of the skin material from the mold to the mold can be eliminated. A method as shown in the publication is proposed.
[0005]
JP-A-5-301243 discloses that a resin sheet is vacuum-sucked on a molding surface with a concavo-convex pattern having air permeability and pressure resistance to form a skin, and then sucked as it is. By supplying and compressing the molten resin between the first mold and the opposing second mold, the molten resin is spread into the cavity between the two molds, and the base material is molded together with the skin and the skin is attached. This is a method of integrally molding a resin molded product. When it is necessary to detach the skin material from mold to mold, the skin material must be strong enough not to be deformed during detachment, and the finished molded product must have unnecessary thickness and strength. Although there is a problem that it is necessary to detach the skin material from one mold to another as in this method, it is not necessary to have a large strength.
[0006]
However, since the outer peripheral clamper is removed after the vacuum forming of the outer skin material is finished, the outer periphery of the outer skin is likely to be lifted, and air enters from here and vacuum leakage occurs. When vacuum leakage occurs from the outer periphery, if the strength of the skin material is insufficient, the skin material will lift up to the center, especially if it floats on the design surface, the design of the uneven design will be disturbed and appearance defects will occur There is a problem of doing. In order to prevent the skin outer periphery from being lifted up, it has been attempted to provide an uneven portion for retaining the skin in the shape of a round hole, groove or the like in the molded product as shown in FIG. There was a problem that could not be completely prevented.
[0007]
[Problems to be solved by the invention]
The present invention solves the above-mentioned problems, and can use a skin material molding die and a base material molding cavity die, and is formed during the transition from the skin material molding process to the base material molding process. The present invention has been made in order to provide a method for manufacturing a skin-integrated molded article and a mold for molding that do not float from the mold surface of the cavity mold and do not cause poor appearance.
[0008]
[Means for Solving the Problems]
The manufacturing method of the skin integral molded product of the present invention made to solve the above problems uses a molding die composed of a cavity mold and two core molds for skin material molding and base material molding, A method for manufacturing a skin-integrated molded article in which a skin material is set in a cavity mold and the skin material is molded by vacuum molding, and then the base material is molded, and the terminal portion of the skin material after vacuum molding is used as a core for molding the skin material Clamp the outer periphery of the cavity mold by pushing it into the outer periphery of the cavity mold from the mold side, hold the end of the skin material on the outer periphery of the cavity mold, and then clamp the cavity mold and the core mold for molding the base material. And the base material is molded integrally.
[0009]
Further, the molding die for the skin-integrated molded product of the present invention made for the same purpose is a molding die for the skin-integrated molded product comprising a cavity mold, a core mold for molding the skin material, and a core mold for molding the substrate. And, the outer skin insert means for pushing the end of the skin material into the cavity mold side on the outer periphery of the core mold for molding the skin material, and the outer skin material end pushed by the skin insertion means on the outer periphery of the cavity mold Each of the clamping means is provided, and the end portion of the skin material after vacuum forming is pushed into the outer periphery of the cavity mold from the core material side of the skin material molding to be held on the outer periphery of the cavity mold. The base material is molded between the two.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 shows an example of a molding die according to the present invention, which comprises a cavity die 1 as a lower die and a first core die 2 and a second core die 3 as upper die. It is possible to use the cavity mold 1 as the upper mold and the first core mold 2 and the second core mold 3 as the lower mold. However, in handling the skin material, the cavity mold 1 is thus referred to as the lower mold. It is preferable to do this.
[0011]
The cavity mold 1 is for vacuum-forming the design surface of the skin material, the first core mold 2 is for skin material molding, and the second core mold 3 is for molding the back surface of the base material. The cavity mold 1, the first core mold 2, and the second core mold 3 are respectively set in a molding machine (not shown), and the cavity mold 1 faces the second core mold 3 from a position facing the first core mold 2. It is possible to move to the position where In addition, the first core mold 2 and the second core mold 3 are not shown in the drawings, in which the first core mold 2 and the second core mold 3 are moved up and down to open and close the mold for mold closing, respectively. A vertical mechanism is provided.
[0012]
The cavity mold 1 is provided with a number of air passages 4 and 4 for evacuation, and the number of air passages 4 and 4 are collectively connected to a vacuum suction device (not shown). A molding machine (not shown) is provided with a clamper 5 for clamping the skin material before and during vacuum forming at a position around the cavity mold 1 facing the first core mold 2 as in the prior art. On the outer periphery of the mold 1, clamps 6 and 6, which are clamping means for holding the skin material after vacuum forming in the cavity mold 1, are provided so as to be freely opened and closed. In the figure, 7 and 7 are cylinders for opening and closing the clamps 6 and 6.
[0013]
On the outer periphery of the first core mold 2, skin insertion plugs 8, 8 serving as skin insertion means for pushing the skin material into the cavity mold 1 side are provided so as to be movable up and down. 9 is moved up and down. The second core mold 3 is for forming a cavity with a skin material vacuum-formed in a clamped state, and injecting resin into the cavity to mold the base material. In order to supply the resin to the cavity The gate 10 is provided.
[0014]
The molding die thus configured is mounted on a molding machine, and the cavity mold 1 is brought into a state where the first core mold 2 is raised at a position facing the first core mold 2, and the skin material is placed on the cavity mold 1. 11 is placed, clamped by the clampers 5 and 5, and the skin material 11 is set as shown in FIG. Vacuum suction is performed through the air passages 4 and 4, and the first core mold 2 is lowered as shown in FIG. 3 in a state where the skin insertion plugs 8 and 8 are at the upper limit position, and the skin is molded by clamping. As a result, the skin material 11 is sucked by the cavity mold 1 and extends along the mold surface, and is shaped as shown in FIG. 3 to form a design on the surface of the skin material 11. Prior to this vacuum suction, the skin material 11 is heated and softened to a predetermined temperature at which vacuum forming is possible, as in the conventional case.
[0015]
After vacuum suction, the outer skin portion 11 is folded by the outer periphery of the cavity mold 1 as shown in FIG. Will be. In this state, if the skin plugs 8 and 8 are raised and returned, the clamps 6 and 6 are closed and the first core mold 2 is raised, the outer periphery of the skin material 11 is clamped as shown in FIG. The cavity mold 1 is held by the cavity mold 1 by 6 and 6, and the cavity mold 1 is detached from the first core mold 2 and is movable.
[0016]
When the cavity mold 1 is moved to a position facing the second core mold 3 as shown in FIG. 6 and the second core mold 3 is lowered and clamped, the substrate is molded as shown in FIG. Therefore, when the molten resin is injected from the gate 10, the base material 13 is molded as shown in FIG. 8, and at the same time, a molded product in which the skin material 11 is integrated is completed. The base 13 is molded by a compression molding method in which a molten resin is supplied to the cavity 12 before the second core mold 3 is completely lowered, and is compressed by the mold clamping and then pushed into the cavity 12, polyurethane after the mold clamping, etc. It is possible to use a reaction injection molding method in which the resin is injected, foamed, reacted, and solidified in a mold, and in the case of the reaction injection molding method, it is preferable to mix and strengthen a reinforcing material such as glass fiber.
[0017]
【The invention's effect】
As is apparent from the above description, the present invention shares the cavity mold for skin material molding and base material molding, so there is no need to remove the skin material between the skin material molding process and the base material molding process, Since the outer peripheral portion of the vacuum-formed skin material is continuously clamped and finally held on the outer periphery of the cavity mold, the outer peripheral portion of the skin does not float even when the strength of the skin material is insufficient. Therefore, the skin material does not rise due to the intrusion of air from here and the occurrence of vacuum leakage, and the appearance quality of the molded product is not deteriorated. Therefore, the present invention is extremely large in that it contributes to the industry as providing a manufacturing method and a molding die for an integrated skin molded product that solves all the conventional problems.
When the cavity mold is the lower mold, the skin is clamped by gravity when the skin is clamped by the clamper after vacuum molding of the skin and the periphery of the skin is folded into the outer periphery of the cavity using a skin insertion plug. There is an effect that the peripheral portion of the material is easily folded into the outer periphery of the cavity mold.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an example of a molding die of the present invention.
FIG. 2 is a cross-sectional view showing a state in which a skin material is set in a cavity mold.
FIG. 3 is a cross-sectional view showing a state in which a skin material is molded.
FIG. 4 is a cross-sectional view showing a state in which the outer periphery of the skin material is folded.
FIG. 5 is a cross-sectional view showing a state in which the outer periphery of the skin material is clamped in a cavity mold.
FIG. 6 is a cross-sectional view showing a state where a cavity mold is moved.
FIG. 7 is a cross-sectional view showing a state where the second core mold is clamped.
FIG. 8 is a cross-sectional view showing a state in which a base material is molded.
FIG. 9 is a cross-sectional view showing an example of a conventional method for preventing the outer periphery of the skin material from rising.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Cavity type | mold 2 1st core type | mold 3 2nd core type | mold 4 Air passage 5 Clamper 6 Clamp 7 Cylinder 8 Skin plug 9 Cylinder 10 Gate 11 Skin material 12 Cavity 13 Base material

Claims (2)

Using a mold consisting of a cavity mold and two core molds for skin material molding and base material molding. After setting the skin material to the cavity mold and molding the skin material by vacuum molding, the base material is molded. A method for manufacturing a skin-integrated molded product, wherein the end portion of the skin material after vacuum forming is pushed into the outer periphery of the cavity mold from the core mold side for skin material molding, and clamped to the outer periphery of the cavity mold, A method for producing a skin-integrated molded product, comprising: holding a cavity mold on an outer periphery of the cavity mold, and clamping the cavity mold and a core mold for molding a substrate, and molding the substrate integrally with the skin material. This is a molding die for skin integrated molding consisting of a cavity die, a core die for skin material molding, and a core die for base material molding, and the end portion of the skin material is provided on the outer periphery of the core die for skin material molding. A skin insertion means to be pushed into the cavity mold side, and a clamp means to hold the end of the skin material pushed by the skin insertion means on the outer periphery of the cavity mold are provided, and the end portion of the skin material after vacuum forming is used for molding the skin material. For molding a skin-integrated molded product characterized in that the core is pressed from the core mold side into the cavity mold outer periphery and held on the outer periphery of the cavity mold, and the substrate is molded between the core mold and the cavity mold for molding the substrate. Type.

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