JP5874926B2 - Manufacturing method of three-dimensional molded product - Google Patents

Description

  The present invention relates to a method for producing a three-dimensional molded article suitable for obtaining a three-dimensional shape with a decorated surface, particularly a box shape with an inner surface (inner surface) decorated.

Conventionally, this type of technology has been described in Patent Document 1.
This is because the skin material is set inside a mold composed of one mold half and the other mold half, and the mold is closed, and synthetic resin is introduced into the cavity in the mold and molded integrally with the skin material. That's it.

Japanese Patent Laid-Open No. 03-286818

  However, in the above prior art, when applied to obtain a three-dimensional shape with a decorated surface, particularly a box shape with an inner surface (inner surface) decorated, the skin material does not follow the box shape. At the corners, the excess of the epidermis increases and wrinkles occur.

  The present invention has been made in view of the above situation, and when obtaining a box shape with an inner surface (inner surface) decorated, the remainder of the skin at the corner of the inner surface of the box shape is minimized. It is an object of the present invention to provide a method for producing a three-dimensionally shaped product that can suppress generation.

The said subject is solved by making the manufacturing method of a three-dimensional molded product into the structure of each following aspect.
As with the claims, each aspect is divided into sections, each section is numbered, and is described in a form that cites the numbers of other sections as necessary. This is merely for the purpose of facilitating the understanding of the present invention, and the technical features described in this specification and combinations thereof should not be construed as being limited to those described in the following sections. . In addition, when a plurality of items are described in one section, it is not always necessary to employ the plurality of items together, and it is also possible to take out only a part of the items and employ them.

  Of the following items, (1) corresponds to claim 1, (2) corresponds to claim 2, and (3) corresponds to claim 3.

(1) A method for manufacturing a three-dimensional molded product whose inner surface is decorated with a skin, which is integrally formed by a planar integral molding process in which a flat plate-shaped substrate and a skin are integrally molded, and the planar integral molding process. A method for producing a three-dimensional molded product, comprising: a shaping step of shaping a flat plate-shaped molded article formed into a three-dimensional shape.
(2) The base material is formed into a flat plate shape developed from the final molded product shape which is the three-dimensional shape before or during the integral molding. Manufacturing method for three-dimensional molded article.
(3) The method for producing a three-dimensional molded article according to (1) or (2), wherein an integral hinge is formed on the base material at a location corresponding to a corner portion of the three-dimensional shape. .

According to the present invention, when obtaining a box shape in which the inner surface (inner surface) is decorated, generation of wrinkles can be suppressed by minimizing the remainder of the skin at the corners of the inner surface of the box shape.
In addition, by forming the integral hinge at a position corresponding to the three-dimensional corner of the base material, the molded product can be easily and reliably shaped into the three-dimensional shape.

It is a figure which shows an example of the solid shape obtained by applying the method of the present invention. It is a flowchart which shows the manufacturing method of the solid-shaped molded article which concerns on one Embodiment of this invention. It is explanatory drawing of the planar integral molding process in FIG. It is a figure which shows an example of the molded article obtained through the molding process same as the above. It is explanatory drawing of the specific example of the integral molding method of the base material and outer_skin | epidermis in a shaping | molding process same as the above.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, the same code | symbol shows the same or an equivalent part between each figure.
The method of the present invention is a method for producing a three-dimensional molded product for obtaining a three-dimensional shape with an inner surface (inner surface) 1a decorated as shown in FIG. 1, here a box shape 1, as shown in FIG. In addition, a planar integrated molding step 201 and a shaping step 202 are provided.

As shown in FIG. 3, the box shape 1 is first a flat substrate 2 for forming the box shape 1 and a skin 3 having a shape corresponding to the substrate 2 in the planar integrated molding step 201. Are integrally molded to obtain a molded product 4 (see FIG. 4). Next, in the shaping step 202, the molded product 4 is shaped into the box shape 1.
The skin 3 is integrally formed on the flat surface of the base material 2 that becomes the inner surface side of the box shape 1 when the molded product 4 is shaped into the box shape 1 (shaped so that the skin 3 becomes the inner surface of the box shape 1. Shaped).
A synthetic resin that can be bent from a flat plate shape to a box shape 1 is used for the substrate 2, and a skin material such as a knitted fabric or a woven fabric is used for the skin 3, for example.

In the present embodiment, as described above, the base material 2 and the skin 3 are first integrally molded. However, the base material 2 is formed before the integral molding with the skin 3 or during the integral molding. Is formed into a flat plate shape obtained by developing the final molded product shape (see FIG. 3).
And the base material 2 formed or formed in the flat plate shape and the planar skin 3 having an outer shape corresponding to the outer shape of the base material 2 are integrally formed, and the molded product shown in FIG. Get 4.
Thereafter, the molded product 4 is shaped to obtain the box shape 1 shown in FIG. 1 in which the inner surface 1a is decorated.

In addition, in order to hold the base material 2 in the box shape 1, an engaging claw and an engaging hole for claw fitting are formed.
Further, the position 2a (see FIG. 3) which is the corner portion of the box shape 1 along the fold line when the flat plate-shaped base material 2 which has been developed is assembled into the box shape 1 is used as an integral hinge. It is formed thin to make it function.
Although the outer shape of the skin 3 is made to correspond to the outer shape of the base material 2, this may be performed by cutting the skin material after the integral molding with the base material 2 is finished.

A specific example of the integral molding method of the base material 2 and the skin 3 in the planar integral molding step 201 will be described below with reference to FIGS.
First, the skin 3 formed by cutting the skin material into a planar shape in which the box shape 1 (final molded product shape) is developed is disposed on one mold half 52 of the mold 51. The skin material may be cut after being integrally formed with the base material 2 as described above.

Next, the mold 51 is closed, and a material 54 of a thermoplastic resin such as polypropylene (PP) is filled in the space between the other mold half 53 and the skin 3 disposed in the one mold half 52 and cured. As the filling method, methods such as extrusion press molding, injection molding, injection compression molding, and injection press molding (SPM) are used.
When the thermoplastic resin (raw material 54) is cured, the thermoplastic resin is impregnated and solidified in a part of the skin 3 and joined to the skin 3, and the base material 2 and the skin 3 are integrally molded, and thereafter molding is performed. The mold 51 is opened and the molded product 4 shown in FIG. 4 is taken out (the planar integrated molding step 201 is completed).
As described above, the portion 2a (see FIG. 3) that becomes the corner portion of the box-shaped 1 of the flat-plate-shaped base material 2 that is developed is formed thin in order to function as an integral hinge.
For the molded product 4 taken out from the mold 51, trimming is performed on unnecessary portions in the outer periphery and the like, and then the box shape 1 shown in FIG.

According to the above-described embodiment, the inner surface when the inner surface 1a is decorated, that is, when the box shape 1 is obtained, the flat base material 2 in which the shape is developed becomes the box shape 1. The skin 3 was integrally formed on the side plane, and the integrally molded product 4 was shaped into the box shape 1.
According to this, since the follow-up to the box shape 1 of the skin 3 at the time of shaping is performed better than the prior art, the remainder of the skin 2 at the inner corner of the box shape 1 after shaping is minimized. It is possible to suppress the occurrence of wrinkles at the inner corners of the box shape.
Moreover, since the integral hinge was formed in the location which hits the box-shaped corner part of the base material 2, the shaping | molding of the molded article 4 to the box shape 1 can be performed easily and reliably.

  1: Box shape (three-dimensional shape), 2: base material, 3: skin, 4: molded product, 201: planar integrated molding process, 202: shaping process.

Claims (3)

It is a manufacturing method of a three-dimensional molded product whose inner surface is decorated with a skin,
A planar integrated molding process for integrally molding a flat plate-shaped base material and skin,
A shaping step of shaping a flat plate-shaped molded product integrally formed by this planar integral molding step into a three-dimensional shape;
The manufacturing method of the three-dimensional molded product characterized by comprising.   2. The three-dimensional shape molding according to claim 1, wherein the base material is formed into a flat plate shape developed from the final molded product shape which is the three-dimensional shape before or during the integral molding. Product manufacturing method.   The method for producing a three-dimensional molded article according to claim 1 or 2, wherein an integral hinge is formed on the base material at a position corresponding to a corner portion of the three-dimensional shape.

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