JPH0212735B2 - - Google Patents

Description

[Detailed Description of the Invention] <Industrial Application Field> The present invention relates to a compression molding method that simultaneously attaches metal fittings. A metal fitting such as a retainer whose contact surface is burred on the surface of a molded base material made by compression molding a molded raw fabric such as a pine-like raw fabric mixed with a polyester resin etc. can be made by performing compression molding at the same time. The present invention relates to a compression molding method for manufacturing an integrally attached molded product.

<Prior Art> Molded products with integrated fittings as described above are used as molded parts for automobile doors and other interior parts. Conventionally, when manufacturing such three-dimensional molded products, a molded material such as a resin sheet or fibrous pine is cold-compressed or hot-compressed into a predetermined shape using a pair of male and female molds. molded base material 25
In addition, the contact surface part 23 as shown in FIGS. 4A and B
a, 24a have burring processing parts, and the top surface part 2
Metal fittings such as hat-shaped retainers 23 and 24 having clip attachment holes 23d and 24d formed in the retainers 3c and 24c are attached by hammering or by post-processing one or more retainers one by one using a riveting method. Then, the molded product with integral fittings obtained by attaching the retainers 23 and 24 in this way is attached to the metal inner panel 27 of the door of the automobile using the fixing clip 26, etc., as shown in FIG. 4C and D. There is.

<Problems to be Solved by the Invention> However, in the above-mentioned conventional method, the metal fittings are attached by a driving method after manufacturing the molded base material, which increases the number of man-hours and has poor processing efficiency.
Even when the metal fittings are attached to a predetermined position, misalignment is likely to occur, and there are problems such as poor positional accuracy with the mounting holes of the inner panel or the like.

Therefore, the above problem can be solved by providing a groove in the mold, performing compression molding with the metal fitting embedded in the groove, and attaching the metal fitting to the molding base material at the same time as the compression molding. However, the molded product with integrated fittings manufactured by such a method has a molded base material 29 as shown in FIG.
The disadvantage is that the portion located in the gap between the retainer 30 and the retainer 30 becomes an uncompressed portion and bulges toward the retainer, resulting in defective molding.

<Means for Solving the Problems> The compression molding method of the present invention that simultaneously attaches metal fittings is a compression molding method that uses a pair of male and female molds to compression mold a molded material to create a molded base material. , drop a metal fitting having a contact surface on which a mounting piece is formed into a groove provided on the molding surface with the contact surface mounting piece exposed to the surface, and place the metal fitting in the gap between the metal fitting and the molding surface at a height higher than the gap height. After inserting the thin core into the mold while keeping it floating on the molding surface side, place the molding fabric on the molding surface and compression mold it to bury the mounting piece of the metal fitting contact surface into the molding base material. The gist of this method is to take out the core from the gap after the pressure is released.

In addition to the above configuration, by devising the shape of the core so that the upper surface of the core held in the gap protrudes from the upper surface of the mold and compressing the molding material, the side surface of the metal fitting can be compressed. Even if the height of the part is small and it is difficult to insert the clip, the molded base material will be molded into the recessed part by the protrusion of the core, and as a result, there will be no need to cut down the molded base material after compression molding in order to insert the clip. can be eliminated.

<Function> By using the above configuration, the portion of the molding original fabric located in the gap with the metal fittings is pressed by the core and compression molded, so it is possible to eliminate molding defects in the same portion of the molding base material. In addition, since the thickness of the core is lower than the above gap height, a hollow space is formed between the core and the metal fitting after compression molding, allowing easy and smooth removal of the core from the molded product. . Furthermore, since the method involves attaching the metal fittings to the molding base material at the same time as compression molding, it is possible to solve the problems of conventional methods, such as the large number of man-hours and poor processing efficiency.

<Examples> Example 1 In FIG. 1A, grooves 10 are provided at predetermined positions on the molding surface 1a of the mold 1, respectively. The groove 10 has a retainer contact surface support surface 10a,
It is formed of a retainer side surface contact surface 10b, a retainer top support surface 10c, a core support surface 10d, and a hollow side surface 10e. Inside this groove 10, there is a metal retainer 2 consisting of a burred contact surface 2a, a side surface 2b, and a top surface 2c having a clip attachment hole 2d, and a side surface 2b of the retainer 2. Metal cores 3 having a slightly narrower width and a thickness thinner than the gap height, which will be described later, are successively dropped into or held in place as shown in FIG. 1B. At this time, as shown in FIG. 1C, the upper surface of the contact surface 2a of the retainer 2 and the upper surface of the core 3 are flush with the mold molding surface 1a, and the burring process part of the retainer contact surface is the mold molding surface. An appropriate hollow portion 3a is formed protruding from the core 1a and between the lower surface of the core 3 and the top surface portion 2c of the retainer 2. In addition, the above-mentioned gap is the distance from the top surface of the retainer to the mold molding surface 1a in FIG. 1C.
(In the same figure, it refers to the distance between the top surface of the retainer and the top surface of the core.)

Next, a compression molding process of a molded original fabric performed using the mold 1 having the above structure will be described.

First, as shown in Figure 1D, place a 20mm
A molding original fabric 4 made of fibrous matt with a certain thickness is placed, and a mold 5 forming a pair with the mold 1 is positioned on top of the shaping fabric 4. The positional relationship near the retainer 2 at this time is as shown in FIG. 1E. next,
By moving the mold 1 upward or the mold 5 downward, the original fabric 4 is compression-molded by the molds 1 and 5 as shown in FIG. 1F. At this time, the molded original fabric 4 becomes a molded base material 6 having a thickness of about 2 mm, which is compression-molded by the molds 1 and 5, and the burring part on the contact surface 2a of the retainer 2 as shown in FIG. 1G. is buried and fixed in the molded base material 5. here,
Even when the height of the burring part of the retainer contacting surface is higher than the thickness of the molding base material, the burring part can always be kept within the thickness range of the molding base material 6 by the pressure of the molds 1 and 5.

When the compression molding is completed, as shown in FIG. 1H, the molds 1 and 5 are separated and the pressure is released to take out the molded product with integrally attached fittings. The structure around the retainer in this molded product is as shown in FIG. and remove it from the gap. Then, attach one side of the fastening clips 7 and 8 to the clip attachment hole 2d of the retainer 2 as shown in FIG. 1 J and K, and after attachment, as shown in FIG. 1 L.
The fastening clip 7 is inserted into the clip mounting hole 9b provided in the inner panel 9a of the door 9 as shown in FIG.
By attaching the other side of 8, an automobile door part as shown in FIG. 1M is created.

Example 2 Next, Example 2 will be described using FIGS. 2A to 2G.

In FIG. 2A, the molding surface 11 of the mold 11
Metal divided bodies 12 each having a diameter of about 50 mm are fitted and fixed in grooves formed at predetermined positions on a. The upper surface 12a of the divided body 12 is flush with the molding surface 11a, and is provided with a groove 20. The groove 20 has a retainer contact surface support surface 20a, a retainer side surface contact surface 20b, a retainer top support surface 20c, and a core support surface 20.
d, and a hollow part side surface 20e.
This groove 20 includes a burring-processed contact surface 13a, a side surface 13b, and a clip attachment hole 1.
3d, a base 14a that is slightly wider than the side surface 13b of the retainer 13 and thinner than the gap height described later, and a protrusion 14b that is thicker than the base 14a and located in the center. The cores 14 are sequentially dropped or held as shown in FIG. 2B. At this time, as shown in FIG.
a and the mold molding surface 11a, and the burring part of the contact surface of the retainer and the protruding part 14b of the core 14 protrude from the upper surface 12a and the mold molding surface 11a, and are flush with the lower surface of the core 14. An appropriate hollow portion 14c is formed between the retainer 13 and the top surface portion 13c. Note that the above gap refers to the second gap.
In Figure C, from the top surface of the retainer to the mold molding surface 1
1a (in the figure, the same as the distance between the top surface of the retainer and the top surface of the core base). Also, core 1
The difference in thickness between the base portion 14a and the protrusion portion 14b of No. 4 is as follows:
The height is set smaller than the height of the hollow portion 14c.

Next, the mold 11 having the divided body 12 having the above structure is
The compression molding process of the molded original fabric performed using the following will be explained. Incidentally, since the compression molding process itself is the same as in Example 1, the following description will focus on the state near the groove 20 of the divided body 12.

First, Example 1 was applied to the molding surface 11a of the mold 11.
A molding material 15 similar to the above is placed, and a mold 11 is placed on top of it.
A mold 16 that is paired with the mold 16 is positioned. The positional relationship near the retainer 13 at this time is as shown in FIG. 2D. Next, when the mold material 15 is compression molded by moving the mold, the burring part on the contact surface 13a of the retainer 13 is buried and fixed in the molding base material 17, as shown in FIG. 2E. ,
The portion of the molding base material 17 that comes into contact with the protrusion 14b of the core 14 becomes a recess 17a that fits into the protrusion of the core, and this portion is thinner than the other portions accordingly.

When the compression molding is completed, the molds 11 and 16 are separated, the pressure is released, and the molded product with integral fittings is taken out. The structure around the retainer in this molded product is as shown in Figure 2F, and from this state the retainer 1
3 and the molding base material 17, first move the core 14 downward in the figure to remove its protrusion 14b from the recess 17a of the molding base material 17, and then slide it toward the front or back in the figure. Let it out and take it out. Then, as shown in FIG. 2G, one side of the fixing clip 18 is pressed and inserted into the clip attachment hole 13d of the retainer 13 to attach it. At this time, attach clip 1
Even if the height of one side of the clip 8 is higher than the height of the contact surface 13a and top surface 13c of the retainer 13, the recess 17a of the molded base material 17 allows one side of the clip 18 to be attached without any support. It goes without saying that it can be done.

Note that instead of directly forming grooves for embedding metal fittings, etc. on the molding surface of the mold as in Example 2, a split body having a similar groove and detachable from the mold may be used. By doing this, even if the molding shape changes and the mold is changed, the same compression molding can be performed using the same divided body by simply forming a groove for embedding the divided body in the mold. , mold machining costs can be kept low by the amount of concave groove machining. In addition, if it is not necessary to attach metal fittings to the molding base material, it is possible to use the same mold by inserting a divided body without a groove into the groove for embedding the divided body of the mold. Another advantage is that two types of molded products can be made.

Example 3 This Example 3 is the same as Example 2 except for the shape of the core used, the shape of the groove, and the accommodation state of the core in the groove, so only the differences will be explained in the following description.

As shown in FIG. 3A, the entire surface of the upper surface 21a, which is the side surface of the molding surface of the core 21, has a raised circular arc shape. The arcuate surface of the upper surface 21a includes both end lines extending in the core width direction of the protruding portion 14b of the core 14 used in Example 2, as indicated by dotted lines in the figure. Further, on the opposite side of the core 21, there is a lower surface 21b concave in the shape of an arc at the center,
A pair of flat seating surfaces 21c and 21d are formed on both sides of the lower surface 21b. Here, the upper surface 21a and the lower surface 21b of the core 21 are concentric circular arc surfaces. On the other hand, the core support surface of the groove 30 in which the core 21 is accommodated and held is flush with the top support surface. Furthermore, the thickness at both ends in the longitudinal direction of the core is the same as the depth of the core supporting surface of the groove 30. Therefore, when the core 21 is accommodated in the groove 30, the seating surface 21c of the core 21 , 21d is the concave groove 3
While it is in contact with and supported by the core support surface of 0, the lower surface 2
1b is located above the top support surface, and the top surface 2
1a protrudes from the upper surface 32a of the divided body 32 and from the molding surface (not shown) of the mold. This core 21
The structure around the retainer in the molded product with integrated fittings obtained by compression molding the original fabric as in Example 2 using the same method as in Example 2 is as shown in Figure 3B.
The core 21 is moved in its longitudinal direction or in the arcuate direction of the upper surface 21a to be taken out from between the molded base material recess and the top surface of the retainer.

<Effects of the Invention> The compression molding method of the present invention is as explained above, and the portion of the molded material located in the gap between the retainer and the molding material is compressed and molded by the core during compression molding. This eliminates molding defects in the portion of the molded base material located in the gap with the retainer, and allows compression molding of this portion in the same way as other portions. In addition, since the metal fittings are attached to the molded base material at the same time as compression molding, all of the problems of the conventional method described above can be solved, and the metal fittings can be accurately attached to the predetermined position on the molded base material in one step at the same time as compression molding. ,
This eliminates the need for post-processing, greatly improving production efficiency, and also has the effect of preventing the tip of the burring part of the retainer from protruding onto the surface of the molding base material, allowing that surface to be molded flush. .

Furthermore, the present inventor has confirmed that the strength of attaching the metal fittings to the molded substrate can be significantly increased compared to the conventional method. To explain this improvement in mounting strength in detail, like the retainer used in the example, there are 8 pieces in total, 4 on each of the left and right contact surfaces.
When a molded product with integral fittings is manufactured using a conventional method using a retainer with burring parts, the mounting strength of one retainer is 32 to 35 kg (4 to 4.5 kg for one burring part). On the other hand, in the case of the present invention, it is 55 to 60 kg (same as 7 kg).
~7.5Kg), and the installation strength is approximately
Improved by 1.7 times.

[Brief explanation of drawings]

FIGS. 1 A to M are explanatory diagrams of Embodiment 1 of the present invention, FIGS. 2 A to G are explanatory diagrams of Embodiment 2, FIGS. 3 A and B are explanatory diagrams of Embodiment 3, and FIG. 4 A is an explanatory diagram of Embodiment 3. -D and FIG. 5 are explanatory diagrams of the prior art. 1, 5, 11, 16...Mold, 2, 13, 2
3, 24, 31...retainer, 3, 14, 21
... Core, 4, 15 ... Molding original fabric, 6, 17, 2
5, 29, 35... Molding base material, 7, 8, 18, 2
6... Clip for attachment, 10, 20... Concave groove, 1
2...Divided body, 27...Inner panel.

Claims (1)

[Scope of Claims] 1. In a compression molding method for producing a molded base material by compression molding a molded original fabric using a pair of male and female molds, a metal fitting having a contact surface portion on which a mounting piece is formed is molded with a mold. Drop the contact surface mounting piece into the groove provided on the surface with the contact surface part exposed to the surface, and place a core with a thickness thinner than the gap height in the gap between the fitting and the molding surface with it floating on the molding surface side. After being held and inserted, a molding material is placed on the molding surface of the mold, compression molding is performed, the mounting piece of the metal fitting contacting surface is buried in the molding base material, and the core is taken out from the gap after the pressure is released. Compression molding method that performs installation at the same time. 2. Claim 1, characterized in that the core has a protrusion formed in the center on the side of the molding surface, and this protrusion protrudes from the molding surface on the side of the molding material. Compression molding method as described. 3 The side surface of the mold forming surface of the core is raised in an arc shape and protrudes from the mold forming surface toward the molding material side, and the surface opposite to the side surface of the mold forming surface is in an arc shape concentric with the mold forming side surface. 2. The compression molding method according to claim 1, wherein the molding is concave.