JP2004223896A - Method for manufacturing monolithically molded object with skin and molding tool - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a monolitically molded object with a skin which can jointly use both molding tool for a skin material and a cavity mold for molding a base and prevents the molded skin material from being loosely apart from the mold surface of the cavity mold during its transfer from a skin material molding process to a base molding process and generates no appearance defect, and a molding tool. <P>SOLUTION: This method for manufacturing a monolithically molded object with the skin is to mold the base 13 after setting the skin material 11 in the cavity mold 1 and vacuum-mold the skin material 11 using the molding tool comprising the cavity mold 1, a first core 2 for molding the skin material 11 and a second core 3 for molding the base 13. In this method, the end part of the vacuum-molded skin material 11 is squeezed into the outer periphery of the cavity mold 1 from the first core 2 side, then clamped to the outer periphery of the cavity mold 1 and retained on the outer periphery of the cavity mold 1. After that, the cavity mold 1 and the second core 3 are clamped and thus the base 13 is monolithically molded with the skin material 11. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
TECHNICAL FIELD The present invention relates to a method for manufacturing a molded article of a skin used for an interior of an automobile or the like and a molding die.
[0002]
[Prior art]
[Patent Document 1] JP-A-3-138114 [Patent Document 2] JP-A-5-301243
For example, as an interior material for an automobile such as a door trim or an instrument panel, a skin-integrated synthetic resin molded product in which a base material is integrally formed on the back surface of a skin material is used. As a molding method of such a skin-integrated synthetic resin molded article, as disclosed in Japanese Patent Application Laid-Open No. 3-138114, a skin material is vacuum-suctioned with a vacuum mold, and then the skin is removed from the vacuum mold. And set it on the upper mold of 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 spread it out into the cavity and mold the base material At the same time, a method is known in which the skin and the base material are integrated.
[0004]
However, such a method requires a troublesome desorption step of removing the skin material from the vacuum forming die and setting it on the upper die of the compression molding machine, and the distance between the upper die of the compression molding machine and the skin material is required. There is a problem that the shape accuracy of the molded article is reduced due to the air. Furthermore, it is necessary to prepare both a vacuum forming die and an upper die for compression molding, and since the molded skin material shrinks between the time of setting it in the die for compression molding after vacuum forming, Had to be made in consideration of this. In order to solve these problems, Japanese Patent Application Laid-Open No. Hei 5-301243 discloses that vacuum molding of a skin material and compression molding of a base material can be continuously performed by a common mold to eliminate the detachment of the skin material from the mold to the mold. A method such as that disclosed in Japanese Patent Application Laid-Open Publication No. H10-209,837 has been proposed.
[0005]
Japanese Unexamined Patent Publication No. Hei 5-301243 discloses that a resin sheet is vacuum-suctioned on a molding surface of a first mold having a gas-permeable and pressure-resistant pattern with a concavo-convex pattern to form a skin and then sucked as it is. By supplying and compressing the molten resin between the first mold and the second mold facing the mold, the molten resin is pushed out into the cavity between the two molds and spreads, forming the base material and attaching the base material and the skin at the same time with the skin This is a method of integrally molding a resin molded product. If the skin material needs to be detached from the mold to the mold, it must be strong enough not to deform when it is attached to or detached from the skin material, and the finished molded product must have unnecessary thickness and strength. Although there is a problem that the material must be removed, there is no need to increase the strength when the skin material does not need to be detached from the mold to the mold as in this method.
[0006]
However, when the vacuum forming is completed, the outer peripheral clamp of the outer skin material is removed, so that the outer circumference of the outer skin is easily lifted up, and air enters from the outer surface to cause vacuum leakage. If vacuum leakage occurs from the outer periphery, if the strength of the skin material is not sufficient, the rise of the skin material will reach the center part, especially if it rises on the design surface, it will cause fine irregularities in the design and disturb the appearance There is a problem of doing. In order to prevent the rise of the outer periphery of the skin, conventionally, it has been attempted to provide a molded article as shown in FIG. There was a problem that it was not possible to completely prevent the problem.
[0007]
[Problems to be solved by the invention]
The present invention solves the above problems, and can share a skin material forming mold and a base material forming cavity mold, and a skin material formed during the transition from the skin material forming step to the base material forming step. The present invention has been made in order to provide a method of manufacturing a molded article integrally formed with a skin and a molding die, which does not rise from the mold surface of the cavity mold and does not cause poor appearance.
[0008]
[Means for Solving the Problems]
The method for producing a skin-integrated molded product of the present invention made to solve the above-mentioned problem uses a molding die composed of a cavity mold and two core dies for molding a skin material and molding a base material, A method for manufacturing a skin-integrated molded product in which a skin material is set in a cavity mold, and the skin material is formed by vacuum forming, and then the base material is formed. Press the mold into the cavity mold outer periphery, clamp it to the cavity mold outer periphery, hold the end of the skin material on the cavity mold outer periphery, then clamp the cavity mold and the core mold for molding the base material, And forming a substrate integrally therewith.
[0009]
Further, the mold for molding the integral skin product of the present invention, which is made for the same purpose, is a mold for molding the integral skin product comprising a cavity mold, a core mold for molding the skin material, and a core mold for molding the base material. In the outer periphery of the core mold for forming the skin material, a skin inserting means for pushing the end portion of the skin material into the cavity mold side is held, and on the outer periphery of the cavity mold, an end of the skin material pushed by the skin inserting means is held. 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 mold side for forming the skin material to be held on the outer periphery of the cavity mold. And forming a base material between them.
[0010]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described 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 an upper mold and the first core mold 2 and the second core mold 3 as lower molds. However, in handling the skin material, the cavity mold 1 is referred to as the lower mold. Is preferred.
[0011]
The cavity mold 1 is for vacuum forming the design surface of the skin material, the first core mold 2 is for molding the skin material, 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 each 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 can be moved to the position where Further, the first core mold 2 and the second core mold 3 are not shown in which the first core mold 2 and the second core mold 3 are moved up and down, respectively, to open and close the molding mold and to clamp the mold. A vertical mechanism is provided.
[0012]
The cavity mold 1 is provided with a large number of air passages 4 for vacuuming, and the large number of air passages 4 are collectively connected to a vacuum suction device (not shown). A molding machine (not shown) is provided with a clamper 5 for clamping a skin material before and during vacuum forming at a position around the cavity mold 1 facing the first core mold 2 in the same manner as in the related art. On the outer periphery of the mold 1, clamps 6, 6 as clamp means for holding the skin material after vacuum forming in the cavity mold 1 are provided so as to be freely opened and closed. Numerals 7 and 7 in the drawing denote cylinders for opening and closing the clamps 6 and 6, respectively.
[0013]
On the outer periphery of the first core mold 2, skin insertion plugs 8, 8 as skin insertion means for pushing a skin material into the cavity mold 1 side are provided so as to be vertically movable, and the skin insertion plugs 8, 8 are cylinders 9, 9 to move up and down. The second core mold 3 forms a cavity between a vacuum-molded skin material in a clamped state, and injects a resin into the cavity to form a base material. Gate 10 is provided.
[0014]
The molding die thus configured is mounted on a molding machine, and the cavity mold 1 is set in a state where the first core mold 2 is raised at a position facing the first core mold 2, and a skin material is placed on the cavity mold 1. 11 is placed and 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, 4, and the first core mold 2 is lowered as shown in FIG. 3 in a state where the skin insertion plugs 8, 8 are at the upper limit position, and the mold is clamped to form the skin. As a result, the skin material 11 is sucked by the cavity mold 1 and follows the mold surface, and is formed as shown in FIG. 3 to form a design on the surface of the skin material 11. Prior to the vacuum suction, the skin material 11 is heated to a predetermined temperature capable of vacuum forming and softened as in the conventional case.
[0015]
After the vacuum suction, the skin material 11 is unclamped by the clampers 5, 5, and at the same time, the skin insertion plugs 8, 8 are lowered, so that the outer peripheral portion of the skin material 11 is folded into the outer periphery of the cavity mold 1 as shown in FIG. Will be. In this state, the skin insertion plugs 8, 8 are lifted and returned, and the clamps 6, 6 are closed and the first core mold 2 is raised, so that the outer peripheral portion of the skin material 11 is clamped as shown in FIG. The cavity mold 1 is held by the cavity mold 6, and the cavity mold 1 is separated from the first core mold 2 and becomes 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 mold-clamped, a base material is formed as shown in FIG. When the molten resin is injected from the gate 10, the base material 13 is formed as shown in FIG. 8 and at the same time, a molded product in which the skin material 11 is integrated is completed. The molding of the base material 13 includes a compression molding method in which molten resin is supplied to the cavity 12 before the second core mold 3 is completely lowered, and is compressed by mold clamping to spread out the cavity 12, polyurethane after clamping, and the like. Injection of the resin may be performed by a reaction injection molding method of foaming, reacting, and solidifying in the mold. 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 clear from the above description, the present invention shares the cavity mold for the skin material molding and the substrate molding, so there is no need to desorb the skin material between the skin material molding step and the substrate molding step, Since the outer peripheral portion of the vacuum-formed skin material is continuously clamped sequentially and finally held on the outer periphery of the cavity mold, the outer peripheral portion of the skin does not rise even if the strength of the skin material is not sufficient. Therefore, the skin material does not rise due to the infiltration of air from here and the occurrence of vacuum leakage, and the appearance quality of the molded product is not deteriorated. Therefore, it is extremely important to contribute to the industry as providing a method for manufacturing a skin-integrated molded product and a mold for molding which solve all the conventional problems.
When the cavity mold is used as the lower mold, when the skin material is clamped by the clamper after the vacuum molding of the skin material and the peripheral part of the skin material is folded into the outer periphery of the cavity mold by the skin insertion plug, the skin is caused by gravity. This has the 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 sectional view showing an example of a molding die of the present invention.
FIG. 2 is a 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 where a skin material is molded.
FIG. 4 is a cross-sectional view showing a state where the outer periphery of the skin material is folded.
FIG. 5 is a cross-sectional view showing a state where the outer periphery of the skin material is clamped in a cavity mold.
FIG. 6 is a sectional view showing a state in which a cavity mold has been 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 where 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 a skin material from lifting.
[Explanation of symbols]
Reference Signs List 1 cavity mold 2 first core mold 3 second core 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 cavity mold and two core molds for molding the skin material and molding the base material, setting the skin material in the cavity mold, molding the skin material by vacuum molding, and then molding the base material A method of manufacturing a skin-integrated molded product, comprising: pressing a terminal portion of a skin material after vacuum forming from a core mold side for forming a skin material into an outer periphery of a cavity mold to clamp the outer periphery of the cavity mold; After the mold is held on the outer periphery of the cavity mold, the cavity mold and the core mold for forming the base material are clamped, and the base material is formed integrally with the skin material. This is a mold for forming a skin integral molded product comprising a cavity mold, a core mold for molding a skin material, and a core mold for molding a base material, and a terminal portion of the skin material is provided on an outer periphery of the core mold for molding the skin material. Skin insertion means for pushing into the cavity mold side, clamping means for holding the end of the skin material pushed by the skin insertion means are provided on the outer periphery of the cavity mold, and the end of the skin material after vacuum forming is used for forming the skin material. For molding a skin-integrated molded product characterized in that the core mold is pressed into the cavity mold periphery from the core mold side and held on the periphery of the cavity mold, and the base material is molded between the core mold and the cavity mold. Type.

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