JP2012179777A - Method of molding resin panel member - Google Patents

Method of molding resin panel member Download PDF

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Publication number
JP2012179777A
JP2012179777A JP2011043566A JP2011043566A JP2012179777A JP 2012179777 A JP2012179777 A JP 2012179777A JP 2011043566 A JP2011043566 A JP 2011043566A JP 2011043566 A JP2011043566 A JP 2011043566A JP 2012179777 A JP2012179777 A JP 2012179777A
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Prior art keywords
mold
base material
pad
resin
panel member
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Junji Kashihara
淳二 樫原
Mitsuharu Kaneko
満晴 金子
Junichi Ogawa
淳一 小川
Tsuguhisa Miyamoto
嗣久 宮本
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Mazda Motor Corp
DaikyoNishikawa Corp
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Mazda Motor Corp
DaikyoNishikawa Corp
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Priority to JP2011043566A priority Critical patent/JP2012179777A/en
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Abstract

PROBLEM TO BE SOLVED: To eliminate a post expansion bulge phenomenon by sufficiently cooling and curing a thin solid part without prolonging a molding cycle.SOLUTION: When a pad 13 is integrally molded on a base material 3 by a core back method for enlarging a cavity volume, a projecting part 109a provided to be projected on a die molding surface 109 of a core die 103 holding the base material 3 is fit in an opening 27 corresponding to the outer peripheral part of the pad 13 of the base material 3 to face the cavity 117 and a thermoplastic resin in the cavity space 117a is cooled and cured before the cavity volume is enlarged, and as a result, a thin solid part 29 is formed at the outer peripheral part of the pad 13.

Description

この発明は、コアバック法（Moving Cavity法）により、樹脂製基材の表面に樹脂製パッドが一体に成形された樹脂パネル部材の成形方法に関するものである。   The present invention relates to a method for molding a resin panel member in which a resin pad is integrally formed on the surface of a resin substrate by a core back method (Moving Cavity method).

コアバック法とは、固定型と可動型とからなる成形型を型閉じしてキャビティに熱可塑性樹脂を充填し、該熱可塑性樹脂の型成形面近傍にスキン層が生成され始めた時点で、上記可動型を型開き方向に僅かに後退させてキャビティ容積を拡大させることで上記熱可塑性樹脂を発泡させ、これにより、樹脂密度が高いソリッド層からなるスキン層の内部に該スキン層に比べて樹脂密度が低い発泡層が一体に成形された発泡層を得る方法である。   With the core back method, a mold composed of a fixed mold and a movable mold is closed and a cavity is filled with a thermoplastic resin, and when a skin layer starts to be generated in the vicinity of the mold surface of the thermoplastic resin, The thermoplastic mold is foamed by slightly retracting the movable mold in the mold opening direction to expand the cavity volume, and thereby, compared with the skin layer inside the skin layer composed of a solid layer having a high resin density. This is a method of obtaining a foam layer in which a foam layer having a low resin density is integrally formed.

このコアバック法により、樹脂製基材の表面に樹脂製パッド（発泡層）が一体に成形された樹脂パネル部材を成形する場合、例えば、固定型の型成形面に予め成形した基材をセットして可動型を接近させて型閉じしたり、あるいは成形した基材を固定型に残したままで、可動型をパッド成形用の可動型と取り替えて型閉じし、キャビティに熱可塑性樹脂を充填する。そして、この熱可塑性樹脂の基材表面近傍及び可動型の型成形面近傍にスキン層が生成され始めた時点で、可動型を型開き方向に移動させてキャビティ容積を拡大し、上記熱可塑性樹脂を発泡させる。これにより、樹脂密度が高いソリッド層からなるスキン層の内部に該スキン層に比べて樹脂密度が低い発泡層が一体に成形された厚肉の樹脂製パッドが上記基材上に一体に成形された樹脂パネル部材が得られる。   When molding a resin panel member in which a resin pad (foamed layer) is integrally formed on the surface of a resin base material by this core back method, for example, a pre-molded base material is set on the mold surface of a fixed mold Then close the mold by moving the movable mold close, or replace the movable mold with the movable mold for pad molding and close the mold while leaving the molded base material in the fixed mold, and fill the cavity with thermoplastic resin . Then, when the skin layer starts to be generated in the vicinity of the surface of the base material of the thermoplastic resin and in the vicinity of the mold forming surface of the movable mold, the movable mold is moved in the mold opening direction to enlarge the cavity volume, and the thermoplastic resin Foam. As a result, a thick resin pad in which a foam layer having a resin density lower than that of the skin layer is integrally formed inside the skin layer made of a solid layer having a high resin density is integrally formed on the substrate. A resin panel member is obtained.

ところで、パッドの外周縁部に薄肉ソリッド部が形成されている樹脂パネル部材の場合、成形サイクルを短縮しようとしてコアバックのタイミングを早めると、上記薄肉ソリッド部が十分に硬化しておらず、しかも、可動型はコアバックにより薄肉ソリッド部から離れているため、薄肉ソリッド部が発泡してしまう，いわゆる後発泡膨れ現象が起きる。さりとて、コアバックのタイミングを遅くして薄肉ソリッド部の十分な硬化を待つと、パッドのスキン層が必要以上に厚くなってしまう。   By the way, in the case of a resin panel member in which a thin solid portion is formed on the outer peripheral edge of the pad, if the core back timing is advanced in an attempt to shorten the molding cycle, the thin solid portion is not sufficiently cured, Since the movable type is separated from the thin solid portion by the core back, a so-called post-foaming swelling phenomenon occurs in which the thin solid portion foams. When the core back timing is delayed and the thin solid portion is sufficiently cured, the pad skin layer becomes thicker than necessary.

特許文献１には、コアバック法により基材上に一体に成形した発泡層の外周縁部をコアバック時に後発泡膨れしない程度にまで硬化させる技術が開示されている。そのやり方は、キャビティ周縁部のキャビティ空間を他の箇所のキャビティ空間よりも狭小にして当該箇所において熱可塑性樹脂の冷却を促進させている。具体的には、基材周縁部の肉厚を厚くすることで当該箇所のキャビティ空間を狭小にしたり、あるいは、キャビティ周縁部において基材と対向する型の型成形面を基材に接近させることで当該箇所のキャビティ空間を狭小にしている。そして、この技術を上述の如き樹脂パネル部材の成形方法に適用することが考えられる。   Patent Document 1 discloses a technique for curing an outer peripheral edge portion of a foam layer integrally formed on a substrate by a core back method to such an extent that it does not swell after foaming at the time of core back. In this method, the cavity space at the peripheral edge of the cavity is made narrower than the cavity space at other locations, and cooling of the thermoplastic resin is promoted at the locations. Specifically, by increasing the thickness of the peripheral edge of the base material, the cavity space at the location is narrowed, or the mold forming surface of the mold facing the base material is made close to the base material at the peripheral edge of the cavity. In this way, the cavity space of the part is narrowed. And it is possible to apply this technique to the molding method of the resin panel member as described above.

特開平６−３２８４７０号公報（段落００２０〜００２３欄、段落００３３欄、段落００３６欄、図１，２，５，６）JP-A-6-328470 (paragraphs 0020-0023, paragraph 0033, paragraph 0036, FIGS. 1, 2, 5, 6)

しかし、上記の特許文献１では、基材周縁部の肉厚が他の箇所に比べて厚かったり、あるいは基材全体が同じ厚みであるため、キャビティ周縁部の熱可塑性樹脂に基材側の型の型温が影響し難く、特許文献１を上述の如き樹脂パネル部材の成形方法に適用すると、薄肉ソリッド部が冷え難く、基材と対向する型がコアバックにより薄肉ソリッド部から離れていることもあって、薄肉ソリッド部が発泡して後発泡膨れ現象が起きてしまい、樹脂パネル部材の品質が低下する。   However, in the above-mentioned Patent Document 1, since the thickness of the peripheral edge of the base material is thicker than other parts, or the entire base material has the same thickness, the thermoplastic resin at the peripheral edge of the cavity has a mold on the base side. The mold temperature is difficult to affect, and when Patent Document 1 is applied to the method for molding a resin panel member as described above, the thin solid part is difficult to cool, and the mold facing the base material is separated from the thin solid part by the core back. For this reason, the thin-walled solid portion is foamed to cause a foam expansion phenomenon, and the quality of the resin panel member is deteriorated.

この発明はかかる点に鑑みてなされたものであり、その目的とするところは、成形サイクルを長くすることなく、薄肉ソリッド部を十分に冷却硬化させて後発泡膨れ現象をなくすことである。   The present invention has been made in view of this point, and an object of the present invention is to sufficiently cool and cure the thin solid portion without lengthening the molding cycle and eliminate the post-foaming phenomenon.

上記の目的を達成するため、この発明は、基材側の型の型形成面に突設した突出部を基材のパッド外周縁部に対応する箇所に嵌入させることを特徴とする。   In order to achieve the above object, the present invention is characterized in that a protruding portion protruding from a mold forming surface of a mold on the base material side is fitted into a portion corresponding to the pad outer peripheral edge portion of the base material.

具体的には、この発明は、第１型に保持された樹脂製基材と、上記第１型に対向して配置された第２型との間のキャビティに熱可塑性樹脂を充填し、該熱可塑性樹脂の基材表面近傍及び第２型の型成形面近傍にスキン層が生成され始めた時点で、上記第１型又は第２型を型開き方向に移動させてキャビティ容積を拡大して上記熱可塑性樹脂を発泡させることにより、樹脂密度が高いソリッド層からなるスキン層の内部に該スキン層に比べて樹脂密度が低い発泡層が一体に成形された厚肉の樹脂製パッドを上記基材上に一体に成形する樹脂パネル部材の成形方法を対象とし、次のような解決手段を講じた。   Specifically, the present invention fills the cavity between the resin base material held by the first mold and the second mold disposed facing the first mold with a thermoplastic resin, When the skin layer starts to be generated near the base material surface of the thermoplastic resin and near the molding surface of the second mold, the cavity volume is increased by moving the first mold or the second mold in the mold opening direction. By foaming the thermoplastic resin, a thick resin pad in which a foam layer having a resin density lower than that of the skin layer is integrally formed inside the skin layer made of a solid layer having a high resin density is used as the base. The following solution was taken for the molding method of a resin panel member molded integrally on a material.

すなわち、第１の発明は、上記第１型の型成形面には、突出部が上記パッドの外周縁部に対応するように突設され、パッド成形時、上記突出部がキャビティに臨むか、又は上記基材に形成された薄肉部に接触して他の箇所よりもキャビティに接近し、当該キャビティ空間の熱可塑性樹脂がキャビティ容積拡大前に冷却硬化して上記パッドの外周縁部に薄肉ソリッド部を形成することを特徴とする。   That is, according to the first aspect of the present invention, the projecting portion of the first mold is projected so as to correspond to the outer peripheral edge of the pad, and when the pad is molded, the projecting portion faces the cavity, Or, it comes into contact with the thin wall portion formed on the base material and comes closer to the cavity than other places, and the thermoplastic resin in the cavity space is cooled and cured before the cavity volume is expanded, and the thin solid is formed on the outer peripheral edge portion of the pad. Forming a portion.

第２の発明は、第１の発明において、上記パッドは、基材露出部を有するように上記基材上に一体に成形され、パッド外周縁部には、上記基材露出部よりも一段高くなるように段差部が傾斜して設けられ、上記第１型の突出部は、上記段差部に対応するように形成されていることを特徴とする。   According to a second invention, in the first invention, the pad is integrally formed on the base material so as to have a base material exposed portion, and the pad outer peripheral edge portion is one step higher than the base material exposed portion. The step portion is provided so as to be inclined, and the protrusion of the first type is formed so as to correspond to the step portion.

第３の発明は、第２の発明において、上記基材の段差部対応箇所には、上記突出部が嵌入する開口部が形成され、パッド成形時、上記突出部が上記開口部からキャビティに臨んでいることを特徴とする。   According to a third invention, in the second invention, an opening into which the protruding portion is fitted is formed at a position corresponding to the step portion of the base material, and the protruding portion faces the cavity from the opening during pad molding. It is characterized by being.

第４の発明は、第２の発明において、上記基材裏面の段差部対応箇所には、上記突出部が嵌入する嵌入凹部が形成され、当該嵌入凹部対応箇所の基材の肉厚が他の箇所よりも薄く形成されて上記薄肉部を構成していることを特徴とする。   According to a fourth aspect of the present invention, in the second aspect, an insertion concave portion into which the protruding portion is inserted is formed in the step portion corresponding position on the back surface of the base material. The thin-walled portion is formed by being thinner than the portion.

第５の発明は、第１の発明において、上記パッドは、上記基材全体を覆うように基材上に一体に成形されることを特徴とする。   In a fifth aspect based on the first aspect, the pad is integrally formed on the base material so as to cover the entire base material.

第１の発明によれば、突出部が第２型の型成形面に他の箇所に比べて接近しているため、当該箇所のキャビティ空間の熱可塑性樹脂が、上記突出部の型温の影響により他の箇所よりも多く熱を奪われ、キャビティ容積拡大前に確実に冷却硬化して薄肉ソリッド部が形成され、上記第２型がコアバックにより薄肉ソリッド部から離れても、該薄肉ソリッド部は後発泡膨れ現象が起きず、短い成形サイクルで品質の優れた樹脂パネル部材が確実に得られる。   According to the first aspect of the invention, since the protrusion is closer to the molding surface of the second mold than the other part, the thermoplastic resin in the cavity space of the part is affected by the mold temperature of the protrusion. As a result, the heat is taken away more than other parts, and the thin solid part is formed by cooling and hardening surely before expanding the cavity volume. Even if the second mold is separated from the thin solid part by the core back, the thin solid part No post-blowing phenomenon occurs, and a resin panel member with excellent quality can be reliably obtained in a short molding cycle.

第２の発明によれば、基材露出部を有し、かつパッド外周縁部に基材露出部よりも一段高くなるように段差部(23)が傾斜して設けられているタイプの樹脂パネル部材を、後発泡膨れ現象なく、短い成形サイクルで品質良好に成形できる。   According to the second invention, there is provided a resin panel having a base material exposed portion and provided with a stepped portion (23) inclined at the pad outer peripheral edge portion so as to be one step higher than the base material exposed portion. The member can be molded with good quality in a short molding cycle without a post-foaming phenomenon.

第３の発明によれば、突出部先端面がキャビティ空間の熱可塑性樹脂（薄肉ソリッド部）に直接に接触しているため、該薄肉ソリッド部が突出部の型温の影響により他の箇所よりも多く熱を奪われて速やかに冷却硬化される。   According to the third invention, since the front end surface of the protruding portion is in direct contact with the thermoplastic resin (thin solid portion) in the cavity space, the thin solid portion is more affected by the mold temperature of the protruding portion than other locations. Too much heat is taken away and quickly cooled and hardened.

また、キャビティへの熱可塑性樹脂充填時、キャビティ内の気体を突出部と開口部との間を通して型外に排出でき、パッド表面にガス焼けによる見栄え不良をなくすことができる。   Further, when the cavity is filled with the thermoplastic resin, the gas in the cavity can be discharged out of the mold through the gap between the protruding portion and the opening, and appearance defects due to gas burning on the pad surface can be eliminated.

第４の発明によれば、突出部先端面がキャビティ空間の熱可塑性樹脂（薄肉ソリッド部）に他の箇所に比べて接近して当該箇所の基材が薄肉になって薄肉部を構成しているため、第３の発明と同様に、該薄肉ソリッド部が突出部の型温の影響により他の箇所よりも多く熱を奪われて速やかに冷却硬化される。   According to the fourth invention, the tip end surface of the protruding portion approaches the thermoplastic resin (thin solid portion) in the cavity space as compared with other portions, and the base material in the corresponding portion is thinned to constitute the thin portion. Therefore, as in the third aspect of the invention, the thin solid portion is deprived of heat more quickly than other portions due to the mold temperature of the protruding portion, and is quickly cooled and hardened.

また、基材の突出部対応箇所は薄肉ではあるが、開口部が形成されている第３の発明の場合に比べて薄肉ソリッド部対応箇所の剛性を確保できる。   Further, although the portion corresponding to the protruding portion of the base material is thin, the rigidity of the portion corresponding to the thin solid portion can be ensured as compared with the case of the third invention in which the opening is formed.

さらに、基材の基材露出部と基材非露出部との境界（パッドの段差部）が、第３の発明の方法により成形された樹脂パネル部材では、基材に開口部が形成されていることによって弾性変形し易くなっているため、また、第４の発明の方法により成形された樹脂パネル部材では、基材に嵌入凹部が形成されていることによって弾性変形し易くなっているため、衝撃が段差部に加わっても、その衝撃を上記段差部で吸収緩和することができる。   Furthermore, in the resin panel member in which the boundary between the base material exposed portion and the base material unexposed portion of the base material (pad stepped portion) is formed by the method of the third invention, an opening is formed in the base material. Since the resin panel member molded by the method of the fourth invention is easily elastically deformed because it is easily deformed elastically by forming an insertion recess in the base material, Even if an impact is applied to the stepped portion, the impact can be absorbed and relaxed by the stepped portion.

第５の発明によれば、パッドが基材全体を覆っているタイプの樹脂パネル部材を、後発泡膨れ現象なく、短い成形サイクルで品質良好に成形できる。   According to the fifth invention, a resin panel member in which the pad covers the entire substrate can be molded with good quality in a short molding cycle without a post-foaming phenomenon.

実施形態１に係る成形方法により成形された樹脂パネル部材としての車両用インストルメントパネル部材の斜視図である。It is a perspective view of the vehicle instrument panel member as a resin panel member shape | molded by the shaping | molding method which concerns on Embodiment 1. FIG. 図１のＡ−Ａ線で破断した斜視図である。It is the perspective view fractured | ruptured by the AA line of FIG. 図２に対応する基材の斜視図である。It is a perspective view of the base material corresponding to FIG. 実施形態１において成形型のキャビティ内に熱可塑性樹脂を射出充填した状態を示すインストルメントパネル部材の成形工程である。It is a shaping | molding process of the instrument panel member which shows the state which injected and filled the thermoplastic resin in the cavity of the shaping | molding die in Embodiment 1. FIG. 実施形態１において成形型の可動型をキャビティ容積が拡大する方向に後退させてインストルメントパネル部材が成形された状態を示す成形工程図である。FIG. 5 is a molding process diagram showing a state where an instrument panel member is molded by retracting the movable mold of the molding die in the direction in which the cavity volume is enlarged in the first embodiment. 実施形態１で使用する成形型の図１におけるＢ−Ｂ線に対応する概略構成図である。It is a schematic block diagram corresponding to the BB line in FIG. 1 of the shaping | molding die used in Embodiment 1. FIG. 実施形態２の図２相当図である。FIG. 3 is a diagram corresponding to FIG. 2 of the second embodiment. 実施形態２の図３相当図である。FIG. 4 is a diagram corresponding to FIG. 3 of the second embodiment. 実施形態２の図４相当図である。FIG. 5 is a diagram corresponding to FIG. 4 of the second embodiment. 実施形態２の図５相当図である。FIG. 6 is a diagram corresponding to FIG. 5 of the second embodiment. 実施形態３に係る成形方法により成形された樹脂パネル部材としてのコンソールリッドアウターが適用されたコンソールリッドを実線で示す車両用コンソールの斜視図である。It is a perspective view of the console for vehicles which shows the console lid to which the console lid outer as a resin panel member shape | molded by the shaping | molding method which concerns on Embodiment 3 was applied with a continuous line. 図１１のＤ−Ｄ線に対応するコンソールリッドアウターの断面図である。It is sectional drawing of the console lid outer corresponding to the DD line of FIG. 実施形態３の図４相当図である。FIG. 5 is a diagram corresponding to FIG. 4 of the third embodiment. 実施形態３の図５相当図である。FIG. 6 is a diagram corresponding to FIG. 5 of Embodiment 3.

以下、この発明の実施形態について図面に基づいて説明する。   Hereinafter, embodiments of the present invention will be described with reference to the drawings.

（実施形態１）
図１は、この発明の実施形態１に係る成形方法により成形された樹脂パネル部材としての車両用インストルメントパネル部材（アッパパネル）１を示し、当該成形方法を説明する前に、このインストルメントパネル部材１の構成を説明する。このインストルメントパネル部材１は、左右のロアパネル（図示せず）とセンタパネル（図示せず）との四者で、自動車のフロントガラス下方に配設されるインストルメントパネルを構成する。 (Embodiment 1)
FIG. 1 shows an instrument panel member (upper panel) 1 for a vehicle as a resin panel member molded by the molding method according to Embodiment 1 of the present invention, and before explaining the molding method, this instrument panel member 1 will be described. This instrument panel member 1 is an instrument panel that is arranged under the windshield of an automobile with four members, a left and right lower panel (not shown) and a center panel (not shown).

上記インストルメントパネル部材１は、図２及び図３に示すように、インストルメントパネル部材１の本体を構成する樹脂製基材３を備えている。この基材３は、例えば、ポリプロピレン、ＡＢＳ（アクリロニトリル−ブタジエン−スチレン）樹脂、ノリル樹脂等からなる。   The said instrument panel member 1 is equipped with the resin-made base materials 3 which comprise the main body of the instrument panel member 1, as shown in FIG.2 and FIG.3. The base material 3 is made of, for example, polypropylene, ABS (acrylonitrile-butadiene-styrene) resin, noryl resin, or the like.

上記インストルメントパネル部材１の車体前方側領域は、上記基材３が露出した単層構造であり、以下、当該露出部分を基材露出部５という。この基材露出部５には、車幅方向に延びるフロントデフロスターエア吹出口７が形成され、上記基材３の基材露出部５よりも車体後方側領域には、サイドベントエア吹出口９、センターパネル取付部１１等が形成されている（図１参照）。   The vehicle body front side region of the instrument panel member 1 has a single layer structure in which the base material 3 is exposed. Hereinafter, the exposed portion is referred to as a base material exposed portion 5. A front defroster air outlet 7 extending in the vehicle width direction is formed in the base material exposed portion 5, and a side vent air outlet 9 is provided in the vehicle body rear side region of the base material 3 relative to the base material exposed portion 5. A center panel mounting portion 11 and the like are formed (see FIG. 1).

上記基材３の基材露出部５よりも車体後方側領域には、厚肉の樹脂製パッド１３が一体に成形されている。このパッド１３は、例えば、サーモプラスチックオレフィン、サーモプラスチックスチレン等の熱可塑性エラストマーからなり、表裏両面に亘って形成された樹脂密度が高いソリッド層からなる薄肉のスキン層１５の内部に該スキン層１５に比べて樹脂密度が低い発泡層１７が一体に成形されて構成され、発泡層１７の内部に多数の空隙（図示せず）を有している。   A thick resin pad 13 is integrally formed in the rear side region of the base material 3 relative to the base material exposed portion 5 of the base material 3. The pad 13 is made of, for example, a thermoplastic elastomer such as thermoplastic olefin or thermoplastic styrene, and is formed inside the thin skin layer 15 made of a solid layer having a high resin density formed on both the front and back surfaces. The foamed layer 17 having a resin density lower than that of the foamed layer 17 is integrally formed and has a large number of voids (not shown) inside the foamed layer 17.

上記基材３のうちパッド１３で覆われた基材非露出部２１は、基材露出部５よりも一段高くなっていて、両者は、車体前方に向かって前下がりに傾斜する車幅方向に間隔をあけた複数個（図３では１個のみ表れる）の橋絡部２５で連結され、これら橋絡部２５により複数個の開口部２７が車幅方向に間隔をあけて形成されている。そして、上記パッド１３の外周縁部は、上記橋絡部２５及び開口部２７を覆っていて、該外周縁部には、薄肉ソリッド部２９からなる段差部２３が車体前方に向かって前下がりに傾斜するように形成され、該薄肉ソリッド部２９は、上記開口部２７内には入らず、上記橋絡部２５に支えられている。これにより、上記基材３の段差部２３対応箇所に上記開口部２７が形成されている。   The base material unexposed portion 21 covered with the pad 13 in the base material 3 is one step higher than the base material exposed portion 5, and both of them are in the vehicle width direction inclined forward and downward toward the front of the vehicle body. A plurality of bridge portions 25 (only one appears in FIG. 3) are connected at intervals, and a plurality of openings 27 are formed by these bridge portions 25 at intervals in the vehicle width direction. The outer peripheral edge portion of the pad 13 covers the bridging portion 25 and the opening 27, and a step portion 23 made of a thin solid portion 29 is forwardly lowered toward the front of the vehicle body at the outer peripheral edge portion. The thin solid portion 29 is formed so as to be inclined, and is supported by the bridging portion 25 without entering the opening 27. Thereby, the opening 27 is formed at a position corresponding to the step portion 23 of the base material 3.

上述の如きインストルメントパネル部材１を成形するに際し、図６に示すような成形型１０１を用意する。   In forming the instrument panel member 1 as described above, a forming die 101 as shown in FIG. 6 is prepared.

上記成形型１０１は、第１型としてのコア型１０３と、基材キャビ型１０５と、第２型としてのパッドキャビ型１０７とを備えている。   The mold 101 includes a core mold 103 as a first mold, a base mold 105, and a pad mold 107 as a second mold.

上記コア型１０３の両側面には、基材３の裏面形状に対応した型成形面１０９がそれぞれ同形状に形成されている。上記コア型１０３は、上下両面に突設された回転軸１１１回りに駆動装置（図示せず）により鉛直面内で１８０°反転可能になっている。上記型成形面１０９には、図４及び図５に示すように、複数個の突出部１０９ａが上記パッド１３の外周縁部である段差部２３に対応するように突設されている。この各突出部１０９ａの突出寸法は、パッド１３成形時に各突出部１０９ａが上記各開口部２７に嵌入して上記各橋絡部２５と面一になるように設定されている。   On both side surfaces of the core mold 103, mold forming surfaces 109 corresponding to the shape of the back surface of the substrate 3 are formed in the same shape. The core mold 103 can be inverted 180 ° in a vertical plane by a driving device (not shown) around a rotating shaft 111 protruding on both upper and lower surfaces. As shown in FIGS. 4 and 5, a plurality of projecting portions 109 a are provided on the mold forming surface 109 so as to correspond to the step portions 23 that are the outer peripheral edge portions of the pad 13. The projecting dimensions of the projecting portions 109a are set so that the projecting portions 109a are fitted into the opening portions 27 when the pad 13 is formed and are flush with the bridging portions 25.

上記基材キャビ型１０５には、上記基材３の表面形状に対応した型成形面１１３が形成されている（図６参照）。この型成形面１１３には、上記パッド１３の段差部２３（基材露出部５と基材非露出部２１との間）に対応して傾斜面（図示せず）が形成され、該傾斜面は、基材３成形時に上記各突出部１０９ａ先端面に当接し、コア型１０３の型成形面１０９と基材キャビ型１０５の型成形面１１３との間にキャビティ（図示せず）を形成するようになっている。   A mold forming surface 113 corresponding to the surface shape of the substrate 3 is formed on the substrate mold 105 (see FIG. 6). An inclined surface (not shown) corresponding to the stepped portion 23 (between the substrate exposed portion 5 and the substrate non-exposed portion 21) of the pad 13 is formed on the mold forming surface 113. Is in contact with the tip surface of each of the protrusions 109a when the base material 3 is formed, and a cavity (not shown) is formed between the mold forming surface 109 of the core mold 103 and the mold forming surface 113 of the base mold 105. It is like that.

上記パッドキャビ型１０７には、パッド１３の表面形状に対応した型成形面１１５が形成されている（図６参照）。この型成形面１１５には、図４及び図５に示すように、上記パッド１３の段差部２３に対応する傾斜面１１５ａが形成されているとともに、車幅方向に延びる凸条部１１５ｂが上記傾斜面１１５ａに連続して形成され、該凸条部１１５ｂは、パッド１３成形時に基材３の基材露出部５に当接し、該基材３と型成形面１１５との間にキャビティ１１７を形成するようになっている。このキャビティ１１７の上記傾斜面１１５ａと各突出部１０９ａ先端面との間のキャビティ空間１１７ａは、他の箇所に比べて狭小に設定され、パッド１３成形時、上記各突出部１０９ａが上記開口部２７から上記狭小なキャビティ空間１１７ａに臨むようになっている。また、上記傾斜面１１５ａの傾斜角度方向は、最小の型抜き角度を有してパッドキャビ型１０７の型開き方向（図４矢印Ｃ方向）とほぼ同じ方向に設定されている。   The pad mold 107 has a molding surface 115 corresponding to the surface shape of the pad 13 (see FIG. 6). As shown in FIGS. 4 and 5, an inclined surface 115a corresponding to the stepped portion 23 of the pad 13 is formed on the mold forming surface 115, and a ridge 115b extending in the vehicle width direction is inclined. The protrusion 115b is formed continuously with the surface 115a, and abuts against the substrate exposed portion 5 of the substrate 3 when the pad 13 is formed, thereby forming a cavity 117 between the substrate 3 and the mold forming surface 115. It is supposed to be. A cavity space 117a between the inclined surface 115a of the cavity 117 and the front end surface of each protrusion 109a is set to be narrower than other portions, and when the pad 13 is formed, each protrusion 109a is formed in the opening 27. From the narrow cavity space 117a. In addition, the inclination angle direction of the inclined surface 115a is set to the same direction as the mold opening direction (the direction of arrow C in FIG. 4) of the pad cavity mold 107 with the minimum die-cutting angle.

図４及び図５中、１１９は高温の樹脂温の熱影響で型温が上昇するのを抑制するために冷却水を循環させる冷却水通路である。   4 and 5, reference numeral 119 denotes a cooling water passage for circulating the cooling water in order to suppress the mold temperature from rising due to the heat effect of the high resin temperature.

このように構成された成形型１０１を用いてインストルメントパネル部材１を成形する要領について説明する。なお、以下に括弧書で付した番号は成形工程の順番を示す。   The point which shape | molds the instrument panel member 1 using the shaping | molding die 101 comprised in this way is demonstrated. In addition, the number attached | subjected in the parenthesis below shows the order of a shaping | molding process.

（１）コア型１０３と基材キャビ型１０５とを型閉めしてコア型１０３と基材キャビ型１０５との間にキャビティを形成し、該キャビティに例えば、ポリプロピレン、ＡＢＳ（アクリロニトリル−ブタジエン−スチレン）樹脂、ノリル樹脂等からなる熱可塑性樹脂を充填する。これにより、図３に示すように、パッド１３で覆われる基材非露出部２１が基材露出部５よりも一段高くなった基材３が成形され、基材非露出部２１と基材露出部５との間に、車体前方に向かって前下がりに傾斜する複数個（図３では１個のみ表れる）の橋絡部２５が車幅方向に間隔をあけて形成され、これら橋絡部２５により複数個の開口部２７が車幅方向に間隔をあけて形成されている。   (1) The core mold 103 and the base mold 105 are closed to form a cavity between the core mold 103 and the base mold 105, and for example, polypropylene, ABS (acrylonitrile-butadiene-styrene) is formed in the cavity. ) A thermoplastic resin made of resin, noryl resin or the like is filled. As a result, as shown in FIG. 3, the base material 3 in which the base material unexposed portion 21 covered with the pad 13 is one step higher than the base material exposed portion 5 is formed, and the base material nonexposed portion 21 and the base material exposed portion are exposed. A plurality of bridging portions 25 (only one appears in FIG. 3) inclined forward and downward toward the front of the vehicle body are formed between the portions 5 at intervals in the vehicle width direction. Thus, a plurality of openings 27 are formed at intervals in the vehicle width direction.

（２）基材キャビ型１０５を後退させてコア型１０３と基材キャビ型１０５とを型開きする。成形された基材３は、コア型１０３に保持され、各突出部１０９ａが上記各開口部２７に嵌入して上記各橋絡部２５と面一になり、各突出部１０９ａ先端面が各開口部２７から露呈している。この状態でコア型１０３を回転軸１１１回りに駆動装置（図示せず）により鉛直面内で１８０°反転させる。   (2) The base mold 103 and the base mold 105 are opened by retracting the base mold 105. The molded base material 3 is held by the core mold 103, and each protrusion 109a is fitted into each opening 27 to be flush with each bridge 25, and the tip of each protrusion 109a is open to each opening. Part 27 is exposed. In this state, the core mold 103 is inverted 180 ° around the rotation axis 111 by a driving device (not shown) in the vertical plane.

（３）パッドキャビ型１０７を進出させて上記コア型１０３とパッドキャビ型１０７とを型閉めし、図４に示すように、基材３とパッドキャビ型１０７との間にキャビティ１１７を形成する。このキャビティ１１７は、パッドキャビ型１０７の傾斜面１１５ａと各突出部１０９ａ先端面との間の間隔が他の箇所に比べて狭小に設定されて、狭小なキャビティ空間１１７ａを構成し、上記各突出部１０９ａが上記狭小なキャビティ空間１１７ａに臨んで他の箇所よりもキャビティ１１７に接近している。   (3) The pad mold 107 is advanced to close the core mold 103 and the pad mold 107, and a cavity 117 is formed between the substrate 3 and the pad mold 107 as shown in FIG. . The cavity 117 has a narrow space between the inclined surface 115a of the pad cavity mold 107 and the front end surface of each protruding portion 109a as compared with other portions, thereby forming a narrow cavity space 117a. The portion 109a faces the narrow cavity space 117a and is closer to the cavity 117 than other portions.

（４）このように、上記コア型１０３に保持された基材３と、上記コア型１０３に対向して配置されたパッドキャビ型１０７との間のキャビティ１１７に例えば、サーモプラスチックオレフィン、サーモプラスチックスチレン等の熱可塑性エラストマーからなる熱可塑性樹脂Ｒを充填する。この熱可塑性樹脂Ｒとしては、例えば、化学反応によりガスを発生させる化学的発泡剤や、MuCell（ミューセル：登録商標） Processのように二酸化炭素ガス及び窒素ガス等の不活性ガス（物理的発泡剤）等が超臨界状態で混入された熱可塑性樹脂であり、ガラス繊維等の繊維が混入されていてもよいが、必ずしもこれらを混入していなくてもよい。   (4) In this manner, for example, in the cavity 117 between the base material 3 held by the core mold 103 and the pad cavity mold 107 disposed to face the core mold 103, for example, thermoplastic olefin, thermoplastic A thermoplastic resin R made of a thermoplastic elastomer such as styrene is filled. Examples of the thermoplastic resin R include a chemical foaming agent that generates a gas by a chemical reaction, and an inert gas (physical foaming agent) such as carbon dioxide gas and nitrogen gas as in the MuCell (registered trademark) process. ) And the like are thermoplastic resins mixed in a supercritical state, and fibers such as glass fibers may be mixed, but these are not necessarily mixed.

（５）上記熱可塑性樹脂Ｒの基材３表面近傍及びパッドキャビ型１０７の型成形面１１５近傍が型温により冷却されて当該箇所にスキン層１５が生成され始めた時点で、上記パッドキャビ型１０７を基材３から型開き方向（図４矢印Ｃ方向）に移動（後退）させてキャビティ容積を拡大する。このキャビティ１１７の容積拡大により、それまで基材３とパッドキャビ型１０７との間で圧縮されている熱可塑性樹脂Ｒが、パッドキャビ型１０７に引っ張られるとともに、熱可塑性樹脂Ｒ中の化学反応によって発生したガスや不活性ガス等の内部ガスによって発泡膨張するが、上記狭小なキャビティ空間１１７ａの熱可塑性樹脂Ｒが上記突出部１０９ａの型温の影響により他の箇所よりも多く熱を奪われ、キャビティ容積拡大前に冷却硬化して、上記パッド１３の外周縁部に薄肉ソリッド部２９が一足早く形成される。   (5) When the vicinity of the surface of the base material 3 of the thermoplastic resin R and the vicinity of the molding surface 115 of the pad cavity mold 107 are cooled by the mold temperature, and the skin layer 15 starts to be generated at the location, the pad cavity mold 107 is moved (retracted) from the substrate 3 in the mold opening direction (direction of arrow C in FIG. 4) to enlarge the cavity volume. Due to the volume expansion of the cavity 117, the thermoplastic resin R that has been compressed between the base material 3 and the pad mold 107 is pulled by the pad mold 107, and by a chemical reaction in the thermoplastic resin R. Although the foaming expansion is caused by the generated gas or an internal gas such as an inert gas, the thermoplastic resin R in the narrow cavity space 117a is deprived of heat more than other portions due to the mold temperature of the protrusion 109a, Cooling and hardening is performed before the cavity volume is expanded, and a thin solid portion 29 is quickly formed on the outer peripheral edge of the pad 13.

その結果、熱可塑性樹脂Ｒの外周りに樹脂密度が高いソリッド層からなるスキン層１５が形成され、該スキン層１５の内部に該スキン層１５に比べて樹脂密度が低い発泡層１７が一体に成形された厚肉のパッド１３が、車体前方側領域に基材露出部５を有するように上記基材３上に一体に成形されたインストルメントパネル部材１が得られる。   As a result, a skin layer 15 made of a solid layer having a high resin density is formed around the outer periphery of the thermoplastic resin R, and a foam layer 17 having a resin density lower than that of the skin layer 15 is integrally formed inside the skin layer 15. The instrument panel member 1 is obtained in which the molded thick pad 13 is integrally formed on the base material 3 so that the base material exposed portion 5 is provided in the vehicle front side region.

また、上記傾斜面１１５ａの傾斜角度方向は、最小の型抜き角度を有してパッドキャビ型１０７の型開き方向（図４矢印Ｃ方向）とほぼ同じ方向に設定されているので、上記パッドキャビ型１０７を基材３から型開き方向（図４矢印Ｃ方向）に移動させても、薄肉ソリッド部２９の熱可塑性樹脂Ｒがパッドキャビ型１０７によって膨張する方向へ引っ張られることはない。   In addition, the inclination angle direction of the inclined surface 115a is set to the same direction as the mold opening direction (the direction of arrow C in FIG. 4) of the pad mold mold 107 with the minimum die-cutting angle. Even if the mold 107 is moved from the base material 3 in the mold opening direction (direction of arrow C in FIG. 4), the thermoplastic resin R of the thin solid portion 29 is not pulled in the direction of expansion by the pad-cavity mold 107.

（６）パッドキャビ型１０７を後退させてコア型１０３とパッドキャビ型１０７とを型開きし、成形されたインストルメントパネル部材１をコア型１０３から脱型する。なお、このようにパッドキャビ型１０７側で基材３表面にパッド１３を成形する過程で、基材キャビ型１０５側では、前述した要領で基材３を成形する。   (6) The pad mold 107 is moved backward to open the core mold 103 and the pad mold 107, and the molded instrument panel member 1 is removed from the core mold 103. In the process of forming the pad 13 on the surface of the base material 3 on the pad mold 107 side, the base material 3 is formed on the base mold 105 side in the manner described above.

上述した工程を繰り返すことで、コア型１０３の両側面でインストルメントパネル部材１の成形を連続して行う。   By repeating the above-described steps, the instrument panel member 1 is continuously formed on both side surfaces of the core mold 103.

このように、実施形態１では、コア型１０３の各突出部１０９ａ先端面をパッドキャビ型１０７の型成形面１１５に他の箇所に比べて接近させているので、当該箇所の狭小なキャビティ空間１１７ａの熱可塑性樹脂Ｒから上記各突出部１０９ａの型温の影響により他の箇所よりも多く熱を奪い、上記熱可塑性樹脂Ｒをキャビティ容積拡大前に確実に冷却硬化させて薄肉ソリッド部２９を形成し、上記パッドキャビ型１０７がコアバックにより薄肉ソリッド部２９から離れても、該薄肉ソリッド部２９に後発泡膨れ現象が起きないようにすることができ、短い成形サイクルで品質の優れたインストルメントパネル部材１を確実に得ることができる。   As described above, in the first embodiment, the front end surface of each protruding portion 109a of the core mold 103 is brought closer to the mold forming surface 115 of the pad cavity mold 107 as compared with other portions, and therefore, the narrow cavity space 117a at the corresponding portion. The thermoplastic resin R is deprived of heat more than other places due to the mold temperature of the protrusions 109a, and the thermoplastic resin R is cooled and hardened securely before the cavity volume is expanded to form a thin solid portion 29. In addition, even if the pad mold 107 is separated from the thin solid portion 29 by the core back, it is possible to prevent the post-foaming phenomenon from occurring in the thin solid portion 29, and an instrument having excellent quality in a short molding cycle. The panel member 1 can be obtained reliably.

また、実施形態１では、上記各突出部１０９ａ先端面が狭小なキャビティ空間１１７ａの熱可塑性樹脂Ｒ（薄肉ソリッド部２９）に直接に接触しているので、該薄肉ソリッド部２９から各突出部１０９ａの型温の影響により熱を速やかに奪い、薄肉ソリッド部２９の冷却硬化を一段と促進させることができる。   In the first embodiment, the front end surface of each projection 109a is in direct contact with the thermoplastic resin R (thin solid portion 29) in the narrow cavity space 117a, so that each projection 109a extends from the thin solid portion 29. Due to the influence of the mold temperature, the heat can be quickly taken away, and the cooling and hardening of the thin solid portion 29 can be further promoted.

さらに、実施形態１では、キャビティ１１７への熱可塑性樹脂Ｒ充填時、キャビティ１１７内の気体を各突出部１０９ａと各開口部２７との間から基材３の裏面とコア型１０３の型成形面１０９との間を通して型外に排出できるので、パッド１３表面にガス焼けによる見栄え不良をなくすことができる。   Furthermore, in the first embodiment, when the thermoplastic resin R is filled into the cavity 117, the gas in the cavity 117 flows from between the protrusions 109 a and the openings 27 to the back surface of the substrate 3 and the molding surface of the core mold 103. Since it can discharge | emit out of a type | mold through 109, the appearance defect by gas burning can be eliminated on the pad 13 surface.

さらにまた、実施形態１では、基材３の基材露出部５と基材非露出部２１との境界（パッド１３の段差部２３）を、基材３に形成された複数個の開口部２７によって弾性変形し易くしているので、歩行者が衝突してフロントガラスを突き破って段差部２３に当たっても、その際の衝撃を上記段差部２３で吸収緩和することができ、歩行者保護の観点から望ましい。   Furthermore, in the first embodiment, a plurality of openings 27 formed in the base 3 at the boundary (the stepped portion 23 of the pad 13) between the base exposed portion 5 and the base non-exposed portion 21 of the base 3. Therefore, even if a pedestrian collides, breaks through the windshield and hits the stepped portion 23, the shock at that time can be absorbed and relaxed by the stepped portion 23, from the viewpoint of protecting the pedestrian. desirable.

（実施形態２）
図７〜１０は実施形態２に係る成形方法及び該成形方法により成形された樹脂パネル部材としての車両用インストルメントパネル部材１を示す。実施形態２では、実施形態１の開口部２７に代えて、各突出部１０９ａが嵌入する嵌入凹部３１を基材３裏面の段差部２３対応箇所に複数個形成し、当該嵌入凹部３１対応箇所の基材３の肉厚が他の箇所よりも薄く形成されて薄肉部３３を構成している。つまり、各突出部１０９ａの突出寸法が実施形態１に比べて短くなっている。そのほかは、実施形態１と同様に構成されているので、同一の構成箇所には同一の符号を付してその詳細な説明を省略する。 (Embodiment 2)
7 to 10 show a molding method according to Embodiment 2 and a vehicle instrument panel member 1 as a resin panel member molded by the molding method. In the second embodiment, instead of the opening 27 of the first embodiment, a plurality of insertion recesses 31 into which the respective protrusions 109a are inserted are formed in the corresponding portions of the stepped portion 23 on the back surface of the base material 3, and The thickness of the base material 3 is formed to be thinner than other portions to constitute the thin portion 33. That is, the protrusion dimension of each protrusion 109a is shorter than that of the first embodiment. Other than that, the configuration is the same as that of the first embodiment, and therefore, the same components are denoted by the same reference numerals and detailed description thereof is omitted.

したがって、実施形態２では、各突出部１０９ａ先端面を狭小なキャビティ空間１１７ａの熱可塑性樹脂Ｒ（薄肉ソリッド部２９）に他の箇所に比べて接近させて基材３の突出部１０９ａ対応箇所を薄肉にして薄肉部３３としているので、実施形態１と同様に、該薄肉ソリッド部２９から各突出部１０９ａの型温の影響により熱を速やかに奪い、薄肉ソリッド部２９の冷却硬化を一段と促進させることができる。したがって、上記パッドキャビ型１０７がコアバックにより薄肉ソリッド部２９から離れても、該薄肉ソリッド部２９に後発泡膨れ現象が起きないようにすることができ、短い成形サイクルで品質の優れたインストルメントパネル部材１を確実に得ることができる。   Therefore, in the second embodiment, the front end surface of each protrusion 109a is brought closer to the thermoplastic resin R (thin solid portion 29) in the narrow cavity space 117a as compared with the other portions, and the portions corresponding to the protrusions 109a of the base material 3 are arranged. Since the thin portion is used as the thin portion 33, as in the first embodiment, heat is quickly taken away from the thin solid portion 29 due to the mold temperature of each protrusion 109a, and the cooling and hardening of the thin solid portion 29 is further promoted. be able to. Therefore, even if the pad mold 107 is separated from the thin solid portion 29 by the core back, it is possible to prevent the after-foaming phenomenon from occurring in the thin solid portion 29, and an instrument having excellent quality in a short molding cycle. The panel member 1 can be obtained reliably.

また、実施形態２では、基材３の１０９ａ対応箇所は薄肉ではあるが、開口部２７が形成されている実施形態１の場合に比べて薄肉ソリッド部２９対応箇所の剛性を確保することができる。   In Embodiment 2, the portion corresponding to 109a of the base material 3 is thin, but the rigidity of the portion corresponding to the thin solid portion 29 can be ensured as compared to the case of Embodiment 1 in which the opening 27 is formed. .

さらに、実施形態２では、基材３の基材露出部５と基材非露出部２１との境界（パッド１３の段差部２３）を、基材３に形成された嵌入凹部３１によって弾性変形し易くしているので、歩行者が衝突してフロントガラスを突き破って段差部に当たっても、その際の衝撃を上記段差部２３で吸収緩和することができ、歩行者保護の観点から望ましい。   Furthermore, in the second embodiment, the boundary (the stepped portion 23 of the pad 13) between the base material exposed portion 5 and the base material unexposed portion 21 of the base material 3 is elastically deformed by the insertion concave portion 31 formed in the base material 3. Therefore, even if a pedestrian collides and breaks through the windshield and hits the stepped portion, the impact at that time can be absorbed and relaxed by the stepped portion 23, which is desirable from the viewpoint of pedestrian protection.

（実施形態３）
図１１は車両用コンソール５１を示す。このコンソール５１は、コンソール本体５３（仮想線で示す）とコンソールリッド５５とからなり、該コンソールリッド５５は、図１２に示すように、コンソールリッドアウター５７とコンソールリッドインナー５９（仮想線で示す）とで構成されている。図１２中、６１は上記コンソールリッドアウター５７裏面に一体に突設されたボスであり、該ボス６１のネジ挿入孔６１ａにタッピングネジ６３をねじ込むことで、上記コンソールリッドインナー５９をコンソールリッドアウター５７に固定してコンソールリッド５５を組み立てるようになっている。６５はコンソールリッドインナー５９をコンソールリッドアウター５７に位置決めするリブである。そして、上記コンソールリッドアウター５７が、実施形態３に係る成形方法により成形された樹脂パネル部材である。 (Embodiment 3)
FIG. 11 shows the vehicle console 51. The console 51 includes a console main body 53 (indicated by phantom lines) and a console lid 55. As shown in FIG. 12, the console lid 55 has a console lid outer 57 and a console lid inner 59 (indicated by phantom lines). It consists of and. In FIG. 12, reference numeral 61 denotes a boss integrally projecting from the back surface of the console lid outer 57. By screwing a tapping screw 63 into the screw insertion hole 61 a of the boss 61, the console lid inner 59 is connected to the console lid outer 57. The console lid 55 is assembled by being fixed to. Reference numeral 65 denotes a rib for positioning the console lid inner 59 on the console lid outer 57. The console lid outer 57 is a resin panel member molded by the molding method according to the third embodiment.

上記コンソールリッドアウター５７は、基材３と該基材３全体を覆うように基材３上に一体に成形されたパッド１３とで構成され、基材３外周縁部には薄肉部３３が全周に亘って形成されている。上記パッド１３は、実施形態１，２と同様に、表裏両面に亘って形成された樹脂密度が高いソリッド層からなる薄肉のスキン層１５の内部に該スキン層１５に比べて樹脂密度が低い発泡層１７が一体に成形されて構成され、発泡層１７の内部に多数の空隙（図示せず）を有している。   The console lid outer 57 is composed of the base material 3 and the pad 13 integrally formed on the base material 3 so as to cover the whole base material 3, and the thin wall portion 33 is entirely formed on the outer peripheral edge of the base material 3. It is formed over the circumference. In the same manner as in the first and second embodiments, the pad 13 is a foam having a resin density lower than that of the skin layer 15 in the thin skin layer 15 formed of a solid layer having a high resin density formed on both the front and back surfaces. The layer 17 is integrally formed and has a large number of voids (not shown) inside the foam layer 17.

図１３及び図１４は、上記コンソールリッドアウター５７を成形するためのコア型１０３及びパッドキャビ型１０７を示す。   FIGS. 13 and 14 show a core mold 103 and a pad cavity mold 107 for molding the console lid outer 57.

上記コア型１０３の型成形面１０９外周縁部には、突出部１０９ａが上記基材３の薄肉部３３に対応するように全周に亘って突設され、該基材３の薄肉部３３と上記コア型１０３の突出部１０９ａとは共に、上記パッド１３外周縁部に対応するように形成されている。そのほか、実施形態１と同じ型構造部分には同じ符号を付している。   On the outer peripheral edge portion of the molding surface 109 of the core mold 103, a protruding portion 109 a protrudes over the entire circumference so as to correspond to the thin portion 33 of the base material 3, and the thin portion 33 of the base material 3 and Together with the protruding portion 109a of the core mold 103, it is formed so as to correspond to the outer peripheral edge portion of the pad 13. In addition, the same reference numerals are given to the same mold structure as in the first embodiment.

上記コンソールリッドアウター５７は実施形態１で説明した要領にて成形される。そして、パッド１３成形時、上記突出部１０９ａが上記基材３の薄肉部３３に接触して他の箇所よりもキャビティ１１７に接近し、当該キャビティ空間１１７ａの熱可塑性樹脂Ｒがキャビティ容積拡大前に冷却硬化して上記パッド１３外周縁部に薄肉ソリッド部２９を形成するようになっている。   The console lid outer 57 is formed as described in the first embodiment. When the pad 13 is molded, the protruding portion 109a comes into contact with the thin portion 33 of the base material 3 and comes closer to the cavity 117 than the other portions, so that the thermoplastic resin R in the cavity space 117a is before the cavity volume is expanded. The thin solid portion 29 is formed on the outer peripheral edge of the pad 13 by cooling and hardening.

したがって、実施形態３では、各突出部１０９ａ先端面をキャビティ空間１１７ａの熱可塑性樹脂Ｒ（薄肉ソリッド部２９）に他の箇所に比べて接近させて基材３の突出部１０９ａ対応箇所を薄肉にして薄肉部３３としているので、実施形態１と同様に、該薄肉ソリッド部２９から各突出部１０９ａの型温の影響により熱を速やかに奪い、薄肉ソリッド部２９の冷却硬化を一段と促進させることができる。したがって、上記パッドキャビ型１０７がコアバックにより薄肉ソリッド部２９から離れても、該薄肉ソリッド部２９に後発泡膨れ現象が起きないようにすることができ、短い成形サイクルで品質の優れたコンソールリッドアウター５７を確実に得ることができる。   Therefore, in the third embodiment, the front end surface of each protruding portion 109a is brought closer to the thermoplastic resin R (thin solid portion 29) in the cavity space 117a as compared with other portions, and the portion corresponding to the protruding portion 109a of the base material 3 is made thin. Therefore, as in the first embodiment, heat can be quickly removed from the thin solid portion 29 due to the mold temperature of each protruding portion 109a, and the cooling and hardening of the thin solid portion 29 can be further promoted. it can. Therefore, even if the pad mold 107 is separated from the thin solid portion 29 by the core back, it is possible to prevent the after-foaming phenomenon from occurring in the thin solid portion 29, and the console lid having excellent quality in a short molding cycle. The outer 57 can be obtained reliably.

なお、実施形態２において、コア型１０３の突出部１０９ａを車幅方向に連続させて長尺状にすることで、基材３の段差部２３対応箇所を橋絡部２５のない薄肉部３３のみとしてもよい。   In the second embodiment, the protruding portion 109a of the core mold 103 is continuously formed in the vehicle width direction so as to be elongated, so that the portion corresponding to the step portion 23 of the base material 3 is only the thin portion 33 without the bridging portion 25. It is good.

また、実施形態１，２では、樹脂パネル部材が車両用インストルメントパネル部材１であり、実施形態３では、車両のコンソールリッドアウター５７である場合を示したが、ドアトリム等のトリム類、ピラー類、マッドガード等であってもよい。   In the first and second embodiments, the resin panel member is the vehicle instrument panel member 1, and in the third embodiment, the case is the console lid outer 57 of the vehicle. A mud guard or the like may be used.

さらに、実施形態３では、基材３外周縁部に薄肉部３３を全周に亘って形成したが、これを省略してパッド１３外周縁部を基材３外周縁部から延出させてもよい。   Furthermore, in Embodiment 3, although the thin part 33 was formed in the outer periphery part of the base material 3 over the perimeter, even if this was abbreviate | omitted and the pad 13 outer peripheral part extended from the base material 3 outer periphery part, Good.

この発明は、キャビティ容積を拡大させるコアバック法により、樹脂製基材の表面に樹脂製パッドが一体に成形されたインストルメントパネル部材等の樹脂パネル部材の成形方法について有用である。   INDUSTRIAL APPLICABILITY The present invention is useful for a method for molding a resin panel member such as an instrument panel member in which a resin pad is integrally formed on the surface of a resin base material by a core back method for expanding a cavity volume.

１ インストルメントパネル部材（樹脂パネル部材）
３ 基材
５ 基材露出部
１３ パッド
１５ スキン層
１７ 発泡層
２３ 段差部
２７ 開口部
２９ 薄肉ソリッド部
３１ 嵌入凹部
３３ 薄肉部
５７ コンソールリッドアウター（樹脂パネル部材）
１０３ コア型（第１型）
１０７ パッドキャビ型（第２型）
１０９ コア型（第１型）の型成形面
１０９ａ 突出部
１１５ パッドキャビ型（第２型）の型成形面
１１７ キャビティ
１１７ａ キャビティ空間
Ｒ 熱可塑性樹脂 1 Instrument panel member (resin panel member)
3 Substrate 5 Substrate exposed portion 13 Pad 15 Skin layer 17 Foamed layer 23 Stepped portion 27 Opening portion 29 Thin solid portion 31 Insertion recessed portion 33 Thin portion 57 Console lid outer (resin panel member)
103 Core type (first type)
107 Pad Cavity Type (Type 2)
109 Core mold (first mold) mold molding surface 109a Projection 115 Pad mold mold (second mold) mold molding surface 117 Cavity 117a Cavity space R Thermoplastic resin

Claims (5)

第１型(103)に保持された樹脂製基材(3)と、上記第１型(103)に対向して配置された第２型(107)との間のキャビティ(117)に熱可塑性樹脂(R)を充填し、該熱可塑性樹脂(R)の基材(3)表面近傍及び第２型(107)の型成形面(115)近傍にスキン層(15)が生成され始めた時点で、上記第１型(103)又は第２型(107)を型開き方向に移動させてキャビティ容積を拡大して上記熱可塑性樹脂(R)を発泡させることにより、樹脂密度が高いソリッド層からなるスキン層(15)の内部に該スキン層(15)に比べて樹脂密度が低い発泡層(17)が一体に成形された厚肉の樹脂製パッド(13)を上記基材(3)上に一体に成形する樹脂パネル部材の成形方法であって、
上記第１型(103)の型成形面(109)には、突出部(109a)が上記パッド(13)の外周縁部に対応するように突設され、
パッド(13)成形時、上記突出部(109a)がキャビティ(117)に臨むか、又は上記基材(3)に形成された薄肉部(33)に接触して他の箇所よりもキャビティ(117)に接近し、当該キャビティ空間(117a)の熱可塑性樹脂(R)がキャビティ容積拡大前に冷却硬化して上記パッド(13)の外周縁部に薄肉ソリッド部(29)を形成することを特徴とする樹脂パネル部材の成形方法。 The cavity (117) between the resin base material (3) held by the first mold (103) and the second mold (107) disposed to face the first mold (103) is thermoplastic. When the resin (R) is filled and the skin layer (15) starts to be formed near the surface of the base material (3) of the thermoplastic resin (R) and the molding surface (115) of the second mold (107) Then, by moving the first mold (103) or the second mold (107) in the mold opening direction to expand the cavity volume and foam the thermoplastic resin (R), the solid layer having a high resin density is removed. A thick resin pad (13) formed integrally with a foam layer (17) having a resin density lower than that of the skin layer (15) is formed on the substrate (3). A method of molding a resin panel member integrally molded with
On the molding surface (109) of the first mold (103), a protruding portion (109a) is provided so as to correspond to the outer peripheral edge of the pad (13),
When the pad (13) is molded, the protrusion (109a) faces the cavity (117), or comes into contact with the thin wall portion (33) formed on the base material (3) so that the cavity (117 ), The thermoplastic resin (R) in the cavity space (117a) is cooled and hardened before the cavity volume is expanded to form a thin solid portion (29) on the outer peripheral edge of the pad (13). A method for forming a resin panel member. 請求項１に記載の樹脂パネル部材の成形方法において、
上記パッド(13)は、基材露出部(5)を有するように上記基材(3)上に一体に成形され、パッド(13)外周縁部には、上記基材露出部(5)よりも一段高くなるように段差部(23)が傾斜して設けられ、
上記第１型(103)の突出部(109a)は、上記段差部(23)に対応するように形成されていることを特徴とする樹脂パネル部材の成形方法。 In the molding method of the resin panel member according to claim 1,
The pad (13) is integrally formed on the base material (3) so as to have a base material exposed portion (5), and the pad (13) outer peripheral edge portion is formed from the base material exposed portion (5). Step part (23) is provided so as to be higher by one step,
The method for molding a resin panel member, wherein the protruding portion (109a) of the first mold (103) is formed to correspond to the stepped portion (23). 請求項２に記載の樹脂パネル部材の成形方法において、
上記基材(3)の段差部(23)対応箇所には、上記突出部(109a)が嵌入する開口部(27)が形成され、
パッド(13)成形時、上記突出部(109a)が上記開口部(27)からキャビティ(117)に臨んでいることを特徴とする樹脂パネル部材の成形方法。 In the molding method of the resin panel member according to claim 2,
An opening (27) into which the protruding portion (109a) is fitted is formed at a position corresponding to the step portion (23) of the base material (3),
The method for molding a resin panel member, wherein the protrusion (109a) faces the cavity (117) from the opening (27) when the pad (13) is molded. 請求項２に記載の樹脂パネル部材の成形方法において、
上記基材(3)裏面の段差部(23)対応箇所には、上記突出部(109a)が嵌入する嵌入凹部(31)が形成され、当該嵌入凹部(31)対応箇所の基材(3)の肉厚が他の箇所よりも薄く形成されて上記薄肉部(33)を構成していることを特徴とする樹脂パネル部材の成形方法。 In the molding method of the resin panel member according to claim 2,
An insertion recess (31) into which the protruding portion (109a) is inserted is formed at a position corresponding to the step portion (23) on the back surface of the base material (3), and the base material (3) corresponding to the insertion recess (31). The thin-walled portion (33) is formed by forming the thin-wall portion thinner than other portions, and the method for forming the resin panel member is characterized in that: 請求項１に記載の樹脂パネル部材の成形方法において、
上記パッド(13)は、上記基材(3)全体を覆うように基材(3)上に一体に成形されることを特徴とする樹脂パネル部材の成形方法。 In the molding method of the resin panel member according to claim 1,
The method of molding a resin panel member, wherein the pad (13) is molded integrally on the base material (3) so as to cover the entire base material (3).
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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014223843A (en) * 2013-05-16 2014-12-04 河西工業株式会社 Skin material lamination structure for interior component for vehicle

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014223843A (en) * 2013-05-16 2014-12-04 河西工業株式会社 Skin material lamination structure for interior component for vehicle

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