JP3250511B2 - Skin integral lamination molding method - Google Patents
Skin integral lamination molding methodInfo
- Publication number
- JP3250511B2 JP3250511B2 JP3162598A JP3162598A JP3250511B2 JP 3250511 B2 JP3250511 B2 JP 3250511B2 JP 3162598 A JP3162598 A JP 3162598A JP 3162598 A JP3162598 A JP 3162598A JP 3250511 B2 JP3250511 B2 JP 3250511B2
- Authority
- JP
- Japan
- Prior art keywords
- mold
- layer
- skin
- temperature
- skin sheet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
- B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Description
【発明の詳細な説明】DETAILED DESCRIPTION OF THE INVENTION
【0001】[0001]
【発明の属する技術分野】本発明は、クッション性ある
いは断熱性等を付与することを目的として、コア材の賦
形と同時に、裏面もしくは中間層に発泡層を有する表皮
シートをコア層の表面に融着一体化した成形品を得る表
皮一体貼合わせ成形方法に関するものである。BACKGROUND OF THE INVENTION The present invention relates to a skin sheet having a foam layer on the back surface or an intermediate layer on the surface of the core layer at the same time as the shaping of the core material for the purpose of imparting cushioning or heat insulation. The present invention relates to a skin integral lamination molding method for obtaining a fusion-integrated molded product.
【0002】[0002]
【従来の技術】近年、自動車、家電、建材等に使用され
る樹脂成形品は、クッション性、断熱性、手触り感等の
付加価値を付けて品質を高めたり、成形工程の省工程化
によるコストダウンのために、裏面もしくは中間層に発
泡層を有する表皮シートをコア層の表面に融着一体化し
た成形品を、下記に示すような2層成形法で貼合わせ成
形していた。すなわち、 射出成形機を使用して2層成形を行なう方法 型開された両金型間に表皮シートをセットし、型閉して
型締力を作用させた後、表皮シートと金型とで形成され
た金型キャビティ空間内に、射出装置によりコア層とな
る溶融樹脂を射出充填する。保圧、冷却の完了後、型開
して成形品取り出しを行なう。 プレス成形機を使用して2層成形を行なう方法 型開された両金型間に表皮シートをセットし、型閉して
両金型間に所定の型開量を保持したまま、表皮シートと
金型とで形成された金型キャビティ空間内に、樹脂溶融
ユニットによりコア層となる溶融樹脂を吐出する。両金
型を型閉後プレスして型締力を作用させ所定時間冷却の
後、型開して成形品取り出しを行なう。2. Description of the Related Art In recent years, resin molded products used for automobiles, home appliances, building materials, and the like have been improved in quality by adding added values such as cushioning properties, heat insulating properties, and feeling of touch, and costs have been reduced by reducing the number of molding steps. For downing, a molded product obtained by fusing and integrating a skin sheet having a foamed layer on the back surface or the intermediate layer on the surface of the core layer was bonded and formed by a two-layer molding method as described below. That is, a method of performing two-layer molding using an injection molding machine. A skin sheet is set between both molds that have been opened, a mold is closed and a mold clamping force is applied. A molten resin to be a core layer is injected and filled into the formed mold cavity space by an injection device. After completion of the pressure holding and cooling, the mold is opened and the molded product is taken out. Method of performing two-layer molding using a press molding machine Set a skin sheet between both molds that have been opened, close the mold and maintain a predetermined mold opening amount between the two molds, and form a skin sheet with the skin sheet. A molten resin serving as a core layer is discharged by a resin melting unit into a mold cavity space formed by the mold. Both molds are pressed after the molds are closed, a mold clamping force is applied to cool the molds for a predetermined time, and then the molds are opened to take out the molded product.
【0003】[0003]
【発明が解決しようとする課題】しかしながら、このよ
うな従来の方法では、下記に示すような問題があった。 (1)裏面もしくは中間層に発泡層を有する表皮シート
をコア層の表面に融着一体化する際に、発泡層はコア層
樹脂の熱量で高温となり、しかも高圧が負荷されるので
圧縮状態で固定化されるために、クッション性、断熱
性、手触り感等が減失された成形品しか得ることができ
なかった。 (2)このため、成形時に発泡層が圧縮状態で固定化さ
れることを前提にして、クッション性、断熱性、手触り
感等に本来必要な発泡層の厚さよりも格段に厚い発泡層
を用いたり、あるいは、発泡層が圧縮状態で固定化され
難い材質の発泡層を用いたりしてこの問題に対抗してき
たが、コストアップになるばかりでなく、良好な貼合わ
せ成形品を得ることが困難であった。 (3)このような状況から、どうしても良好な貼合わせ
成形品を得たい場合には、前もって通常の射出成形法で
成形したソリッドな成形品に、裏面もしくは中間層に発
泡層を有する表皮シートを手作業で貼合わせる「手貼り
法」で対応していたが、コストアップになるばかりでな
く、生産性に劣るという問題があった。However, such a conventional method has the following problems. (1) When a skin sheet having a foam layer on the back or intermediate layer is fused and integrated to the surface of the core layer, the foam layer becomes hot due to the heat of the core layer resin, and is subjected to a high pressure, so that it is compressed. Because of the immobilization, only molded articles with reduced cushioning properties, heat insulation properties, touch feeling, and the like could be obtained. (2) For this reason, on the premise that the foam layer is fixed in a compressed state at the time of molding, a foam layer that is much thicker than the foam layer originally required for cushioning, heat insulating properties, touch feeling, etc. is used. Although this problem has been countered by using a foam layer made of a material in which the foam layer is difficult to be fixed in a compressed state, it not only increases the cost but also makes it difficult to obtain a good bonded molded product. Met. (3) Under such circumstances, if it is absolutely necessary to obtain a good bonded molded product, a skin sheet having a foamed layer on the back surface or the intermediate layer is added to a solid molded product molded in advance by a normal injection molding method. Although the "hand pasting method" in which the sheets are pasted by hand has been used, there has been a problem that not only the cost is increased but also the productivity is poor.
【0004】[0004]
【課題を解決するための手段】以上のような課題を解決
するために、本発明においては、クッション性あるいは
断熱性等を付与することを目的として、裏面もしくは中
間層に発泡層を有する表皮シートを対向する一対の金型
の間に介在させて型締した後、該表皮シートと該金型と
で形成される金型キャビティ空間内にコア層となる溶融
樹脂を射出充填して該表皮シートと該コア層とを一体成
形する表皮一体貼合わせ成形方法において、コア層とな
る溶融樹脂の射出充填後、予め設定された設定型締力保
持時間が経過した時点で型締力を除去して、表皮シート
と金型キャビティ面との間に該表皮シートの発泡層の厚
さに応じた所定の設定型開量に相当する断熱層としての
隙間を設けて所定の設定時間保持するようにした。Means for Solving the Problems To solve the above problems, in the present invention, a skin sheet having a foamed layer on the back surface or an intermediate layer for the purpose of imparting cushioning properties or heat insulating properties. Is interposed between a pair of opposed dies, and the mold is clamped. Then, a molten resin serving as a core layer is injected and filled into a mold cavity space formed by the skin sheet and the mold to form the skin sheet. In the skin integral lamination molding method of integrally molding the core layer with the core layer, after injection filling of the molten resin to be the core layer, the mold clamping force is removed when a preset mold clamping force holding time has elapsed. A gap is provided between the skin sheet and the mold cavity surface as a heat insulating layer corresponding to a predetermined set mold opening amount corresponding to the thickness of the foam layer of the skin sheet so as to be maintained for a predetermined set time. .
【0005】[0005]
【発明の実施の形態】本発明を実施することにより、以
下のような好ましい成形が実施される。表皮一体貼合わ
せ成形中において、射出充填直後にはコア材樹脂の熱量
により表皮シートは加熱されるが、金型と接触している
最外層には加飾層としてのフィルム層や起毛層を持って
いるため、表皮シートの裏面もしくは中間に設けた発泡
層の温度は大きく上昇する。その後コア樹脂の冷却に伴
って発泡層の温度も下降するが、この間発泡層は圧縮さ
れたままである。つまり、成形中の発泡層は圧縮された
まま温度上昇し、そのまま冷却されている。これに対
し、本発明では、コア材樹脂が冷却される前に、予め設
定された設定型締力保持時間が経過した時点で、型締力
を除去して表皮シートと金型キャビティ面との間に断熱
層としての隙間を設けるようにした。これによって、表
皮シートから金型への熱伝導が遮断されて表皮シートの
発泡層の温度を再上昇させることができ、あわせて、射
出充填時に高圧が負荷されて圧縮状態にあった発泡層が
弾性力により自己回復するための回復スペースを確保す
ることができる。その結果、クッション性あるいは断熱
性等を付与することを目的として、表皮シートの裏面も
しくは中間層に設けた発泡層の温度はそれまでの最高温
度を超える温度となり、発泡層は弾性力により自己回復
し、表皮シート本来のクッション性、断熱性、手触り感
等の回復を達成することができる。DESCRIPTION OF THE PREFERRED EMBODIMENTS By carrying out the present invention, the following preferable molding is carried out. During the integral skin lamination molding, the skin sheet is heated by the heat of the core material resin immediately after injection filling, but the outermost layer in contact with the mold has a film layer or a raised layer as a decorative layer. Therefore, the temperature of the foam layer provided on the back surface or the middle of the skin sheet greatly increases. Thereafter, as the core resin cools, the temperature of the foamed layer also decreases, but during this time, the foamed layer remains compressed. That is, the temperature of the foamed layer during molding rises while being compressed, and is cooled as it is. On the other hand, in the present invention, before the core material resin is cooled, the mold clamping force is removed at the time when the preset mold clamping force holding time has elapsed, and the gap between the skin sheet and the mold cavity surface is reduced. A gap as a heat insulating layer was provided between them. As a result, the heat conduction from the skin sheet to the mold is cut off, and the temperature of the foam layer of the skin sheet can be increased again. A recovery space for self-recovery by elastic force can be secured. As a result, the temperature of the foam layer provided on the back surface or the intermediate layer of the skin sheet exceeds the maximum temperature up to that point for the purpose of imparting cushioning property or heat insulation property, and the foam layer self-heals due to elastic force. In addition, it is possible to achieve the recovery of the original cushioning property, heat insulation property, touch feeling and the like of the skin sheet.
【0006】[0006]
【実施例】以下図面に基づいて本発明の実施例の詳細に
ついて説明する。図1〜図3は本発明の実施例に係り、
図1は表皮材インサート成形装置の全体構成図、図2は
表皮一体貼合わせ成形の成形工程フローチャート、図3
はコア層および発泡層の温度変化の様子を示す説明図で
ある。DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiments of the present invention will be described below in detail with reference to the drawings. 1 to 3 relate to an embodiment of the present invention,
FIG. 1 is an overall configuration diagram of a skin material insert molding apparatus, FIG. 2 is a molding process flow chart of a skin integral lamination molding, FIG.
FIG. 4 is an explanatory view showing a state of a temperature change of a core layer and a foam layer.
【0007】図1に示すように、本発明による表皮材イ
ンサート成形装置100は金型装置10、型締装置2
0、射出装置30及び制御装置60で構成されている。
金型装置10は、型締装置20の固定盤1に取り付けら
れた固定金型3と、型締装置20の可動盤2に取り付け
られた可動金型4とからなり、温度センサ8が組み付け
られている。型締装置20の可動盤2は図示しないタイ
バーに案内され、型締シリンダ22の駆動によって可動
金型4とともに前後進できるよう構成されている。射出
装置30は、スクリュフライト36を備えたスクリュ3
4がバレル32内に回転自在で、かつ、前後進自在に配
設されている。油圧モータ42により駆動されるスクリ
ュ34の回転とともに、ホッパ38に供給された樹脂ペ
レットはスクリュ前方へ送られる。この間に、バレル3
2の外周面に取り付けられている図示しないヒータによ
る加熱を受けるとともに、スクリュ回転による混練作用
を受けることによって樹脂ペレットは溶融する。スクリ
ュ前方へ送られた溶融樹脂は、射出シリンダ40により
駆動されて前進するスクリュ34によってノズル39側
へ押出されて、ノズル39を経由して金型3、4間に形
成される金型キャビティ5内へ射出充填される。射出シ
リンダ40及び油圧モータ42には、油圧供給源50か
ら供給される作動油が、射出制御部61の操作指令を受
けた電磁リリーフ弁52によって設定された一定の圧力
で供給され、スクリュ前進及びスクリュ回転を駆動でき
るように構成されている。As shown in FIG. 1, a skin material insert molding apparatus 100 according to the present invention comprises a mold apparatus 10 and a mold clamping apparatus 2.
0, an injection device 30 and a control device 60.
The mold device 10 includes a fixed mold 3 attached to the fixed plate 1 of the mold clamping device 20 and a movable mold 4 attached to the movable plate 2 of the mold clamping device 20. The temperature sensor 8 is assembled. ing. The movable platen 2 of the mold clamping device 20 is guided by a tie bar (not shown), and is configured to move forward and backward together with the movable mold 4 by driving the mold clamping cylinder 22. The injection device 30 includes a screw 3 having a screw flight 36.
4 is disposed inside the barrel 32 so as to be rotatable and forward and backward. With the rotation of the screw 34 driven by the hydraulic motor 42, the resin pellets supplied to the hopper 38 are sent to the front of the screw. During this time, barrel 3
The resin pellets are melted by being heated by a heater (not shown) attached to the outer peripheral surface of the resin pellets 2 and being kneaded by the rotation of the screw. The molten resin sent to the front of the screw is pushed to the nozzle 39 side by the screw 34 which is driven by the injection cylinder 40 and advances, and the mold cavity 5 formed between the molds 3 and 4 via the nozzle 39. It is injected and filled. Hydraulic oil supplied from a hydraulic supply source 50 is supplied to the injection cylinder 40 and the hydraulic motor 42 at a constant pressure set by an electromagnetic relief valve 52 that has received an operation command from an injection control unit 61, so that screw advance and It is configured to be able to drive screw rotation.
【0008】次に、制御装置60について述べる。制御
装置60は、図1にその概要を示すように、射出制御部
61、型締制御部62、温度モニタ部64、型締条件設
定部66、温度センサ8、図示しない型開量検出部等か
ら構成されている。型締制御部62は型締条件設定部6
6と接続されるとともに射出制御部61とも接続されて
いる。温度センサ8で計測された表皮シートの発泡層の
温度情報は温度モニタ部64に表示されるが、本実施例
ではこの温度情報を制御には直接取り込まず、単に成形
条件を検討するための温度モニタとしている。Next, the control device 60 will be described. As shown in FIG. 1, the control device 60 includes an injection control unit 61, a mold clamping control unit 62, a temperature monitoring unit 64, a mold clamping condition setting unit 66, a temperature sensor 8, a mold opening amount detection unit (not shown), and the like. It is composed of The mold clamping control unit 62 includes a mold clamping condition setting unit 6.
6 and the injection control unit 61. The temperature information of the foam layer of the skin sheet measured by the temperature sensor 8 is displayed on the temperature monitor 64. In the present embodiment, the temperature information is not directly taken into the control, but is merely a temperature for examining the molding conditions. Monitor.
【0009】なお、本実施例では、温度センサ8を表皮
シートの表面側から突出させて検温部が発泡層位置にな
るように配設したが、これに限定されるものではなく、
コア材樹脂側から突出させて配設してもよい。また、本
実施例では、直圧式の型締機構を有する成形装置を用い
たが、トグル式や電動式、あるいは、竪型の型締機構を
有する成形装置を使用してもよい。In this embodiment, the temperature sensor 8 is provided so as to protrude from the surface side of the skin sheet so that the temperature detecting portion is located at the position of the foam layer. However, the present invention is not limited to this.
You may arrange | position so that it may protrude from the core material resin side. Further, in this embodiment, a molding apparatus having a direct pressure type mold clamping mechanism is used, but a molding apparatus having a toggle type, an electric type, or a vertical type mold clamping mechanism may be used.
【0010】図2は表皮一体貼合わせ成形の成形工程フ
ローチャートを示したもので、図2に示す工程にしたが
って説明する。 (1)金型装置10の両金型3、4を型開きした状態
で、金型キャビティ面の所定位置に、たとえば真空吸引
方式や針刺し方式等の手段を用いて表皮シートSをセッ
ト保持する。表皮シートSとしては、要求される加飾特
性に合った加飾層を表面層に有したものを用いる。ま
た、必要に応じて、たとえばコア材樹脂Qとの融着一体
化促進の目的でコア材樹脂Qと同種同系統の樹脂製のシ
ートを裏側にラミネートしたものや、その他の目的で着
色層や接着層を設けた多層構成の表皮シートを用いるこ
ともできる。なお、本実施例ではシート状のものを用い
たが、三次元的な成形品形状に予めプリ成形したものを
表皮シートとして用いてもよい。FIG. 2 is a flow chart showing a molding process of the skin integral lamination molding, which will be described in accordance with the process shown in FIG. (1) The skin sheet S is set and held at a predetermined position on the mold cavity surface by means of, for example, a vacuum suction method or a needle stick method in a state where both the molds 3 and 4 of the mold apparatus 10 are opened. . As the skin sheet S, a sheet having a decorative layer on the surface layer that matches the required decorative characteristics is used. If necessary, for example, a resin sheet of the same type and the same type as the core material resin Q may be laminated on the back side for the purpose of promoting fusion and integration with the core material resin Q, or a colored layer or the like may be used for other purposes. A skin sheet having a multilayer structure provided with an adhesive layer can also be used. In the present embodiment, a sheet-shaped material is used, but a material pre-formed into a three-dimensional molded product shape may be used as the skin sheet.
【0011】(2)次に、表皮シートSをセットした状
態で型閉・型締を行ない、コア層Qとなる溶融樹脂の射
出充填と保圧負荷を行なう。保圧工程完了時に計時開始
するタイマーの実測時間t1が、予め設定された設定型
締力保持時間taに一致した時点で型締力を除去して型
開動作を行なう。(2) Next, the mold is closed and the mold is clamped with the skin sheet S being set, and the injection filling of the molten resin to be the core layer Q and the holding pressure load are performed. When the actual measurement time t1 of the timer which starts counting when the pressure-holding step is completed coincides with the preset mold clamping force holding time ta, the mold clamping force is removed to perform the mold opening operation.
【0012】(3)この型開動作中に、図示しない型開
量センサにより検出した実測型開量Wsが型締条件設定
部66に予め設定されている設定型開量Waに一致した
後は、その型開位置を保持するように制御する。型締条
件設定部66に予め設定されている設定型開保持時間t
bだけこの型開位置で保持した後は、型開工程に続いて
表皮一体貼合わせ成形品(製品)を取り出すことで、1
サイクルの完了となる。(3) During the mold opening operation, after the measured mold opening Ws detected by a mold opening sensor (not shown) matches the set mold opening Wa set in the mold clamping condition setting section 66 in advance. , So that the mold opening position is maintained. Set mold open holding time t preset in mold clamping condition setting section 66
After holding the mold b in this mold opening position, after the mold opening step, the skin-integrally bonded molded product (product) is taken out, whereby 1
The cycle is complete.
【0013】以上述べた表皮一体貼合わせ成形によっ
て、クッション性あるいは断熱性等がより優れた成形品
を得るための成形条件、ならびに、発泡層が弾性力によ
り自己回復するメカニズムを、コア層および表皮シート
の発泡層の温度変化の様子を示す図3を引用して以下に
説明する。[0013] The molding conditions for obtaining a molded article having more excellent cushioning properties or heat insulating properties and the mechanism of self-recovery of the foamed layer due to elastic force by the above-mentioned integral lamination molding of the skin and the core layer and the skin are described. This will be described below with reference to FIG. 3 showing the state of the temperature change of the foam layer of the sheet.
【0014】設定型締力保持時間t1は、表皮シートの
発泡層が弾性力により自己回復する現象に最も密接に関
係する成形条件である。図3に示すように、射出によっ
て金型キャビティの空間内に充填されたコア層となる溶
融樹脂は、熱伝導により金型に熱を奪われて射出直後は
急激に温度低下し、その後は金型温度に漸近するように
徐々に温度低下する。一方、表皮シートの発泡層の温度
は、射出開始の直後にはコア層となる溶融樹脂からの熱
伝導を受け一旦温度上昇するが、その後は金型に熱を奪
われて温度低下して金型温度に漸近する。設定型締力保
持時間t1はこの温度低下途中での型締力除去・型開動
作の開始タイミングとして設定するが、この時間設定に
は注意を要する。図3の破線に示すように、表皮シート
の発泡層温度は型開動作の開始タイミングを遅らせるほ
ど低下する。ただし、型開動作開始後は発泡層温度が上
昇してコア層温度に漸近する。これは、型開によって表
皮シートから金型への熱伝導が遮断されるとともに、コ
ア材樹脂の熱量からの熱伝導を受けることによる。コア
層温度に漸近した後の発泡層温度は、コア層温度と同等
の温度変化で推移する。型開動作の開始タイミングを遅
らせても発泡層温度は上昇するが、それまでの最高温度
を超えることができなくなる。The set mold clamping force holding time t1 is a molding condition most closely related to a phenomenon in which the foam layer of the skin sheet self-recovers due to elastic force. As shown in FIG. 3, the molten resin which becomes the core layer filled in the space of the mold cavity by the injection is deprived of heat by the mold due to heat conduction, and the temperature rapidly decreases immediately after the injection. The temperature gradually decreases to approach the mold temperature. On the other hand, the temperature of the foam layer of the skin sheet rises once immediately after the start of injection due to heat conduction from the molten resin serving as the core layer. Asymptotic to mold temperature. The set mold clamping force holding time t1 is set as the start timing of the mold clamping force removal / mold opening operation during the temperature drop, but care must be taken in setting this time. As shown by the broken line in FIG. 3, the foam layer temperature of the skin sheet decreases as the start timing of the mold opening operation is delayed. However, after the mold opening operation is started, the temperature of the foam layer rises and gradually approaches the core layer temperature. This is because the opening of the mold blocks the heat conduction from the skin sheet to the mold and receives the heat conduction from the calorific value of the core material resin. The foam layer temperature after asymptotically approaching the core layer temperature changes with a temperature change equivalent to the core layer temperature. Even if the start timing of the mold opening operation is delayed, the temperature of the foam layer rises, but it cannot exceed the maximum temperature until then.
【0015】発泡層中のポリマーの分子運動性は、発泡
層温度が高いほど活発であり温度降下とともに減少して
いく。この際に、発泡層の温度差によるポリマーの分子
運動性の減少に見合う分だけ、発泡層は永久歪みを残し
て厚さが薄くなる。ところが、従来の成形方法では、発
泡層の温度が上昇して冷却されるまで型締力が負荷され
ており、この型締力は発泡層を圧縮するには十分な力で
ある。このため、圧縮されたままの発泡層は温度差に見
合うポリマー分子の運動性の差だけ圧縮の永久歪みを残
してしまう。しかしながら、本発明の方法によると、発
泡層の温度は型開動作を行なうことによって再度上昇
し、圧縮されていた時の温度以上となるため、圧縮永久
歪みを残すことがない。従って、温度センサ8で計測さ
れ温度モニタ部64に表示された表皮シートの発泡層の
温度情報が最高温度になるタイミングを確認し、このタ
イミングに型開動作の開始となるような設定型締力保持
時間t1を採用することが、発泡層の永久歪みを残さな
いためには望ましい。一方、コア層の賦形の観点から求
められる冷却程度も考慮し、両者の兼合いで設定型締力
保持時間t1を決定する。The molecular mobility of the polymer in the foamed layer is more active as the foamed layer temperature is higher, and decreases as the temperature decreases. At this time, the thickness of the foam layer is reduced by the amount corresponding to the decrease in the molecular mobility of the polymer due to the temperature difference of the foam layer, while the permanent deformation remains. However, in the conventional molding method, a mold clamping force is applied until the temperature of the foam layer rises and is cooled, and the mold clamping force is a force sufficient to compress the foam layer. For this reason, the compressed foam layer leaves a permanent compression set by the difference in the mobility of the polymer molecules corresponding to the temperature difference. However, according to the method of the present invention, the temperature of the foamed layer rises again by performing the mold opening operation and becomes equal to or higher than the temperature at the time of compression, so that compression set does not remain. Therefore, the timing at which the temperature information of the foam layer of the skin sheet measured by the temperature sensor 8 and displayed on the temperature monitor 64 reaches the maximum temperature is confirmed, and at this timing, the set mold clamping force is set to start the mold opening operation. It is desirable to adopt the holding time t1 in order not to leave permanent deformation of the foam layer. On the other hand, the cooling degree required from the viewpoint of the shaping of the core layer is also taken into consideration, and the set clamping force holding time t1 is determined based on a balance between the two.
【0016】本実施例では、保圧工程完了時に計時開始
するタイマーの実測時間t1が、予め設定された設定型
締力保持時間taに一致した時点で型締力を除去して型
開動作を行なうようにしたが、これに限定されるもので
はなく、温度センサ8により検出した表皮シートSの発
泡層の実測温度が、予め設定されている設定温度に到達
した時点で、型締力を除去して型開動作を行なうように
してもよい。In this embodiment, when the measured time t1 of the timer which starts counting when the pressure-holding step is completed coincides with the preset mold-clamping-force holding time ta set in advance, the mold-clamping force is removed and the mold-opening operation is started. However, the present invention is not limited to this. When the measured temperature of the foam layer of the skin sheet S detected by the temperature sensor 8 reaches a preset temperature, the mold clamping force is removed. Alternatively, the mold opening operation may be performed.
【0017】設定型開量Waは、表皮シートと金型キャ
ビティ面との間に断熱層としての隙間を設けて表皮シー
トから金型への熱伝導を遮断することと、発泡層の厚さ
を回復するためのスペースを確保することを目的として
設定される。後者の目的の面から考えると、設定型開量
Waは発泡層の厚さ相当以上であることが望ましいが、
僅かな型開量(0.1mm)でも効果は得られる。ま
た、他の成形上の都合で、発泡層の厚さ相当よりも大き
な型開量を設定しても同様の効果が得られる。設定型開
位置保持時間tbは、貼合わせ成形中の発泡層の最高温
度よりも高い温度で、発泡層が弾性力により自己回復す
るのに要する時間およびコア材樹脂の冷却に要する時間
として設定され、コア材樹脂の通常の冷却時間の範囲内
で十分に効果が得られることを実験にて確認済みであ
る。本実施例では、表皮シートを片面のみに貼り付けた
が、必要に応じてコア材樹脂の両面に貼り付けてもよ
い。またコア材樹脂にウレタン、エラストマ等の軟質樹
脂材を用いてもよい。The set mold opening Wa is determined by providing a gap as a heat insulating layer between the skin sheet and the mold cavity surface to block heat conduction from the skin sheet to the mold, and to reduce the thickness of the foam layer. Set for the purpose of securing space for recovery. From the viewpoint of the latter purpose, the set mold opening amount Wa is desirably equal to or more than the thickness of the foam layer.
The effect can be obtained even with a small mold opening (0.1 mm). The same effect can be obtained even if a mold opening amount larger than the thickness of the foam layer is set for other molding reasons. The set mold open position holding time tb is set at a temperature higher than the maximum temperature of the foam layer during lamination molding, as a time required for the foam layer to self-recover by elastic force and a time required for cooling the core material resin. It has been confirmed by experiments that sufficient effects can be obtained within the normal cooling time of the core resin. In this embodiment, the skin sheet is stuck on only one side, but it may be stuck on both sides of the core resin if necessary. Further, a soft resin material such as urethane or elastomer may be used as the core material resin.
【0018】[0018]
【発明の効果】以上述べたように、本発明によれば、下
記のような優れた効果が得られる。表皮シートの裏面も
しくは中間層に設けた発泡層が成形時に圧縮状態で固定
化されて表皮シート本来のクッション性、断熱性、遮音
性、手触り感等の特性を損なうことのない、非常に優れ
た表面加飾性能を有する表皮一体貼合わせ成形品を安定
して供給できる。As described above, according to the present invention, the following excellent effects can be obtained. The foam layer provided on the back surface or the intermediate layer of the skin sheet is fixed in a compressed state at the time of molding, and does not impair the properties such as the cushioning property, heat insulation property, sound insulation property, touch feeling, etc. of the skin sheet. It is possible to stably supply a skin-integrated bonded product having surface decoration performance.
【図1】本発明に使用する表皮材インサート成形装置の
全体構成図である。FIG. 1 is an overall configuration diagram of a skin material insert molding apparatus used in the present invention.
【図2】本発明の実施例に係る表皮一体貼合わせ成形工
程のフローチャートである。FIG. 2 is a flowchart of a skin integral lamination molding process according to an embodiment of the present invention.
【図3】本発明の実施例に係るコア層および発泡層の温
度変化の様子を示す説明図である。FIG. 3 is an explanatory view showing a state of a temperature change of a core layer and a foam layer according to an example of the present invention.
1 固定盤 2 可動盤 3 固定金型 4 可動金型 5 金型キャビティ 8 温度センサ 10 金型装置 20 型締装置 22 型締シリンダ 30 射出装置 32 バレル 34 スクリュ 36 スクリュフライト 38 ホッパ 39 ノズル 40 射出シリンダ 42 油圧モータ 50 油圧供給源(射出回路) 52 電磁リリーフ弁(射出回路) 60 制御装置 61 射出制御部 62 型締制御部 64 温度モニタ部 66 型締条件設定部 69 電磁リリーフ弁(型締回路) 70 油圧供給源(型締回路) 100 表皮材インサート成形装置 Q コア層(コア材樹脂) S 表皮シート(表皮材) ta 設定型締力保持時間 t1 実測型締力保持時間 Wa 設定型開量 Ws 実測型開量 tb 設定型開位置保持時間 t2 実測型開位置保持時間 DESCRIPTION OF SYMBOLS 1 Fixed board 2 Movable board 3 Fixed mold 4 Movable mold 5 Mold cavity 8 Temperature sensor 10 Mold device 20 Mold clamping device 22 Mold clamping cylinder 30 Injection device 32 Barrel 34 Screw 36 Screw flight 38 Hopper 39 Nozzle 40 Injection cylinder 42 hydraulic motor 50 hydraulic supply source (injection circuit) 52 electromagnetic relief valve (injection circuit) 60 control device 61 injection control unit 62 mold clamping control unit 64 temperature monitor unit 66 mold clamping condition setting unit 69 electromagnetic relief valve (mold clamping circuit) 70 Hydraulic pressure supply source (mold clamping circuit) 100 Skin material insert molding device Q Core layer (core material resin) S Skin sheet (skin material) ta Setting mold clamping force holding time t1 Measured mold clamping force holding time Wa Setting mold opening Ws Actual measurement type opening amount tb Setting type open position holding time t2 Actual measurement type opening position holding time
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.7 識別記号 FI B29L 31:58 B29L 31:58 ──────────────────────────────────────────────────続 き Continued on front page (51) Int.Cl. 7 Identification code FI B29L 31:58 B29L 31:58
Claims (1)
ることを目的として、裏面もしくは中間層に発泡層を有
する表皮シートを対向する一対の金型の間に介在させて
型締した後、該表皮シートと該金型とで形成される金型
キャビティ空間内にコア層となる溶融樹脂を射出充填し
て該表皮シートと該コア層とを一体成形する表皮一体貼
合わせ成形方法において、 コア層となる溶融樹脂の射出充填後、予め設定された設
定型締力保持時間が経過した時点で型締力を除去して、
表皮シートと金型キャビティ面との間に該表皮シートの
発泡層の厚さに応じた所定の設定型開量に相当する断熱
層としての隙間を設けて所定の設定時間保持することを
特徴とする表皮一体貼合わせ成形方法。1. A skin sheet having a foamed layer on a back surface or an intermediate layer is interposed between a pair of opposed molds and clamped for the purpose of imparting cushioning property or heat insulation property, and then the skin is closed. A skin integral lamination molding method for integrally molding the skin sheet and the core layer by injecting and filling a molten resin serving as a core layer into a mold cavity space formed by the sheet and the mold, comprising: After the injection filling of the molten resin, the mold clamping force is removed when a preset mold clamping force holding time has elapsed,
It is characterized in that a gap is provided between the skin sheet and the mold cavity surface as a heat insulating layer corresponding to a predetermined set mold opening amount corresponding to the thickness of the foam layer of the skin sheet, and held for a predetermined set time. Skin integral lamination molding method.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP3162598A JP3250511B2 (en) | 1998-02-13 | 1998-02-13 | Skin integral lamination molding method |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP3162598A JP3250511B2 (en) | 1998-02-13 | 1998-02-13 | Skin integral lamination molding method |
Publications (2)
Publication Number | Publication Date |
---|---|
JPH11226993A JPH11226993A (en) | 1999-08-24 |
JP3250511B2 true JP3250511B2 (en) | 2002-01-28 |
Family
ID=12336407
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Application Number | Title | Priority Date | Filing Date |
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JP3162598A Expired - Fee Related JP3250511B2 (en) | 1998-02-13 | 1998-02-13 | Skin integral lamination molding method |
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JP (1) | JP3250511B2 (en) |
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JP3843705B2 (en) * | 2000-06-29 | 2006-11-08 | 宇部興産機械株式会社 | Lamination molding method |
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1998
- 1998-02-13 JP JP3162598A patent/JP3250511B2/en not_active Expired - Fee Related
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JPH11226993A (en) | 1999-08-24 |
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