JPH0374891B2 - - Google Patents
Info
- Publication number
- JPH0374891B2 JPH0374891B2 JP60158392A JP15839285A JPH0374891B2 JP H0374891 B2 JPH0374891 B2 JP H0374891B2 JP 60158392 A JP60158392 A JP 60158392A JP 15839285 A JP15839285 A JP 15839285A JP H0374891 B2 JPH0374891 B2 JP H0374891B2
- Authority
- JP
- Japan
- Prior art keywords
- skin
- thin wall
- mold
- base layer
- molding surface
- 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 - Lifetime
Links
- 239000000463 material Substances 0.000 claims description 63
- 238000000465 moulding Methods 0.000 claims description 54
- 238000000034 method Methods 0.000 claims description 19
- 239000002131 composite material Substances 0.000 claims description 11
- 238000004519 manufacturing process Methods 0.000 claims description 9
- 238000007666 vacuum forming Methods 0.000 claims description 3
- 239000010410 layer Substances 0.000 description 63
- 210000003491 skin Anatomy 0.000 description 51
- 238000002347 injection Methods 0.000 description 17
- 239000007924 injection Substances 0.000 description 17
- 239000004744 fabric Substances 0.000 description 12
- 229920005989 resin Polymers 0.000 description 7
- 239000011347 resin Substances 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 5
- 229920003002 synthetic resin Polymers 0.000 description 5
- 239000000057 synthetic resin Substances 0.000 description 5
- 238000001816 cooling Methods 0.000 description 4
- 239000011162 core material Substances 0.000 description 4
- 238000001746 injection moulding Methods 0.000 description 4
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 3
- 239000012790 adhesive layer Substances 0.000 description 3
- 239000000498 cooling water Substances 0.000 description 3
- 210000002615 epidermis Anatomy 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- 229920005992 thermoplastic resin Polymers 0.000 description 3
- 238000007796 conventional method Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 230000002950 deficient Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005187 foaming Methods 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229920002725 thermoplastic elastomer Polymers 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000002313 adhesive film Substances 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 230000009969 flowable effect Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000012778 molding material Substances 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920003217 poly(methylsilsesquioxane) Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
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
- B29C45/14065—Positioning or centering articles in the mould
-
- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
- B29C43/183—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
-
- 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
- B29C2045/1486—Details, accessories and auxiliary operations
- B29C2045/14901—Coating a sheet-like insert smaller than the dimensions of the adjacent mould wall
- B29C2045/14909—Coating a sheet-like insert smaller than the dimensions of the adjacent mould wall the edge of the sheet-like insert being hidden, e.g. in a groove or protruding into the injected material
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Description
【発明の詳細な説明】
産業上の利用分野
本発明は基体層の外面部分に、柔軟な表皮の端
末が基体層の狭い凹溝の奥に埋め込まれた状態で
貼り付けられている複合成形体の製造方法に関す
る。[Detailed Description of the Invention] Industrial Application Field The present invention relates to a composite molded article in which the ends of a flexible skin are stuck to the outer surface of a base layer with the ends of the flexible skin embedded deep inside the narrow grooves of the base layer. Relating to a manufacturing method.
従来技術
絵付け成形法として、射出成形型の成形面の一
部に印刷されたシートを載置した状態で基体とな
る合成樹脂を射出成形して、表面に絵が描かれた
成形品を得る方法は従来より広く知られている。
しかし、シートの端部が成形品の表面に存在する
ため、射出成形時の熱、圧力によりシートの端末
が溶融して射出した樹脂の流れ方向に変形した
り、射出した樹脂がシート表面にはみ出して成形
品の外観を著しく劣化させていた。Prior art In the decorative molding method, a printed sheet is placed on a part of the molding surface of an injection mold and a synthetic resin base is injection molded to obtain a molded product with a picture drawn on the surface. The method is well known.
However, since the edges of the sheet are on the surface of the molded product, the heat and pressure during injection molding can cause the edges of the sheet to melt and deform in the flow direction of the injected resin, or the injected resin can protrude onto the sheet surface. This significantly deteriorated the appearance of the molded product.
また、車両用内装品、化粧用建築部材、家庭用
電気製品の外装部分に表皮として布地を貼付し
て、部分的に材質・色柄を異ならせて外観を豪華
にした合成樹脂製品が見受けられる。そして布地
の端末の処理方法について工夫がなされている
が、いずれも煩雑な工程によるものか若しくは見
劣りのするものであつた。たとえば車両のドアト
リムにおいて、アームレストの上方または下方に
オーナメントと呼ばれる装飾用の布地が、その他
の部分の表皮と材質または色柄を異ならせて取付
けられている。第１図および第２図に示した例に
おいては、塩化ビニル樹脂塗料を塗布したハード
ボードは基体層１とし、ウエルダー溶着可能なウ
レタンフオームをクツシヨン材２とし、軟質塩化
ビニルシートを表皮３とした積層板４の所望位置
に、装飾用カーペツトよりなる布地５の端末を塩
化ビニル樹脂製のモール６で隠蔽し、かつ基体層
１とモール６間を高周波ウエルダーで溶着一体化
したものである。このとき布地５の端部をクツシ
ヨン性のある積層板４の表皮３面上でモール６の
溶着面の幅の範囲内に固定することが困難で、布
地５の端末がモール６の外側にはみ出したりモー
ル６との間に隙間を生じ表皮３がのぞくような不
良品がしばしば発生した。第３図の例も第１図の
例と同様の用途に利用されているもので、鉄板よ
りなる芯材７にウレタンフオームよりなるクツシ
ヨン層８を介して布地５で巻込み布地５の端部を
芯材７の裏面に接着し、芯材７に取付けられてい
るクリツプ９により、あらかじめ形成されている
積層板４の所望位置に布地５を含む装飾用構成品
１０を固定したものである。この場合芯材７は布
地５を展張させるために不可欠であり、このため
製品の重量が増し部分点数が多くなり、かつ布地
５の巻込みも手間取る作業であつた。 In addition, synthetic resin products can be seen where fabric is attached as a skin to the exterior parts of vehicle interior parts, decorative building materials, and household electrical appliances, and the materials and color patterns are partially varied to give a luxurious appearance. . Some attempts have been made to treat the ends of the fabric, but all of these methods involve complicated processes or are of poor quality. For example, in the door trim of a vehicle, a decorative fabric called an ornament is attached above or below the armrest and is made of a different material or color pattern from the skin of other parts. In the examples shown in Figures 1 and 2, the hardboard coated with vinyl chloride resin paint serves as the base layer 1, the weldable urethane foam serves as the cushion material 2, and the soft vinyl chloride sheet serves as the skin layer 3. The end of a fabric 5 made of decorative carpet is hidden at a desired position of the laminate 4 with a molding 6 made of vinyl chloride resin, and the base layer 1 and the molding 6 are welded together with a high-frequency welder. At this time, it is difficult to fix the end of the fabric 5 on the surface 3 of the cushioned laminate 4 within the width of the welding surface of the molding 6, and the end of the fabric 5 protrudes outside the molding 6. In many cases, defective products were produced in which a gap was formed between the molding 6 and the skin 3 and the skin 3 was exposed. The example shown in FIG. 3 is also used for the same purpose as the example shown in FIG. is adhered to the back surface of the core material 7, and a decorative component 10 including the fabric 5 is fixed at a desired position on the pre-formed laminate 4 using clips 9 attached to the core material 7. In this case, the core material 7 is essential for stretching the fabric 5, which increases the weight of the product and increases the number of parts, and winding up the fabric 5 is also a time-consuming task.
発明が解決しようとする問題点
本発明は基体層材料の成形と同時にその外面の
所望位置に表皮を被着させた複合成形体の製造方
法であつて、上記従来の方法のような表皮の端部
が変形したり、基体層材料が表皮の端末位置から
はみ出して表皮の外表側にまで侵出したり、また
は表皮の端末位置がずれるというような不良品の
発生の防止と、芯材やクリツプを使用するための
重量増や工程の煩雑化を解消するものであり、ま
た表皮層を有する複合成形体を効率良く製造する
ものである。Problems to be Solved by the Invention The present invention is a method for manufacturing a composite molded article in which a skin is applied at a desired position on the outer surface of the base layer material at the same time as the molding of the material for the base layer. To prevent the occurrence of defective products such as deformation of parts, base layer material protruding from the end position of the skin and seepage to the outer surface of the skin, or misalignment of the end position of the skin, and This eliminates the need for increased weight and complication of processes for use, and also enables efficient production of a composite molded article having a skin layer.
問題点を解決するための手段
本複合成形体の製造方法に係る第１の発明は、
一対の成形型のいずれか一方または双方の型の成
形面の所望位置に成形面から突出した薄壁を設
け、その薄壁で区分された領域に柔軟な表皮を敷
設するとともに、薄壁の内面に沿つてその表皮の
端部を立上がらせ、その端末を薄壁に係止したの
ち、一対の成形型の一方の型の成形面に、直接も
しくは表皮の上から、基体層材料を載置して型締
めするか、または一対の成形型を型締めしたの
ち、キヤビテイ内に基体層材料を注入するもので
あり、第２の発明は、一対の成形型の一方の型の
全成形面に多数の排気孔を開孔せしめ、かつその
型の成形面の所望位置に成形面から突出した薄壁
を設け、その薄壁で区分された領域に通気性の柔
軟な表皮を敷設するとともに、薄壁の内面に沿つ
てその表皮の端部を立上がらせ、その端末を薄壁
に係止し、該表皮を介して全成形面にわたつて表
装材層を真空成形、圧空成形もしくは真空圧空成
形したのち、その表装材層上もしくは他方の型の
成形面に基体層材料を載置して型締めするか、ま
たは一対の成形型を型締めしたのち、キヤビテイ
内に基体層材料を注入するものとした。Means for Solving the Problems The first invention related to the method for manufacturing the present composite molded article is as follows:
A thin wall protruding from the molding surface is provided at a desired position on the molding surface of one or both of the pair of molds, a flexible skin is laid in the area divided by the thin wall, and the inner surface of the thin wall is After raising the end of the skin along the surface and locking the end to the thin wall, the base layer material is placed on the molding surface of one of the pair of molds, either directly or on top of the skin. The second invention is to inject the base layer material into the cavity after the molds are clamped or after the pair of molds are clamped. A large number of exhaust holes are formed, and a thin wall is provided at a desired position on the molding surface of the mold, protruding from the molding surface, and an air permeable flexible skin is laid in the area divided by the thin wall. The end of the skin is raised along the inner surface of the wall, the end is locked to the thin wall, and the facing material layer is vacuum formed, pressure-formed, or vacuum-pressure formed over the entire molding surface via the skin. After that, the base layer material is placed on the surface material layer or the molding surface of the other mold and the mold is clamped, or after the pair of molds are clamped, the base layer material is injected into the cavity. And so.
作 用
したがつて、本発明の前記手段によれば、表皮
の端末位置において、基体層には成形型に設けら
れた成形面から突出した薄壁により、断面がほぼ
「Ｕ」型の幅の狭い凹溝が形成され、その凹溝の
奥に表皮の端末が収納されている形態で、表皮が
直接基体層材料または表装材層を介して基体層材
料の所望位置に被着された成形品が得られる。こ
のため表皮の端末は外部から隠蔽されているので
見栄えが良く、作業が容易で加工時間も短い。Therefore, according to the means of the present invention, at the end position of the skin, the base layer has a thin wall protruding from the molding surface provided in the mold, so that the cross section is approximately "U" shaped in width. A molded product in which a narrow groove is formed and the end of the skin is housed in the depth of the groove, and the skin is directly adhered to the desired position of the base layer material via the base layer material or the facing material layer. is obtained. For this reason, the ends of the skin are hidden from the outside, giving a good appearance, making the work easier, and requiring less processing time.
実施例 以下図面により本発明の詳細を説明する。Example The details of the present invention will be explained below with reference to the drawings.
第４図は第１の実施例としてたとえば車両のド
アの車室側に装着する、外面部分に柔軟な表皮１
１として布地を被着させたドアトリム１８（第６
図）を第１の発明によつて成形する際に使用する
上型２１と下型２２とからなる一対の成形型２０
の断面図を示す。図において一対の成形型２０に
はドアトリム１８の外面形状に対応する成形面が
それぞれ形成されており、また下型２２の成形面
にはドアトリム１８の表皮１１を被着させる所望
部分の外縁形状に対応する所定領域の外縁に成形
面から突出した薄壁２３が巡らされている。さら
に必要に応じて一対の成形型２０には多数の冷却
水循環用孔２４およびヒーター２５を備えたり、
成形材料の一部をトリミングする切断刃２６およ
び逃げ溝２７が形成されている。 FIG. 4 shows a first embodiment of a flexible outer skin 1 that is attached to the passenger compartment side of a vehicle door, for example.
Door trim 18 (6th door trim) covered with fabric as 1
A pair of molds 20 consisting of an upper mold 21 and a lower mold 22 used when molding (Fig.) according to the first invention.
A cross-sectional view is shown. In the figure, a pair of molds 20 are each formed with a molding surface corresponding to the outer surface shape of the door trim 18, and a molding surface of the lower mold 22 is formed with a molding surface corresponding to the outer edge shape of a desired portion of the door trim 18 to which the skin 11 is to be applied. A thin wall 23 protruding from the molding surface is wrapped around the outer edge of the corresponding predetermined area. Furthermore, the pair of molds 20 may be provided with a large number of cooling water circulation holes 24 and heaters 25 as necessary.
A cutting blade 26 and an escape groove 27 are formed to trim a portion of the molding material.
ドアトリム１８の製造にあたり、まず柔軟な表
皮１１を、第４図に示したように薄壁２３で区分
された所定領域の成形面に沿つてその表側が成形
面に接するように敷設するとともに、その端部を
薄壁２３の内面に沿つて立上がらせ、その端末を
薄壁２３の頂部に係止する。つぎにあらかじめ加
熱され、溶融状態にある基体層１４材料を下型２
２の成形面全体に亘つて表皮１１の上から載置し
て、図示していない加圧装置により両型２１，２
２を型締めする。必要に応じて成形品の加熱また
は／および冷却と周囲のトリミングをすることに
より第６図に示すようなドアトリム１８が得られ
る。 In manufacturing the door trim 18, first, the flexible skin 11 is laid along the molding surface in a predetermined region divided by the thin wall 23, as shown in FIG. The end portion is made to rise along the inner surface of the thin wall 23, and the end thereof is locked to the top of the thin wall 23. Next, the base layer 14 material, which has been preheated and is in a molten state, is placed in the lower mold 2.
The molds 21 and 2 are placed over the entire molding surface of the molds 21 and 2, and are pressed together using a pressure device (not shown).
Clamp 2. A door trim 18 as shown in FIG. 6 is obtained by heating and/or cooling the molded product and trimming the surrounding area as required.
第５図は第２の実施例を示す上型３１と下型３
２とからなる一対の成形型２０の断面図を示す。
上型３１と下型３２を型締めすると、ドアトリム
１８の形状に対応するキヤビテイ３３が構成され
る。また上型３１には基体層１４材料を注入する
注入孔３４が設けられているほか、第１の実施例
と同様の薄壁２３が下型３２に、多数の冷却水循
環用孔２４およびヒーター２５も両型３１，３２
に備えている。 FIG. 5 shows an upper mold 31 and a lower mold 3 showing a second embodiment.
2 is a cross-sectional view of a pair of molds 20 consisting of.
When the upper mold 31 and the lower mold 32 are clamped together, a cavity 33 corresponding to the shape of the door trim 18 is formed. In addition, the upper mold 31 is provided with an injection hole 34 for injecting the material of the base layer 14, and the lower mold 32 is provided with a thin wall 23 similar to the first embodiment, a large number of cooling water circulation holes 24, and a heater 25. Both types 31, 32
We are preparing for
製造にあたり、まず柔軟な表皮１１を第５図に
示したように下型３２の成形面から突出した薄壁
２３で区分された所定領域の成形面に沿つて、そ
の表側が成形面に接するように敷設するととも
に、その端部を薄壁２３の内面に沿つて立上がら
せ、その端末を薄壁２３の頂部に係止する。つぎ
に上型３１と下型３２とを図示していない加圧装
置により型締めしたのち、基体層１４材料を注入
孔３４から通常の射出成形法または注入法でキヤ
ビテイ３３を満たす。つぎに両型３１，３２を加
熱または／および冷却ののち、型開きし、注入孔
３４部分の材料を除去することによりドアトリム
１８が得られる。 In manufacturing, first, as shown in FIG. 5, the flexible skin 11 is placed along the molding surface of a predetermined region divided by thin walls 23 protruding from the molding surface of the lower mold 32 so that its front side is in contact with the molding surface. At the same time, the end thereof is raised along the inner surface of the thin wall 23, and the end thereof is locked to the top of the thin wall 23. Next, after the upper mold 31 and the lower mold 32 are clamped by a pressure device (not shown), the cavity 33 is filled with the material of the base layer 14 through the injection hole 34 by a conventional injection molding method or injection method. Next, after heating and/or cooling both the molds 31 and 32, the molds are opened and the material at the injection hole 34 portion is removed to obtain the door trim 18.
なお上記の第１および第２の実施例において、
薄壁２３が下型２２，３２の成形面に設けた例を
示したが上型２１，３１の成形面に設けてもよ
く、また双方の型の成形面に設けてもよい。なお
この場合、注入孔３４は薄壁２３で区分された所
定領域外に設ける必要がある。また第１の実施例
において、上型２１に薄壁２３を設け、ここに表
皮１１を係止する場合には、基体層１４材料は、
下型２２に直接載置される。 Note that in the above first and second embodiments,
Although an example is shown in which the thin wall 23 is provided on the molding surfaces of the lower molds 22 and 32, it may be provided on the molding surfaces of the upper molds 21 and 31, or may be provided on the molding surfaces of both molds. In this case, the injection hole 34 needs to be provided outside the predetermined area divided by the thin wall 23. Further, in the first embodiment, when the thin wall 23 is provided on the upper mold 21 and the skin 11 is secured thereto, the material of the base layer 14 is
It is placed directly on the lower mold 22.
第７図は本願第２の発明である第３の実施例を
示す上型４１と下型４２とからなる一対の成形型
２０の断面図を示す。上型４１と下型４２を型締
めすると、第８図のドアトリム１９の形状に対応
するキヤビテイが構成されるよう、両型４１，４
２にそれぞれの成形面が形成されている。下型４
２の成形面には多数の排気孔４３が削孔されてお
り、その一端は成形面に開孔しており、他端は連
通溝４４および排気管４５を通じて、図示してい
ない真空ポンプに連通している。また第２の実施
例と同様、成形面から突出した薄壁２３、多数の
冷却水循環用孔２４、および必要に応じてヒータ
ー２５も備えている。 FIG. 7 shows a cross-sectional view of a pair of molds 20 consisting of an upper mold 41 and a lower mold 42, showing a third embodiment, which is the second invention of the present application. When the upper mold 41 and the lower mold 42 are clamped together, the molds 41 and 4 are assembled so that a cavity corresponding to the shape of the door trim 19 shown in FIG. 8 is formed.
Each molding surface is formed on 2. Lower mold 4
A large number of exhaust holes 43 are drilled in the molding surface of No. 2, one end of which is open in the molding surface, and the other end communicates with a vacuum pump (not shown) through a communication groove 44 and an exhaust pipe 45. are doing. Further, like the second embodiment, a thin wall 23 protruding from the molding surface, a large number of cooling water circulation holes 24, and a heater 25 as required are also provided.
製造にあたり、まず通気性のある柔軟な表皮１
２を第７図に示したように下型４２の薄壁２３で
区分された所定領域の成形面に沿つてその表側が
成形面に接するように敷設するとともに、その端
部を薄壁２３の内面に沿つて立上がらせ、その端
末を薄壁２３の頂部に係止する。この表皮１２を
成形面に敷設するとき、真空吸引機構を作動させ
て排気孔４３から空気を吸引しながら作業する
と、しわが発生しないように表皮１２を伸展する
ことができ、成形面に密着させることができる。
つぎにあらかじめ加熱軟化された表装材層１３を
クランプ枠４６で挟持した状態で下型４２上から
下型４２を囲んで下降させ、第７図のように部分
的に表皮１２を介して下型４２の成形面上に真空
成形する。つぎに成形した表装材層１３を必要に
応じて冷却したのち、両型４１，４２を型締めし
てキヤビテイ内に基体層１４材料を注入孔３４か
ら射出成形または注入する。両型４１，４２を加
熱または／および冷却ののち、型開きし、注入孔
３４部分と表装材層１３の不要部分を除去すると
ドアトリム１９が得られる。なお表装材層１３の
不要部分の一部を基体層１４側に折り返し、基体
層１４の裏面で固定すると、その基体層１４の側
面を表装材層１３部分で隠蔽することができ、端
部が美しく仕上げられた成形品が得られる。ま
た、両型４１，４２の突き当り面に、その部分の
みを加熱するヒーター４７と断熱材４８を配設
し、両型４１，４２の型締時に表装材層１３の不
要部分を加熱圧縮してさらに薄肉化すると成形品
の端部をさらに美しく仕上げることができる。 During manufacturing, we first create a breathable and flexible epidermis 1.
As shown in FIG. It is made to stand up along the inner surface, and its end is locked to the top of the thin wall 23. When laying this skin 12 on the molding surface, by activating the vacuum suction mechanism and sucking air from the exhaust hole 43, the skin 12 can be stretched to avoid wrinkles and can be brought into close contact with the molding surface. be able to.
Next, the covering material layer 13, which has been heated and softened in advance, is clamped between the clamp frames 46 and lowered from above the lower mold 42, enclosing the lower mold 42, and as shown in FIG. Vacuum forming is performed on the molding surface of 42. Next, after cooling the molded surface material layer 13 as necessary, both molds 41 and 42 are clamped, and the material for the base layer 14 is injection molded or injected into the cavity through the injection hole 34. After heating and/or cooling both the molds 41 and 42, the molds are opened and the injection hole 34 portion and unnecessary portions of the facing material layer 13 are removed to obtain the door trim 19. Note that if a part of the unnecessary portion of the facing material layer 13 is folded back to the base layer 14 side and fixed on the back side of the base layer 14, the side surface of the base layer 14 can be hidden by the facing material layer 13, and the edges can be A beautifully finished molded product can be obtained. In addition, a heater 47 and a heat insulating material 48 are provided on the abutment surfaces of both molds 41 and 42 to heat only that part, and when the molds 41 and 42 are clamped, unnecessary parts of the facing material layer 13 are heated and compressed. By making the wall thinner, the edges of the molded product can be finished more beautifully.
第２の発明による第４の実施例は、第４図に示
した下型２２に第７図に示した第３の実施例の下
型４２と同様な真空吸引機能を追加し、第３の実
施例と同様に下型成形面に通気性のある柔軟な表
皮を敷設し、ついで表装材層を真空成形したの
ち、その表装材層上に基体層材料を載置し、加圧
装置により両型を型締めして、表皮、表装材層お
よび基体層が一体となつた複合体を得るものであ
る。なお、この第４の実施例において、上型と下
型の位置関係を上下反転して実施することもで
き、この場合基体層材料は下側の型の成形面に載
置される。 The fourth embodiment according to the second invention adds a vacuum suction function similar to the lower mold 42 of the third embodiment shown in FIG. 7 to the lower mold 22 shown in FIG. As in the example, a breathable and flexible skin was laid on the molding surface of the lower mold, and then a facing material layer was vacuum formed, and then the base layer material was placed on the facing material layer, and both sides were pressed together using a pressure device. The mold is clamped to obtain a composite body in which the skin, the facing material layer, and the base layer are integrated. In this fourth embodiment, the upper mold and the lower mold may be reversed in position, and in this case, the base layer material is placed on the molding surface of the lower mold.
本発明に使用される柔軟な表皮１１，１２とし
ては、織布、不織布、編布、カーペツトなどの布
地や、軟質の合成樹脂製のフイルムまたはシート
があるが、第２の発明に使用する表皮１２につい
ては、通気性を有する必要がある。それらの表皮
１１，１２の裏側には、基体層１４または表装材
層１３との接着性を向上させるために接着材層が
あらかじめまたは敷設後設けられるが熱溶着が可
能な場合は接着材層は必要としない。 The flexible skins 11 and 12 used in the present invention include fabrics such as woven fabrics, non-woven fabrics, knitted fabrics, and carpets, as well as soft synthetic resin films or sheets. Regarding No. 12, it is necessary to have air permeability. An adhesive layer is provided on the back side of these skins 11 and 12 in advance or after laying to improve adhesion with the base layer 14 or facing material layer 13, but if heat welding is possible, the adhesive layer is do not need.
表装材層１３としては、PVD、EVA、PE、
PP、熱可塑性エラストマーなどのフイルムの単
層やそれらのフイルムにクツシヨン層として、
PVD、EVA、PE、PP、熱可塑性エラストマー、
ポリウレタンなどの高発泡体を積層した複合シー
トを使用することができる。 As the surface material layer 13, PVD, EVA, PE,
As a single layer of films such as PP and thermoplastic elastomer, or as a cushion layer on those films,
PVD, EVA, PE, PP, thermoplastic elastomer,
A composite sheet laminated with highly foamed materials such as polyurethane can be used.
第１および第４の実施例で示した方法で使用で
きる基体層１４材料としては、PVD、PE、PP、
ABSなどの溶融状態にある熱可塑性樹脂シート
状物のほかに、未硬化のポリエステル、フエノー
ル樹脂、ウレタン樹脂などの流動性のある熱可塑
性樹脂シート状物や、それら樹脂に、ガラス樹脂
や各種充填剤を添加したシート状物、紙やフエル
トなどの繊維ウエブに合成樹脂を添加した流動性
のあるシート状物および上記それらの材料のブロ
ツク状物が挙げられる。 Materials for the base layer 14 that can be used in the methods shown in the first and fourth embodiments include PVD, PE, PP,
In addition to thermoplastic resin sheets in a molten state such as ABS, fluid thermoplastic resin sheets such as uncured polyester, phenolic resin, and urethane resin, as well as glass resin and various fillings, are also available. Examples include sheet-like materials to which additives have been added, flowable sheet-like materials made by adding synthetic resin to fiber webs such as paper or felt, and block-like materials made of the above-mentioned materials.
第２および第３の実施例で示した方法で使用で
きる基体層１４材料は、前述の熱可塑性樹脂が射
出成形法により、同じく熱硬化性樹脂が射出成形
法または注入法により適用される。さらに第３の
実施例においては、基体層１４材料として発泡性
樹脂粒子を使用してキヤビテイに充填後加熱発泡
成形させる方法や、液状の発泡性樹脂を注入して
発泡成形させる方法も利用することができる。 As for the material of the base layer 14 that can be used in the methods shown in the second and third embodiments, the above-mentioned thermoplastic resin is applied by the injection molding method, and the thermosetting resin is also applied by the injection molding method or the injection method. Furthermore, in the third embodiment, a method of using foamable resin particles as the material of the base layer 14 and heating and foaming molding after filling the cavity, or a method of injecting liquid foamable resin and foaming molding may also be used. I can do it.
薄壁２３は帯金、鋸刃などの適宜な硬質帯状材
料を成形型面の所望位置に、成形面より３〜20mm
突出させて成形型２０に固着されている。薄壁２
３の厚さは0.2〜3.0mmで、基体層１４材料の成形
時に変形しない限りできるだけ薄くすることが好
ましい。また表皮１１，１２を成形型面に敷設す
るとき、その端末を薄壁２３に係止するが、これ
は次の工程で表装材層１３を被着させたり、基体
層１４材料を成形する際、表皮１１，１２が薄壁
２３の内側または外側にずれ動くことを防ぐため
であつて、この作用をより確実に得られるよう
に、薄壁２３の頂部に針状もしくは鋸刃状の突起
５１や（第９図ａ）、薄壁２３の内側面に面フア
スナーのフツク部５２（第９図ｂ）などの係止部
を備えたり、または第９図ｃのように薄壁の頂部
をまたいだ表皮１１，１２の端部をその上から断
面Ｕ字型の嵌込み式の係止具５３を使用して係止
すると有利である。 The thin wall 23 is made by placing an appropriate hard strip material such as a metal band or a saw blade at a desired position on the mold surface, 3 to 20 mm from the mold surface.
It is fixed to the mold 20 in a protruding manner. thin wall 2
The thickness of the base layer 3 is 0.2 to 3.0 mm, and it is preferable to make it as thin as possible unless the material of the base layer 14 is deformed during molding. Furthermore, when the skins 11 and 12 are laid on the mold surface, their ends are locked to the thin wall 23. , in order to prevent the skins 11 and 12 from shifting inside or outside the thin wall 23, and in order to more reliably achieve this effect, a needle-like or serrated projection 51 is provided on the top of the thin wall 23. (Fig. 9a), a locking part such as a hook part 52 of a hook-and-loop fastener (Fig. 9b) is provided on the inner surface of the thin wall 23, or the top of the thin wall is straddled as shown in Fig. 9c. It is advantageous to lock the ends of the outer skins 11, 12 from above by means of snap-in locks 53 having a U-shaped cross section.
さらに第１０図に示す如く成形型２０の薄壁２
３で区分された領域部分５５を着脱自在な入子型
５６とし、第１１図の如くその入子型５６と対応
するプレス型５７とをそれぞれ複数個用意するこ
とにより、前述の表皮１１，１２の予備成形、そ
の端末の薄壁２３の頂部への係止およびその周辺
の裁断を、成形型２０が次の工程を実施中に、別
の設備で同時に実施することができるので成形型
２０の占拠時間を短縮することができる。また、
入子型５６とプレス型５７との間に予備成形した
表皮１１，１２を挿入したまま成形型２０の所望
位置に移動設置し、入子型５６用の排気パイプ５
９を排気することにより表皮１１，１２を入子型
５６の真空成形型面に吸着させながらプレス型を
除去し、次いで次の工程の成形を実施すれば、表
皮１１，１２は予備成形から次の工程までの間に
もどり変形することがないので、表皮１１，１２
が腰の強い場合特に有利である。 Furthermore, as shown in FIG.
The above-mentioned skins 11, 12 are formed by forming a removable nesting mold 56 into the area 55 divided by 3, and by preparing a plurality of press molds 57 corresponding to the nesting mold 56 as shown in FIG. While the mold 20 is performing the next process, the preforming of the mold 20, the locking of the end to the top of the thin wall 23, and the cutting of the surrounding area can be simultaneously performed using separate equipment. Occupation time can be shortened. Also,
The preformed skins 11 and 12 are inserted between the nesting mold 56 and the press mold 57 and moved to a desired position of the mold 20, and the exhaust pipe 5 for the nesting mold 56 is installed.
The press mold is removed while the skins 11 and 12 are adsorbed to the vacuum mold surface of the nested mold 56 by evacuating the gas 9, and then the next step of molding is carried out. Since the epidermis 11 and 12 will not be deformed until the step of
This is especially advantageous if you have strong hips.
成形型２０の上型に設ける注入孔３４は、第５
図または第７図のような所謂ダイレクト型のほ
か、ピンポイント型も採用することができる。ピ
ンポイント型の注入口を多数設け、表皮１１，１
２および表装材層１３を介して薄壁２３の両側面
にかかる基体層１４材料の成形圧力を等しくし
て、成形圧による薄壁２３の湾曲を防ぐことがで
きる。基体層１４材料の注入圧力が大きく注入時
温度が高い場合、注入口に対向する表皮１１，１
２または表装材層１３部分が溶融したり、それら
の表皮を通つて成形品１８，１９の表側に浸透す
ることがある。これを防ぐためには、注入口に対
向する表皮部分に金属薄片、石綿シート、紙など
を貼付しておくとよい。 The injection hole 34 provided in the upper mold of the mold 20 is the fifth
In addition to the so-called direct type as shown in FIG. 7 or FIG. 7, a pinpoint type can also be adopted. A large number of pinpoint injection ports are provided, and the epidermis 11,1
By equalizing the molding pressure of the material of the base layer 14 on both sides of the thin wall 23 through the thin wall 23 and the facing material layer 13, it is possible to prevent the thin wall 23 from curving due to the molding pressure. When the injection pressure of the base layer 14 material is high and the temperature during injection is high, the skin 11, 1 facing the injection port
2 or the surface material layer 13 may melt or penetrate into the front side of the molded products 18, 19 through their skins. To prevent this, it is recommended to attach thin metal pieces, asbestos sheets, paper, etc. to the part of the skin facing the injection port.
基体層１４材料との接着性を向上するため表皮
１１，１２または表装材層１３の裏面に設ける接
着材層としては加熱により活性化する接着剤や接
着フイルムが好ましい。 The adhesive layer provided on the back surface of the skins 11, 12 or the facing material layer 13 in order to improve the adhesiveness with the material of the base layer 14 is preferably an adhesive activated by heating or an adhesive film.
また第２の発明において、表皮の上から全成形
面に亘つて表装材層を真空成形する代りに、これ
を圧空成形または真空圧空成形することもでき
る。 In the second aspect of the invention, instead of vacuum forming the facing material layer over the entire molding surface from the top of the skin, it can also be formed by air pressure forming or vacuum pressure forming.
発明の効果
以上述べたように本発明の方法によれば、成形
体の外面に基体を被着させるにあたり、表皮の端
末を、基体層材料または表装材層を介して基体層
材料の幅の狭い凹部の奥に隠蔽するものであるか
ら、表皮の端末が変形したり、基体層材料が表皮
の端末位置からはみ出して、その表皮の表側にま
で侵出することがなく、またモールを使つての表
皮の端末処理や芯材、クリツプなどを使用するた
めの重量増、工程の煩雑化を解消するとともに、
基体層材料としては広範囲の合成樹脂を使用する
ことができ、かつ基体層の厚さを部分的に変更す
ることが可能であるから成形品として要求される
機械的性質と重量制限を満足する複合成形品を簡
素な工程で、短時間に、見栄えが良く豪華に製造
することができる。Effects of the Invention As described above, according to the method of the present invention, when attaching a substrate to the outer surface of a molded article, the ends of the skin are attached to the narrow width of the substrate layer material through the substrate layer material or the facing material layer. Since it is hidden deep within the recess, the end of the skin will not be deformed, the base layer material will not protrude from the end of the skin, and will not seep into the front side of the skin. In addition to eliminating the increase in weight and complication of the process due to the end treatment of the skin, the use of core materials, clips, etc.,
A wide range of synthetic resins can be used as the base layer material, and the thickness of the base layer can be partially changed, making it a composite material that satisfies the mechanical properties and weight restrictions required for molded products. A molded product can be manufactured in a simple process, in a short time, and with good appearance and luxury.
第１図は従来法により製造された車両のドアト
リムの斜視図、第２図は第１図の断面部分図、第
３図は別の従来法により製造されたドアトリムの
断面部分図、第４図および第５図は第１の発明の
実施例を示す成形型の断面図、第６図は第４図ま
たは第５図の成形型により製造された複合成形体
の断面図、第７図は第２の発明の実施例を示す成
形型の断面図、第８図は第７図の成形型で製造さ
れた複合成形体の断面図、第９図ａ，ｂ，ｃは表
皮の端部を係止する係止部または係止具の係止状
態を示す断面図、第１０図は成形型のさらに他の
例を示す断面図、第１１図は表皮を挿入した入子
型とプレス型の断面図である。
１１，１２……表皮、１３……表装材層、１４
……基体層、２０……成形型、２３……薄壁、３
３……キヤビテイ、４３……排気孔。
Figure 1 is a perspective view of a vehicle door trim manufactured by a conventional method, Figure 2 is a partial cross-sectional view of Figure 1, Figure 3 is a partial cross-sectional view of a door trim manufactured by another conventional method, and Figure 4. 5 is a cross-sectional view of a mold showing an embodiment of the first invention, FIG. 6 is a cross-sectional view of a composite molded article produced by the mold of FIG. 4 or FIG. 5, and FIG. FIG. 8 is a cross-sectional view of a composite molded article produced using the mold shown in FIG. 7, and FIGS. A cross-sectional view showing the locked state of the locking part or the locking tool, FIG. 10 is a cross-sectional view showing still another example of the mold, and FIG. 11 is a cross-section of the nesting mold and press mold into which the skin is inserted. It is a diagram. 11, 12...Skin, 13...Surface material layer, 14
... Base layer, 20 ... Molding mold, 23 ... Thin wall, 3
3...Cavity, 43...Exhaust hole.
Claims (1)
の成形面の所望位置に成形面から突出した薄壁を
設け、その薄壁で区分された領域に柔軟な表皮を
敷設するとともに、薄壁の内面に沿つてその表皮
の端部を立上がらせ、その端末を薄壁に係止した
のち、一対の成形型の一方の型の成形面に、直接
もしくは表皮の上から、基体層材料を載置して型
締めするか、または一対の成形型を型締めしたの
ち、キヤビテイ内に基体層材料を注入する複合成
形体の製造方法。 ２ 一対の成形型の一方の型の全成形面に多数の
排気孔を開孔せしめ、かつその型の成形面の所望
位置に成形面から突出した薄壁を設け、その薄壁
で区分された領域に通気性の柔軟な表皮を敷設す
るとともに、薄壁の内面に沿つてその表皮の端部
を立上がらせ、その端末を薄壁に係止し、該表皮
を介して全成形面にわたつて表装材層を真空成
形、圧空成形もしくは真空圧空成形したのち、そ
の表装材層上もしくは他方の型の成形面に基体層
材料を載置して型締めするか、または一対の成形
型を型締めしたのち、キヤビテイ内に基体層材料
を注入する複合成形体の製造方法。[Claims] 1. A thin wall protruding from the molding surface is provided at a desired position on the molding surface of one or both of a pair of molds, and a flexible skin is laid in the area divided by the thin wall. At the same time, the end of the skin is raised along the inner surface of the thin wall, and after the end is locked to the thin wall, it is applied directly or from above the skin to the molding surface of one of the pair of molds. A method for manufacturing a composite molded article, in which a base layer material is placed and the mold is clamped, or a pair of molds is clamped, and then the base layer material is injected into the cavity. 2 A large number of exhaust holes are formed on the entire molding surface of one of a pair of molds, and a thin wall protruding from the molding surface is provided at a desired position on the molding surface of the mold, and the mold is divided by the thin wall. A breathable flexible skin is laid over the area, and the ends of the skin are raised up along the inner surface of the thin wall, and the ends are latched to the thin wall and spread over the entire molding surface through the skin. After vacuum forming, pressure forming, or vacuum pressure forming the facing material layer, the base layer material is placed on the facing material layer or the molding surface of the other mold and the mold is clamped, or a pair of molds is molded. A method for manufacturing a composite molded body in which a base layer material is injected into the cavity after tightening.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP15839285A JPS6219419A (en) | 1985-07-19 | 1985-07-19 | Manufacture of composite molded body |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP15839285A JPS6219419A (en) | 1985-07-19 | 1985-07-19 | Manufacture of composite molded body |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS6219419A JPS6219419A (en) | 1987-01-28 |
| JPH0374891B2 true JPH0374891B2 (en) | 1991-11-28 |
Family
ID=15670726
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP15839285A Granted JPS6219419A (en) | 1985-07-19 | 1985-07-19 | Manufacture of composite molded body |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS6219419A (en) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5091031A (en) * | 1990-05-02 | 1992-02-25 | Vittorio Strapazzini | Method for forming plastic molded panels with inserts |
| US5395668A (en) * | 1990-08-29 | 1995-03-07 | Toyoda Gosei Co., Ltd. | Air bag apparatus |
| US6004498A (en) * | 1994-04-04 | 1999-12-21 | Toyoda Gosei Co. Ltd. | Method for molding resin to skin members |
| US5804117A (en) * | 1994-04-05 | 1998-09-08 | Toyoda Gosei Co., Ltd. | Molding method for resin articles |
| US5919324A (en) * | 1997-01-17 | 1999-07-06 | Ut Automotive Dearborn Inc. | Method of securing decorative insert to underlying plastic skin for trim panel |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5933293A (en) * | 1982-08-19 | 1984-02-23 | Sumitomo Chem Co Ltd | N-phenyltetrahydrophthalimide derivative, its preparation and herbicide containing the same as active constituent |
| JPS5952056A (en) * | 1982-09-20 | 1984-03-26 | 松下電工株式会社 | Building panel |
-
1985
- 1985-07-19 JP JP15839285A patent/JPS6219419A/en active Granted
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5933293A (en) * | 1982-08-19 | 1984-02-23 | Sumitomo Chem Co Ltd | N-phenyltetrahydrophthalimide derivative, its preparation and herbicide containing the same as active constituent |
| JPS5952056A (en) * | 1982-09-20 | 1984-03-26 | 松下電工株式会社 | Building panel |
Also Published As
| Publication number | Publication date |
|---|---|
| JPS6219419A (en) | 1987-01-28 |
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| Date | Code | Title | Description |
|---|---|---|---|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
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| EXPY | Cancellation because of completion of term |