JPS61229526A - Mold for vacuum molding - Google Patents
Mold for vacuum moldingInfo
- Publication number
- JPS61229526A JPS61229526A JP60071987A JP7198785A JPS61229526A JP S61229526 A JPS61229526 A JP S61229526A JP 60071987 A JP60071987 A JP 60071987A JP 7198785 A JP7198785 A JP 7198785A JP S61229526 A JPS61229526 A JP S61229526A
- Authority
- JP
- Japan
- Prior art keywords
- electroformed shell
- layer
- shell
- synthetic resin
- mounting flange
- 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.)
- Granted
Links
Landscapes
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
Description
【発明の詳細な説明】
Ａ丁′発明あ目″的 □
ｔｉ） 産業上の利用分野
゛本発明は、合成樹脂シートを所定の形状に成瘤す゛ム
゛；めに扇いらｉ真空晟形型社関する。′（２）゛従来
の技′術
本出願人は先″に□、精密模型の表面に電鋳処理を５
、 、・ ・ ・）、坂・ ネ ・施し
てその模型に忠実で通気性を有する電鋳殻を藺゛発己’
ｔｊ’ ＜’ｍｍｖｉＭ ｉ６’−２６６９号参照）。[Detailed Description of the Invention] A. Aim of the Invention □ ti) Industrial Field of Use The present invention is a method for forming a synthetic resin sheet into a predetermined shape; Regarding the mold company.'(2) ``Conventional technique'' The present applicant previously □ applied electroforming treatment to the surface of a precision model.
, , , , , ), Saka ne , created an electroformed shell that is faithful to the model and has breathability.
tj'<'mmviMi6'-2669).
−”ｎ’ｉａ□電゛鋳殻畝それを精密模型から離型しｈ
後ｉ２’ｏ支持゛赫□に門付けε゛れて成形作ｉ供され
る。-"n'ia□Electric cast shell ridge. Release it from the precision model.
Afterwards, it is attached to the i2'o support and subjected to molding.
（３） 発明が解決しようとする問題点□゛しかｔ″
な゛が′ら前記電鋳殻は肉厚が非常に１く低剛性でぷる
゛か′ニ、型合□せ□時、゛成形体の製造時等に□１
一撃力示作用すると、変形し易いという゛問題かある。(3) The problem that the invention seeks to solve □゛Butt''
However, the electroformed shell has a very thin wall thickness, low rigidity, and is flexible, so that it deforms when subjected to a blow force during mold assembly, manufacturing of a molded object, etc. The problem is that it is easy to do.
またｔｊｉ讐は端一模型に強く密着しているあで離型作
業が容易でなく、薯の上電鋳工綽で生じた内部応男註工
す離型時において電鋳殻が変形すると゛む−う゛問題も
ある。この変形ｉ車晶用インストルメンドパネルを成形
する電鋳殻のように大型で複雑な成形部を持つものにお
いて生じ易い。In addition, it is not easy to release the mold because the edges are tightly attached to the model, and the electroformed shell may be deformed during mold release due to the internal cracks that occur during the electroforming process. There is also a problem. This problem is likely to occur in products with large and complicated molded parts, such as the electroformed shell used to mold the instrument panel for deformed i-car crystals.
本発明は上記問題を解消し得る前記真空成形型を提供す
ることを目的とする。An object of the present invention is to provide the vacuum forming mold that can solve the above problems.
Ｂ０発明の構成
（１）問題点を解決するための手段
本発明は、合成樹脂シートを所定の形状に成形する成形
部の外周に、取付フランジ部を連設した通気性を有する
電鋳殻と；枠本体の下向き開口部を前記成形部により覆
われて該下向き開口部周縁の支持フランジ部を前記取付
フランジ部に重合連結し、また前記枠本体に設けられた
吊持部材により前記成形部を吊持する支持枠と；前記枠
本体内に収容され、前記成形部の背面に一体に接合され
た通気性を有するバックアツプ体と；より構成したこと
を特徴とする。B0 Structure of the Invention (1) Means for Solving the Problems The present invention comprises an electroformed shell having air permeability and having a mounting flange connected to the outer periphery of a molding part for molding a synthetic resin sheet into a predetermined shape. ; The downward opening of the frame body is covered by the molded part, and the support flange around the downward opening is overlappingly connected to the mounting flange, and the molded part is covered by the hanging member provided on the frame body. It is characterized by comprising: a supporting frame to be suspended; and a back-up body having air permeability and housed in the frame main body and integrally joined to the back surface of the molded part.
（２）作 用
型合せ時、成形型の製造時等に電鋳殻の成形部に衝撃力
が作用しても成形部はバックアツプ体により補強されて
いるので変形することはない。また電鋳殻の取付フラン
ジ部は支持枠の支持フランジ部に重合連結されると共に
成形部は吊持部材に吊持されているので、バックアツプ
体の重量により成形部が変形することはない。(2) Operation Even if an impact force is applied to the molded part of the electroformed shell when fitting the molds together or manufacturing the mold, the molded part will not be deformed because it is reinforced by the back-up body. Further, since the mounting flange portion of the electroformed shell is overlappingly connected to the support flange portion of the support frame and the molded portion is suspended by the suspension member, the molded portion is not deformed by the weight of the back-up body.
ざらに電鋳殻を精密模型から離型する前に、電鋳殻を支
持枠に吊持させることが可能で、これにより離型作業の
容易化および電鋳殻の変形防止が図られる。Before roughly releasing the electroformed shell from the precision model, it is possible to suspend the electroformed shell on a support frame, which facilitates the release process and prevents deformation of the electroformed shell.
（３）実施例
車両用インストルメントパネルを成形するための真空成
形型ｌは、第１．第２図に示すニッケル製電鋳殻２を、
第５図に示すように支持枠８に支持させ、また支持枠８
内にバックアツプ体１９を収容することにより構成され
る。(3) Example Vacuum molding mold l for molding a vehicle instrument panel is the first one. The electroformed nickel shell 2 shown in FIG.
As shown in FIG.
It is constructed by accommodating a backup body 19 inside.
電鋳殻２は、平面において長方形をなすと共に通気性を
有し、その厚さは０．６〜３Ｗ程度である。The electroformed shell 2 is rectangular in plan, has air permeability, and has a thickness of about 0.6 to 3W.
その電鋳殻２は合成樹脂シートをインストルメントパネ
ルの形状に成形する凹凸部分を備えた成形部２ａと、そ
の外周に連設されて後述する支持枠に取付けられる取付
フランジ部２ｂとより構成される。電鋳殻２の前面、即
ち第２図において下向きのシート重合面４には第３図に
示すように牛革に忠実な凹凸模様ｐが形成される。また
第４図に示すよう電鋳殻２にはその厚さ方向に無数の通
気孔５が全体に亘って均一に分布するように形成され、
それら通気孔５は真空吸引孔として用いられる。それら
通気孔５のシート重合面４における開口部５ａは縦およ
び横方向に約０．２鰭のピッチで配列しており、それら
の直径は＜）、０３〜０．０５＋ｎである。このように
通気孔５の開口部５ａは極めて小径であるため凹凸模様
ｐを何等損なうことがない。The electroformed shell 2 is composed of a molded part 2a having an uneven part for molding a synthetic resin sheet into the shape of an instrument panel, and a mounting flange part 2b connected to the outer periphery of the molded part 2a and attached to a support frame to be described later. Ru. As shown in FIG. 3, an uneven pattern p faithful to cowhide is formed on the front surface of the electroformed shell 2, that is, the sheet overlapping surface 4 facing downward in FIG. 2. Furthermore, as shown in FIG. 4, the electroformed shell 2 is formed with numerous ventilation holes 5 uniformly distributed throughout its thickness.
These vent holes 5 are used as vacuum suction holes. The openings 5a of the ventilation holes 5 in the sheet overlapping surface 4 are arranged in the vertical and horizontal directions at a pitch of about 0.2 fins, and their diameters are <), 0.3 to 0.05+n. As described above, since the opening 5a of the vent hole 5 has an extremely small diameter, the uneven pattern p is not damaged in any way.
電鋳殻２の成形部２ａ背面には、第１図に示す′ように
多数のナツト部材６１が成形部２ａ全体に亘って分散す
るように縦横に配列されてスタンド溶接により溶着され
る。また取付フランジ部２ｂの背面にも、多数のナンド
部材６□が取付フランジ部２ｂ全体に亘って分散するよ
うにスタッド溶接により溶着される。これらナツト部材
６１，６２は電鋳殻２を後述する支持枠に吊持するため
に用いられる。As shown in FIG. 1, a large number of nut members 61 are welded to the back surface of the molded part 2a of the electroformed shell 2 by stand welding, arranged vertically and horizontally so as to be distributed over the entire molded part 2a. Also, a large number of NAND members 6□ are welded to the back surface of the mounting flange portion 2b by stud welding so as to be distributed over the entire mounting flange portion 2b. These nut members 61 and 62 are used to suspend the electroformed shell 2 from a support frame which will be described later.
このようにスタッド溶接法を適用すると、多数のナツト
部材６１．６ｔを極薄の電鋳殻２に溶着してもその電鋳
殻２に溶接歪を生じないという利点がある。When the stud welding method is applied in this manner, there is an advantage that even if a large number of nut members 61.6t are welded to the extremely thin electroformed shell 2, no welding distortion occurs in the electroformed shell 2.
取付フランジ部２ｂの背面には、その全体に繊維強化合
成樹脂体３が接合されている。この繊維強化合成樹脂体
３は強化用繊維とそれに充填複合される熱硬化性合成樹
脂とよりなり、強化用繊維としてはガラス繊維、炭素繊
維、金属繊維等よりなる長繊維またはこれら繊維の１つ
以上を用いて形成される不織布等が該当し、また熱硬化
性合成樹脂としてはエポキシ樹脂等が該当する。A fiber-reinforced synthetic resin body 3 is bonded to the entire back surface of the mounting flange portion 2b. This fiber-reinforced synthetic resin body 3 is made of reinforcing fibers and a thermosetting synthetic resin filled and composited with the reinforcing fibers, and the reinforcing fibers are long fibers made of glass fibers, carbon fibers, metal fibers, etc., or one of these fibers. Non-woven fabrics formed using the above materials fall under this category, and thermosetting synthetic resins include epoxy resins and the like.
繊維強化合成樹脂体３の作製に当たっては、電鋳殻２の
取付フランジ部２ｂ背面全体に、前記ナツト部材６□を
溶着した後前記繊維を所定の厚さおよび配向を以て配設
し、これに前記熱硬化性合成樹脂液を含浸させてその樹
脂を加熱硬化するもので、この繊維強化合成樹脂体３の
作製と同時にそれは取付フランジ部２ｂと一体に接合さ
れる。In producing the fiber-reinforced synthetic resin body 3, the nut member 6□ is welded to the entire back surface of the mounting flange portion 2b of the electroformed shell 2, and then the fibers are arranged with a predetermined thickness and orientation. The fiber-reinforced synthetic resin body 3 is impregnated with a thermosetting synthetic resin liquid and cured by heating, and at the same time as the fiber-reinforced synthetic resin body 3 is produced, it is integrally joined to the mounting flange portion 2b.
この繊維強化合成樹脂体３の作製は、電鋳殻２を離型す
る前、即ち電鋳殻２が精密模型Ｍ上にあるときに行われ
る。This fiber-reinforced synthetic resin body 3 is produced before the electroformed shell 2 is released from the mold, that is, while the electroformed shell 2 is on the precision model M.
このように成形部２ａの外周に、取付フランジ部２ｂと
これに接合された繊維強化合成樹脂体３とより高剛性な
複合部７を形成すると、この複合部７により成形部２ａ
の変形が抑制されるので、電鋳殻２の保形性が良好とな
り、離型時において電鋳工程で生じた内部応力に起因す
る電鋳殻２の変形を防止することができる。When a higher rigidity composite part 7 is formed on the outer periphery of the molded part 2a with the mounting flange part 2b and the fiber-reinforced synthetic resin body 3 joined thereto, this composite part 7 forms the molded part 2a.
Since the deformation of the electroformed shell 2 is suppressed, the shape retention of the electroformed shell 2 becomes good, and deformation of the electroformed shell 2 due to internal stress generated in the electroforming process at the time of mold release can be prevented.
前記電鋳殻２は、第５．第６図に示すように支持枠８に
取付けられて昇降自在な第１可動部９゜を構成し、その
第１可動部９１はそれの下方において昇降自在に配設さ
れた第２可動部９冨と共にインストルメントパネルの製
造に供される。The electroformed shell 2 has the fifth. As shown in FIG. 6, the first movable part 91 is attached to the support frame 8 and is movable up and down, and the first movable part 91 is arranged below the second movable part 9, which is movable up and down. Together with Tomi, it is used to manufacture instrument panels.
第１可動部９１において、支持枠８′は、天壁ｌＯを備
えた平面長方形の箱状をなす枠本体８ａと、その枠本体
８ａの下向き開口部近傍においてその長・手方向と直交
するように等間隔魁ｊ配設されて両端部を枠本体８ａ内
面に溶着された複数のアングル形桟材８ｂと、上端面を
天壁１０に、また下端面を各桟材８ｂに溶着された支持
板８Ｃとよりなる。In the first movable part 91, the support frame 8' includes a frame body 8a having a rectangular box-like shape with a top wall lO, and a frame body 8a that is perpendicular to the longitudinal and longitudinal directions of the frame body 8a in the vicinity of the downward opening of the frame body 8a. A plurality of angle-shaped crosspieces 8b are arranged at regular intervals and have both ends welded to the inner surface of the frame body 8a, and supports whose upper end surfaces are welded to the ceiling wall 10 and whose lower end surfaces are welded to each crosspiece 8b. It consists of plate 8C.
枠本体８ａの下向き開口部は電鋳殻２の成形部２ａによ
り覆われ、下向き開口部周縁に突設された支持フランジ
部１１は電鋳殻２における取付フランジ部・２ｂの前面
、したがって複合部７における繊維強化合成樹脂体３に
当て板１′２を介して重量され、両フランジ部２ｂ、１
１は枠本体８ａの周囲に沿って多数の締付ボルト１ ’
３ Ｉおよびす′ント１４により連結される。この場合
複合部７は優れた変形抵抗性を有するので、締付ボルト
１３等により締付１すられても変形することがない、当
て板１２の内側において支持フランジ部１１と複合部７
間にｉよ真空シール材１５示介装される。 ′電鋳殻２
の成形部２ａに溶着されたナツト部材６Ｉにおいて第１
図の各横列のナツト部材６１は各桟材８ｂに対向するよ
′う社配設されており１、各ナツト部材６．と各桟材８
ｂ間には筒状スペーサ１７、が介装され、桟材８ｂおよ
び筒状スペーサ１７、を貫通する吊持ボルト１８．がナ
ツト部材６、に螺着される。筒状スペーサ１７１は吊持
ポル）１８１の締付力を所定量に規制して取付フランジ
部２ｂの変形を防止する機能を有□す′為。The downward opening of the frame body 8a is covered by the molded part 2a of the electroformed shell 2, and the support flange part 11 protruding from the periphery of the downward opening is the front surface of the mounting flange part 2b of the electroformed shell 2, and therefore the composite part. The fiber-reinforced synthetic resin body 3 at
1 is a large number of tightening bolts 1' along the periphery of the frame body 8a.
3 I and component 14. In this case, since the composite part 7 has excellent deformation resistance, the support flange part 11 and the composite part 7 do not deform even when tightened by the tightening bolt 13 etc. on the inside of the backing plate 12.
A vacuum sealing material 15 is inserted between them. 'Electroformed shell 2
In the nut member 6I welded to the molded part 2a of
The nut members 61 in each horizontal row in the figure are arranged so as to face each crosspiece 8b, and each nut member 6. and each crosspiece 8
A cylindrical spacer 17 is interposed between the crosspiece 8b and the cylindrical spacer 17, and a suspension bolt 18.b is inserted through the crosspiece 8b and the cylindrical spacer 17. is screwed onto the nut member 6. The cylindrical spacer 171 has the function of regulating the clamping force of the suspension pole 181 to a predetermined amount to prevent deformation of the mounting flange portion 2b.
かくして各ナツト部材６３、桟材８ｂ養よび吊持ボルト
１８．は成形部２ａを吊持する吊持部材を構成する。
□ □
枠本体８ａの内面には、電鋳殻２の取付フランジ部２ｂ
背面に溶着された各ナツト部材６８に対応してアングル
材１６が溶着される。各ナツト部材６ｚと各アングル材
１６間には筒状スペーサ１７２が介装され、アングル材
１６ｉＢ′よび筒状スペーサ１７８を貫通する吊持ボル
ト１８！がナンド部材６：に螺着される。 □
支持枠８内には、主として電鋳殻２の成形部２ａを補強
するバックアツプ体１９が、収容され、電鋳殻２と一体
に接合される。そのバックアツプ体１９は、電鋳殻２側
に配設されてステンレス鋼等の耐食性に優れた無数の鋼
球の相隣るもの相互間をエポキシ樹脂等の熱硬化性゛合
成樹脂により部分接合した通気性を有する第１層１９１
と、その第１層１９１に積層されて無数のガラス粒子の
相隣るもの相互間を前記同様の熱硬化性合成樹脂により
部分接合した通気性を有する第２層１９ｇとよりなる。In this way, each nut member 63, the support member 8b and the suspension bolt 18. constitutes a suspension member that suspends the molded part 2a.
□ □ The inner surface of the frame body 8a has a mounting flange portion 2b for the electroformed shell 2.
Angle members 16 are welded to correspond to each nut member 68 welded to the back surface. A cylindrical spacer 172 is interposed between each nut member 6z and each angle member 16, and a suspension bolt 18 passes through the angle member 16iB' and the cylindrical spacer 178! is screwed onto the NAND member 6:. □ A back-up body 19 that mainly reinforces the molded part 2a of the electroformed shell 2 is housed in the support frame 8 and is integrally joined to the electroformed shell 2. The back-up body 19 is arranged on the side of the electroformed shell 2 and partially joins adjacent steel balls made of stainless steel or the like with excellent corrosion resistance using thermosetting synthetic resin such as epoxy resin. The first layer 191 has breathability.
A second layer 19g having air permeability is laminated on the first layer 191 and has numerous adjoining glass particles partially bonded with the same thermosetting synthetic resin as described above.
′ ・ −このように電
鋳殻２の背面側にバンクアップ体１９を設けても、電鋳
殻２の取付フランジ部２ｂ、したがうて複合部７が支持
枠８の支持フランジ部１′１に重谷連結され、また複合
部７および成形部２ａが多１＆め吊持ボルトＩＬ、１８
ｇにより各桟材８ｂおよびアンパル材１６に吊持されて
いるので、電＆Ｉ殻２がバックアツプ体１９の重量によ
り垂れ下がって変形するといった問題を生じることがな
い。□
第１層１９．を形成する場合には、電鋳殻２の背面にお
いて天壁１０のない枠本体８ｂ内に、第７−に示すよう
に表面に薄い前記熱硬化性合成樹脂よ’Ｊ ｆＬ ４ｍ
１ｌｆＪＩ Ｒｔ ＠ａｔ ４４０〜５０ 、Ｉｆ、（
７）１ｍ球２０を所定量注入し、その後鋼球２０および
樹脂膚凱を５０〜・６０℃に加熱して樹脂層Ｒ＋の相隣
る鋼球２０間の接点に位置する部位を接合し、各接合点
で囲まれる空隙Ｖ１を形成するものである。この空隙■
１により第１層１９．に連続気孔が形成される。この鋼
球２０相互間の接合時に第１層１９．と電鋳殻２間も前
記樹脂層Ｒ１により接合される。' - Even if the bank up body 19 is provided on the back side of the electroformed shell 2 in this way, the mounting flange part 2b of the electroformed shell 2, and hence the composite part 7, cannot be attached to the support flange part 1'1 of the support frame 8. The composite part 7 and the molded part 2a are connected by multiple suspension bolts IL, 18.
Since the electric & I shell 2 is suspended from each crosspiece 8b and the unpalm material 16 by the support members 8b and 16, the problem that the electric & I shell 2 is sagged and deformed due to the weight of the back-up body 19 does not occur. □ First layer 19. In the case of forming a thin thermosetting synthetic resin on the surface, as shown in No.
1lfJI Rt @at 440~50, If, (
7) Inject a predetermined amount of 1 m balls 20, then heat the steel balls 20 and the resin layer to 50 to 60°C to join the parts of the resin layer R+ located at the contact points between adjacent steel balls 20, This forms a void V1 surrounded by each junction. This void■
1 to the first layer 19. Continuous pores are formed. When the steel balls 20 are joined together, the first layer 19. and the electroformed shell 2 are also joined by the resin layer R1.
また第２層１９□を形成する場合には、軽量化のために
凹部１９ａを形成すべくそれと同形の部材（図示せず）
を枠本体８ｂ内に吊持し、第１層１９１の上に第８図に
示すように表面に薄い前記・樹脂層Ｒ８を有する５００
〜６００μのガラス粒子２１を所定量注入し、その後、
ガラス粒子２１および樹脂層Ｒｔを５０〜６０℃に加熱
して樹脂層Ｒ２の相隣るガラス粒子２１間の接点に位置
する部位を接合し、各接合点で囲まれる空隙Ｖ、を形成
するものである。この空隙ｖ２により第２層１９、に連
続気孔が形成される。このガラス粒子２１相互間の接合
時に第１層１９．と第２層１９２間も前記樹脂Ｒ２によ
りそれぞれ接合される。In addition, when forming the second layer 19□, a member (not shown) having the same shape as the recess 19a is used to reduce the weight.
500 suspended in the frame body 8b and having the thin resin layer R8 on the surface as shown in FIG. 8 on the first layer 191.
A predetermined amount of glass particles 21 of ~600μ are injected, and then,
The glass particles 21 and the resin layer Rt are heated to 50 to 60°C to bond the portions of the resin layer R2 located at the contact points between adjacent glass particles 21 to form a void V surrounded by each bond point. It is. Continuous pores are formed in the second layer 19 by the voids v2. When the glass particles 21 are bonded to each other, the first layer 19. and the second layer 192 are also bonded by the resin R2.
支持板８Ｃには、複数の窓２２が形成され、これら窓２
２によりガラス粒子２１の注入時その流れが支持板８Ｃ
により妨げられないようになっている。A plurality of windows 22 are formed on the support plate 8C, and these windows 2
2, when the glass particles 21 are injected, the flow is caused by the support plate 8C.
so that it is not obstructed by this.
第１層１９１には、成形部２ａを全域に亘り均等に冷却
し得るように冷却管２３が蛇行して埋設される。この場
合第１層１９．は鋼球２０．を主体とするので熱伝導性
が良好であり、したがって成形部２ａを効率良く冷却す
ることができる。また冷却管２３の蛇行埋設により第１
層１９１が補強される。A cooling pipe 23 is embedded in the first layer 191 in a meandering manner so that the molded part 2a can be uniformly cooled over the entire area. In this case the first layer 19. is steel ball 20. Since it mainly consists of , it has good thermal conductivity, and therefore the molded part 2a can be efficiently cooled. Also, by burying the cooling pipe 23 in a meandering manner, the first
Layer 191 is reinforced.
支持枠８内は切換弁２４を介して真空ポンプ２５Ｉおよ
びブロア２６に接続される。The inside of the support frame 8 is connected to a vacuum pump 25I and a blower 26 via a switching valve 24.
第２可動部９ｔは下記のように構成される。The second movable part 9t is configured as follows.
底壁２７を備えた平面長方形の支持枠２８の上向き開口
部には成形部２ａと嵌合関係にある押圧型２９が固着さ
れる。その押圧型２９の上面には芯材Ｃを嵌め込むため
の凹部３０が形成され、また押圧型２９において、成形
部２ａと対向する部分にはその部分を貫通するように複
数の真空吸引孔３１が形成される。支持枠２８内は真空
ポンプ２５□に接続される。A pressing mold 29 is fixed to an upward opening of a planar rectangular support frame 28 provided with a bottom wall 27 and is fitted into the molding part 2a. A recess 30 for fitting the core material C is formed on the upper surface of the pressing mold 29, and a plurality of vacuum suction holes 31 are formed in the portion of the pressing mold 29 facing the molding portion 2a so as to penetrate through that portion. is formed. The inside of the support frame 28 is connected to a vacuum pump 25□.
インストルメントパネルは合成樹脂シートＳと芯材Ｃと
よりなり、その合成樹脂シートＳとしては、ポリ塩化ビ
ニル等よりなるシート単体、またはそのシートを表皮層
とし、これにポリプロピレン発泡シートをクッション層
として貼合わせた積層シートが該当する。The instrument panel consists of a synthetic resin sheet S and a core material C, and the synthetic resin sheet S can be a single sheet made of polyvinyl chloride or the like, or the sheet can be used as a skin layer, and a polypropylene foam sheet can be used as a cushion layer. This applies to laminated sheets that have been bonded together.
また芯材Ｃは、ＡＢＳ樹脂等よりなる板に複数の小径真
空吸引孔３２を形成し、この板を押圧型２９の凹部３０
に合致するように成形したものである。In addition, the core material C has a plurality of small-diameter vacuum suction holes 32 formed in a plate made of ABS resin or the like, and this plate is inserted into the recess 30 of the pressing die 29.
It is molded to match.
次に、インストルメントパネルの製造について説明する
。Next, manufacturing of the instrument panel will be explained.
芯材Ｃの表面に接着剤としてホントメルト接着剤を塗布
し、その接着剤を加熱軟化する。A true melt adhesive is applied as an adhesive to the surface of the core material C, and the adhesive is softened by heating.
第５図に示すように第１可動部９．を上昇させ、また第
２可動部９□を下降させて電鋳殻２と押圧型２９を開き
、その押圧型２９の凹部３０に前記芯材Ｃをその接着剤
塗布面を外側に向けて嵌め込み、その各真空吸引孔３２
を押圧型２９の各真空吸引孔３１に合致させる。As shown in FIG. 5, the first movable part 9. is raised, and the second movable part 9□ is lowered to open the electroformed shell 2 and the pressing mold 29, and the core material C is fitted into the recess 30 of the pressing mold 29 with its adhesive coated surface facing outward. , each vacuum suction hole 32
are aligned with each vacuum suction hole 31 of the press die 29.
表皮層ａおよびクッション層すよりなる合成樹脂シート
Ｓを略１８０℃に高温加熱して軟化させ、その表皮層ａ
を上にして合成樹脂シートＳを第１および第２可動部９
１．９□間に配設する。A synthetic resin sheet S consisting of a skin layer a and a cushion layer is heated to approximately 180°C to soften it, and the skin layer a
Place the synthetic resin sheet S on the first and second movable parts 9 with
1. Place between 9□.
第９図に示すように第１可動部９１を下降させ、また第
２可動部９．を上昇させて電鋳殻２と押圧型２９間に合
成樹脂シートＳを挟着する。合成樹脂シートＳは押圧型
２９により電鋳殻２の表面に押圧されるので、その表面
に対するなじみ性が良い。As shown in FIG. 9, the first movable part 91 is lowered, and the second movable part 9. is raised, and the synthetic resin sheet S is sandwiched between the electroformed shell 2 and the pressing die 29. Since the synthetic resin sheet S is pressed against the surface of the electroformed shell 2 by the pressing mold 29, it has good conformability to the surface.
第１可動部９１の支持枠８内を切換弁２４を介して真空
ポンプ２５．に接続し、その真空ポンプ２５、により合
成樹脂シートＳを真空吸引する。A vacuum pump 25. The synthetic resin sheet S is vacuum-suctioned by the vacuum pump 25.
電鋳殻２の成形部２ａは、その全体に亘って無数の微細
通気孔５を有し、また合成樹シートＳは成形部２ａの表
面に抑圧型２９により充分になじませられているので、
そのシートＳは成形部２ａの表面全体に強く密着し、こ
れによりシートＳの表面には凹凸模様ｐが正確且つ明瞭
に転写され、同時にシートＳは成形部２ａの形状に成形
される。The molded part 2a of the electroformed shell 2 has countless fine ventilation holes 5 throughout it, and the synthetic resin sheet S is sufficiently blended into the surface of the molded part 2a by the suppression die 29, so that
The sheet S tightly adheres to the entire surface of the molding section 2a, whereby the uneven pattern p is accurately and clearly transferred to the surface of the sheet S, and at the same time, the sheet S is molded into the shape of the molding section 2a.
成形部２ａは冷却管２３により冷却されているので、ン
−）Ｓは直ちに冷却され、凹凸模様ｐおよび形状の崩れ
が防止される。Since the molded part 2a is cooled by the cooling pipe 23, the n-)S is immediately cooled, and the uneven pattern p and shape collapse are prevented.
第２可動部９！側の真空ポンプ２５８を作動させて前記
シートＳより成形された成形体を押圧型２９および芯材
Ｃの表面に真空吸引すると共に第、１可動部９．の支持
枠８内を切換弁２４を介しプロア２６側に切り換えて成
形体にブロー圧をかける。Second movable part 9! The side vacuum pump 258 is operated to vacuum-suction the molded body formed from the sheet S onto the surfaces of the pressing mold 29 and the core material C, and the first movable part 9. The inside of the support frame 8 is switched to the blower 26 side via the switching valve 24 to apply blow pressure to the molded body.
これにより成形体は成形部２ａより離型すると共に芯材
Ｃに密着してそれと−、体に接合される。As a result, the molded body is released from the molded part 2a and is brought into close contact with the core material C to be joined to the core material C and the body.
成形体は成形部２ａに強く密着しているので前記真空吸
引作用およびブロー圧を併用することは、成形体の離型
を促進するために極めて有効な手段である。 。Since the molded body is strongly adhered to the molded part 2a, the combination of the vacuum suction action and the blow pressure is an extremely effective means for promoting release of the molded body. .
ブロア２６を停止し、また第２可動部９鵞の支持枠２８
内を大気に切換え、その後第１可動部９を上、昇させ、
また第２可動部９、雪を下降させて押圧型２９よりイン
ストルメントパネルを外す。The blower 26 is stopped, and the support frame 28 of the second movable part 9
Switch the inside to the atmosphere, then raise the first movable part 9,
Further, the second movable part 9 lowers the snow and removes the instrument panel from the pressing die 29.
このインストルメントパネルの表面には、凹凸模様ｐが
流れることなく明瞭に付され、また合成樹脂シートＳよ
りなる成形体と芯材Ｃとの接合強度も大きく、耐久性に
優れている。The surface of this instrument panel has a concavo-convex pattern P clearly formed thereon without running off, and the bonding strength between the molded body made of the synthetic resin sheet S and the core material C is high, resulting in excellent durability.
前記□製造時において、電鋳殻２の成形部２ａにはそれ
が押圧型２９と嵌合する際衝撃力が作用するが、その成
形部２ａは背面側をバックアツプ体１９により補強され
ているので成形部２ａが変形するようなことはない。□ During manufacturing, an impact force acts on the molded part 2a of the electroformed shell 2 when it fits into the press die 29, but the molded part 2a is reinforced on the back side by the back-up body 19. Therefore, the molded part 2a will not be deformed.
次に第１０図の原理図により前記電鋳殻２の製造につい
て説明する。Next, the production of the electroformed shell 2 will be explained with reference to the principle diagram shown in FIG.
（ａ）工程
牛革よりエポキシ樹脂を用いて前記凹凸模＊ｐを有する
精密模型Ｍを作製する。(a) Process A precision model M having the above-mentioned uneven pattern *p is produced from cowhide using an epoxy resin.
伽）工程
精密模型Ｍ・の凹凸模様ｐを有す・る表面に銀鏡処理を
施して銀よりなる薄い導電層Ｃｏを形成しミその導電層
ＣＯの表面全体に凹凸模様ｐを現出させる。(b) Process The surface of the precision model M having the uneven pattern p is subjected to silver mirror treatment to form a thin conductive layer Co made of silver, and the uneven pattern p is made to appear on the entire surface of the conductive layer CO.
（Ｃ）′工程 ・ ・ ・
・］精密模型Ｍの周囲を絶縁筒体Ｔで囲み、導電層Ｃｏ
の表面全体に溶出可能で微細な粒子として直径０．２鶴
の無数のポリスチレン粒子Ｐｓを積層して層ｌを形成し
、その上にガラス粒子をナイロン製の網に入れた浮き上
がり防止体Ｗを載せて鰻下層のポリスチレン粒子Ｐｓを
導電層Ｃｏの表−に密着させる。これにより最下層の各
ポリスチレン粒子Ｐｓは導電装置Ｃｏの表面に点接触状
態で密着する。(C)' process ・ ・ ・
・] The precision model M is surrounded by an insulating cylinder T, and a conductive layer Co
Numerous polystyrene particles Ps with a diameter of 0.2 mm are laminated as fine particles that can be eluted over the entire surface of the layer to form a layer L, and on top of this, an anti-lifting body W containing glass particles encased in a nylon net is placed. The polystyrene particles Ps of the lower layer of the eel are brought into close contact with the surface of the conductive layer Co. As a result, each polystyrene particle Ps in the lowermost layer is brought into close contact with the surface of the conductive device Co in a point contact state.
（ｄ）工程
前記精密模型Ｍを電鋳槽Ｔａのニッケルメッキ液Ｓｏ中
に入れて導電層Ｃｏを電源Ｅｓの（＋）極に、また浮き
上がり防止体Ｗと対向する電極Ｅを電源Ｅｓの（−）極
にそれぞれ接続して精密模型Ｍに電鋳処理を施す、この
電鋳処理工程中に、析出したニッケルｎが導電層Ｃｏの
ポリスチレン粒子Ｐｓとの密着部を除く導電層Ｃｏとポ
リスチレン粒子Ｐｓ間および相隣るポリスチレン粒子２
３間の空間を満たし、これにより凹凸模様ｐを有する電
鋳殻２を得る。この電鋳殻２の厚さは、最上層のポリス
チレン粒子Ｐｇの上部周面が電鋳殻゛２より僅かに露出
する程度となるように前記粒子の層ｌよりも薄く設定さ
れる。 □上記工程を経て得られた電鋳殻２
を離型、したがって電；鋳殻・２を導電層Ｃ’ｏより剥
離した後、・トルエン、・塩化メチレン等の溶剤中に浸
漬してポリスチレン粒・子Ｐｓを電鋳殻２より溶出し、
第４図に示す通気孔５を形・成する。この場合電鋳殻２
め：凹凸模様ｐ゛を有゛する表面および裏面には粒子の
層瀘・の・一部が露出しているので、それら露出部分か
らポリスチレン粒子Ｐ＄が溶解して開口部５ａ。(d) Process The precision model M is placed in the nickel plating solution So in the electroforming tank Ta, the conductive layer Co is connected to the (+) pole of the power source Es, and the electrode E facing the anti-lifting body W is connected to the (+) pole of the power source Es. -) conductive layer Co and polystyrene particles, in which the precipitated nickel n is removed from the areas in close contact with the polystyrene particles Ps of the conductive layer Co and the polystyrene particles. Polystyrene particles 2 between and adjacent to Ps
3, thereby obtaining an electroformed shell 2 having an uneven pattern p. The thickness of the electroformed shell 2 is set to be thinner than the layer 1 of the particles so that the upper circumferential surface of the uppermost layer of polystyrene particles Pg is slightly exposed from the electroformed shell 2. □Electroformed shell 2 obtained through the above process
After separating the cast shell 2 from the conductive layer C'o, immerse it in a solvent such as toluene or methylene chloride to elute the polystyrene particles Ps from the electroform shell 2,
A ventilation hole 5 shown in FIG. 4 is formed. In this case, electroformed shell 2
Me: Since part of the layer of particles is exposed on the front and back surfaces having the uneven pattern P, the polystyrene particles P are dissolved from these exposed parts to form the opening 5a.
５ｂが１形成され、また電鋳殻２内部にはポリスチレン
粒子Ｐｓ”溶出後の空孔５Ｃおよび相隣るポリ□・スチ
レシ粒子Ｐｓ等の接点であったところに相隣る空孔５Ｃ
間を連通ずる連通孔５ｄが形成される。5b is formed, and inside the electroformed shell 2, there are pores 5C after elution of polystyrene particles Ps'' and pores 5C adjacent to each other at points of contact between adjacent polystyrene particles Ps, etc.
A communication hole 5d communicating between the two is formed.
これにより表裏両面に極めて小径の開口部５ａ・。As a result, extremely small diameter openings 5a are formed on both the front and back surfaces.
５ｂを有する無数の通気孔５を持っ゛た電鋳殻２が得ら
れ為、□ □
溶出可能な粒子としては、前記ポリスチレン粒子Ｐ３の
外にパラフィン粒子、アルミニウム粒子等の使用が可能
であり、パラフィン粒子の場合は加熱により電鋳殻２よ
り溶出し、またアルミニウム粒子の場合は加熱または化
学エツチング処理により電鋳殻２より溶出する。Since the electroformed shell 2 having countless ventilation holes 5 having 5b is obtained, it is possible to use paraffin particles, aluminum particles, etc. in addition to the polystyrene particles P3 as particles that can be eluted. Paraffin particles are eluted from the electroformed shell 2 by heating, and aluminum particles are eluted from the electroformed shell 2 by heating or chemical etching.
次に電鋳殻２の離型作業について説明する。Next, the demolding operation of the electroformed shell 2 will be explained.
第１１図に示すように精密模型Ｍ上の電鋳殻２の背面に
多数のナツト部材６＋、６ｇを前記のように溶着する。As shown in FIG. 11, a large number of nut members 6+, 6g are welded to the back surface of the electroformed shell 2 on the precision model M as described above.
また取付フランジ部２ｂの背面全体に前記のように繊維
強化合成樹脂体３を接合する。Further, the fiber-reinforced synthetic resin body 3 is joined to the entire back surface of the mounting flange portion 2b as described above.
次いで、第１２図に示すように天壁１０を溶着していな
い支持枠８を電鋳殻２に被せ、前記のように電鋳殻２を
各桟材８ｂおよび各アングル材１６に筒状スペーサ１７
＋、１７ｇおよび吊持ボルトＩＬ、１８ｇを介して吊持
する。Next, as shown in FIG. 12, the electroformed shell 2 is covered with the support frame 8 to which the top wall 10 is not welded, and the electroformed shell 2 is attached to each crosspiece 8b and each angle member 16 with a cylindrical spacer as described above. 17
+, 17g and suspension bolt IL, 18g.
その後支持枠８を引き上げて電鋳殻２を精密模型Ｍより
離型する。Thereafter, the support frame 8 is pulled up and the electroformed shell 2 is released from the precision model M.
この離型時において、複合部７および支持枠８により電
鋳殻２が保形されているので、電鋳工程で生じた内部応
力に起因する電鋳殻２の変形が防止される。During this mold release, the shape of the electroformed shell 2 is maintained by the composite portion 7 and the support frame 8, so that deformation of the electroformed shell 2 due to internal stress generated during the electroforming process is prevented.
第１３図は電鋳殻２の背面に多数の吊持ボルト１８、．
１Ｂ、をスタッド溶接により溶着し、各ボルト１Ｂ、、
ｉｓ、にナツト３３１．３３□を螺着するようにした変
形例を示す。FIG. 13 shows a large number of suspension bolts 18, .
1B, are welded by stud welding, and each bolt 1B,...
A modification example is shown in which a nut 331.33□ is screwed onto the is.
Ｃ０発明の効果
本発明によれば、電鋳殻の成形部をバックアツプ体によ
り補強したので、型合せ時、成形体の製造時等に成形部
に衝撃力が作用してもその成形部が変形することがない
。また電鋳殻の取付フランジ部を支持枠の支持フランジ
部に重合連結すると共に成形部を吊持部材により吊持し
たので、バックアツプ体の重量により成形部が変形する
ことがない。したがって本発明に係る真空成形型は優れ
た耐久性を有する。C0 Effects of the Invention According to the present invention, the molded part of the electroformed shell is reinforced with a back-up body, so even if an impact force is applied to the molded part during mold matching, manufacturing of a molded body, etc., the molded part will not be damaged. Never deformed. Further, since the mounting flange portion of the electroformed shell is overlappingly connected to the support flange portion of the support frame and the molded portion is suspended by the suspension member, the molded portion is not deformed by the weight of the back-up body. Therefore, the vacuum forming mold according to the present invention has excellent durability.
さらに電鋳殻の背面側に支持枠を配設するので、電鋳殻
を精密模型から離型する前にその電鋳殻を支持枠に吊持
させてその支持枠を介し離型作業を行うことが可能とな
り、これにより離型作業を容易に行うと共に電鋳殻を支
持枠により保形して電鋳工程で生じた内部応力に起因す
る電鋳殻の変形を防止することができる。Furthermore, since a support frame is installed on the back side of the electroformed shell, before the electroformed shell is released from the precision model, the electroformed shell is suspended from the support frame and the mold release operation is performed via the support frame. This makes it possible to easily perform the mold release operation and to maintain the shape of the electroformed shell with the support frame to prevent deformation of the electroformed shell due to internal stress generated during the electroforming process.
第１図は電鋳殻の背面図、第２図は第１図■−■線断面
図、第３図は電鋳殻の正面図、第４図は第３図ＩＶ−Ｉ
Ｖ線断面図、第５図はインストルメントパネル製造装置
における製造作業前の縦断面図、第６図は第５図Ｖｌ−
Ｖｌ線断面図、第７図はバックアツプ体における第１層
の一部の拡大断面図、第８図はバックアツプ体における
第２層の一部の拡大断面図、第９図は前記装置における
製造作業中の縦断面図、第１０図は電鋳殻の製造工程説
明図、第１１図は電鋳殻と精密模型の関係を示す縦断面
図、第１２図は電鋳殻の離型作業を示す縦断面図、第１
３図は電鋳殻の吊持構造の変形例の要部縦断面図である
。
Ｓ・・・合成樹脂シート、
２・・・電鋳殻、２ａ・・・成形部、２ｂ・・・取付フ
ランジ部、８・・・支持枠、８ａ・・・枠本体、１１・
・・支持フランジ部、１９・・・バンクアップ体、６１
．８ｂ。
１８Ｉ・・・吊持部材を構成するナツト部材、桟材およ
び吊持ボルト
特 許 出 願 人 本田技研工業株式会社第４図
−゛
、 ゛
、５ 、 、 ゛ ぴ
□ １１１．°□５い、ソープ
□１．−じ、い□
、 □第８図５− 、ぐ：、・１−。
第３図
□
・、 パ
５ 。
“ 、、・・
・°・、第７図
１１１２図
第１１図
〜
第１３図
手続補正書（自制
昭和 ６０年１２月−４日Figure 1 is a rear view of the electroformed shell, Figure 2 is a sectional view taken along the line ■-■ in Figure 1, Figure 3 is a front view of the electroformed shell, and Figure 4 is Figure 3 IV-I.
5 is a longitudinal sectional view before manufacturing work in the instrument panel manufacturing equipment, and FIG. 6 is a sectional view taken along line V, FIG.
7 is an enlarged sectional view of a part of the first layer in the backup body, FIG. 8 is an enlarged sectional view of a part of the second layer in the backup body, and FIG. A longitudinal cross-sectional view during manufacturing work, Fig. 10 is an explanatory diagram of the manufacturing process of the electroformed shell, Fig. 11 is a longitudinal cross-sectional view showing the relationship between the electroformed shell and the precision model, and Fig. 12 is the demolding work of the electroformed shell. A vertical cross-sectional view showing the first
FIG. 3 is a longitudinal cross-sectional view of a main part of a modification of the electroformed shell suspension structure. S... Synthetic resin sheet, 2... Electroformed shell, 2a... Molded part, 2b... Mounting flange part, 8... Support frame, 8a... Frame body, 11...
...Support flange portion, 19...Bank up body, 61
．． 8b. 18I... Nut members, crosspieces and suspension bolts constituting the suspension member Patent Applicant: Honda Motor Co., Ltd. Figure 4
-゛, ゛, 5, , ゛ pi□ 111. °□5 Soap□1. -J, I□, □Figure 8 5-, gu:,・1-. Figure 3□・, Pa5. “ ,,... ・°・, Figure 7 1112 Figure 11 - Figure 13 Procedural amendment (Self-restraint December-4, 1985)
Claims (1)
、取付フランジ部を連設した通気性を有する電鋳殻と；
枠本体の下向き開口部を前記成形部により覆われて該下
向き開口部周縁の支持フランジ部を前記取付フランジ部
に重合連結し、また前記枠本体に設けられた吊持部材に
より前記成形部を吊持する支持枠と；前記枠本体内に収
容され、前記成形部の背面に一体に接合された通気性を
有するバックアップ体と；よりなる真空成形型。an electroformed shell having air permeability and having a mounting flange connected to the outer periphery of a molding part for molding a synthetic resin sheet into a predetermined shape;
The downward opening of the frame body is covered by the molded part, the support flange around the downward opening is overlappingly connected to the mounting flange, and the molded part is suspended by a suspension member provided on the frame body. A vacuum forming mold comprising: a support frame having a support frame; and a backup body having air permeability housed within the frame main body and integrally joined to the back surface of the molding part.
Priority Applications (7)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP60071987A JPS61229526A (en) | 1985-04-05 | 1985-04-05 | Mold for vacuum molding |
| IN815/MAS/85A IN166394B (en) | 1984-10-18 | 1985-10-15 | |
| US06/787,774 US4714424A (en) | 1984-10-18 | 1985-10-15 | Vacuum mold |
| CA000493229A CA1262302A (en) | 1984-10-18 | 1985-10-17 | Vacuum mold |
| GB08525739A GB2167340B (en) | 1984-10-18 | 1985-10-18 | Vacuum moulds |
| BE2/60819A BE903474A (en) | 1984-10-18 | 1985-10-18 | VACUUM FORM |
| KR1019850007690A KR900000297B1 (en) | 1984-10-18 | 1985-10-18 | Mold with embossed pattern for synthetic resin sheet |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP60071987A JPS61229526A (en) | 1985-04-05 | 1985-04-05 | Mold for vacuum molding |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS61229526A true JPS61229526A (en) | 1986-10-13 |
| JPH0334454B2 JPH0334454B2 (en) | 1991-05-22 |
Family
ID=13476320
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP60071987A Granted JPS61229526A (en) | 1984-10-18 | 1985-04-05 | Mold for vacuum molding |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS61229526A (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH02153719A (en) * | 1988-12-05 | 1990-06-13 | Honda Motor Co Ltd | Method and apparatus for forming synthetic resin laminate |
| JP2007118235A (en) * | 2005-10-25 | 2007-05-17 | Kasai Kogyo Co Ltd | Mold and its manufacturing method |
| JP2010030159A (en) * | 2008-07-29 | 2010-02-12 | Toyota Boshoku Corp | Mold for injection molding |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2007182035A (en) * | 2006-01-10 | 2007-07-19 | Calsonic Kansei Corp | Manufacturing method of vacuum-formed product |
-
1985
- 1985-04-05 JP JP60071987A patent/JPS61229526A/en active Granted
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH02153719A (en) * | 1988-12-05 | 1990-06-13 | Honda Motor Co Ltd | Method and apparatus for forming synthetic resin laminate |
| JP2007118235A (en) * | 2005-10-25 | 2007-05-17 | Kasai Kogyo Co Ltd | Mold and its manufacturing method |
| JP2010030159A (en) * | 2008-07-29 | 2010-02-12 | Toyota Boshoku Corp | Mold for injection molding |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0334454B2 (en) | 1991-05-22 |
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