JP5437657B2 - Molding apparatus and molding method - Google Patents

Description

  The present invention relates to a molding apparatus and a molding method used when molding a resin product having a cushion layer between a base material and a skin layer provided on the surface side of the base material.

Conventionally, as a vehicle interior material, for example, a resin product having a cushion layer between a base material and a skin layer provided so as to cover the surface side of the base material has been used (for example, Patent Document 1, 2). The cushion layer of the resin product of Patent Documents 1 and 2 is molded by a so-called reaction injection molding method in which a raw material is injected into a cavity and reaction-cured while the mold is closed. . In this reaction injection molding method, the raw material injected into the cavity flows in the cavity by its own foaming action.
JP 2004-314314 A JP 2005-14370 A

  By the way, for example, a resin product may have a vertical wall and the cushion layer may be as thin as several millimeters. In such a case, since the cavity is partially narrow, the raw material injected into the cavity by the reaction injection molding method cannot easily reach every corner of the cavity only by its own foaming action. If the cushion layer material does not reach the entire cavity, the hardness when touched by the hand varies depending on the part of the finished resin product, resulting in deterioration of the touch feeling, or depressions etc. appearing on the surface of the resin product. Cause inconvenience.

  The present invention has been made in view of such points, and the object is to form the cushion layer as intended even if the resin product has a vertical wall and the cushion layer is thin. This makes it possible to improve the feel of the resin product and to suppress the occurrence of molding defects.

  In order to achieve the above object, in the present invention, with the mold opened, the cushion layer raw material is supplied in an amount corresponding to the volume of the cavity, and then the mold is closed to reduce the pressing force by the mold. The material of the cushion layer was used to flow.

Specifically, in the first invention, a molding apparatus for a resin product having a cushion layer between a base material and a skin layer provided on the surface side of the base material, corresponding to the skin layer side of the resin product A first molding die having a concave molding surface arranged so as to perform, a second molding die arranged to correspond to the base side of the resin product and having a convex molding surface that falls within the concave molding surface; A mold drive device that switches the first mold and the second mold between a mold closed state and a mold open state, and a foaming raw material that becomes a cushion layer is formed by a cavity formed by the concave mold surface and the convex mold surface. And a cushion layer raw material supply device for supplying an amount corresponding to the volume of the first mold and the second mold are opened by the mold driving device and held in the first mold. A member to be a skin layer, and the second It was allowed to supply the foaming material by the cushion layer material supply device between the substrate held in the form type, the mold closing state the first mold and the second mold by the mold driving device It is assumed that, while switching, the foaming raw material is expanded in the cavity by the base material before foaming .

  According to this configuration, a resin product having a vertical wall is formed by the concave molding surface and the convex molding surface. In the molding step, the cushion layer raw material in an amount corresponding to the volume of the cavity is supplied between the member to be the skin layer and the base material by the cushion layer raw material supply device. When the first mold and the second mold are closed by the mold driving device, the raw materials of the cushion layer are expanded in the cavity by the base material when both molds approach each other. As a result, the material of the cushion layer is forced to flow by the pressing force of the molding die without using its own foaming action as in the case of the reaction injection molding method, so that the cushion layer material reaches every corner of the cavity.

  According to a second invention, in the first invention, a skin layer material supply device is provided for supplying the skin layer material to the molding surface of the first mold.

  According to this configuration, the material for the skin layer is supplied to the first molding surface by the skin layer material supply device, so that the member to be the skin layer is molded on the molding surface of the first molding die, and then is not demolded. The cushion layer can be molded to obtain a resin product that is integral with the base material.

According to a third invention, in the first or second invention, a primer supply device for applying a primer for improving adhesion to the cushion layer is provided on the cushion layer side of the base material.

  According to this structure, the base material hold | maintained at the 2nd shaping | molding die comes to adhere | attach firmly with a cushion layer via a primer.

According to a fourth aspect of the present invention, there is provided a molding method for a resin product having a cushion layer between a base material and a skin layer provided on the surface side of the base material, and the resin product is disposed so as to correspond to the skin layer side of the resin product. A first mold having a concave mold surface and a step of holding a member to be a skin layer, and a convex mold that is disposed so as to correspond to the substrate side of the resin product and enters the concave mold surface A step of holding a substrate in a second mold having a surface, a member to be a skin layer held by the first mold, and a substrate held by the second mold Between the step of supplying the foaming raw material to be the cushion layer with the first molding die and the second molding die being opened in an amount corresponding to the volume of the cavity, and supplying the foaming raw material to be the cushion layer later, while closing the said first mold and said second mold, the By the base foam material before foaming a configuration that a step of spreading pressed in the cavity.

  According to this configuration, as in the first invention, the raw material of the cushion layer is forced to flow and reaches every corner of the cavity.

  According to the first aspect of the present invention, after the cushion layer raw material is supplied between the member to be the skin layer and the base material in an amount corresponding to the volume of the cavity, the first mold and the second mold are closed. At this time, since the raw material of the cushion layer can be pushed and expanded by the base material, the raw material of the cushion layer can be forced to flow and spread throughout the cavity. Thereby, even if the resin product has a vertical wall and the cushion layer is thin, the cushion layer can be molded as intended, so that the tactile sensation can be improved and the occurrence of molding defects can be suppressed.

  According to the second invention, a resin product can be obtained while being held in the first mold without removing the member to be the skin layer molded on the molding surface of the first mold. Therefore, when a pattern such as a grain is provided on the surface of the skin layer, it is possible to avoid a pattern collapse caused by demolding and holding it in another mold, and a clear pattern can be obtained.

According to the third invention, since the primer for improving the adhesion with the cushion layer is applied to the cushion layer side of the base material, the cushion layer and the base material are simultaneously formed when the cushion layer is formed. Can be firmly bonded.

According to the fourth invention, similar to the first invention, even when the resin product has a vertical wall and the cushion layer is thin, the cushion layer can be molded as intended, and the tactile sensation is improved. And the occurrence of molding defects can be suppressed.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. It should be noted that the following description of the preferred embodiment is merely illustrative in nature, and is not intended to limit the present invention, its application, or its use.

  FIG. 1 shows a molding apparatus 1 according to an embodiment of the present invention. The molding apparatus 1 is for molding an automobile interior material (resin product) 100 (shown in FIG. 7). As shown in FIG. 8, the interior material 100 includes a base material 101, a skin layer 102 provided on the surface side of the base material 101, and a cushion layer 103 provided between the base material 101 and the skin layer 102. I have. The code | symbol 104 in FIG. 8 is a primer. Moreover, as shown in FIG. 7, the interior material 100 includes a main body plate portion 100a and a vertical plate portion (corresponding to a vertical wall) 100b protruding from the peripheral edge portion of the main body plate portion 100a in the thickness direction of the main body plate portion 100a. The main body plate portion 100a and the vertical plate portion 100b are integrally formed. The thickness of the cushion layer 103 of the vertical plate portion 100b is, for example, 3 mm or less. The interior material 100 includes, for example, a door trim, an instrument panel, an armrest, and the like. The molding apparatus 1 according to the present embodiment is particularly suitable for molding the interior material 100 used in a portion that is touched by an occupant's hand. Is suitable.

  The base material 101 is made of polypropylene, the skin layer 102 is made of urethane-based paint, and the cushion layer 103 is made of urethane.

  As shown in FIG. 1, the molding apparatus 1 supplies a fixed mold (first molding mold) 10 and a movable mold (second molding mold) 11, a mold driving device 12 that drives the movable mold 11, and a release agent. A release agent supply device 20 for performing the above, a cushion layer raw material supply device 30 for supplying the raw material for the cushion layer 103, a skin layer raw material supply device 40 for supplying the raw material for the skin layer 102, and a primer supply device 50 for supplying the primer 104. And a control device 60.

  As shown in FIG. 2, the upper surface of the fixed mold 10 is formed with a concave molding surface 10 a that is open upward and includes a concave surface that substantially matches the shape of the skin layer 102 of the interior material 100. The concave molding surface 10 a is provided with a minute uneven shape for forming a texture pattern on the surface of the skin layer 102. The member A (shown in FIG. 4) that becomes the skin layer 102 of the interior material 100 is molded by the concave molding surface 10a of the fixed mold 10, and the molded member A that becomes the skin layer 102 is formed into the concave shape without being removed. It is held by the surface 10a.

  As shown in FIG. 5, the movable mold 11 is disposed above the fixed mold 10. On the lower surface of the movable mold 11, a convex molding surface 11 a that substantially matches the shape of the base material 101 of the interior material 100 is formed so as to enter the concave molding surface 10 a when the mold is closed. The base material 101 is held on the convex molding surface 11 a of the movable mold 11. Due to the concave molding surface 10a and the convex molding surface 11a, the interior material 100 has a shape having a vertical wall at its peripheral edge as shown in FIG.

  The mold driving device 12 is configured by a known hydraulic cylinder or the like, and is connected to the upper end portion of the movable mold 11. With this mold driving device 12, the movable mold 11 can be moved in the vertical direction, that is, in the direction in which the movable mold 11 is in contact with or separated from the fixed mold 10.

  As shown in FIG. 4, the cushion layer raw material supply device 30 includes a supply pipe 31 connected to a tank (not shown) that stores the raw material of the cushion layer 103, and a spray nozzle 32 attached to the tip of the supply pipe 31. And a robot arm (not shown) for moving the spray nozzle 32, the raw material in the tank is discharged from the spray nozzle 32 through the supply pipe 31, and the spray nozzle 32 is moved by the robot arm. An arbitrary amount of raw material can be supplied to an arbitrary portion of the fixed mold 10. The spray nozzle 32 and the robot arm are connected to a control device 60 and are controlled by the control device 60.

  As shown in FIG. 3, the skin layer raw material supply device 40 includes a supply pipe 41, a spray nozzle 42, and a robot arm (not shown), similar to the cushion layer raw material supply device 30. The robot arm is controlled by the control device 60. As shown in FIG. 2, the release agent supply device 20 also includes a supply pipe 21, a spray nozzle 22, and a robot arm (not shown), and the spray nozzle 22 and the robot arm are controlled by a control device 60. It is like that.

  As shown in FIG. 6, the primer supply device 50 also includes a supply pipe 51, a spray nozzle 52, and a robot arm (not shown), and the spray nozzle 52 and the robot arm are controlled by the control device 60. It is like that.

  As shown in FIG. 1, the control device 60 is configured to control the mold driving device 12, the release agent supply device 20, the cushion layer material supply device 30, the skin layer material supply device 40, and the primer supply device 50. Yes.

  Next, the point which shape | molds the interior material 100 using the shaping | molding apparatus 1 comprised as mentioned above is demonstrated.

  First, the movable mold 11 is moved upward from the fixed mold 10 by the mold driving device 12 so that both molds 10 and 11 are opened (see FIG. 1). Then, the release agent 23 is applied to the concave molding surface 10 a of the fixed mold 10 by the release agent supply device 20. This is the release agent application step. The release agent 23 may be, for example, a release agent generally used at the time of molding a urethane skin, and examples thereof include a polyethylene wax type and an α-methylstyrene modified dimethylpolysiloxane type. Moreover, it is preferable to set the temperature of the concave molding surface 10a when applying the release agent 23 in the range of 50 ° C. or more and 85 ° C. or less, for example.

  After the release agent coating step, the member A to be the skin layer 102 is molded by the concave molding surface 10a of the fixed mold 10. That is, as shown in FIG. 3, the urethane layer coating material 43 serving as the material of the skin layer 102 is applied to the concave molding surface 10 a to which the release agent 23 is adhered by the skin layer material supply device 40. Examples of the paint 43 include a solvent-based paint in which polyurethane is dissolved in an organic solvent, and a water-based paint in which polyurethane is dispersed in water. Moreover, it is preferable to set the temperature of the concave molding surface 10a when applying the urethane-based paint 43 within a range of, for example, 50 ° C. or more and 85 ° C. or less.

  As the urethane-based paint 43 applied to the concave molding surface 10a is solidified, a member A that becomes the skin layer 102 is obtained as shown in FIG. A texture pattern is formed on the surface of the member A, which is the skin layer 102, by the concave molding surface 10a. The member A to be the skin layer 102 is held on the concave molding surface 10a without being removed. This is a step of setting the skin layer 102 to the fixed mold 10.

  Next, as shown in the drawing, the foamable urethane material mixed solution 33 that is the raw material of the cushion layer 103 is supplied to the back side of the member A that becomes the skin layer 102 by the cushion layer raw material supply device 30. The foamable urethane material mixed liquid 33 is obtained by mixing raw materials immediately before supply. The mixing timing is adjusted so as to be in a state in which spraying is possible when spraying from the spray nozzle 32.

  The supply amount of the urethane material mixed liquid 33 per one time is an amount corresponding to the volume of the cavity formed by the concave molding surface 10a and the convex molding surface 11a. In this embodiment, the volume is increased by foaming. The amount is considered. The urethane material mixed solution 33 may be deposited on the back surface of the member A to be the skin layer 102. The urethane material mixed solution 33 is adjusted so as to be finely foamed. The fine foaming refers to a degree of foaming in which the volume after foaming is not more than twice the volume before foaming. The foaming degree of the urethane material mixed liquid 33 can be arbitrarily adjusted by the addition amount of the foaming agent, and the foaming ratio may be made larger than two times.

  Here, examples of the polyol contained in the urethane material mixed solution 33 include polyether polyol and polyester polyol.

  Examples of the polyether polyol include polypropylene glycol-based polyol, or an ethylene oxide-modified product, an amine-modified product, and a polyether polyol such as polyoxytetramethylene glycol.

  Examples of the polyester polyol include dicarboxylic acids such as adipic acid, isophthalic acid, and terephthalic acid, and polyols such as ethylene glycol, propylene glycol, diethylene glycol, butylene glycol, 1,6-hexanediol, trimethylolpropane, and neopentyl glycol. Examples include condensation reaction products, polycaprolactone polyols, and polycarbonate polyols.

  Of these, the polyol may be composed of a single species or a mixture of a plurality of species.

  Examples of the isocyanate contained in the urethane material mixed solution 33 include aliphatic diisocyanates such as 1,4-tetramethylene diisocyanate, 1,6 hexamethylene diisocyanate, and lysine diisocyanate, isophorone diisocyanate, hydrogenated xylylene diisocyanate, and hydrogenated 4 , 4'-diphenylmethane diisocyanate and other alicyclic diisocyanates, xylene diisocyanate, tolylene diisocyanate, 4,4'-diphenylmethane diisocyanate, tolidine diisocyanate, p-phenylene diisocyanate, aromatic diisocyanates such as 1,5-naphthylene diisocyanate, etc. Is mentioned. Isocyanate may be composed of a single species or a mixture of a plurality of species.

  On the other hand, as shown in FIGS. 9 and 10, the base material 101 is formed by another forming apparatus 70. The structure of the molding apparatus 70 will be described. The molding apparatus 70 includes an injection molding machine (not shown), a fixed mold 71, and a movable mold 72. Since the injection molding machine is conventionally well-known, detailed description is omitted. On the upper surface of the fixed mold 71, a molding surface 71a for molding the back surface side of the base material 101 is formed. The fixed mold 71 is provided with a runner 71b that communicates with the nozzle of the injection molding machine and opens on the molding surface 71a. On the lower surface of the movable mold 72, a molding surface 72a for molding the surface side of the substrate 101 is formed. The substrate 101 is obtained by injecting polypropylene from an injection molding machine and filling the cavity with the fixed mold 71 and the movable mold 72 closed. The base material 101 is held by the movable mold 11 as shown in FIG. This is a step of setting the base 101 to the movable mold 11.

  After the base material 101 is held on the movable mold 11, the primer 104 is applied to the back surface side of the base material 101 by the primer supply device 50 as shown in FIG. 6. The primer 104 enhances the adhesiveness between polypropylene and urethane, and is composed of, for example, a modified polyolefin dissolved in a solvent.

  The modified polyolefin is obtained by grafting a functional group to a polyolefin such as polyethylene or polypropylene. For example, an acid-modified polyolefin such as acrylic acid-modified polyethylene, acrylic acid-modified polypropylene, maleic anhydride-modified polyethylene, or maleic anhydride-modified polypropylene is used. Can be mentioned. Among these, in the next step, from the viewpoint that high adhesion to the main component polypropylene of the substrate 101 can be obtained, the same polyacid-modified polypropylene as the main component polypropylene of the substrate 101 is preferable. Examples of the solvent include ketones, alcohols and glycols.

  As for the application condition of the primer 104, for example, the temperature of the movable mold 11 is preferably 50 to 85 ° C.

  Although it is preferable to supply the urethane material mixed solution 33 by the cushion layer raw material supply device 30 after the base material 101 is held on the movable mold 11, the reverse order may be used.

  Thereafter, the fixed mold 10 and the movable mold 11 are switched to the mold closed state. In other words, the movable mold 11 is moved downward by the mold driving device 12 to approach the fixed mold 10. Then, the surface side of the base material 101 is pressed against the urethane material mixed solution 33, and the urethane material mixed solution 33 is expanded in the cavity and is forced to flow by the pressing force of the movable mold 11. At this time, the urethane material mixed solution 33 is pressed against the stationary mold 10 and the movable mold 11 without flowing by its own foaming action as in the reaction injection molding method, and therefore, as shown in FIG. Go across every corner. Furthermore, since the urethane material mixed liquid 33 is foamed, it has higher fluidity than the non-foamed raw material, and this also makes it easy to reach every corner of the cavity.

  When the urethane material mixed solution 33 is foam-cured, the cushion layer 103 is formed. The polar group of the modified part of the modified polyolefin resin contained in the primer 104 exerts an intermolecular force on the skin layer 102 or an anchor effect by forming a chemical bond, so that the primer 104 is firmly attached to the skin layer 102. In close contact. On the other hand, the modified polyolefin resin contained in the primer 104 is in close contact with the resin material forming the substrate 101. As a result, the skin layer 102 is firmly adhered and integrated with the base material 101 formed of a resin material mainly composed of polypropylene via the primer 104.

  Then, the fixed mold 10 and the movable mold 11 are opened and the interior material 100 is taken out.

  As described above, according to this embodiment, after supplying the raw material of the cushion layer 103 between the member A to be the skin layer 102 of the fixed mold 10 and the base material 101 of the movable mold 11, the mold driving device 12. Since the fixed mold 10 and the movable mold 11 are brought close to each other and the raw material of the cushion layer 103 is pushed and expanded by the base material 101, the raw material of the cushion layer 103 is forced to flow and spread over every corner of the cavity. Can do. Thereby, even if the cushion layer 103 is thin and the interior material 100 has a shape having a vertical wall, the cushion layer 103 can be molded as intended, so that the tactile sensation can be improved and the occurrence of molding defects can be suppressed.

  In addition, the interior material 100 can be obtained while being held on the fixed mold 10 without removing the member A to be the skin layer 102 formed on the concave mold surface 10 a of the fixed mold 10. Therefore, there is no fear that the wrinkle pattern will be crushed unlike the case where the member A which becomes the skin layer 102 is once removed from the mold and held in another mold, and a clear wrinkle pattern can be obtained.

  Further, since the cushion layer 103 is in a slightly foamed state with an expansion ratio of 2 times or less, it is possible to sufficiently ensure scratch resistance while giving a cushion feeling.

  In addition, since the urethane material mixed liquid 33 is caused to flow by the movement of the movable mold 11, the urethane material mixed liquid 33 only needs to be deposited on the back surface of the member A to be the skin layer 102, and it is not necessary to spray it evenly. Therefore, an inexpensive nozzle can be used as the spray nozzle of the cushion layer supply device 30, and the control of the robot arm can be simplified, so that the cost of the molding device 1 can be reduced. The spray nozzle 32 may be omitted, thereby further reducing the cost.

In addition, when the urethane material mixed liquid 33 is injected into the cavity, the injection pressure may concentrate on a part of the member A that becomes the skin layer 102 to cause damage. As in the embodiment, the pressure of the urethane material mixed liquid 33 acting on the member A to be the skin layer 102 can be lowered by causing the urethane material mixed liquid 33 to flow by the movement of the movable mold 11, thereby The damage to the member A that becomes the skin layer 102 can be suppressed, and the deviation of the member A can also be suppressed .

  Further, the member A to be the skin layer 102 may be held on the concave molding surface 10a of the fixed mold 10 after being molded by another molding apparatus.

  In the above embodiment, the control device 60 controls the mold driving device 12, the release agent supply device 20, the cushion layer material supply device 30, the skin layer material supply device 40, and the primer supply device 50. Not limited to this, the devices 12, 20, 30, 40, and 50 may be individually operated by an operator.

  Further, the urethane material mixed liquid 33 may be sprayed on the entire surface without being deposited on the member A to be the skin layer 102. Also in this case, the urethane material mixed liquid 33 can be forced to flow by closing the fixed mold 10 and the movable mold 11. Therefore, there may be unevenness in spraying the urethane material mixed liquid 33, and therefore an inexpensive spray nozzle 32 can be used. Further, the urethane material mixed liquid 33 may be spread on the back surface of the member A by shaking the stationary mold 10 after the urethane material mixed liquid 33 is deposited on the member A to be the skin layer 102.

  As described above, the molding apparatus and the molding method according to the present invention are suitable for molding an automobile interior material, for example.

It is a block diagram of the shaping | molding apparatus which concerns on embodiment. It is a figure which shows the process of apply | coating a mold release agent to a fixed mold | type. It is a figure which shows the process of supplying the raw material of an outer skin layer. It is a figure which shows the process of supplying the raw material of a cushion layer. It is a figure which shows the process of hold | maintaining a base material to a movable mold | type. It is a figure which shows the process of apply | coating a primer to a base material. It is a figure which shows the process which shape | molded the cushion layer and obtained the interior material. It is a partial expanded sectional view of interior material. It is a figure which shows the shaping | molding apparatus of a base material. FIG. 10 is a view corresponding to FIG. 9 showing a state where a base material is molded.

1 Molding device 10 Fixed mold (first mold)
11 Movable mold (second mold)
12 type drive device 30 cushion layer material supply device 40 skin layer material supply device 50 primer supply device 60 control device 100 interior material (resin product)
101 Base material 102 Skin layer 103 Cushion layer 104 Primer

Claims (4)

A resin product molding apparatus having a cushion layer between a base material and a skin layer provided on the surface side of the base material,
A first molding die having a concave molding surface arranged to correspond to the skin layer side of the resin product;
A second mold having a convex molding surface that is disposed so as to correspond to the base material side of the resin product and enters the concave molding surface;
A mold driving device for switching the first mold and the second mold between a mold closed state and a mold open state;
A cushion layer raw material supply device for supplying the foam raw material to be a cushion layer by an amount corresponding to the volume of the cavity formed by the concave molding surface and the convex molding surface;
The first mold and the second mold are opened by the mold driving device, and a member to be a skin layer held by the first mold and a base held by the second mold The foaming raw material is supplied between the materials by the cushion layer raw material supply device, and then the foaming raw material is foamed while the first molding die and the second molding die are switched to the closed state by the die driving device. A molding apparatus configured to be expanded in the cavity by the base material before . The molding apparatus according to claim 1,
A molding apparatus comprising a skin layer material supply device for supplying a material for a skin layer to a molding surface of a first mold. The molding apparatus according to claim 1 or 2 ,
A molding apparatus comprising a primer supply device for applying a primer for improving adhesion to the cushion layer on the cushion layer side of the substrate. A resin product molding method having a cushion layer between a base material and a skin layer provided on the surface side of the base material,
A step of holding a member to be a skin layer in a first mold having a concave molding surface arranged to correspond to the skin layer side of the resin product;
A step of holding the base material in a second mold having a convex molding surface that is arranged to correspond to the base side of the resin product and enters the concave molding surface;
In a state where the first mold and the second mold are opened between the member serving as the skin layer held by the first mold and the base material held by the second mold Supplying a foaming raw material to be a cushion layer by an amount corresponding to the volume of the cavity;
A step of expanding the foaming raw material in the cavity by the base material before foaming while closing the first molding die and the second molding die after supplying the foaming raw material to be the cushion layer. A molding method characterized by the above.

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