JPH03184816A - Laminate molding device - Google Patents

Abstract

PURPOSE:To upgrade the quality and reduce the cost by extruding molten resin from an injection machine or an extruder into a space of a mold opened in the sheet shape and mold clamping and pressing a skin material fed simultaneously in the laminated shape. CONSTITUTION:A given set quantity of a skin material 2 of a rolled body 4 is fed into a space between molds by a skin material driving roll 5 and a sequence controller in the sate of opening the molds 6 and 7. Simultaneously a sheet-shaped molten material 1 is extruded into a space between molds similarly to the skin material 2 by a screw 10. Successively, when the movable side mold 7 and the fixed side mold 6 are closed, the skin material 2 and the sheet- shaped molten material 1 are cut into the given shape. Immediately after that, the skin material 2 and the sheet-shaped molten material 1 are shape processed while being bonded and integrated along the cavity shape of the molds. Skin integrated molded product 1-2 and the sheet-shaped molten material 1 are cooled and solidified by the cooling water of the molds which are not shown in the drawing while being pressed by a clamp ram. Then, molds are opened and the skin integrated molded product 1-2 is released by an ejector pin 14.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a molding device for a laminated molded product that simultaneously laminates and shapes a skin material made of a flexible material and a plastic material.

(Prior art) Plastic molded products for automobile interiors tend to have a softer finish in order to promote safety in the event of a collision or the luxury of the interior, and flexible materials such as cloth, carpets, or polyurethane foam are used. There is an increasing demand for composite molded products in which a skin material made of a material is attached to the surface of a plastic molded product. In the current molding method, a hard fiberboard or a plastic molded product is used as a core material, and the cloth or polyurethane foam is laminated thereon in a separate process.

FIG. 9 shows a conventional pressure forming method. The plastic sheet 20 is heated by heaters 22 and 23, and an adhesive is applied to the cloth material 21, followed by bonding and shaping using molds 24 and 25. This method is expensive because it involves many steps such as cutting the plastic sheet, applying adhesive, and preheating.
There are problems such as increased processing energy for reheating the plastic sheet.

In addition, there is a flocking method in which short fibers such as iron or acrylic fibers are made to stand upright on the surface of the molded product after pre-processing the pre-shaped molded product and applying an adhesive, and the roots are glued to create a velvet-like finish. be. Although this method has a good finished appearance, it has the same problems as the above-mentioned methods, such as increased costs and processing energy due to the complicated process.

Naturally, the processing methods of these methods differ depending on the shape of the molded product and the fabrics to be laminated.

On the other hand, as shown in FIG. 8, in order to rationalize the above-mentioned processing method, Japanese Patent Application Laid-Open No. 60-212343 "'Laminated molded product having a raised skin" has been proposed.

This is a molding method in which a skin material 26 is placed in an injection mold and then injection molded to obtain an integrally molded product 27 of the skin material and resin.

However, in this processing method, since the filling pressure in the mold is high due to injection filling, there is a problem that the resin tends to penetrate into the skin material and spoils the soft feel of the skin material. Furthermore, if the number of gates is increased in order to lower the filling pressure, there is a problem in that wrinkles, etc., occur in the skin material at the resin merging section, which impairs the appearance.

(Problems to be solved by the invention) (1) As mentioned above, in the conventional pressure molding method and flocking method, the temperature of the core material of the plastic is low, so an adhesive is always required to attach it to the skin material. , the number of steps increases, leading to an increase in costs.

(2) In particular, the pressure forming method cannot provide a reinforced structure with ribs.

(3) Furthermore, in the injection molding method proposed in JP-A No. 1-212343, a narrow gap (2 to 3 N) between the skin material installed in the mold and the mold surface is filled with resin. As a result, the surface appearance quality of the skin material may be impaired if the antlers invade the skin material and make it hard, or if the skin material receives heat from the molten resin.

In large molded products (size 50 or more), weld lines occur at the resin confluence section due to the increased number of gates.
Due to this influence, wrinkles are likely to occur in the skin material.

The present invention solves these problems and provides a plastic molding apparatus having an integral structure with a skin material, which can achieve high quality and reduce costs.

(Means for Solving the Problem) That is, the configuration of the present invention includes a movable mold facing a fixed mold,
It consists of an extrusion mechanism that extrudes and supplies a molten resin sheet to the intermediate part between the opened fixed mold and the movable mold, and an arrangement means that arranges a sheet-like skin made of a flexible material on one mold surface. , a laminated molding apparatus characterized in that a cutting mechanism for cutting a laminated integral molded product of a molten resin sheet and a skin body is provided in a peripheral part of the cavity formed by the fixed mold and the movable mold, This is a means to solve the above problem.

(Function) Molten resin is extruded from an injection machine or an extruder into the space of an open mold in the form of a sheet, and the skin material supplied at the same time is pressed to close the mold in a laminated form, so that the skin material and resin are bonded together. At the same time as bonding, shaping is performed into a shape that includes simple ribs, etc.

Further, the edges of the skin material and the sheet-like melt are processed by a cutting mechanism using a mold during the mold closing process. As a measure to prevent so-called dripping, in which the sheet-like molten material drips from the goo, rather than using an extruder in which the screw rotates continuously once the operation starts and constantly supplies molten resin, the screw is operated intermittently and supplies molten resin intermittently. It is preferable to use an injection machine that

However, even if the extruder is equipped with a surge tank for storing molten resin during the pressing process, an electromagnetic clutch, or a controller that commands the start and stop of screw rotation, nasal drip from the goo will not occur. It is possible to use it fully.

During the subsequent press operation of the sheet-shaped melt extruded from the gou, the molten resin penetrates into the back side of the skin material, and the anchoring effect of this resin causes the skin material and the plastic molded product to firmly adhere.

In order to prevent the sheet-like melt from sagging due to its own weight, it is necessary to increase the viscosity of the resin and increase the elasticity of the resin. However, even if the resin viscosity is increased, adhesive strength and shaping processability can be sufficiently maintained.

(Embodiment) FIG. 1 shows a configuration example as an embodiment of the present invention. The raw material resin is transferred from the raw material Honba (not shown) to the screw cylinder I.
The screw 10 is plasticized and melted by the rotation of the screw 10 which can be reciprocated by the heater 9 and the piston 12 of I.
It is stored at the tip (left side). A die 3 is provided at the tip of the screw cylinder 11 via an adapter 8. The above plasticizing unit slides on the slide mousse 13 by the hydraulic cylinder 19. The die 3 may be a standard die used for sheet bottom shapes, and is replaced according to the shape of the molded product. However, since the die 3 has a half-split structure as shown in FIG. 3, the width of the sheet-like molten material 1 can be changed by inserting a baffle plate 3a at the die outlet.

A fixed mold 6 and a movable mold 7 are installed opposite to each other below the die 3, and the movable mold 7 is reciprocated back and forth by a clamp ram 17. The installation position of the die 3 is above the space when the fixed mold 6 and the movable mold 7 are open.

Further, above the same space, a representation driving roll 5 is disposed on the movable mold 7 side of the die 3, and the skin body 2 is moved between the fixed mold 6 and the representation body driving roll 5 by the winding ball 4 and the representation driving roll 5. It is supplied to the space between the movable molds 7.

The expression drive roll 5 is operated intermittently by a sequence controller 18 according to the process.

Each external portion 6a, 7a of the cavity 28 formed by the stationary side mold 6 and the movable side mold 7 has a second
As shown in detail in the figure, it has a gap of about 0.05 to 0.1 rrtm, and has the function of cutting the sheet-like molten material 1 and the skin body 2 that are joined and integrated. Further, a protrusion is formed on the inner surface of the outer edge of the cavity on the movable side to hold the integrally molded skin product 1-2 so that it does not move when the mold is opened. After opening the mold, the skin-integrated molded product 1-2 is taken out from the mold by the ejection pin 14 attached to the ejection plate 15.

The press mechanism may be the same as a conventional mold clamping mechanism.

Next, the operation will be explained in order of steps. The operation details of the process are explained in the fourth section.
The specific movements of each part are shown in FIGS. 5 to 7. In these figures, with the molds 6.7 opened, a predetermined amount of the skin 2 of the rolled ball 4 is supplied to the space between the molds by the expression drive roll 5 and the sequence controller 18. At the same time, the sheet-like melt 1 is extruded by the screw 10 into the space between the molds, similarly to the skin body 2.

The thickness of the sheet-like melt 1 can be easily adjusted by adjusting the gap between the dies 3, adjusting the resin viscosity, or adjusting the extrusion speed of the screw.

As shown in FIG. 4, the mold closing process by the clamp ram 17 starts midway through the supply of the skin body 2 and sheet-like melt 1, and the state shown in FIG. 5 is reached. Subsequently, as shown in FIG. 6, when the movable mold 7 and the fixed mold 6 are closed, the skin 2 and the sheet-like molten material 1↓ are cut into a predetermined shape.

Immediately thereafter, the skin body 2 and the sheet-like molten body 1 are shaped and bonded together along the cavity shape of the mold. The excess skin body 2 and sheet-like melted body 1 that are cut off here fall downward due to gravity and become scrap. Epidermal body 2
The skin-integrated molded product 1-2 of the sheet-like molten material 1 is pressed by a clamp ram 17 and cooled and solidified by cooling water from a mold (not shown). As shown in the process diagram of FIG. 4, the screw finishes plasticizing the next shot during this cooling and solidifying time.

Subsequently, as shown in FIG. 7, a mold opening operation is performed, and the skin-integrated molded product 1-2 is taken out by the ejector pins 14. All of the above steps are controlled by the sequence controller 18.

(Effects of the Invention) (1) Compared to the conventional pressure forming method, the apparatus of the present invention simplifies the process and reduces the number of times molded products are handled, leading to cost reductions. Furthermore, since there is no need to reheat the plastic sheet, energy can be saved.

(2) Furthermore, in the present invention, compared to the pressure forming method, it is possible to increase the rigidity of the molded product and create a structure with no ribs to prevent warping.

(3) Furthermore, according to the present invention, compared to the injection molding method in which the skin body is fixed in a mold, the skin body is less likely to stretch or wrinkle due to the flow pressure of the resin, so there is less damage to the skin body.
A molded product with a good appearance can be obtained. Furthermore, even in the case of large molded products of approximately 50 cm or more, molded products with excellent strength can be obtained, with no weld lines due to poor bonding of resin confluence parts.

(4) In general, resin grades with high tensile strength have poor fluidity, so it is difficult to use the injection molding method described above. Since it is extruded, molding is possible without flow resistance being a problem. Therefore, according to the molding method using the apparatus of the present invention, it is possible to make the resin grade thinner with a high tensile strength, and the molding cost can be reduced.

[Brief explanation of drawings]

FIG. 1 is a schematic configuration diagram of a molding device according to an embodiment of the present invention, FIG. 2 is an enlarged view of a cut section of the same device, FIG. 3 is a sectional view taken along line B-B in FIG. 1, and FIG. FIGS. 5 to 7 are explanatory diagrams showing the operation timing of the apparatus of the present invention. FIGS. 5 to 7 are explanatory diagrams of the molding process. FIG.
The figure is a diagram showing the principle of a conventional pressure molding method, and FIG. 10 is an explanatory diagram showing the principle of forming a laminate molded product by injection molding. Explanation of main parts in the figure 1 - Sheet-shaped melt 2 - Skin body 3 - Die 4 - Roll 5 - Expression body driving roll 6 - Fixed side mold 7 - Movable side mold - (fixed side) outer periphery Part 1a - (movable side) outer peripheral part 17 - Clamp ram Patent Applicant Mitsubishi Heavy Industries, Ltd. Figure 5 Figure 7 Figure 6 Figure 7 Figure 8 (A) Condolences 1u (D) □00□ (C)

Claims (1)

[Claims] A movable mold facing the fixed mold, an extrusion mechanism that extrudes and supplies a molten resin sheet to the middle part between the opened fixed mold and the movable mold, and a sheet made of flexible material on one mold surface. A cutting mechanism is provided around the cavity formed by the fixed mold and the movable mold to cut the laminated integral molded product of the molten resin sheet and the skin. A laminated molding device characterized by: