JPH09314593A - Skin integral molding method and skin integral mold - Google Patents

Abstract

(57) Abstract: [PROBLEMS] To provide a skin-integrated molding method and a skin-integrated molding die capable of manufacturing a component having a skin on a part of a base material in one step. SOLUTION: In a skin integral molding method for integrally resin-molding a resin base material portion and a skin material 21 covering a part of the base material portion with a mold, (a) one end portion of the skin material 21 has a wood grain of the core 11. After being held by being sandwiched between the rib portion 11b for use and the preceding pressing portion 15a of the trim lower die 15, (b) a resin material serving as a base material is injection-molded on the back surface of the outer skin 21 and the trim lower die 15 side where the outer skin does not exist. To do.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a skin integral molding method and a skin integral molding die for injection molding a component such as an automobile interior trim having a decorative skin fixed on a base material.

[0002]

2. Description of the Related Art In automobile interior trims, a woven fabric or leather skin for decoration is fixedly attached to a part of the design surface. Next, a conventional manufacturing method for fixing the surface skin to the surface of the base material of the interior trim will be described. In the conventional first manufacturing method, the automobile interior trim is vertically
The upper member, which is divided and has the outer skin fixed thereto, and the lower member, which does not have the outer skin, are separately manufactured. Here, as a method of manufacturing the upper member for joining the skin to the base material, for example,
The SPM method was used. The SPM method is to set the skin between the upper mold and the lower mold of the injection molding machine, inject the resin in the mold open state, and clamp the mold at a predetermined timing so that the skin and the base are kept under low pressure. It is a method of manufacturing an integrally molded product of a material. The reason why the resin is injected at a low pressure is that when the resin is injected at a high pressure, wrinkles are formed on the skin due to the resin pressure, resulting in a defective product. Then, finally, the upper member and the lower member are joined by ultrasonic welding to complete the interior trim. As a method for joining the upper member and the lower member, in addition to the joining method by ultrasonic welding, caulking joining, screwing joining and the like have been used.

As a modified example of the method for manufacturing the upper member of the first manufacturing method, for example, in the case where the base material is a wood board formed of wood fiber and phenol resin, a wood board formed in advance is used. The manufacturing method of sticking the epidermis has been adopted. That is, the epidermis, which has been heated and made easy to stretch, is vacuum-sucked and attached to a wood board coated with an adhesive to bond the epidermis to the wood board.

Further, as a second conventional manufacturing method, for example, JP-A-8-25382 and JP-A-8-2538.
There is a method described in Japanese Patent No. 3 publication. That is, this is a method in which the surface skin is shaped in advance into a product shape, and the shaped skin is insert-molded in a mold of an injection molding machine to obtain a partially decorated molded product. Here, it is necessary to preliminarily shape the outer skin by preforming and trim the outer circumference. The shaping means that a soft and easily deformable skin is solidified into a final shape with a solid material or the like.

[0005]

However, the conventional method for manufacturing an interior trim has the following problems. (1) In the first conventional method, the upper member and the lower member are manufactured separately and then joined in different steps, so that the number of processing steps is large and the cost is increased. (2) Further, JP-A-8-25382 and JP-A-8-25382
The technique of Japanese Patent No. 25383 requires a step of shaping the epidermis, which again requires a large number of processing steps and leads to an increase in cost. If injection molding is performed without shaping the skin, there is a problem that the skin is stretched depending on the product shape and wrinkles occur on the surface. Since the skin is originally added for decoration, wrinkles on the surface reduce the commercial value and pose a problem. Further, the raised hair on the surface of the epidermis may be crushed or the epidermis itself may be damaged by the resin pressure and the resin temperature.

The present invention solves the above-mentioned problems and provides a method for integrally forming a skin and a die for integrally forming a skin, which can manufacture a part having a skin on a part of a base material in one step. To aim.

[0007]

In order to solve the above problems, the method for integrally forming a skin of the present invention employs the following method. (1) In a method of integrally molding a skin, in which a resin base material portion and a skin covering a part of the base material portion are integrally resin-molded by a mold, (a) one end portion of the skin is a female mold and a male mold. After being sandwiched and held by a mold, (b) a resin material as a base material is injection-molded on the back surface of the skin and the portion where the skin does not exist. (2) In the method described in (1), by holding the other end of the skin on the outside of the mold, the skin is held in a sandwiched state in the mold. To do. (3) In the method described in (1) or (2), the female mold holding one end of the epidermis is provided with a wood grain projection and the male mold is provided at a position corresponding to the wood grain projection. , Characterized by having a wood grain groove portion provided with a convex row portion of a predetermined interval.

The outer skin integral molding die of the present invention has the following construction. (4) A skin-integral molding die for integrally resin-molding a resin base material portion and a skin covering a part of the base material portion, and a pair of male mold holding portions for holding one end portion of the skin in between. And a skin holding device and a skin setting device that holds the other end of the skin on the outside of the mold, and holds the skin while sandwiching it in the mold. (5) Further, in the die described in (4), the female die is divided into a first female die having a holding portion for the epidermis and a second female die, and the second female die It is characterized in that the die has a movement control means for moving in synchronization with the male die. (6) In the die according to (4) or (5), the female die holding one end of the epidermis has a grained convex portion, and the male die corresponds to the grained convex portion. In addition, it is characterized by having a wood grain groove portion provided with a convex row portion at a predetermined interval.

In the above structure, the method of insert-molding the outer skin is described, but the present invention can be applied to any member other than the outer skin that is soft and is not fixed in shape.

According to the above-mentioned method for integrally forming the skin and the die for integrally forming the skin, the resin is injected to the back side of the skin while the male mold and the female mold of the mold are held by sandwiching the skin first. ,
Wrinkles do not occur on the epidermis during injection molding, and naps on the surface of the epidermis are not crushed due to the occurrence of wrinkles. If the outer skin is attached to the mold, the interior trim can be manufactured in one step, so that the cost can be reduced. In addition, when holding the epidermis between the male and female molds, the other end face of the epidermis is in a state of being stretched on the outside. There is no occurrence of fire. Further, since the male mold has a wood grain groove portion provided with a convex row portion at a predetermined interval, which is formed at a position facing the female wood grain convex part that holds the outer skin, the resin is injection-molded. At this time, the resin enters the concave portions of the convex row from both sides of the wood grain groove, so that the base material portions on both sides can be connected with a predetermined strength.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION A skin integral molding die and a skin integral molding method according to an embodiment of the present invention will be described in detail with reference to the drawings. FIG. 8 is a perspective view showing the male die 10 and the epidermis setting device 24. 10 shows a front view, FIG. 11 shows a side view of FIG. 10, and FIG. 12 shows a plan view. As shown in FIG. 8, the male mold 10 is composed of a core 11 and a convex portion 11 a protruding from the surface of the core 11. Further, a wood graining rib portion 11b having ribs that are convex rows in the vertical direction is formed in the wood graining groove in the central portion. Next, the configuration of the skin setting device 24 attached to the outside of the convex portion 11a will be described. The two support shafts 14 standing upright on the core 11 are held by being biased outward by a spring 20. A U-shaped skin retaining member 13 is fixed to the support shaft 14. A space for sandwiching and fixing the skin 12 is formed near the support shaft 14 of the skin holding member 13, and four fixing bolts 19 for attaching and detaching the skin 12 are attached to the space.

Next, the female die 23 will be described with reference to FIG. The trim upper mold 16 is fixed to the base 25 of the female mold 23. Also, trim upper type 1
The trim lower die 15 is held by the four spring members 18 so as to be movable with respect to the trim upper die 16 in contact with the trim upper die 16. Also, the trim upper mold 1 of the trim lower mold 15
The front pressing portion 15a is formed so that the surface in contact with 6 projects. The outer shape of the interior trim 21 is shown in FIG. 13 in a plan view in (a) and in an AA sectional view in (b). The interior trim 21 includes an upper trim portion 21a and a lower trim portion 21b.
It is composed of The interior trim 21 is configured such that the skin 12 is fixed to the surface of the upper trim portion 21a of the base material portion 32. The lower end surface of the skin 12 is processed by the concave wood grain portion 33 so as not to be seen from the outside.

Next, a method of manufacturing the interior trim 21 using the skin-integrated molding die having the above structure will be described.
1 to 7 show the steps of the manufacturing method with sectional views of the mold.
FIG. 1 shows a state in which the mold is open. In this state, the operator sets the epidermis 12 on the epidermis setting device 24. That is, the outer skin 12 is held by the outer skin setting device 24 with the fixing bolt 19 in a state where the outer skin 12 is stretched to the left and right. Next, as shown in FIG. 2, the driving means of the molding device (not shown) is driven to move the core 11 to the left, and the front presser portion 15a and the grain portion rib portion 11b sandwich and hold the skin 12. 2 and the following figures,
The skin setting device 24 is omitted for the sake of clarity.

Next, as shown in FIG. 3, the core 11 further moves to the left. At this time, the trim lower die 15 moves leftward as the spring member 18 is compressed. The core 11 is stopped just before the bottom dead center of the mold device. At this time, the entire outer circumference of the outer skin 12 is sandwiched and held by the core 11 and the trim upper mold 16. Further, the gap formed by the core 11 and the trim upper mold 16 constitutes a space for forming the upper trim portion 21a with the skin 12 sandwiched therebetween. Next, as shown in FIG. 4, the valve gate 25a of the core 11 is opened only on the side of the trim upper mold 16 to inject the resin. This allows
The resin flows along the back surface of the skin 12. Air escapes through the opening at the top. At this time, the resin slightly wraps around the portion of the rib portion 11b for graining that presses the skin 12. In the device of the present embodiment, it was confirmed that a resin having a thickness of about 0.5 mm wraps around. When the skin 12 is pressed against the entire surface of the rib part 11b for graining, this 0.5 m
Although it is necessary to give strength to that portion with a resin having a thickness of m, in the present embodiment, at the wood grain portion where the skin 12 is sandwiched and fixed, the rib portion 11b for wood grain shown in FIG. Since the resin enters the recesses between the ribs and is molded, sufficient strength can be obtained.

Next, as shown in FIG. 5, the core 11 is further moved to the left to fully close the mold. At this time, the gap formed by the core 11 and the trim lower die 15 constitutes a space for forming the lower trim portion 21b. Then, the valve gate 25b is opened and the trim lower type 15
Inject resin to the side. Even at this time, the resin also enters the concave portion of the wood grain rib portion 11b, so that the upper trim portion 21a and the lower trim portion 21b can be connected to each other with a predetermined strength. At this time, the resin also flows into the trim upper mold 16 side, but since the resin that has flowed in is hidden behind the outer skin 12, the appearance is not adversely affected. Next, as shown in FIG. 6, the resin is solidified by cooling the mold, and the interior trim 21 is manufactured. Next, as shown in FIG. 7, the core 11 is moved to the right and the interior trim 21 is taken out from the mold. Since the end portion of the outer skin is located at the back of the wood grain portion, trimming processing of the outer skin is unnecessary, and the interior trim 21 is completed in this state.

As described in detail above, according to the method for integrally forming the skin and the die for integrally forming the skin according to the present embodiment, one end of the skin 12 is provided with the rib portion 11b for graining the wood grain of the male die 10.
After being sandwiched and held by the preceding pressing portion 15a of the female die 23, the resin material as the base material is injection-molded on the back surface of the outer skin 12 and the trim lower die 15 side where the outer skin 12 does not exist. Wrinkles do not occur on the surface skin 12 during molding, and the raised hair on the surface of the surface skin 12 is not crushed due to the generation of wrinkles. Further, if the outer skin 12 is attached to the mold, the interior trim can be manufactured in one step, so that the cost can be reduced.

Further, according to the method of integrally forming the skin and the die for integrally forming the skin of the present embodiment, the skin 12 is stretched by holding the left and right ends of the skin 12 by the skin setting device 24 outside the mold. In the state, the rib part 1 for the wood grain of the mold
Since it is held by being sandwiched between 1b and the preceding pressing portion 15a, wrinkles do not occur on the skin 12 when the wood-cutting rib portion 11b and the preceding pressing portion 15a sandwich the skin 12. Further, according to the method for integrally forming a skin and the die for integrally forming a skin according to the present embodiment, the rib portion 11b for graining which holds one end of the skin 12 is provided with a groove portion for graining, and the rib portion 11b for graining is preceded by Holding part 15a
Since the ribs, which are convex rows at predetermined intervals, are provided at positions corresponding to, when the resin is injection-molded, the resin enters into the concaves of the convex rows from both sides of the wood grain groove, so the upper trim section 21a and the base material portion of the lower trim portion 21b can be connected with a predetermined strength.

The skin-integral molding method and the skin-integral molding die of the present invention are not limited to those shown in the above embodiments, and various modifications can be made without departing from the spirit of the invention. For example, in the present embodiment, the case where the outer skin is integrally molded has been described, but the present invention can be applied to other cases as long as the outer skin having a non-uniform shape is integrally molded by injection molding. Further, in the present embodiment, the door panel has been described as the interior trim, but it goes without saying that it can also be applied to an instrument panel and other interior panels.

[0019]

EFFECTS OF THE INVENTION According to the method for integrally forming a skin and the die for integrally forming a skin according to the present invention, after one end of the skin is held by being sandwiched between the male mold and the female mold, the back surface of the skin and a portion where the skin does not exist. Since the resin material serving as the base material is injection-molded, the wrinkles do not occur on the skin during the injection molding, and the raised hair on the surface of the skin does not collapse due to the wrinkles.
Further, if the outer skin is attached to the mold, the interior trim can be manufactured in one step, so that the cost can be reduced.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing a first step of a method for integrally forming a skin.

FIG. 2 is an explanatory view showing a second step of the method for integrally forming a skin.

FIG. 3 is an explanatory diagram showing a third step of the method for integrally forming a skin.

FIG. 4 is an explanatory view showing a fourth step of the method for integrally forming a skin.

FIG. 5 is an explanatory view showing a fifth step of the method for integrally forming a skin.

FIG. 6 is an explanatory view showing a sixth step of the method for integrally forming a skin.

FIG. 7 is an explanatory view showing a seventh step of the method for integrally forming a skin.

FIG. 8 is a perspective view showing the configurations of the male mold 10 and the epidermis setting device 24.

9 is a perspective view showing a configuration of a female die 23. FIG.

FIG. 10 is a front view showing the configurations of the male die 10 and the epidermis setting device 24.

11 is a side view showing the configurations of the male mold 10 and the epidermis setting device 24. FIG.

FIG. 12 is a plan view showing the configurations of the male mold 10 and the epidermis setting device 24.

FIG. 13 is an external view showing a configuration of an interior trim 21,
(A) is a front view, (b) is an AA sectional view.

[Explanation of symbols]

 10 male mold 11 core 11b rib part for wood grain 12 skin 13 skin holding member 14 support shaft 15 trim lower mold 15a preceding pressing part 18 spring member 19 fixing bolt 21 interior trim 21a upper trim part 21b lower trim part 23 female mold 24 skin set apparatus

 ─────────────────────────────────────────────────── --- Continuation of the front page (72) Inventor Torao Kanayama 100 Kanayama, Ichiriyama-cho, Kariya city, Aichi Prefecture Toyota Toyota Auto Body Co., Ltd.

Claims (6)

[Claims] 1. A method of integrally molding a skin, wherein a resin base material part and a skin covering a part of the base material part are integrally resin-molded by a mold, wherein one end of the skin part is a female mold of the mold. A method for integrally molding a skin, which comprises sandwiching a male mold and holding it, and then injection-molding a resin material as a base material on the back surface of the skin and a portion where the skin does not exist. 2. The method according to claim 1, wherein the other end of the skin is held outside the mold so that the skin is sandwiched and held by the mold. A feature of the integral skin molding method. 3. The method according to claim 1 or 2, wherein the female die holding one end of the epidermis has a wood grain projection, and the male die corresponds to the wood grain projection. A method for integrally forming a skin, characterized by having a wood grain groove portion provided with convex row portions at predetermined intervals. 4. A skin integral molding die for integrally resin-molding a resin base material and a skin covering a part of the base material, wherein a pair of male mold holders holds one end of the skin in between. A part and a female mold holding part, and a skin setting device that holds the other end of the skin outside the mold, and holds the skin while sandwiching it in the mold. A skin integral molding die to be used. 5. The mold according to claim 4, wherein the female mold includes a first female mold including a holding portion for the skin.
A skin integrated molding die, which is divided into a second female die and has a movement control means for moving the second female die in synchronization with the male die. 6. The mold according to claim 4 or 5, wherein the female mold holding one end portion of the epidermis has a wood grain projection and the male mold corresponds to the wood grain projection. A skin-integrated molding die, characterized in that it has a wood-grooved groove portion provided at a predetermined position with convex row portions.