JPH11245247A - Molding method and mold apparatus for composite molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To ensure the accurate and secure molding using an installation of a smallest scale by first setting a skin material in a pair of dies, then cutting the skin material to a desired shape while securely holding it at a specified position in the dies and supplying a thermoplastic resin as a base to at least, the back face part of the skin material held and further, press-molding the thermoplastic resin. SOLUTION: A skin material S is set on a set pin 7 for the skin material S. Next, a movable die 1 is moved closer in the direction of a stationary die 2, and the skin material S is squeezed into a recessed molding face 4 on the movable die 1 side using the projecting part 10 of the stationary die 2. Then a skin material holding/cutting means 16 on the stationary die 2 side projects from the surface of the projecting part 10 of the stationary die 2 and is pressed against the skin material S so that a projecting skin material cutting blade 18 is strongly pressed to cut the skin material S to a specified shape. In addition, the movable die 1 is progressively clamped and at the same time, a thermoplastic resin is supplied to the back part and an area between the remaining molding faces 4, 9. The supplied thermoplastic resin finds its way further into the area between the molding faces 4, 9 as the die clamping procedure progresses, to produce moldings.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and a mold apparatus for molding a composite molded article in which a part of the surface of a substrate made of a synthetic resin is covered with a skin material using a pair of opposed molds.

[0002]

2. Description of the Related Art Conventionally, a composite molded product in which a part of the surface of a base material made of a synthetic resin is covered with a skin material is used for automobile interior parts,
It is widely used for home appliances, indoor furniture, etc. As a method of molding it, 1) a method of covering a surface of a preformed base material with a skin material and bonding it with an adhesive, 2) pressing a base material in a mold press A method is adopted in which a skin material is set in a mold in advance at the time of molding, and the skin material is integrally attached to the base material simultaneously with the formation of the base material. However, in the above method 1), the molding of the base material and the molding and sticking of the skin material are performed in separate steps, so that many facilities are required and it takes time to complete the molding. In recent years, these methods have not been implemented except in special circumstances. On the other hand, the above-mentioned method 2) is widely practiced because there is no such problem.

[0003]

When a composite molded article is to be obtained by the above method 2), there are the following problems.
It is difficult to keep the boundary line between the exposed part of the base material and the part covered by the skin material constant at all times, and it is troublesome to accurately set the pre-cut skin material terminal to the predetermined position of the mold. The content was nervous and required skill.
For this reason, there has been an economical problem that many defective products occur due to the inability to accurately set the skin material. SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and a molding method which forms a composite molded product in which a part of a base material is covered with a skin material with high quality and reliability is economically advantageous. It is an object of the present invention to provide a mold apparatus that performs the following.

[0004]

Means for Solving the Problems In order to achieve the above object, a method for molding a composite molded article according to the present invention comprises the steps of: forming a composite molded article in which a part of the surface of a substrate is covered with a skin material;
A method of molding using a pair of opposing dies, a step of setting a skin material between molding surfaces of the pair of opposing dies, and bringing the skin material closer to the pair of dies. A step of releasing the set of the skin material after being squeezed and brought into contact with and supported by the molding surface of the mold; and a process of projecting the skin material holding / cutting means provided in the pair of molds from the molding surface of the mold. A step of cutting the skin material into a desired shape after firmly and elastically holding the material, and a back surface position of the skin material left between the molding surfaces of the pair of molds after removing unnecessary portions of the cut skin material. And supplying a thermoplastic resin between the molding surfaces of the remaining molds, further closing the pair of molds, and expanding the supplied thermoplastic resin to spread the entirety thereof; and Release the holding of the skin material by the material holding cutting means A step of closing the pair of molds, final molding the thermoplastic resin, and adhering a skin material integrally with the molds, and a metal mold for carrying out this molding method. The mold device is a mold device for molding a composite molded product in which a part of the surface of the base material is covered with a skin material using a pair of opposed dies, and one of the pair of dies. A skin material holding portion for holding the skin material at its tip and a skin material cutting blade for cutting the skin material are provided in the mold and elastically supported so as to be able to advance and retreat from the inside of the mold to the outside of the molding surface. A skin material holding and cutting means, and a thermoplastic resin is provided between the molding surfaces of the molds at least on the back side of the cut skin material, the thermoplastic resin being provided through the front and back surfaces of one of the pair of molds. And a resin supply means.

According to the present invention, by employing the above solution, the skin material is cut along a predetermined line while being set and held in a mold, and the skin material and the base material are simultaneously formed at the same time as the formation of the base material. Since the sticking is performed, the quality of the composite molded article to be molded is always stable, the number of working facilities is reduced, and it is economically advantageous.

[0006]

Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 is a longitudinal sectional view of the mold apparatus, and FIG. 2 is a view taken along the line AA in FIG. The mold apparatus includes a movable mold 1 and a fixed mold 2. The movable mold 1 has a concave die 5 having a concave molding surface 4 attached to the front surface of a movable die base 3. Is provided with a skin material set pin 7 which appears and disappears on the parting surface by the operation of the cylinder 6 so that the skin material S having a hole formed at a predetermined upper position can be locked and suspended (see FIG. 1). I have. On the other hand, the fixed die 2 has a convex die 10 having a molding surface 9 corresponding to the concave die 5 mounted on a front surface of a fixed die base 2A via a mount 8.

[0007] Further, the convex member 10 is attached to urging means 14 and 14 comprising a cylinder via a plate 15, and the distal end thereof is always in a position corresponding to the surface of the convex member 10. Means 16 are provided, and the front end of the skin material holding and cutting means 16 has a flat skin material holding portion 17 along a boundary line between the base material and the skin material S, and a projecting skin material cutting blade 18. Is formed. (See FIG. 3) Further, on the molding surface 4 on the movable mold 1 side, a planar skin material for holding the skin material S in the form of sandwiching the skin material S therebetween in cooperation with the skin material holding portion 17 Holder 17A and skin material cutting blade 1
A flat skin material cutting portion 18A that cuts the skin material S by cooperating with the surface material 8 and sandwiching and pressing the skin material S therebetween is formed. Further, a guide pin 19 is fixed to the back of the plate 15, and a through hole 20 for passing the guide pin 19 is formed at a position of the gantry 8 corresponding to the guide pin 19. The plate 15 in the gantry 8
A stop block 23 for determining a retreat position (a position where the tip thereof coincides with the surface of the convex mold 10) is attached to the rear position of the skin material holding / cutting means 16. Further, the fixed die 2 is provided with a fixed die base 2A, a resin supply means 24 which penetrates the convex 10 from the base 8 to the molding surface 9 and supplies a thermoplastic resin between the molding surfaces 4 and 9; The resin supply means 24 includes a resin passage 25, a heater 26 surrounding the resin passage 25, and a valve gate 27 provided at a tip end, and is appropriately opened between the back surface of the cut skin material S and the remaining molding surfaces 4 and 9. Have been.

[0008] A procedure for molding a composite molded article by the thus configured mold apparatus will be described. The cylinder 6 of the movable mold 1 is extended to operate so that the skin material set pin 7 protrudes from the parting surface, and the skin material set pin 7 is set in a state where the hole of the skin material S is locked and suspended. Next, the movable mold 1 is moved closer in the direction of the fixed mold 2, and the skin material S
Is narrowed down to the concave molding surface 4 on the movable mold 1 side by the convex mold 10 of the fixed mold 2, and the skin material S is contact-supported at a position between the fixed mold 2 and the movable mold 1. Next, after the cylinder 6 is contracted and the skin material set pin 7 is retracted to release the engagement of the skin material S, the approaching movement of the movable mold 1 is further advanced and the movable mold 1 is moved to a predetermined position. The approach movement of the movable mold 1 is temporarily stopped when approaching. Next, the urging means 14 of the skin material holding / cutting means 16 on the fixed mold 2 side is operated, and the skin material holding / cutting means 16 is projected from the surface of the convex mold 10 of the fixed mold 2 and pressed against the skin material S. The skin material S is strongly held by the skin material holding portion 17 and the skin material holding portion 17A formed on the molding surface 4 of the movable mold 1, and the protruding skin material cutting blade 18 formed in the vicinity and the movable metal Molding surface 4 of mold 1
The skin S is cut into a predetermined shape by strongly pressing the skin S with the flat skin cutting portion 18A formed in the above.
(See FIG. 4) Next, after the cut off end material of the skin material S is manually removed, the movable mold 1 is further moved and approached, and the skin material S is moved by the convex mold 10 of the fixed mold 2 to the movable mold 1. It is further narrowed down to the concave forming surface 4 on the side. On the other hand, the skin material holding and cutting means 16 is retracted by the urging means 14 formed of a cylinder being pushed by the approaching movement pressure of the movable mold 1, but the skin material S is cut by the cut material ends by the skin material holding portions 17, 17A. It is narrowed down while being held firmly.

Further, when the mold closing of the movable mold 1 is advanced and the mold interval becomes about 15 mm, the movement of the movable mold 1 is temporarily stopped, and the thermoplastic resin is supplied by the resin supply means 24 through the resin passage 25 through the skin. The material S is supplied to the back and between the remaining molding surfaces 4 and 9, and after closing the valve gate 27, the mold is closed and the mold is closed. At this time, the mold interval is set to a predetermined value (10 to 3 mm).
At that time, the skin material holding / cutting means 16 is forcibly retracted by the retracting operation of the urging means 14, 14, and the plate 15 hits the stop block 23 and is located at the retracted end. Then, the supplied thermoplastic resin is pressed by the molding surface or the back surface of the skin material S by closing the mold, and is spread between the molding surfaces 4 and 9 of the mold as the closing of the mold proceeds. Further, since the retreat timing of the skin material holding / cutting means 16 is set as described above, the resin is somewhat in contact with the skin material S and the convex mold 10.
And the skin material S is pressed and fixed to the movable mold 1 side, so that no displacement of the skin material S occurs. In addition, the resin supplied to the portion where the skin material S is present precedes the resin supplied to the portion where the skin material S is not present with the skin material holding portion 17 of the skin material holding and cutting means 16 as a boundary. So that the valve gate 2
The resin supply amount is controlled in advance by adjusting (7).
By doing so, it is possible to prevent the resin from going around the front side of the skin material S. When there are few portions that are not covered by the skin material S, it is not necessary to supply the resin in advance to this portion, and the resin supplied to the back surface of the skin material S is spread out by closing the mold, and this portion is spread. You will be overwhelmed. Thereafter, the molded product is cooled for a predetermined time, the mold is opened, and the molded product is taken out.

In the embodiments shown in FIGS. 3 and 4,
The cutting of the skin material S is performed by slashing with the protruding skin material cutting blade 18, but the cutting may be performed by the concave shear cutting blade 18 as shown in FIGS. 9 and 10. Further, when the cut end of the skin material S is to be mounted on the base material in a wood-grained state, the skin material holding portion 17 of the skin material holding and cutting means 16 is recessed as shown in FIGS. The corresponding movable mold 1 side is provided with a corresponding convex surface material holding portion 17A, and the skin material cutting blade 18 is provided at the end of the concave surface material holding portion 17 or the movable mold. If it is provided at the end of the skin material holding portion 17A, which is a convex surface on one side, the end of the skin material S is held in a groove receiving shape, and is attached in a wood grain state at the time of molding and sticking with resin. Further, by providing small irregularities on one or both of the skin material holding portions 17 and 17A, slippage when holding the skin material S can be prevented.

[0011]

As apparent from the above description, the present invention sets the skin material in a pair of molds, and then securely holds the skin material at a predetermined position in the mold, cuts the skin material into a predetermined shape, and at least holds the skin material. Since the thermoplastic resin as the base material is supplied to the back part of the skin material and press-molded, all processes from cutting molding of the skin material to molding of the base material and sticking of the skin material are completed in the mold. In addition, the molding equipment can be minimized, and the surface material can be stably adhered with a stable boundary line with high accuracy and the effect thereof is greatly improved.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view of a mold apparatus for carrying out the method of the present invention.

FIG. 2 is a view as viewed in the direction of arrows AA in FIG. 1;

FIG. 3 is an enlarged detail view showing a skin material holding / cutting means;

FIG. 4 is an enlarged detailed view showing a state in which the skin material is held and cut by the skin material holding and cutting means.

FIG. 5 is an enlarged detailed view showing another skin material holding and cutting means.

FIG. 6 is an enlarged detailed view showing a state in which the skin material is held and cut by the skin material holding and cutting means shown in FIG. 5;

FIG. 7 is an enlarged detail view showing still another skin material holding and cutting means.

FIG. 8 is an enlarged detail view showing a state in which the skin material is held and cut by the skin material holding and cutting means shown in FIG. 7;

FIG. 9 is an enlarged detail view showing a skin material holding / cutting means in which a shearing cutting blade is formed.

10 is an enlarged detailed view showing a state of holding and cutting the skin material by the skin material holding and cutting means shown in FIG. 9;

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 movable mold 2 fixed mold 14 urging means 16 skin material holding and cutting means 17 17A skin material holding part 18 skin material cutting blade 18A skin material cutting part 24 resin supply means 27 valve gate S skin material

Claims (10)

[Claims] 1. A method of molding a composite molded article having a part of the surface of a base material covered with a skin material using a pair of opposed dies, wherein a molding surface of the opposed pair of dies is provided. A step of setting a skin material in between, a step of bringing the pair of dies closer to each other, squeezing the skin material onto a molding surface of the pair of dies, and supporting the contact material, and then releasing the setting of the skin material; A step of projecting the skin material holding and cutting means provided in the mold from the molding surface of the mold to firmly and elastically hold the skin material, and then cutting the skin material into a desired shape; and A step of supplying a thermoplastic resin between the molding surface of the skin material remaining between the molding surfaces of the pair of molds and the molding surface of the remaining mold after removing the unnecessary portion, and further mold the pair of molds. Close and push the supplied thermoplastic resin to spread the whole The step of spreading and the step of closing the pair of molds and closing the pair of molds to form the thermoplastic resin and simultaneously attaching the skin material while releasing the holding of the skin material by the skin material holding and cutting means, A method of molding a composite molded article, characterized by comprising: 2. A method for molding a composite molded article having a part of the surface of a base material covered with a skin material using a pair of opposed dies, the molding surfaces of the opposed pair of dies. A step of setting a skin material in between, a step of bringing the pair of dies closer to each other, squeezing the skin material onto a molding surface of the pair of dies, and supporting the contact material, and then releasing the setting of the skin material; A step of projecting the skin material holding and cutting means provided in the mold from the molding surface of the mold to firmly and elastically hold the skin material, and then cutting the skin material into a desired shape; and Supplying a thermoplastic resin between the molding surfaces at the back surface position of the skin material left between the molding surfaces of the pair of molds after removing the unnecessary portion, and further closing the pair of molds to form the thermoplastic resin. A step of spreading the supplied thermoplastic resin, and the skin material A step of closing the pair of molds while releasing the holding of the skin material by the holding and cutting means, forming the thermoplastic resin over the entire body, forming the thermoplastic resin, and adhering the skin material integrally. Characteristic method for forming composite molded products. 3. The holding of the skin material by the skin material holding / cutting means is performed by forming a recessed groove on the back side of the skin material and holding the skin on the surface side by an uneven surface having a projection corresponding to the recessed groove. The method of molding a composite molded article according to claim 1 or 2, wherein 4. The thermoplastic resin to be supplied is expanded by closing a pair of molds so that the resin on the back surface of the skin material precedes the resin between the molding surfaces of the remaining molds. 2. The method of molding a composite molded article according to claim 1, wherein the composite article is supplied after being adjusted so as to reach an end of the skin material. 5. A mold apparatus for molding a composite molded article in which a part of the surface of a base material is covered with a skin material using a pair of opposed dies, wherein A skin material holding portion for holding the skin material at its tip and a skin material cutting blade for cutting the skin material are provided in one mold, and are elastically supported so as to be able to advance and retreat from the inside of the mold to the outside of the molding surface. A skin material holding / cutting means, and a thermoplastic resin that extends from the outside of one of the pair of molds to the molding surface of the mold, and at least between the molding surfaces of the mold on the back surface of the cut skin material. And a resin supply means for supplying the resin. 6. A skin material holding portion of the skin material holding / cutting means, wherein one mold side is formed as a concave surface formed as a recessed groove, and the other mold side is formed as a convex surface corresponding to the concave surface. The mold apparatus according to claim 5, characterized in that: 7. The die apparatus according to claim 5, wherein the skin material cutting blade of the skin material holding / cutting means is a protruding cutting blade or a blade receiving surface for applying and cutting. 8. The die apparatus according to claim 5, wherein the skin material cutting blade of the skin material holding / cutting means is a cutting blade for a shear cutting blade. 9. The mold apparatus according to claim 5, wherein said resin supply means includes a heater. 10. The resin supply means is provided with a valve gate at a tip end thereof.
The described mold apparatus.