JP2004001537A - Mold for molding multi-layer molding and method for manufacturing multi-layer molding using the mold - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To manufacture a multi-layer molding in which a skin material partially set in a mold is not dislocated and is stuck correctly at a prescribed position, and the boundary part between a skin material-stuck part and a skin material-nonstuck part is clear. <P>SOLUTION: A molding mold comprises a pair of male and female molds for manufacturing the multi-layer molding in which the skin material is partially stuck on the surface of a base material of a thermoplastic resin. The mold has a molten resin supply passage opened in the skin material-stuck part of a mold surface. Further, the mold is composed of a male or female mold surface having at least one recessed part into which a part or the whole of a skin material peripheral terminal in a part or the whole of a position corresponding to the peripheral part of the skin material to be stuck, and an insert block which holds the skin material peripheral terminal inserted into the recessed part and is engaged with the recessed part to constitute the mold surface fixably and uniformly. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
[Industrial applications]
The present invention relates to a mold for molding a multilayer molded article and a method for producing a multilayer molded article using the same.
[0002]
[Prior art]
Conventionally, multilayer molded products in which a skin material is partially adhered to the surface of a base material made of a thermoplastic resin have been widely used for automotive interior parts such as door trims, rear trims and instrument panels of automobiles, and home appliances. ing.
In general, a multilayer molded article having such a skin material partially adhered thereto is supplied with a molten resin after the skin material is placed at a predetermined position on a mold surface, and the cavity clearance is applied to the final product thickness. It is manufactured by a compression molding method in which the mold is pressed and clamped until it becomes.
However, in such a method, it is difficult to accurately hold the skin material at a predetermined position on the mold surface, and the skin material is supplied by the supply pressure of the molten resin or the flow of the molten resin in the mold at the time of mold clamping. However, there has been a problem that a displacement occurs in a molding process and a skin material cannot be stuck to a predetermined place.
[0003]
In order to solve such a problem, for example, Japanese Patent Publication No. Hei 4-26289 discloses a method in which a partition wall is provided on a mold surface corresponding to a peripheral portion of a skin material, and a peripheral edge of the skin material is arranged along the partition wall and is surrounded by the partition wall. A method of fixing the skin material by placing the skin material so that the surface of the skin material is in contact with the mold surface in the region where the surface is in contact with the mold surface, or making the apex of the partition wall into a sawtooth shape and locking the skin material peripheral end. I have.
However, even in this method, although the skin material is placed in the partition wall, the skin material is not particularly fixed to the mold surface, or even if the skin material peripheral terminal is locked at the top of the partition wall. Because the locking force is not sufficient, the skin material moves beyond the partition walls due to the supply pressure of the molten resin or the flow of the molten resin in the mold during mold clamping, and it has been difficult to reliably prevent the displacement. . For this reason, in the case of this method, the skin material used is limited to a thick fiber material or the like which is not easily affected by the supply pressure of the molten resin or the flow of the molten resin in the mold at the time of mold clamping. There was a problem that the skin material had to be preformed so as to fit inside.
[0004]
Further, as the multilayer molded body to which the skin material is partially adhered, a molded body whose base material surface forms the molded body surface as it is except that the skin material is partially adhered as described above. In addition, a so-called multi-colored multilayer body in which a part of the substrate surface is partially adhered with the skin material 1 and the other substrate surface part is adhered with another skin material 2 is also known. As a manufacturing method, Japanese Patent Application Laid-Open No. 2-206513 discloses that a peripheral edge portion of a skin material 1 to be partially adhered is inserted into a circumferential groove provided on a mold surface, and further covered thereover. A method is known in which another skin material 2 is placed on the entire surface of a mold, and then molten resin is supplied between the skin material and the mold surface.
However, also in this method, since the peripheral edge of the skin material 1 is simply inserted into the peripheral groove and has no fixing means, the supply pressure of the molten resin and the molten resin in the mold at the time of mold clamping are not increased. The skin material was moved by the flow, and it was difficult to accurately adhere the skin material to a predetermined position.
[0005]
[Problems to be solved by the invention]
From these facts, the present inventors have proposed a molded article in which the surface of the base material forms the surface of the molded article as it is, except that the skin material is partially adhered to the surface of the thermoplastic resin substrate. A part of the surface of the material is partially adhered with the skin material 1, and at least one other surface material is partially covered with at least one kind of skin material such as a multicolored multi-layer molded body adhered with the other skin material 2. As a result of studying to easily manufacture a multilayer molded body having a part that is partially adhered without causing displacement, the peripheral edge of the skin material partially placed in the mold is fixed to the mold surface. In developing a mold suitable for fixing to the above, by manufacturing a multilayer molded body as described above using this mold, the skin material partially placed in the mold in the molding process Manufacture multi-layer molded products with the skin material accurately adhered to the specified position without causing displacement. It found that it is possible, leading to the present invention.
[0006]
[Means for Solving the Problems]
The present invention is a molding die composed of a pair of male and female for producing a multilayer molded body in which a skin material is partially adhered to the surface of a base material made of a thermoplastic resin, and the skin material on the mold surface is provided. At least one concave portion having a molten resin supply path opened in the attaching portion and capable of inserting a part or all of the skin material peripheral terminal into a part or all of a position corresponding to a peripheral portion of the skin material to be attached. Either of the male and female mold surfaces and the peripheral edge of the skin material inserted into the recess are sandwiched between the inner wall of the recess, and the recess is formed so as to be fixable and form a uniform mold surface. The present invention also provides a mold for molding a multilayer molded article composed of an insert block and a mold that fits into a surface of a substrate made of a thermoplastic resin by using such a mold. The method of manufacturing a multilayer molded body to which a material is partially adhered Te,
(1) A step of placing a skin material cut into a predetermined shape at a predetermined position on a mold surface and folding a peripheral edge of the skin material into a concave portion provided on the mold surface.
(2) Step of fitting the insert block into the concave portion and fixing and disposing the skin material on the mold surface
(3) At least a step of supplying a molten resin from a molten resin supply path that opens into a skin material attaching portion on a mold surface.
(4) A step of pressurizing and clamping the mold until a predetermined cavity clearance is reached, cooling, and taking out the molded body from the mold.
It is intended to provide a method for producing a multilayer molded body in which a skin material is partially adhered to the surface of a base material comprising:
In addition, the present invention uses the same or different skin materials 1 and 2,
(1) A step of placing the skin material 1 cut into a predetermined shape at a predetermined position on the mold surface and folding the peripheral edge of the skin material into a concave portion provided on the mold surface.
(2) Step of fitting the insert block into the concave portion and fixing and disposing the skin material on the mold surface
(3) A step of placing the skin material 2 over the entire surface of the mold while covering the skin material 1
(4) Step of supplying molten resin from at least a molten resin supply path that is opened in a portion of the mold surface where the skin material 1 is adhered.
(5) Step of pressurizing and mold-clamping until a predetermined cavity clearance is reached, cooling, and removing the molded body from the mold
(6) A step of separating the skin material 2 covering the skin material 1 from the removed molded body along the peripheral edge of the skin material 1
The present invention provides a method for producing a multilayer molded body in which the skin material 1 is partially adhered to the surface of a base material made of and the skin material 2 is adhered to the other surface of the base material.
[0007]
Hereinafter, the present invention will be described.
FIG. 1 shows a book for manufacturing a multilayer molded article of the present invention in which a skin material (4) is partially adhered to the surface of a base resin (16) as exemplified in FIG. FIG. 2 is a schematic cross-sectional view of an example of the mold of the invention, and FIG. 2 is a plan view of a mold surface of the male mold.
The mold is composed of a pair of male and female molds (1) and male molds (2), and is opened on the mold surface of the male mold, inside the skin material sticking portion and on the non-sticking portion of the mold surface, respectively. A plurality of recesses (5) are provided at positions corresponding to the peripheral portion of the molten resin supply path (3) and the skin material (4) to be adhered, and in this example, a continuous form is provided along the peripheral portion of the skin material as a preferred embodiment. A small groove (10) is provided on the mold surface of the male mold, and a continuous band-like projection (12) is provided on the mold surface of the female mold at a position corresponding to the small groove provided on the male mold. Is provided.
The insert block fitted during molding is not shown in this figure.
[0008]
As shown in the schematic cross-sectional view of FIG. 4, the concave portion (5) needs to be provided so that one side of the opening is in contact with the periphery of the skin material and is opened outward from the region where the skin material is adhered.
The shape of the recess is not particularly limited, and the opening may have any shape such as a square, a triangle, a semicircle, and an ellipse, but is generally provided in a square shape, and its side surface is a mold surface. Is generally a right angle, but may be a straight line or an arc in a direction spreading from the bottom surface toward the opening, or the bottom surface is usually a flat surface, but may be a spherical shape. There is no particular limitation as long as an insert block having a shape corresponding to the shape of the recess can be fitted, and the skin material peripheral edge can be sandwiched and fixed between the insert block and the recess.
[0009]
The number of the concave portions is appropriately determined according to conditions such as the size of the skin material sticking portion, the sticking site of the skin material, and the properties of the skin material to be used, but usually at appropriate intervals along the periphery of the skin material. , Two or more are provided discontinuously.
However, the skin material sticking site is not at the center of the molded body but only at the end, and is distinguished from the base material surface of the skin material non-sticking at a part of the entire periphery of the skin material. In this case, only one recess may be provided at an appropriate position along the periphery of the skin material in the mold. In addition, even in the case described above or when the skin material is provided at the center of the molded body, if the skin material is excellent in the heat-sealing property with the molten thermoplastic resin used, the in-plane surface of the mold is used. One continuous recess may be provided along the entire periphery of the skin material.
[0010]
The width of the opening of the concave portion (the length outward from the periphery of the skin material) is appropriately selected according to various conditions such as the type, thickness, and properties of the skin material, the size of the skin material attachment portion, and the size of the mold. There is no particular limitation as long as the insert block can be fitted and the peripheral edge of the skin material can be sandwiched and fixed, but it is generally about 5 to 70 mm. There is no particular problem if the groove width exceeds 70 mm, but there is not much benefit in practically increasing the groove width. There is no particular limitation on the depth of the concave portion (the deepest portion when the depth is not uniform) as long as the skin material can be clamped by fitting the insert block, and generally one third of the thickness of the final molded body. Although provided so as to be as described above, the thickness may be more than the thickness of the molded body.
The length of the opening of the concave portion (the length along the periphery of the skin material) is the same as that of the width of the opening except for the case where the recess is provided along the entire periphery of the skin material in the mold surface. In addition, the number of concave portions to be provided, the length of the skin material peripheral edge in the mold, the shape of the skin material portion to be adhered, and the like are closely related, and are arbitrarily selected within a range where the skin material can be sandwiched by the insert block. However, generally, when the number of recesses is small or the length of the skin material is long, the length is relatively long, and when the number of recesses is large or the length of the skin material is short, the length is relatively short. Often. Of course, regardless of the length of the skin material peripheral edge, if the shape becomes complicated, it is needless to say that an appropriate mode such as shortening the length of the opening and increasing the number of concave portions is adopted.
When providing a plurality of such recesses, each recess need not be the same in all of them, the width of the opening of each recess as required, such as the shape of the skin material to be affixed or the sticking site Needless to say, the length, the depth, and the like may be appropriately changed.
[0011]
When two or more recesses are provided, the intervals are not necessarily required to be equal, and the number of recesses, the length of the opening, the length of the skin periphery, the skin material, so that the skin peripheral edge can be sandwiched and fixed. May be arbitrarily selected according to various conditions such as the shape of the mold at the portion where the is adhered.
[0012]
The mold according to the present invention includes a mold having a recess on the mold surface described above, and an insert block (6) for holding and fixing a skin material peripheral end fitted into the recess and folded into the recess. It is composed of
Nipping and fixing of the peripheral edge of the skin material are performed between the inner wall of the concave portion and the outer wall of the insert block. Usually, as shown in FIG. ) And the outer peripheral surface (8) on the skin material peripheral side of the insert block.
Therefore, the insert block basically has a shape corresponding to the space area of the concave portion. However, when the insert block is fitted into the concave portion, when the insert block is fitted into the concave portion, the outer peripheral surface of the skin material peripheral side of the concave portion of the insert block Are formed in such a size that there is an appropriate interval between them.
This gap H is at least equal to or less than the thickness of the skin material, and specifically varies depending on the type, thickness, properties, etc. of the skin material to be used. It must be determined so that it can be clamped tightly without movement, and is generally in the range of 0.1 to 0.9 times the thickness of the skin material.
[0013]
In order to more securely hold and fix the peripheral edge of the skin material, as shown in FIG. 4- (2), the edge is further bent to the bottom surface of the concave portion, and between the bottom surface of the concave portion and the lower surface of the insert block. However, in order to further secure the pinching force, as shown in FIG. 4C, the pinching force is directed downward from the lower surface of the insert block or upward from the bottom surface of the concave portion. One or more pins or saw-toothed skin material fixing projections (14) are provided, and the peripheral edge of the skin material is pierced by the pins or hooked to the tips of the projections to be fixed, so that the clamping force can be improved. In this case, the height of the insert block may be shortened in consideration of the height of the pin or the protrusion, or a gap capable of receiving these tips may be provided on the lower surface of the opposed insert block or the bottom surface of the concave portion. It can also be provided corresponding to the position of each pin or protrusion.
In any case, when the skin material peripheral edge is further bent to the bottom of the concave portion, the height of the insert block is adjusted so that the mold surface becomes uniform and smooth even after the insert block is fitted. It is necessary to adjust according to the thickness of the folded skin material.
[0014]
The mold of the present invention is basically composed of a mold having such a concave portion and an insert block, and the skin material is fixed to the mold surface by fitting the insert block into the concave portion during use. As shown in FIG. 5, the lower surface of the insert block may be replaced with the lower surface of the recess as a means for more securely fitting at this time or for reliably preventing the insert block from floating during molding. The slide block (9), which is slidable back and forth in the opening direction of the mold provided therethrough, is integrally connected, and the slide shaft is operated back and forth to mechanically insert the insert block. Fitting and disengaging can also be performed.
In this case, as shown in FIG. 5- (1), the sliding shaft is pushed up to separate the insert block from the concave portion, and the peripheral terminal of the skin material is removed from the gap between the insert block and the concave portion. After bending into the recess, as shown in FIG. 5- (2), the insertion block can be lowered and fitted into the recess by the operation of the sliding shaft.
In this case, each of the sliding shafts may be operated individually, or may be operated simultaneously for each appropriate group or all of them in conjunction.
The operation of the sliding shaft can be easily performed, for example, by using a normal hydraulic device or the like.
[0015]
In the mold of the present invention, a small groove (10) for inserting a skin material peripheral end is attached in order to further clarify a boundary portion between the skin material periphery and a portion other than the skin material and improve the appearance. It is effective to provide the mold further along the peripheral edge of the skin material.
The small groove is usually provided such that when the skin material is placed at a predetermined position, the peripheral edge of the skin material is located substantially at the center of the cross section of the groove or on the skin material sticking portion side. Such small grooves usually have a semicircular or U-shaped cross section, but may have a quadrangular shape, a triangular shape open at the top, or a parabolic shape.
The width and depth of the small groove vary depending on the type of the skin material, the thickness of the molded body, and the like, but the width is about 10 or less, preferably about 5 times or less the thickness of the skin material, and the depth is the skin at the deepest part. It is about 10 or less, preferably about 5 times or less of the material thickness.
Further, even in the state after the insert block is fitted, in the portion where the concave portion is provided, the peripheral edge of the concave portion on the surface side of the concave portion is formed so as to be present on the mold surface continuously to the peripheral edge portion of the skin material. And a notch (11) is provided in each skin material side peripheral edge so that the skin material side peripheral edge of the fitted insert block forms a part of the small groove. (FIGS. 5 and 6)
When a small groove is provided on the mold surface, a continuous protrusion (12) is provided on the mold surface facing the mold so as to correspond to the small groove so as to be in contact with the skin material periphery at the time of molding. If the molding is performed while pressing the peripheral edge of the skin material inserted into the small groove, a groove (13) corresponding to the projection is generated at the peripheral edge of the skin material of the obtained multilayer molded body, and the peripheral edge of the skin material and the non-sticking of the skin material are formed. The boundary with the base resin surface is more clearly defined by the groove, and it is very effective to provide such projections on the opposing mold surface. (FIGS. 7 and 8)
The width of the projection provided for this purpose corresponds to the width of the groove at the boundary between the outer periphery of the skin material of the obtained multilayer molded body and the surface of the base material resin on which the skin material is not adhered, so that the required groove width is obtained. Although it is appropriately selected as described above, it is usually provided so as to be narrower than the width of the small groove (10) provided in the opposing mold.
The height of the projection varies depending on the thickness of the obtained multilayer molded body, the depth of the groove (13) to be formed, and the like, but at least a height shorter than the sum of the thickness of the multilayer molded body as a product and the depth of the small groove. It is appropriately determined within the range of the length.
[0016]
Using such a mold of the present invention, in order to produce a multilayer molded body in which a skin material is partially adhered to the surface of a base material made of a thermoplastic resin, for example, a method comprising the following steps is mentioned. Can be
First step: A skin material cut into a predetermined shape is placed at a predetermined position on a mold surface, and a peripheral edge of the skin material is provided in a concave portion provided on the mold surface (and a small groove is formed on the mold surface along the periphery of the skin material). If it is provided, it is folded into its small groove (FIG. 9).
Second step: The insert block is fitted into the recess, and the skin material is fixedly arranged on the mold surface (FIG. 10).
Third step: At least a molten resin is supplied from a molten resin supply passage that opens into the skin material attaching portion on the mold surface (FIG. 11).
Fourth step: pressurizing and pressing the mold until a predetermined cavity clearance is reached, then cooling, and taking out the molded body from the mold (FIG. 12).
[0017]
In the first step, the skin material is cut in advance in accordance with the shape to be attached. At this time, in order to fold the skin material peripheral end into the concave portion provided on the mold surface, a pinching margin (17-1) It is necessary to cut in anticipation.
As shown in FIG. 13, the pinch allowance has a length substantially equal to the length of the opening of the concave portion, corresponding to the position of the concave portion when the skin material is placed at a predetermined position of the mold, and It is preferable to provide the projection so as to have a width corresponding to the length to be inserted into the recess.
When a small groove is provided on the mold surface along the peripheral edge of the skin material, the skin material is so arranged as not to protrude from the groove along the groove of the small groove, to the deepest part of the groove or along the inner wall of the groove. Is folded, it is necessary to cut the skin material in anticipation of the folded portion (17-2) corresponding to the groove of the small groove. Therefore, in this case, the skin material is provided as a folded portion of the small groove and a folded portion of the concave portion. The pinching allowance is the skin material peripheral edge.
The cut skin material is placed in a predetermined position, and if there is a concave portion and a small groove, the skin material peripheral end is folded and inserted into the small groove.
[0018]
In the second step, the insert block is fitted into the concave portion, and the folded skin material peripheral end is sandwiched and fixed between the inner wall of the concave portion and the outer peripheral surface of the insert block. In this case, if the insert block is an independent part, it is fitted by fitting it into the recess, and if the insert block is integrally formed with the mold via a sliding shaft, The drive shaft is operated to fit the insert block into the recess.
[0019]
In the third step of supplying the molten resin (15) between the molds, it is necessary to supply the molten resin from at least a molten resin supply path that opens into the skin material attaching portion on the mold surface.
When the molten resin is supplied from the molten resin supply path that opens into the skin material attaching portion of the mold surface, excess molten resin between the skin material and the mold surface has a skin material peripheral end. In the unfixed portion, that is, in the mold portion other than the concave portion where the skin material is fixed, it flows through the lower edge of the skin material to the mold space where the skin material is not placed, and as a result, the skin material Can be obtained, but the molten resin supplied from the molten resin supply path, which is opened at a portion other than the skin material attaching portion on the mold surface, is half of the supplied molten resin. It does not flow between the closed skin material and the mold surface, and a predetermined multilayer molded body cannot be obtained.
For this reason, the supply of the molten resin is performed only from the molten resin supply path that opens into the skin material attaching portion on the mold surface, or even when the molten resin is supplied from a plurality of molten resin supply paths, It is necessary to perform the supply also from the molten resin supply path that opens into the attachment portion, and it is not preferable to supply the resin only from the molten resin supply path that opens outside the skin material attachment portion.
In addition, when the concave portion is provided on the mold surface along the entire periphery of the skin material, even if the molten resin is supplied only from the molten resin supply path that opens in the skin material attachment portion of the mold surface, Because the entire periphery of the skin material is fixed, the molten resin does not flow to the mold space where the skin material is not placed, so in this case, from the molten resin supply path opened other than the skin material attachment portion Need to supply molten resin.
For the above reason, when supplying the molten resin only from the molten resin supply path that opens into the skin material attaching section, it is necessary to supply the entire amount of the resin necessary for manufacturing the multilayer molded body from the supply path, When the molten resin is supplied from both the molten resin supply path that opens inside the skin material attaching section and the molten resin supply path that opens outside the skin material attaching section, the amount of resin supplied from the former molten resin supply path Is required to be at least the amount of resin necessary to form the base material portion of the skin material sticking portion in the final product, and if it is less than that, a desired multilayer molded article cannot be obtained.
[0020]
After the molten resin is supplied, as a fourth step, the male and female molds are clamped until the cavity clearance reaches the final product thickness, and then cooled to take out the desired multilayer molded body from the mold.
This mold clamping is usually performed after the supply of the molten resin is completed, but depending on the type of the skin material and the thermoplastic resin, the shape of the mold, etc., the cavity clearance may be finalized before the supply of the molten resin is completed. Unless the product thickness is reached, for example, mold clamping while supplying the molten resin, and temporarily stop the mold clamping operation at that time, so that mold clamping is completed simultaneously with the completion of the supply of the molten resin. Alternatively, the mold clamping of the fourth step includes such an embodiment.
When the mold clamping is completed, the mold is cooled according to a conventional method, the mold is opened, and the multilayer molded body on which the skin material is partially adhered is taken out.
[0021]
As shown in FIG. 7, at the time of completion of molding, the multilayer molded body thus obtained is in a state where the skin material peripheral end portion folded into the concave portion partially penetrates to the back surface of the base resin, and the concave portion and the concave portion are formed. Between the base material resin on the skin material sticking part side and the base material resin on the skin material non-sticking part side are integrated through the lower part of the skin material periphery, and a part of the skin material periphery is resin on both sides thereof. A multilayer molded product which is sandwiched and has a clear boundary between the skin material-attached portion and the non-adhered portion can be obtained.
In addition, when the small groove is provided in the mold, the skin material peripheral terminal folded into the concave portion partially penetrates to the back surface of the base resin, and as shown in FIG. A protrusion corresponding to this small groove is formed on the back surface of the molded body, and the skin material peripheral portion folded into the small groove in this protrusion is fixed with resin, so that the skin material sticking portion and the non-sticking portion are more A clearly identified multilayer molding is obtained.
Further, when a continuous projection corresponding to the small groove is provided on the mold surface facing the mold provided with the concave portion and the small groove, the outer periphery of the skin material and the non-sticking of the skin material are provided. Due to the groove (13) formed at the boundary with the base resin surface, a multilayer molded body with a more clear boundary between the skin material-attached portion and the non-adhered portion can be obtained.
Further, when the concave portion is provided on the mold surface along the entire periphery of the skin material, the skin material peripheral terminal continuously penetrates to the back surface of the base resin along the peripheral portion, and the terminal is The separated base resin layers on the skin material side and the non-skin material side are firmly bonded (fused) to the skin material peripheral edge, respectively, and a multilayer molded body bonded through this bonding is obtained. In this case, the boundary between the skin material sticking portion and the skin material non-sticking portion is extremely clear.
In this method, the partial application of the skin material means not only the case where the skin material is partially applied at one place, but also a plurality of independent application portions each having a sea-island pattern on the surface of the base material. It may be provided, and in this case, the skin material of each sticking part may be different, and in any case, these multilayer molded articles can be manufactured in exactly the same manner as the above method.
[0022]
The above method is a production example of a multilayer molded body to which the skin material 4 is partially adhered, but by using the mold of the present invention, the skin material 4 is partially applied to the base material surface according to the above method. , And a multi-layer molded body in which another skin material 4-2 is adhered to the entire surface of the other base material.
An example of producing such a multilayer molded article will be described below.
In this case, a step of placing the skin material 4-2 is added between the second step and the third step in the above method, and a step of separating the covered skin material 4-2 covering the skin material 4 as a final step is included. Added and shown in the following steps.
The first step and the second step are exactly the same as described above.
After the second step, the skin material 4-2 is placed on the entire surface of the mold while covering the skin material 4 as a third step (FIG. 14).
The fourth and fifth steps are exactly the same as the third and fourth steps described above, respectively. (FIGS. 15 and 16)
As a sixth step, the skin material 4-2 covering the skin material 4 is cut off from the removed molded body along the periphery of the skin material 4. (FIG. 17)
[0023]
Here, the skin material 4-2 in the third step may be the same as the skin material 4, but usually a skin material different from the skin material 4 is used.
When placing the skin material 4-2 on the mold surface in this step, the end of the skin material 4-2 may be held by a clamp or the like provided on the outer periphery of the mold, or a clamp may be provided. Instead, it may be held on the parting surfaces of the male and female molds at the time of mold clamping, and a normal method is employed.
The method for supplying the molten resin in the fourth step is exactly the same as described above, and it is necessary to supply the molten resin from at least the molten resin supply path that opens in the bonding portion of the skin material 4 on the mold surface. Therefore, even if the molten resin is supplied only from the molten resin supply path that opens into the bonding portion of the skin material 4-2, a desired multilayer molded body cannot be obtained.
After completion of the fifth step, the molded body is adhered to the base resin except for the skin material 4 while covering the upper surface of the skin material 4 without attaching the skin material 4-2 to the skin material 4, The apparent shape is a state in which the skin material 4-2 is adhered to the entire surface of the base resin.
The sixth step is a step of separating the skin material 4-2 covering the upper surface of the skin material 4 from such a molded body along the periphery of the skin material 4.
In this case, a mold is used in which a small groove is provided on the mold surface along the periphery of the skin material 4 and a continuous projection corresponding to the small groove is provided on the mold surface facing the mold. In this case, since a groove is formed on the periphery of the skin material 4 of the obtained molded body, it is very easy to cut off the skin material 4-2 along the groove.
[0024]
By this method, it is possible to manufacture a multilayer molded body in which the skin material 4 is partially adhered to the surface of the base material and the other skin material 4-2 is adhered to the entire surface of the other substrate surface. However, also in this case, the skin material 4 and the skin material 4-2 may be the same or different from each other as described above, and only when the skin material 4 is partially adhered at one place. Alternatively, a plurality of portions may be provided independently of each other, and the skin material 4 may be different at this time.
[0025]
In the method for producing such a multilayer molded body, as the thermoplastic resin used for forming the base material, a thermoplastic resin, a thermoplastic elastomer or the like usually used in press molding, injection molding, extrusion molding, or the like is used as it is. Applicable, for example, polypropylene, polyethylene, acrylonitrile-styrene-butadiene block copolymer, polystyrene, polyvinyl chloride, polycarbonate, acrylic resin, polyacrylate or its copolymer, styrene-butadiene block copolymer, polyamide such as nylon, etc. Thermoplastic resins, thermoplastic elastomers such as EPM and EPDM, mixtures thereof, and polymer alloys using them, and these may be foamable or non-foamable.
In addition, these thermoplastic resins may contain a glass fiber, a carbon fiber, various reinforcing fibers such as organic fibers, and fillers such as various organic or inorganic fillers, if necessary. Of course, various additives such as various commonly used stabilizers, pigments, lubricants, antistatic agents and the like may be blended.
[0026]
Examples of the skin material applied to this method include various woven fabrics, knitted fabrics, nonwoven fabrics and sheets or films of a thermoplastic resin or a thermoplastic elastomer, and various types of conventionally used skin materials such as meshes. Is not particularly limited.
The surface of the skin material may be decorated with an uneven pattern such as a grain, printing, dyeing, or the like according to the purpose.
In addition, each of these skin materials can be used alone as well as a composite skin material obtained by laminating two or more kinds with an adhesive or heat fusion, and particularly, a backing of a foam sheet such as a polypropylene foam sheet. A thermoplastic elastomer sheet such as a polyvinyl chloride sheet or EPDM is preferably used.
These skin materials are often used in the form of a sheet, but may be used by preheating the skin material for the purpose of improving the adhesiveness between the skin material and the thermoplastic resin.
[0027]
【The invention's effect】
By using the molding die of the present invention to produce a multilayer molded product in which the skin material is partially adhered by the method of the present invention, the skin material partially placed in the mold is displaced. It is possible to manufacture a multilayer molded body in which the skin material is accurately adhered to a predetermined position without causing any rise, and in which the boundary between the skin material affixing portion and the non-sticking portion is clear.
[0028]
【Example】
Hereinafter, the present invention will be described in more detail with reference to Examples, but it goes without saying that the present invention is not limited thereto.
[0029]
Example 1
The opening has a rectangular recess (5) (length: 20 mm, width: 40 mm, depth: 25 mm) at a position corresponding to the periphery of the skin material, and is located at a position corresponding to the entire circumference of the periphery of the skin material. Male and female comprising a male mold (2) having a small groove (width: 5 mm, depth: 7 mm) and a female mold (1) having continuous projections (width: 2 mm, height: 6 mm) corresponding to the small groove. Using both molds (FIGS. 1 and 2), a multilayer molded body having a skin material partially adhered thereto was produced by the following method.
As shown in the figure, the skin material (4) (thickness: 0, 1) cut so as to have a clip margin (17-1, 17-2) so that the peripheral edge of the skin material can be inserted into the concave portion and the small groove. A composite skin material in which a polypropylene foam sheet having a foaming ratio of 15 and a thickness of 3 mm is laminated on the back surface of a 6 mm grained polyvinyl chloride sheet, and the metal mold of a male mold is placed so that the foam layer side is the mold surface side. It was placed at a predetermined position on the mold surface, and the clip margin was bent and inserted into the concave and small grooves.
At this time, the pinch margin folded into the small groove has a width (fold length) of 5 mm, the pinch margin folded into the concave portion has the same 20 mm width as the length of the opening of the concave portion, and the folded length is the same as that of the concave portion. It was 25 mm, the same as the depth.
Next, an insert block (6) having a length of 20 mm, a width of 38.5 mm, and a height of 25 mm corresponding to the space shape of the concave portion is fitted into the concave portion, and a gap between the outer peripheral wall of the insert block and the inner peripheral wall of the skin material of the concave portion ( (Clearing: 1.5 mm) to clamp the pinching allowance and fix the skin material.
The mold clamping device is operated to stop the mold when the clearance between the male and female molds becomes 30 mm. At this stop position, the molten resin supply opening into the skin material attaching portion on the mold surface of the male mold. A 200 ° C. molten polypropylene (Sumitomo Noblen BPZ5077: manufactured by Sumitomo Chemical Co., Ltd.) was supplied from a molten resin supply passage opening to the road and the skin material non-sticking portion of the mold surface.
At this time, the supply ratio of the molten polypropylene supplied from both supply paths is set to be 20% larger than the amount of the base resin at the skin material attaching portion from the former supply path and a predetermined amount from the latter molten resin supply path. This amount was subtracted from the total resin amount.
After supplying the resin, the mold clamping device is operated again to resume mold clamping, pressurizing and clamping so that the cavity clearance becomes the desired final product thickness of 5 mm, cooling while keeping the pressure, and then opening the mold. The multilayer molded body to which the skin material was partially adhered was taken out.
In the obtained multilayer molded body, the skin material is accurately stuck at a predetermined position without causing displacement, and the boundary portion between the skin material stuck portion and the base material surface (the skin material non-stuck portion). A small groove was formed in which the peripheral edge of the skin material was embedded in the resin, and the boundary between the two was identified by the groove and was very clear and had a good appearance.
[0030]
Comparative Example 1
Without providing a concave portion, using a male mold provided with only a small groove, the skin material was partially formed in the same manner as in Example 1 except that the clip margin of the skin material peripheral edge was bent and inserted only in the small groove. The laminated multilayer molded body was manufactured.
In the obtained multilayer molded body, the skin material is displaced, and the skin layer forming portion is pushed into the formed groove, a portion composed only of resin is mixed, and the skin material peripheral terminal is partially It had jumped out to the substrate surface.
Although this production example was repeated, the position where the skin material was adhered was different each time, and a multilayer molded body could not be stably obtained.
[0031]
Example 2
Using the same mold as in Example 1, a multilayer molded body having the entire surface of the base material stuck with two kinds of skin materials was produced according to the following method according to Example 1.
However, the width of the small groove provided on the mold surface of the male mold was 6 mm, and the width of the insert block was changed to 37.5 mm.
A skin material (4) cut so as to have a clip margin (17-1, 17-2) so that the skin material peripheral end can be inserted into the concave portion and the small groove (on the back surface of a 2 mm thick polyester fabric, A composite skin material obtained by laminating a polypropylene foam sheet having a foaming ratio of 15 times and a thickness of 3 mm) is placed at a predetermined position on the mold surface of the male mold so that the foam layer side is the mold surface side, and the concave portion is formed. And the pinch margin was bent and inserted into the small groove.
At this time, the width of the pinch folded into the small groove is 5 mm, the width of the pinch folded into the concave portion is 20 mm, which is the same as the length of the opening of the concave portion, and the folded length is 25 mm, which is the same as the depth of the concave portion. there were.
Next, the insert block (6) is fitted into the concave portion, and a gap (clearance: 2.5 mm) between the outer peripheral wall of the insert block and the inner peripheral wall of the concave portion of the concave portion is clamped to fix the skin material (4). did.
Then, a skin material (4-2) (a composite skin material in which a 3 mm thick polypropylene foam sheet with a foaming ratio of 15 times laminated on the back surface of a 0.6 mm thick grained polyvinyl chloride sheet) was used. It was placed so as to cover the entire surface of the mold while covering the skin material (4) so as to be on the mold surface side.
Thereafter, supply of molten polypropylene (same as in Example 1), mold clamping, and cooling were performed in the same manner as in Example 1 to obtain a molded body entirely covered with the skin material (4-2).
Thereafter, the skin material (4-2) overlapping the upper surface of the skin material (4) was cut by a cutter along a groove formed on the peripheral edge of the skin material (4).
In the obtained multilayer molded article, the surface of the base material is entirely adhered with the skin material (4) and the skin material (4-2), and the skin material (4) is in a predetermined shape without any displacement. And the periphery of the skin material (4) fits neatly in the formed groove, and the skin material (4) and the skin material (4-2) are bounded by the groove. ) Was clearly identified and had a good appearance.
[0032]
Comparative Example 2
A male mold having only a small groove was used without providing a concave portion, and the same procedure as in Example 2 was performed except that the pinching margin (17-2) of the skin material (4) peripheral edge was bent and inserted only in the small groove. Thus, a two-color multilayer molded product in which the surface of the base material was adhered with the skin material (4) and the skin material (4-2) was produced.
In the obtained multilayer molded body, the displacement of the skin material (4) was severe, and the skin material (4) protruded outside the formed groove, or the skin material (4-2) was stuck to the inside of the groove. Had been.
Although this production example was repeated, the position where the skin material (4) was adhered and the state of adhesion were different each time, and a multilayer molded body could not be stably obtained.
[0033]
Example 3
Two pins having a length of 3 mm are provided on the back surface, and an insert block whose height including the height of the pins is the same as the depth of the concave portion on the mold surface is used. In the same manner as in Example 1 except that the peripheral edge of the skin material was fixed by inserting a pin on the back surface of the insert block, a multilayer molded body to which the skin material was partially adhered was obtained.
The obtained multilayer molded article had no displacement of the skin material at all, and similarly to the multilayer molded article obtained in Example 1, the boundary between the skin material-attached portion and the non-adhered part was very clear, and the appearance was very high. It was good.
[0034]
Example 4
The mold and the insert block are integrated by a sliding shaft provided in the mold so that the mold and the insert block penetrate the bottom of the recess and slide freely in the opening and closing direction of the mold, and each insert block operates simultaneously. A multi-layer molded article having a skin material partially adhered was obtained in the same manner as in Example 1 except that a mold apparatus in which the operation of the sliding shaft was adjusted was used.
In the case of this method, the trouble of individually fitting the insert blocks is omitted, and the obtained multilayer molded body has no misalignment and good appearance as in the case of Example 1. there were.
[Brief description of the drawings]
FIG. 1 is a schematic cross-sectional view of a mold surface of a molding die of the present invention.
FIG. 2 is a plan view of a mold surface shown in FIG.
FIG. 3 is a perspective view showing an example of a multilayer molded article produced by the method of the present invention.
FIG. 4 is a diagram showing a state in which a skin material peripheral end is sandwiched and fixed by an insert block and a mold recess in a mold according to the present invention.
FIG. 5 shows a state where fitting and disengaging of an insert block are performed using a sliding shaft in the mold of the present invention.
FIG. 6 shows the insert block having a notch according to the present invention, and a state in which a skin material peripheral end is sandwiched and fixed between the insert block and a notch having a notch.
FIG. 7 shows a state in a mold between mold recesses after completion of molding of a multilayer molded body in the method of the present invention.
FIG. 8 shows a state of a portion where a small groove and a projection are provided on a mold surface after completion of molding of a multilayer molded body in the method of the present invention.
FIG. 9 is a schematic view of a mold section showing a manufacturing process of the present invention.
FIG. 10 is a schematic view of a mold section showing a manufacturing process of the present invention.
FIG. 11 is a schematic view of a mold section showing a manufacturing process of the present invention.
FIG. 12 is a schematic view of a mold section showing a manufacturing process of the present invention.
FIG. 13 shows a cut state of a skin material applied to the method of the present invention.
FIG. 14 is a schematic view of a mold section showing a manufacturing process of the present invention.
FIG. 15 is a schematic view of a mold section showing a manufacturing process of the present invention.
FIG. 16 is a schematic view of a mold section showing a manufacturing process of the present invention.
FIG. 17 shows a state in which a multilayered molded body obtained by the method of the present invention is taken out of a mold, and then an overlapping skin material portion is cut off.
[Explanation of symbols]
1: Female mold
2: Male mold
3: molten resin supply path
4, 4-2: skin material
5: recess
6: Insert block
7: Inner wall of the skin material peripheral side of the concave portion
8: Outer peripheral surface of the skin material of INART Nuloc
9: sliding shaft
10: Small groove
11: Notch
12: protrusion
13: groove
14: Skin material fixing projection
15: Molten resin
16: base resin

Claims (4)

A molding die consisting of a pair of male and female for manufacturing a multilayer molded body in which a skin material is partially adhered to the surface of a base material made of a thermoplastic resin, and in a skin material affixing portion on a mold surface. It has a molten resin supply path that opens, and has at least one recess in which a part or all of the peripheral edge of the skin material can be inserted at a part or all of the position corresponding to the peripheral part of the skin material to be attached. Either the male or female mold surface and the skin material peripheral terminal inserted into the concave portion are sandwiched between the concave portion inner wall, and are fixed and fitted into the concave portion so as to form a uniform mold surface. A mold for forming a multilayer molded article, comprising: an insert block. The mold for forming a multilayer molded article according to claim 1, wherein a continuous or discontinuous band-shaped projection is provided on a mold surface at a position corresponding to the small groove of the mold facing the mold having the small groove. A method for producing a multilayer molded article in which a skin material is partially adhered to a surface of a substrate made of a thermoplastic resin, using the mold apparatus for molding a multilayer molded article according to claim 1,
(1) A step of placing the skin material cut into a predetermined shape at a predetermined position on the mold surface and folding the peripheral edge of the skin material into a concave portion provided on the mold surface. (2) Fitting the insert block into the concave portion, (3) At least a step of supplying a molten resin between the skin material and the mold surface from a molten resin supply path that opens into a skin material attachment portion of the mold surface (4). ) Multi-layer molding in which the skin material is partially adhered to the surface of the base material, comprising the steps of pressurizing until the predetermined cavity clearance is reached, clamping the mold, cooling, and removing the molded body from the mold. How to make the body. 4. The method for producing a multilayer molded body according to claim 3, wherein the cut surface material is provided by providing a folding allowance in a concave portion provided on a mold surface.

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