JPS58119818A - Method of molding resin item with skin material - Google Patents

Abstract

PURPOSE:To obtain efficiently the title item good in quality, by mounting a core material on a vacuum forming mold, placing a softened skin material on said core material, subjecting them to vacuum forming so that they are firmly joined, and welding the required sections by ultrasonic welding with them being in the drawn state. CONSTITUTION:The core material 1 that has been previously molded to have pieced holes is mounted on the vacuum forming mold 2, then the skin material 4 (e.g. one having a double structure that includes a vinyl chloride skin and a foamed sheet) that has been softened by a heater 5 is placed thereon, and vacuum is applied to bring them into contact with each other to mold them. With the drawn state being kept, an ultrasonic welding machine 6 is lowered, and the required sections are welded by horns 7 to obtain the intended item. EFFECT:A receiving table for ultrasonic welding is not required and cost of equipments can also be reduced. USE:The method is useful for obtaining an instrument panel or the like with a skin material of automobiles.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides a method for molding a resin molded product in which the surface of an interior component such as an automobile instrument panel, door trim, dash board, etc. is covered with a skin material such as a cushioned foam sheet with a good feel. Conventionally, in the production of automobile instrument panels with skin materials, a foamed sheet as the skin material was first vacuum-formed into the desired shape, and then this was molded by injection molding etc. to make polypropylene. The core material is bonded using an adhesive such as adhesive or ultrasonic welding. However, vacuum-formed foam sheets shrink significantly and it is difficult to accurately control their dimensions, making it difficult to accurately set the foam sheet on top of the previous Ht core material, and the difference between the core material and the foam sheet. The current situation is that the adhesion is not working well. In particular, when there is an opening in the core material or foam sheet, a gap is created between the core material and the foam sheet at the edges of both openings.
Due to this gap, there was a drawback that the adhesion between the two was not successful. Furthermore, conventional ultrasonic welding requires a special pedestal for setting the core material, which has the disadvantage of increasing equipment costs and thereby increasing the cost of the product.

The present invention has been made in view of the above, and by making the vacuum molding die double as a pedestal for ultrasonic welding, it increases the productivity of resin molded products with a skin material, and
The object of the present invention is to provide a method for molding a resin molded product with a skin material that can reduce molding equipment costs.

The present invention will be explained in detail below based on embodiments shown in the drawings.

Reference numeral 1 denotes a core material injection molded by an injection molding machine (not shown), and the core material 1 is injection molded into a desired shape by well-known means. 2 is a vacuum molding mold having appropriate vacuum holes 3; 4 is a skin pad consisting of a skin made of, for example, vinyl chloride; and a foam layer integrally formed on the back side of the skin; 5 is a vacuum molding mold having appropriate vacuum holes 3; A heater for softening, 6 an ultrasonic welder, 7 a horn of the ultrasonic welder, and 8 a resin molded product with a skin material.

Next, the procedure for molding the resin molded product 8 with a skin material will be described. First, a core material 1 which has been injection molded in advance is placed in a vacuum acid mold 2.
set on top. During this setting, through holes 1' are formed at appropriate locations in the core material 1 so that the vacuum holes 3 are not blocked by the core material 1. After the core material 1 is set on the vacuum mold 2 in this way, the skin pad 4, which has been softened by the heater 5, is placed on the core material l, and then, before the skin pad 4 hardens, the skin pad 4 is placed on the core material 1. The vacuum hole 3 of the vacuum forming mold 2 is applied with negative pressure to form the skin pad 4 and the core material'.
1 and bring them into close contact. (See FIG. 4) Next, while maintaining the suction state from the vacuum hole 3, the ultrasonic welding machine 6 is lowered, and the necessary parts of the core material 1 and the skin pad 4 are welded using the horn 7. (If necessary, an appropriate adhesive may be applied to the welded part in advance.) After welding is completed in this way, if the mold is released, a plastic molded product as shown in Figure 6 will be obtained. be. Although the structure of the skin pad 4 in the above embodiment is described as having a two-layer structure of a vinyl chloride skin and a foam sheet, it may be a skin pad that has only a vinyl chloride skin without a foam layer.

As described above, in the present invention, the core material 1 molded by injection molding or the like is mounted on the vacuum mold 2, and then the core material 1 is
A resin molded product with a skin material, in which a skin material 4 is vacuum formed on top, and the core material IK and the skin material 4 are ultrasonically welded while the core material 1 is attached to the vacuum mold 2. Since this is a molding method, the skin material 4 is in close contact with the core material 1, and therefore the core material 1 and the skin material 4 are closely attached without creating a gap, resulting in a good resin molded product with a skin material. is obtained. Furthermore, according to the present invention, the vacuum forming mold can also be used as a pedestal during ultrasonic welding, which eliminates the need for a dedicated pedestal for ultrasonic welding, reducing equipment (equipment) costs. It also has the effect of making it possible. Furthermore, according to the present invention, the polymerized core material and the skin material can be ultrasonically welded without moving them from the vacuum molding die, which has the effect of improving productivity (workability).

[Brief explanation of the drawing]

The drawings all show embodiments of the present invention; Fig. 1 is a sectional view of only the core material, Fig. 2 is a sectional view of the core material set in a vacuum forming mold, and Fig. 3 is a sectional view of the core material set in a vacuum forming mold. An explanatory diagram showing the positioning of the skin pad, heater and ultrasonic welding machine on the mold,
FIG. 4 is a sectional view showing the vacuum suction operation, FIG. 5 is a sectional view showing the ultrasonic welding, and FIG. 6 is a sectional view of the plastic molded product. 1...Core material 1'...Through hole 2...Vacuum forming mold 3...Vacuum hole 4...Skin pad
5... Heater 6... Ultrasonic welding machine 7... Horn 8... Plastic molded product. Figure 1-83-

Claims (1)

[Claims] A core material (1) formed by a molding method such as injection molding is mounted on a vacuum mold (2), and a skin material (4) is vacuum-formed on the core material (1). 1) is attached to the vacuum molding mold (2)k, the core material (1)K and the skin material (
4) A method for molding a resin molded product with a skin material, characterized by t-ultrasonic welding.