WO2013111680A1 - Method for manufacturing resin molding with skin - Google Patents

Description

Manufacturing method of resin molded product with skin

The present invention relates to a method for producing a resin molded product with a skin.

Conventionally, a plate-like resin molded product is known as a door trim attached to the inner side of an inner panel of a vehicle door. The resin molded article generally has a base material made of a synthetic resin having rigidity for holding a shape and for mounting. A skin for enhancing the design is pasted on the surface of the substrate. A plurality of skins with different materials or patterns can be provided to enhance decorativeness. Grooves may be formed at boundaries between the plurality of skins. The edge of each skin is inserted into the groove and extends to the back side of the substrate, and the edge of the skin is processed. Accordingly, the pattern or color is divided by the groove, and the appearance of the resin molded product can have a three-dimensional effect as a whole.

JP-A-2002-240561 discloses a method for producing a resin molded product. In the manufacturing method, a molten synthetic resin material is filled in a mold. At the time of mold clamping, the base material is molded with a synthetic resin material and the skin is integrated on the surface of the base material. When a plurality of skins are used, a base material for each skin is prepared. Each epidermis is affixed to each substrate, the end of the epidermis is extended to the back side, and the edge is processed. A plurality of plate-shaped resin molded products are assembled into a finished product. Thereby, the resin molded product may have a groove at the boundary between the plurality of skins.

Therefore, in the above manufacturing method, it is necessary to manufacture a resin molded product for each skin and assemble a plurality of resin molded products. Therefore, there is a concern about an increase in manufacturing cost. When the strength reduction of the connecting portion of the resin molded product is expected, a reinforcing member is required. Therefore, there is a concern about an increase in the number of parts. There is also concern about the generation of low sound due to the fact that resin molded products rub against each other due to vehicle vibration.

JP-A-5-16163 discloses a method for producing a resin molded product in which a plurality of skins are integrated on a substrate surface. In this method, the second skin is partially overlapped on the first skin covering substantially the entire surface of the substrate, and these are disposed between the molds. The second skin is formed of a material different from that of the first skin and has an outer shape along the groove. A groove convex portion is formed on one side of the mold, and a concave portion corresponding to the convex portion is formed on the other side. During mold clamping, the synthetic resin material is molded while the convex portion inserts the edges of the first skin and the second skin into the concave portion.

In the above method, the first epidermis and the second epidermis are overlapped. Therefore, there is a concern that the yield rate is bad or the weight is increased. The first skin and the second skin are cut on a plane. However, the resin molded product may have a deep-drawn portion, for example, a portion having a shape with a large curvature or a shape with a large undulation such as a door trim. There are many requests to arrange a plurality of skins in a deeply drawn portion.

When the skin is arranged at the deep-drawn part and integrally molded, the skin can be pulled. As a result, the superposed skin is relatively displaced. Or the epidermis may wrinkle. Alternatively, the deep-drawn portion can be thinned by extending the skin as compared to other flat portions. Many of the surface of the skin are given a texture that gives a texture of pear or leather as a design. When the skin is stretched, the wrinkles become shallow and the design properties can be impaired. Concerns of skin slippage or thinning of the skin tend to become more prominent when having multiple skins.

Conventionally, there is a need for a method for producing a resin molded product that can form a base material while integrating a plurality of skins, and suppress the elongation of the skins while suppressing relative displacement of the skins.

According to one characteristic of the present invention, the method for producing a resin-molded article with a skin has the following steps. A plurality of skins are draped along the shape of the resin molded product. The ends of the plurality of skins are integrally and three-dimensionally connected so that the surfaces face each other. A skin is placed between the first mold and the second mold for molding the resin molded product. A 1st shaping | molding die and a 2nd shaping | molding die are made to adjoin, and the connection part of an outer skin is pushed in into the recessed strip part of a 2nd shaping | molding die with the protruding strip part of a 1st shaping | molding die. A plurality of skins are integrated on the surface of the base material while forming the base material with a synthetic resin material filled between the skin and the second mold.

Therefore, multiple skins are integrated on the surface of the substrate. Therefore, increase in manufacturing cost and assembly cost can be suppressed. Since a base material is not a plurality of components, it does not have a portion for connecting a resin molded product for each skin as in the prior art. Therefore, it can suppress that intensity | strength falls by a connection part, or can suppress the increase in a number of parts. Or generation | occurrence | production of the low sound accompanying the rubbing between each resin molded product etc. can be suppressed.

The ends of a plurality of adjacent skins are integrally and three-dimensionally connected so that their surfaces are opposed to each other. Therefore, a decrease in yield rate or an increase in weight can be suppressed as compared with a conventional configuration in which the entire skin is overlapped. The skin is three-dimensionally cut along the surface shape of the resin molded product, and is integrally and three-dimensionally connected. As a result, the plurality of skins have a shape close to the final shape of the finished resin molded product. As a result, the elongation or wrinkle of the skin is suppressed and the appearance of the resin molded product is improved.

The three-dimensional connecting portion of the skin is pushed into the concave part of the second mold by the convex part of the first mold (holding structure). The holding structure forms a groove at the boundary of each epidermis. Therefore, even when the skin is disposed in the deep-drawn portion of the base material, the relative displacement or wrinkle of each skin is suppressed by the formation of the groove of the pressing structure and the draping of the skin. As a result, the resin molded product can have a smooth surface shape.

In the method of manufacturing a resin molded product, a mold is filled with a synthetic resin material and clamped. The base material is molded from the synthetic resin material by clamping, and the skin is integrated on the base material surface. Even when a plurality of skins are integrally formed on the surface of the substrate, the elongation of the skins can be suppressed while the relative displacement between the skins is suppressed.

According to another aspect of the present invention, the first molding die is positioned by the positioning member of the first molding die so that the connecting portion is located between the convex strip portion of the first molding die and the concave strip portion of the second molding die. And between the second mold. Thereby, the relative position shift between each epidermis can be suppressed further.

It is a front view from the vehicle inner side of the door trim manufactured with the method of this invention. FIG. 2 is a sectional view taken along the line II-II in FIG. 1. It is explanatory drawing which shows the process of setting the skin of a door trim to a shaping | molding die. FIG. 4 is a view taken along the line IV-IV in FIG. 3. It is explanatory drawing which shows the process of filling the molding resin with the synthetic resin for base materials of a door trim. It is explanatory drawing which shows the shaping | molding middle process by the shaping | molding die of a door trim. It is explanatory drawing which shows the shaping | molding process by the shaping | molding die of a door trim.

One embodiment of the present invention will be described with reference to FIGS. The resin molded product with a skin is, for example, a door trim 10. The door trim 10 is a plate-shaped resin molded product as shown in FIGS. 1 and 2 and is attached so as to cover the inner side of an inner panel (not shown) of a vehicle door. An armrest portion 14 that protrudes greatly in the thickness direction is integrally formed in a substantially middle region in the vertical direction of the door trim 10. The armrest portion 14 has a deep drawing shape partially in the cross-sectional view of FIG. The deep drawing shape has a surface with a large curvature, a small radius of curvature, or a large undulation.

The door trim 10 has a base material 20 made of a synthetic resin such as polypropylene having a shape or rigidity for mounting as shown in FIGS. The base material 20 is molded so as to have a substantially constant wall thickness. The base material surface 20a is covered with a flexible epidermis (a plurality of epidermis) 30 in order to enhance design properties. The door trim 10 has a plurality of grooves 12 in the lateral direction (vehicle longitudinal direction) and the longitudinal direction (vehicle vertical direction).

The groove 12 is recessed in the thickness direction of the door trim 10 between the skin bodies 30. The end of each epidermis 30 is fitted into the groove 12, and the end edge of each epidermis 30 is processed. In order to enhance the decorativeness of the door trim 10, the epidermis 30 may have different materials, colors, patterns, etc., with the groove 12 as a boundary. The door trim 10 is divided into patterns or colors depending on the combination of different skins. Thereby, the door trim 10 obtains a three-dimensional feeling or texture as a whole.

Each epidermis 30 can be formed of various materials. For example, the epidermis 30 may have a laminated structure including a front surface layer and a back surface layer. The surface layer is formed from polyvinyl chloride (PVC), thermoplastic olefin (TPO) or the like. The back layer is formed from a cushioning material such as polyethylene foam or polypropylene foam. Thereby, the epidermis 30 can have a good touch feeling and can be flexible.

The epidermis 30 includes a plurality of epidermis, and includes, for example, five sheets of a first epidermis 31, a second epidermis 32, a third epidermis 33, a fourth epidermis 34, and a fifth epidermis 35. The first skin 31 to the fifth skin 35 are cut into a shape obtained by developing the surface shape of the position where each door trim 10 is disposed (three-dimensional cutting). In the first skin 31 to the fifth skin 35, adjacent skins are three-dimensionally connected in advance.

As shown in FIG. 2, the surface end portion 31a of the first skin 31 adjacent to the groove 12 and the surface end portion 32a of the second skin 32 are overlapped. The overlapping portion is sewn three-dimensionally (joint stitching) to form an integral and three-dimensional connection portion 36. Thereby, the skin 30 has a three-dimensional shape close to the final shape of the finished door trim 10. The connection part 36 protrudes from the back surface 30 b of the epidermis 30. A trough-shaped groove portion 37 is formed on the surface 30 a of the epidermis 30.

The molding die for molding the door trim 10 includes a first molding die 40, a second molding die 50, and positioning pins (positioning members) 80 as shown in FIG. The first mold 40 is used to mold the surface 10a (see FIG. 2) of the door trim 10. The second mold 50 is used to mold the back surface 10b (see FIG. 2) of the door trim 10. The positioning pin 80 is disposed between the first molding die 40 and the second molding die 50 to position and hold the epidermis 30.

The second mold 50 is a fixed mold. The 2nd shaping | molding die 50 has the back surface molding surface 52 which bulged corresponding to the back surface 10b of the door trim 10 in the whole upper surface. The back molding surface 52 has a flat portion 54 and a deep-drawn portion 56 that forms the armrest portion 14 continuously.

The first mold 40 is disposed above the second mold 50. The first mold 40 is a movable mold that is connected to an elevating mechanism 41 and is moved up and down. The first molding die 40 has a surface molding surface 42 which is recessed corresponding to the surface 10 a of the door trim 10 on the entire lower surface. The front surface molding surface 42 has a shape corresponding to the back surface molding surface 52 of the second mold 50. The front surface molding surface 42 has a flat portion 44 and a deep drawing shape portion 46 corresponding to the flat portion 54 and the deep drawing shape portion 56 of the back surface forming surface 52.

The surface molding surface 42 of the first mold 40 has a ridge 48 that protrudes downward. The ridge 48 is formed corresponding to the groove 12 (see FIGS. 1 and 2). The back molding surface 52 of the second mold 50 has a concave stripe portion 58 corresponding to the convex stripe portion 48. The protruding portion 48 pushes the connecting portion 36 of the epidermis 30 into the recessed portion 58, and the synthetic resin flows into the mold. The concave portion 58 has a depth for integrating the connecting portion 36 of the epidermis 30 and the synthetic resin.

A plurality of resin supply ports 60 for filling the molten synthetic resin material 90 (see FIG. 5) are opened on the back surface 52 of the second mold 50. Each resin supply port 60 is disposed at a position where it does not interfere with the ridge 48 on the back molding surface 52. Each resin supply port 60 communicates with the resin injection device 70 through the resin supply passage 62 in the second mold 50. The resin supply passage 62 is provided with an open / close valve (not shown). The on-off valve has an adjusting mechanism capable of filling the back surface molding surface 52 with an appropriate amount of the molten synthetic resin material 90 supplied from the resin injection device 70 at an appropriate time.

3 and 4, positioning pins 80 are formed on the outer periphery of the surface molding surface 42 of the first molding die 40. The positioning pin 80 holds the skin 30 when the skin 30 is disposed between the first mold 40 and the second mold 50. Thereby, the three-dimensional connection part 36 of the outer skin 30 can be installed between the convex part 48 of the 1st shaping | molding die 40, and the concave part 58 of the 2nd shaping | molding die 50. FIG. An engagement hole 38 h corresponding to the positioning pin 80 is provided in the part external position 38 of the skin 30. The positioning pin 80 is inserted into the engagement hole 38h, and the skin 30 is disposed at a normal position between the first mold 40 and the second mold 50.

The positioning pins 80 are arranged on the entire outer periphery of the epidermis 30. A positioning pin 80 is set for each end portion of each skin so that the three-dimensional connecting portion 36 is properly pushed into the groove 12. Since the skin is draped, the skin before clamping is bent. Therefore, if the outer peripheral portion of the skin is simply suppressed, the connecting portion of the skin may move from the ridge 48 and the ridge 58 for forming the groove 12. On the other hand, the positioning pin 80 is set for each end portion of each skin, and each skin can be reliably restrained.

When the door trim 10 is molded, first, as shown in FIGS. 3 and 4, the first molding die 40 and the second molding die 50 are placed in an open state in which they are spaced apart from each other. The positioning pin 80 is inserted into the engagement hole 38h of the skin 30 and the skin 30 is set in a mold.

Next, as shown in FIG. 5, the lifting mechanism 41 is operated to lower the first mold 40. At this time, the resin injection device 70 provided in the second mold 50 injects the molten synthetic resin material 90. As a result, the synthetic resin material 90 flows out from each resin supply port 60 through the resin supply passage 62 and is filled on the back surface molding surface 52 of the second mold 50.

As shown in FIG. 6, the first mold 40 is lowered by the lifting mechanism 41 and the two molds approach each other. Thereby, the protrusion 48 of the 1st shaping | molding die 40 fits into the trough-shaped groove part 37 of the skin body 30, and each skin is positioned.

As shown in FIG. 7, the epidermis 30 sandwiched between the front molding surface 42 and the rear molding surface 52 by pressing in the thickness direction (pressure molding) accompanying the clamping of the first molding die 40 and the second molding die 50. And the synthetic resin material 90 are molded into the shapes of the molding surfaces 42 and 52. At this time, the three-dimensional connection portion 36 of the epidermis 30 is pushed into the concave strip 58 of the second mold 50. The clamped state of the first mold 40 and the second mold 50 is maintained for a certain time, and the synthetic resin material 90 in the molten state is cooled and cured.

The epidermis 30 is integrated with the base material surface 20a of the base material 20 formed of the synthetic resin material 90. At the same time, the three-dimensional connecting portion 36 is integrated with the synthetic resin material 90 while being pushed into the concave portion 58 of the second mold 50. Thereby, the groove | channel 12 (refer FIG. 1, 2) is formed in the boundary part of each epidermis of the epidermis 30. FIG.

2 and 7, the base material 20 is molded from the synthetic resin material 90 and the epidermis 30 is integrated with the base material surface 20a. The edge part of the epidermis body 30 arrange | positioned at the outer peripheral edge part of the base material 20 plunges into the back surface side, and edge processing is carried out by heat welding. Thereby, the door trim 10 is formed. The edge processing may be ultrasonic bonding or bonding instead of the above method.

As described above, in the method of manufacturing the door trim 10, the epidermis 30 is integrated with the base material surface 20a. Therefore, an increase in manufacturing cost can be suppressed. The base material 20 of the door trim 10 does not have a plurality of parts. Therefore, since there is no portion for connecting a plurality of components, it is possible to suppress a decrease in strength and an increase in the number of components. The generation of low sound due to rubbing between the resin molded products can be suppressed.

The skin body 30 has a configuration in which the surfaces of a plurality of skin end portions adjacent to each other in the groove 12 are integrally and three-dimensionally connected. Therefore, it is possible to suppress a decrease in yield rate and an increase in weight compared to a conventional configuration in which the entire skin is overlapped.

Each skin of the heel skin 30 is cut three-dimensionally along the surface shape of the door trim 10. The edge part of a several adjacent skin has the three-dimensional connection site | part 36 connected so that the surface might mutually oppose. Thereby, the outer skin 30 becomes a shape close to the final shape of the finished door trim 10. As a result, the elongation or wrinkle of the epidermis 30 is suppressed, and the appearance shape is improved.

The three-dimensional connection portion 36 of each skin is pushed into the concave portion 58 of the second molding die 50 by the convex portion 48 of the first molding die 40 (pressing structure). The pressing structure forms a groove 12 at the boundary of each skin. Therefore, even when the skin is disposed in the deep-drawn portion of the base material 20, the relative displacement or wrinkle of each skin is suppressed by the formation of the groove 12 of the pressing structure and the three-dimensional cutting of the skin. As a result, the door trim 10 can have a smooth surface shape.

In the manufacturing method of the door trim 10, the mold is clamped by filling the molten synthetic resin material 90 in the mold. The base material 20 is molded from the synthetic resin material 90 by mold clamping, and the skin is integrated with the base material surface 20a. Even when a plurality of skins are integrally formed on the substrate surface 20a, the elongation of the skins can be suppressed while the relative displacement between the skins is suppressed.

The mold includes a positioning pin 80 (positioning member). The positioning pin 80 holds the skin 30 when the skin 30 is disposed between the first mold 40 and the second mold 50. As a result, the connecting portion 36 of the epidermis 30 can be positioned between the ridges 48 of the first mold 40 and the ridges 58 of the second mold 50. Therefore, the relative position shift between each epidermis can be further suppressed.

Although the embodiments of the present invention have been described with reference to the above structure, it will be apparent to those skilled in the art that many substitutions, improvements, and changes can be made without departing from the object of the present invention. Accordingly, aspects of the invention may include all alterations, modifications, and changes that do not depart from the spirit and scope of the appended claims. For example, the form of the present invention is not limited to the special structure, and can be modified as follows.

For example, the surface layer of the epidermis may be made of materials other than those described above, for example, synthetic leather, artificial leather, woven fabric, non-woven fabric, cloth members such as brushed fabric, and genuine leather.

The plurality of epidermis may be connected at the three-dimensional connecting portion 36 so as to be integrally and three-dimensionally connected as described above, or may be connected at another connecting portion. The above-mentioned connection part 36 is formed by sewing in three dimensions. The sewing method may be seam stitching or other methods such as double stitching and single stitching. For the other connecting portions, thermal welding, an adhesive, ultrasonic welding, or the like that three-dimensionally connects the ends of the plurality of skins can be applied.

As described above, the mold may include the first mold 40 that is a movable mold and the second mold 50 that is a fixed mold, or the first mold that is a fixed mold and the first mold that is a movable mold. You may have 2 molds.

Claims (2)

A method for producing a resin molded product with a skin,
Three-dimensionally cut a plurality of skins along the shape of the resin molded product,
Integrally and three-dimensionally connecting the ends of the plurality of epidermis so that the surfaces face each other,
Placing the skin between a first mold and a second mold for molding the resin molded product,
The first mold and the second mold are brought close to each other, and the connecting portion of the skin is pushed into the concave portion of the second mold by the convex portion of the first mold.
A method for producing a resin-molded article with a skin, in which a plurality of skins are integrated with a surface of the base material while forming the base material with a synthetic resin material filled between the skin and the second mold. A method for producing a resin-molded article with a skin according to claim 1,
The skin is placed on the first mold by the positioning member of the first mold so that the connecting portion is located between the convex section of the first mold and the concave section of the second mold. A method for producing a resin-molded article with a skin installed between the second molds.

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