JP4790552B2 - Method for producing slush molded skin material and slush mold - Google Patents

Description

  The present invention relates to a method for manufacturing a slush molding skin material and an improvement of a slush molding die used in the manufacturing method, and more particularly to measures for removing unnecessary portions from a molded slush skin material.

Generally, the slush mold is set in the raw material storage box with the outer peripheral edge of the mold molding surface abutting the opening edge of the raw material storage box, and the outer periphery is clamped by a clamp jig provided on the raw material storage box side. . The powder resin raw material in the raw material storage box adheres to the molding surface of the slush mold by the reversing operation of the raw material storage box in the vertical direction, and the adhered powder resin raw material is heated and melted by the mold temperature. A molten resin layer is formed, and the molten resin layer is cooled and hardened to form a slush-molded skin material on the entire molding surface. After the molded skin material is removed from the mold, unnecessary parts are removed to obtain a product. In order to make it easy to remove this unnecessary part, the projecting part with a triangular cross section is formed by integrally projecting along the entire outer periphery of the product shape part on the vertical surface part near the outer periphery of the mold forming surface. A thin portion is formed by a V-shaped notch at the boundary between the product portion and the unnecessary portion of the formed skin material (see, for example, Patent Document 1).
JP 63-165112 A

  However, as shown in FIG. 16, when a ridge portion d having a triangular cross section is provided on the vertical surface portion c near the outer peripheral edge of the slush mold a, the tip of the ridge portion d is inward of the mold. Therefore, while the molten resin layer e made of the powder resin raw material that has been supplied to the mold forming surface b of the slush mold a and adhered and melted is cured, the molten resin above the protrusions d is cured. The layer e hangs down toward the tip of the ridge d by the action of gravity, and a thick portion f of the molten resin layer e is formed at the tip of the ridge d, and it is difficult to remove unnecessary portions from the portion after cooling and hardening. Become. In particular, for example, when the skin material is a material that is difficult to shred, such as when the skin material is formed of a material having a high elongation rate, the difficulty of removal increases.

  The present invention has been made in view of such a point, and an object of the present invention is to easily and reliably remove unnecessary portions from a molded skin material.

  In order to achieve the above object, the present invention is characterized in that the protrusion and its direction are devised at the time of molding.

  Specifically, the invention described in claims 1 and 2 relates to a method for manufacturing a slush-molded skin material, of which the solution provided by the invention described in claim 1 is the product shape of the molding surface An outer projecting portion projecting outward from the mold is formed on the outer periphery of the portion, and a pair of first protrusions having a triangular cross section are formed on the outer surface of the outer projecting portion along the outer periphery of the product shape portion. The first ridges are provided with a second protrusion having a triangular cross-section that is integrally projected so as to be arranged in parallel in a close proximity, and whose protrusion is smaller than that of the first protrusion. The slush mold that is integrally projected so as to be parallel to the slush mold is heated, and then a powder resin raw material is supplied to the mold molding surface of the slush mold to be adhered and melted to form a molten resin layer, Cooling and curing the molten resin layer with the first and second protrusions facing down After molding the slush molding skin material Te, characterized by demolding the said surface skin material.

  The solution provided by the invention according to claim 2 is that an outer projecting portion projecting outward from the mold and an inner projecting portion projecting inward from the mold are respectively formed on the outer periphery of the product shape portion of the mold forming surface. A pair of first protrusions having a triangular cross section are integrally projected on the mold surface side of the outer overhanging portion so as to be juxtaposed in proximity to each other along the outer peripheral edge of the product shape portion. A second protrusion having a triangular cross-section with a smaller protrusion than the first protrusion is integrally provided between the one protrusions so as to be parallel to the first protrusion, while The slush mold in which the third ridge portion having a triangular cross section is integrally projected along the outer peripheral edge of the product shape portion on the mold molding surface side of the part is heated, and then the powder is applied to the mold molding surface of the slush mold The body resin raw material is supplied and adhered and melted to form a molten resin layer, and then the tips of the first and second protrusions are lowered. , In a state of facing each top front end of the third ridge portion, after forming the slush molding the skin material is cooled cure the molten resin layer, characterized by demolding the said surface skin material.

  According to the third and fourth aspects of the present invention, a slush skin material is formed by supplying a powdered resin raw material to a heated mold forming surface, adhering and melting it to form a molten resin layer, and cooling and curing the molten resin layer. The solution provided by the invention according to claim 3 is that an outer projecting portion projecting outward from the mold is formed on the outer periphery of the product shape portion of the mold molding surface. A pair of first protrusions having a triangular cross-section are integrally projected on the mold forming surface side of the outer overhanging portion so as to be juxtaposed in proximity to each other along the outer peripheral edge of the product shape portion. In addition, between the first ridges, a second ridge having a triangular cross-section with a smaller protrusion than the first ridge is integrally projected so as to be parallel to the first ridge. The first and second protrusions are held in a posture in which the tip faces downward in the cooling and hardening process of the molten resin layer. Characterized in that it has become to so that.

  According to a fourth aspect of the present invention, there is provided a solution provided by the outer peripheral edge of the product shape portion of the mold forming surface including an outer projecting portion projecting outward from the mold and an inner projecting portion projecting inward from the mold. A pair of first protrusions having a triangular cross section are integrally formed on the mold surface side of the outer overhanging portion so as to be juxtaposed in parallel with each other along the outer periphery of the product shape portion. In addition, a second protrusion having a triangular cross-section with a smaller protrusion than the first protrusion is integrally formed between the first protrusions so as to be parallel to the first protrusion, The third projecting portion having a triangular cross section is integrally projected along the outer peripheral edge of the product shape portion on the mold forming surface side of the inner overhang portion, and the first portion is cooled and cured in the process of cooling and melting the molten resin layer. The second ridge is held in a posture with the tip directed downward, and the third ridge is held in a posture with the tip directed upward. It is characterized in that it is in.

  According to the first aspect of the present invention, the pair of first protrusions whose tips are directed downward while the molten resin layer made of the powder resin raw material that has been supplied to the molding surface of the slush mold and adhered and melted is cured. At the ridge, the molten resin layer hangs down from the base end of the first ridge portion along the inclined surface toward the tip end due to the action of gravity, so the amount of resin between the first ridge portions is reduced, and The thickness of the molten resin layer at the bottom of the valley between both first protrusions is reduced by the protrusion amount of the second protrusion, and the boundary between the product part and the unnecessary part of the skin material formed by cooling and hardening is V. A pair of thick portions are formed by the large notches, and a thin portion is formed by the small V-shaped notches between the thick portions. Therefore, even if the skin material is a material that is difficult to shred, such as when the skin material is molded from a material having a high elongation rate, the thin-walled portion can be obtained by manually pulling unnecessary portions after removing the skin material. Can be easily and reliably removed, and unnecessary portions can be easily and reliably removed from the skin material.

  According to the second aspect of the present invention, the first and second ends are directed downward while the molten resin layer made of the powder resin raw material that is supplied to the mold forming surface of the slush mold and adhered and melted is cured. At the ridge, the molten resin layer hangs down from the base end of the first ridge portion along the inclined surface toward the tip end due to the action of gravity, so the amount of resin between the first ridge portions decreases, In addition, the thickness of the molten resin layer at the bottom of the valley between the first ridges is reduced by the amount of protrusion of the second ridges, and the boundary between the product part and the unnecessary part of the skin material formed by cooling and hardening is used. A pair of thick portions are formed by the large V-shaped notches, and a thin portion is formed by the small V-shaped notches between the thick portions. On the other hand, at the third ridge portion with the tip facing upward, the molten resin layer moves from the tip of the third ridge portion along the inclined surface toward the inner overhanging portion by the action of the surface tension and gravity. Therefore, a thin portion of the molten resin layer is formed at the tip of the third protrusion, and the thin portion is formed by a V-shaped notch at the boundary between the product portion and the unnecessary portion of the skin material formed by cooling and hardening. It is formed. Therefore, even if the skin material is a material that is difficult to cut, such as when the skin material is formed of a material having a high elongation rate, the above two types can be obtained by pulling the unnecessary portion by hand after removing the skin material. The thin-walled portion can be easily and reliably torn off, and unnecessary portions can be easily and reliably removed from the skin material. In this way, the shape of the thin-walled portion is different because, for example, when the molded product has a three-layer structure in which the foam layer is integrally formed between the skin material and the base material, depending on the shape of the base material This is because the contact state between the skin material terminal and the base material terminal may be different.

  According to the invention of claim 3, a slash can be obtained simply by forming an outer overhang on the outer periphery of the product shape portion of the molding surface and projecting the first and second protrusions on the outer overhang. The effect described in claim 1 can be obtained without significantly remodeling the mold structure of the mold.

  According to the invention which concerns on Claim 4, an outer overhang | projection part and an inner overhang | projection part are formed in the product shape part outer periphery of a molding surface, and the 1st and 2nd protrusion part is protrudingly provided in the said outer overhang part In addition, the third projecting portion is provided on the inner overhanging portion in a direction opposite to that of the first and second projecting portions, and the slash molding die structure is not significantly modified. The effect of can be produced.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 13 shows a vehicle instrument panel 1. As shown in FIGS. 14 and 15, the instrument panel 1 includes a resin skin material 3 constituting the surface layer of the instrument panel 1, and a resin base material 5 constituting the back surface layer of the instrument panel 1. Are disposed substantially parallel in cross section, and the urethane foam layer 7 is integrally formed between the skin material 3 and the base material 5. The skin material 3 is formed by slush molding with a resin material such as PVC (polyvinyl chloride), TPO (thermoplastic olefin), or TPU (thermoplastic urethane). The base material 5 is injection-molded with a resin material such as PP (polypropylene) or ABS (acrylonitrile / butadiene / styrene). The urethane foam layer 7 has a semi-rigid structure in which independent foaming and continuous foaming are distributed about half each.

  As shown in FIG. 14, the skin material terminal 3 a of the skin material 3 has an L on the base material 5 side in the outer peripheral region excluding the substantially central portion in the vehicle width direction on which the center panel 9 (see FIG. 15 imaginary line) is mounted. An L-shaped bent end portion 3b that is bent in a letter shape, an outer peripheral area at a substantially central portion in the vehicle width direction on which the center panel 9 is mounted, an opening peripheral area of the side defroster air outlet 11, a meter hood In the forming region 12 and the opening peripheral region of the opening 13 for mounting the airbag device, as shown in FIG. 15 with the center panel 9 side as a representative, a V-shaped bent end portion formed into a V-shape. 3c. On the other hand, the base material terminal 5a of the base material 5 has a concave portion 5b that opens to the skin material 3 side in the outer peripheral region excluding the substantially central portion in the vehicle width direction where the center panel 9 is mounted. In the outer peripheral region of the substantially central portion in the vehicle width direction, the opening peripheral region of the side defroster air outlet 11, the molding region of the meter hood 12, and the opening peripheral region of the airbag device mounting opening 13, the skin material terminal 3a Receiving surface portion 5c. In the outer peripheral region excluding the substantially central portion in the vehicle width direction where the center panel 9 is mounted, the surface of the skin material terminal 3a is in close contact with the inner surface of the outer vertical wall 5d of the recess 5b from the inside, and an L-shaped bent end. The part 3b is embedded in the urethane foam layer 7, and the skin material terminal 3a seals between the skin material 3 and the base material 5 of the urethane foam layer 7 terminal. Further, in the outer peripheral area of the substantially central portion in the vehicle width direction where the center panel 9 is mounted, the opening peripheral area of the side defroster air outlet 11, the molding area of the meter hood 12, and the opening peripheral area of the airbag device mounting opening 13 The tip of the V-shaped bent end 3c of the skin material terminal 3a is in contact with the receiving surface 5c to seal between the two. The V-shaped bent end 3c is covered and hidden by the attached center panel 9 so that it cannot be seen from the outside. In other words, the instrument panel 1 has a three-layer structure in which the urethane foam layer 7 is integrally interposed between the skin material 3 and the base material 5. The base material 5 is exposed without the material 3 and the urethane foam layer 7. Further, the lower panel portion is also free from the skin material 3 and the urethane foam layer 7, and the base material 5 is exposed. In FIG. 13, 14 is a front defroster air outlet, and 15 is provided on the back side of the instrument panel 1 for injecting a foamed urethane resin as a raw material of the urethane foam layer 7 between the skin material 3 and the base material 5. It is a resin injection port.

  Next, the mold structure of a slush mold for molding the skin material 3 will be described with reference to FIG.

  The slush mold 17 includes a flat surface portion 17a for forming most of the skin material 3, and a vertical surface portion 17b for forming the skin material terminal 3a is formed on the outer periphery of the flat surface portion 17a over the entire circumference with a slight inclination angle. It is vertically suspended. In addition, on the peripheral edge of the lower end of the vertical surface portion 17b, the outer peripheral region of the substantially central portion in the vehicle width direction where the center panel 9 is mounted, the opening peripheral region of the side defroster air outlet 11, the molding region of the meter hood 12, and the airbag device mounting An outer projecting portion 17c projecting outward from the mold is formed corresponding to the peripheral edge region of the opening 13 for use, and the inner portion corresponding to the outer peripheral region excluding the substantially central portion in the vehicle width direction in which the center panel 9 is mounted. An inwardly extending portion 17d that protrudes in the direction is formed. A skirt portion 17e is integrally extended over the entire circumference of the overhang end portions of the outer overhang portion 17c and the inner overhang portion 17d, and a flange portion 17f is entirely formed on the outer periphery of the lower end of the skirt portion 17e. It is integrally formed over the circumference. The inner surface excluding the flange portion 17f of the slush molding die 17 is used as a molding surface 19 for molding the skin material 3, and the regions corresponding to the flat surface portion 17a and the vertical surface portion 17b are used as product shape portions.

  As a feature of the present invention, a pair of first protrusions 21 having a triangular cross section are arranged in close proximity to each other along the outer peripheral edge of the product shape portion on the mold forming surface 19 side of the outer overhanging portion 17c. A second protrusion 23 having a triangular cross-section, which is provided integrally with the first protrusion 21 and has a smaller protrusion than the first protrusion 21, is arranged in parallel with the first protrusion 21. So as to project integrally. On the other hand, in the middle of the molding surface 19 side of the inner overhanging portion 17d, a third protrusion 25 having a triangular cross section is integrally projected along the outer periphery of the product shape portion.

  As will be described later, the slush molding die 17 configured in this way supplies a powder resin raw material to a heated mold molding surface 19 to form a molten resin layer by adhesion and melting, and cools and cures the molten resin layer. By doing so, the slash skin material 3 is shape | molded. In the cooling and hardening process of the molten resin layer, the first and second protrusions 21 and 23 are held in a posture in which the tips are directed downward, and the third protrusion 25 is directed to the top. It is designed to be held in the correct posture.

Next, the procedure for forming the skin material 3 using the slush mold 17 will be described. The numbers given in parentheses below indicate the order of the manufacturing process.
(1) As shown in FIG. 2, the slush mold 17 is carried between the upper and lower heaters 27 so that the mold molding surface 19 faces down, and heated to, for example, 220 ° C.
(2) As shown in FIG. 3, with the heated slush mold 17 placed with the mold surface 19 facing down, for example, PVC (polyvinyl chloride), TPO (thermoplastic olefin), TPU The raw material storage box 29 in which the powder resin raw material R1 such as (thermoplastic urethane) is stored is brought into contact with the flange portion 29a of the opening edge of the raw material storage box 29 so that the slash molding die 17 is brought into contact with the raw material storage box 29. The flange portion 17f of the slush molding die 17 is sandwiched by a clamping jig (not shown) provided on the raw material storage box 29 side, and both flange portions 17f, 29a of the slush molding die 17 and the raw material storage box 29 are sandwiched. Are sealed with a sealing material 31.
(3) As shown in FIG. 4, the raw material storage box 29 is turned upside down by rotating the rotating shaft 33 with a rotating device (not shown), and the powder resin raw material R1 stored in the raw material storage box 29 is obtained. Is supplied and attached to the molding surface 19 of the slush molding die 17. In FIG. 4, the dense points along the mold forming surface 19 indicate a state in which the powder resin raw material R <b> 1 is attached to the mold forming surface 19 of the slush mold 17. The powder resin raw material R1 adhering to the mold molding surface 19 is heated and melted by the mold temperature, and a molten resin layer R2 (see FIG. 5) starts to be formed. After that, as shown in FIG. 5, the raw material storage box 29 is turned upside down in the opposite direction to return to the original posture, and the excess powder resin raw material R1 is dropped into the raw material storage box 29 and collected. .
(4) The slush mold 17 is removed from the raw material storage box 29, and, as shown in FIG. The unmelted powder resin raw material R1 adhering to the surface 19 is completely melted. In this state, the first and second protrusions 21 and 23 have their tips directed downward, and the third protrusion 25 has the tip upward. FIG. 7A shows an enlarged view around the first and second protrusions 21 and 23 of the slush mold 17 immediately after the slash mold 17 is removed from the raw material storage box 29, and FIG. The area around the third ridge 25 of the slush mold 17 immediately after the slash mold 17 is removed from the raw material storage box 29 is shown enlarged. At this stage, the thickness of the molten resin layer R2 is uniformly formed on the entire molding surface 19, but changes as shown in FIGS. 8A and 8B with time. That is, at the first and second protrusions 21 and 23 with the tips facing downward, the molten resin layer R2 is formed on the first protrusion 21 by the action of gravity, as shown in FIG. Since it hangs down from the base end along the inclined surface toward the tip end, the amount of resin between the first ridges 21 is reduced, and the thickness of the molten resin layer R2 at the valley bottom between the first ridges 21 is small. The second protrusion 23 is thinned by the amount of protrusion, and a thick portion R2-1 is formed at the tip of the pair of first protrusions 21, and the second protrusion between the thick portions R2-1. 23, a thin portion R2-2 is formed at the tip. On the other hand, at the third ridge portion 25 with the tip facing upward, the molten resin layer R2 is formed at the tip of the third ridge portion 25 by the action of surface tension and gravity, as shown in FIG. Therefore, the thin portion R2-3 of the molten resin layer R2 is formed at the tip of the third protrusion 25.
(5) The slush mold 17 is cooled by blowing air to cure the molten resin layer R2. At this time, the slash molding die 17 has the first and second protrusions 21 and 23 facing forward and the third protrusion 25 facing upward. Thereby, the progress of the dripping phenomenon of the molten resin layer R2 occurring in the previous process is stopped, and the slush-molded skin material 3 is molded in a state where the molten resin layer R2 is dripped (see FIG. 9). The molded skin material 3 has a large V shape at the boundary between the product part S1 and the unnecessary part S2 corresponding to the product shape part of the molding surface 19 at the first and second protrusions 21 and 23. A pair of thick portions S4-1 is formed by the pair of notches S3-1, and a thin portion S4-2 is formed by a small V-shaped notch S3-2 between the pair of thick portions S4-1. . On the other hand, at the third ridge portion 25, a thin portion S4-3 is formed by a V-shaped notch S3-3 at the boundary between the product portion S1 corresponding to the product shape portion of the molding surface 19 and the unnecessary portion S2. ing.
(6) As shown in FIG. 9, the unnecessary portion S2 of the skin material 3 is pulled by hand with the mold molding surface 19 of the slash molding die 17 facing upward, and is peeled off from the mold molding surface 19, and the skin material 3 is removed. Remove from slush mold 17. At this stage, the thin portions S4-2 and S4-3 of the skin material 3 are not torn, and the product portion S1 and the unnecessary portion S2 are connected, but after that, the unnecessary portion S2 is pulled to thin the thin portion S4-. 2, S4-3 is shredded and removed from the product portion S1 (see FIG. 10). As shown in FIG. 14, the product portion S1 terminal (skin material terminal 3a) is placed on the base material 5 side in the outer peripheral region except the substantially central portion in the vehicle width direction where the center panel 9 (see the imaginary line in FIG. An L-shaped bent end portion 3b that is bent in an L-shape, an outer peripheral region at a substantially central portion in the vehicle width direction on which the center panel 9 is mounted, an opening peripheral region of the side defroster air outlet 11, a meter In the shaping | molding area | region of the food | hood 12, and the opening peripheral area | region of the opening part 13 for airbag apparatus mounting | wearing, as shown in FIG. 15, it has the V-shaped bending edge part 3c formed by bending in V shape. .

  Thus, in this embodiment, while the molten resin layer R2 is cured, the product of the skin material 3 is produced by the action of the gravity of the molten resin layer R2 at the pair of first protrusions 21 with the tips directed downward. A thin portion S4-2 can be formed at the boundary between the portion S1 and the unnecessary portion S2 corresponding to the second protrusion 23. On the other hand, at the third protrusion 25 with the tip facing upward, the thin-walled portion S4- at the boundary between the product portion S1 and the unnecessary portion S2 of the skin material 3 due to the surface tension of the molten resin layer R2 and gravity. 3 can be formed.

  Therefore, for example, even when the skin material 3 is made of a material that is difficult to cut, such as when the skin material 3 is formed of a material having a high elongation rate, the unnecessary portion S2 is pulled by hand after the skin material 3 is removed from the mold. The two types of thin-walled portions S4-2 and S4-3 formed due to the difference in the contact state between the skin material terminal 3a and the base material terminal 5a depending on the shape of the base material 5 can be easily and reliably shredded. The unnecessary portion S2 can be easily and reliably removed from the skin material 3.

  Further, in the slush mold 17, the outer projecting portion 17c and the inner projecting portion 17d are formed on the outer peripheral edge of the product shape portion of the molding surface 19, and the first and second protrusions are formed on the outer projecting portion 17c. The slash-molding die 17 can be formed simply by projecting the portions 21 and 23 and projecting the third projecting portion 25 on the inner overhanging portion 17d in the direction opposite to the first and second projecting portions 21 and 23. The effects as described above can be achieved without significantly modifying the structure.

  The skin material 3 molded in this manner is carried into a molding die 101 as shown in FIGS. 11 and 12 together with the base material 5 to be used for manufacturing the instrument panel 1.

  The molding die 101 includes an upper die 103 and a lower die 105. The upper die 103 is provided with an injection head 107. The slide die 109 is extended and contracted by the fluid pressure cylinder 111 in the lower die 105. Is slidable. In FIGS. 11 and 12, reference numeral 103 a denotes an insertion hole into which the injection head 107 is inserted, and 113 denotes a cavity formed between the skin material 3 and the base material 5.

  The procedure for manufacturing the instrument panel 1 is as follows.

  First, as shown in FIG. 11, in a state where the upper mold 103 is raised and the mold 101 is opened, the fluid pressure cylinder 111 is extended to move the slide core 109 forward, and then the skin material 3 is moved to the lower mold. Set to 105. As a result, the skin material terminal 3a corresponding to the outer peripheral region excluding the substantially central portion in the vehicle width direction on which the center panel 9 is mounted comes into contact with the tip of the slide core 109, and the skin material terminal 3a falls outward by the tip of the slide core 109. The skin 3 is positioned on the lower mold 105 while being held. In this state, the skin material 3 is brought into close contact with the lower mold 105 by a negative pressure from a vacuum suction hole (not shown). On the other hand, the base material 5 is set on the upper mold 103. At that time, the substrate 5 is held by a substrate holding device (not shown) so as not to fall from the upper mold 103. In this state, the resin injection port 15 of the substrate 5 communicates with the injection head 107.

  Next, as shown in FIG. 12, the fluid pressure cylinder 111 is contracted to retract the slide core 109, and the upper mold 103 is lowered from the upper side to close the mold 101. Thereby, in the location corresponding to the outer peripheral area excluding the substantially central portion in the vehicle width direction on which the center panel 9 is mounted, the front side of the skin material terminal 3a comes into contact with the outer vertical wall 5d of the base material 5 from the side, and is L-shaped. The bent end portion 3b protrudes between the skin material 3 and the base material 5 (see FIG. 14). Moreover, it corresponds to the outer peripheral area of the vehicle width direction substantially central part where the center panel 9 is mounted, the opening peripheral area of the side defroster air outlet 11, the molding area of the meter hood 12, and the opening peripheral area of the airbag device mounting opening 13. The V-shaped bent end portion 3c of the skin material terminal 3a is in contact with the receiving surface portion 5c of the base material 5 (see FIG. 15).

  Thereafter, with the mold closed, a foamed resin raw material (not shown) is injected from the injection head 107 through the resin injection port 15 of the base material 5 into the cavity 113 between the skin material 3 and the base material 5 to be foam-cured. Thus, the instrument panel 1 in which the urethane foam layer 7 is integrally interposed between the skin material 3 and the base material 5 is obtained (see FIGS. 14 and 15).

  Thereafter, after the holding state of the base material 5 by the base material holding device is released, the upper mold 103 is raised to open the mold 101 and the molded instrument panel 1 is removed from the lower mold 105. .

  In the above embodiment, the L-shaped bent end portion 3b is formed on the skin material terminal 3a corresponding to the outer peripheral region excluding the substantially central portion in the vehicle width direction where the center panel 9 is mounted, and the center panel 9 is mounted. V on the skin material terminal 3a corresponding to the outer peripheral region of the substantially central portion in the vehicle width direction, the opening peripheral region of the side defroster air outlet 11, the molding region of the meter hood 12, and the opening peripheral region of the airbag device mounting opening 13. Although the case where the skin material 3 in which the character-shaped bent end portion 3c is formed is shown (corresponding to claims 2 and 4), the skin material in which only the V-shaped bent end portion 3c is formed on the skin material terminal 3a. 3 may be formed (corresponding to claims 1 and 3). In this case, only the outer projecting portion 17c projecting outward from the mold is formed on the outer peripheral edge of the product shape portion of the mold forming surface 19, and a pair of triangular sections are formed on the mold forming surface 19 side of the outer projecting portion 17c. The first protrusions 21 are integrally protruded along the outer peripheral edge of the product shape part so as to be parallel to each other, and between the first protrusions 21 than the first protrusions 21. A slush mold 17 is used in which the second protrusion 23 having a triangular cross-section with a small protrusion is integrally projected so as to be in parallel with the first protrusion 21. After the slush mold 17 is heated, the powder resin raw material R1 is supplied to the mold molding surface 19 of the slush mold 17 and adhered and melted to form the molten resin layer R2. The melted resin layer R2 is cooled and cured to form the slush-molded skin material 3 with the tips of the two ridges 21 and 23 facing down, and then the skin material 3 may be removed.

  The molded product to which the skin material 3 is applied is not limited to the instrument panel 1 and can be applied to other resin molded products having the skin material 3.

  INDUSTRIAL APPLICABILITY The present invention is useful for a method for manufacturing a slush molded skin material that constitutes a surface layer of a resin molded product such as an instrument panel for a vehicle and a slush mold used in the manufacturing method.

It is sectional drawing of the slash shaping | molding die which concerns on embodiment. It is a heating process figure of the slush shaping | molding die in embodiment. In embodiment, it is process drawing which shows the state which set the slash shaping | molding die to the raw material accommodation box. In embodiment, it is process drawing which shows the state which reversed the raw material accommodation box from the state of FIG. 3, and made the powder resin raw material adhere and fuse | melt on the shaping | molding surface of a slush molding die. In the embodiment, the raw material storage box is returned to the original posture from the state of FIG. 4, the powder resin raw material is collected in the raw material storage box, and the molten resin layer serving as the skin material is formed on the molding surface of the slush mold FIG. It is a reheating process figure of the slush shaping | molding die in embodiment. 6A is an enlarged view corresponding to the portion A in FIG. 6 immediately after the slash mold is removed from the raw material storage box, and FIG. 6B is an enlarged view corresponding to the portion B in FIG. 6 immediately after the slash mold is removed from the raw material storage box. is there. In embodiment, the state which the layer thickness of the molten resin layer in the protrusion part changed is shown, (a) is a 7 (a) equivalent figure, (b) is a 7 (b) equivalent figure. In embodiment, it is process drawing which shows the state which has shape | molded the skin material shape | molded from the slush molding die. It is sectional drawing of the skin material which removed the unnecessary part. It is sectional drawing of the shaping | molding die of the mold open state which set the skin material to the lower mold | type and set the base material to the upper mold | type. It is sectional drawing of the shaping | molding die which shows a mold closed state. It is a perspective view of an instrument panel. It is sectional drawing in the XIV-XIV line | wire of FIG. It is sectional drawing in the XV-XV line | wire of FIG. It is an equivalent figure of FIG. 8 of a prior art example.

Explanation of symbols

3 Skin material 17 Slush mold 17a Plane part (product shape part)
17b Vertical surface part (product shape part)
17c Outer overhanging portion 17d Inner overhanging portion 19 Molding surface 21 First protrusion 23 Second protrusion 25 Third protrusion R1 Powder resin raw material R2 Molten resin layer

Claims (4)

An outer projecting portion projecting outward from the mold is formed on the outer peripheral edge of the product shape portion of the mold forming surface, and a pair of first protrusions having a triangular cross section are formed on the mold forming surface side of the outer projecting portion. A second protrusion having a triangular cross section that is integrally projected along the outer peripheral edge so as to be juxtaposed with each other in a close proximity, and between the first protrusions has a smaller protrusion than the first protrusion. Heats the slush mold that is integrally projected so that is parallel to the first protrusion,
Next, a powder resin raw material is supplied to the mold forming surface of the slush mold and adhered and melted to form a molten resin layer,
Then, with the tips of the first and second ridges facing down, the molten resin layer is cooled and cured to form a slush molded skin material, and then the skin material is demolded. A method for producing a slush molded skin material. An outer projecting portion projecting outward from the mold and an inner projecting portion projecting inward from the mold are respectively formed on the outer peripheral edge of the product shape portion of the mold forming surface, and a triangular cross section is formed on the mold forming surface side of the outer projecting portion. A pair of first ridges having a shape are integrally projected along the outer periphery of the product shape portion so as to be juxtaposed with each other, and between the first ridges, than the first ridges. A second protrusion having a triangular cross-section with a small protrusion amount is integrally projected so as to be in parallel with the first protrusion, while a third protrusion having a triangular cross-section is formed on the molding surface side of the inner overhang. Heat the slush mold with the ribs protruding integrally along the outer periphery of the product shape part,
Next, a powder resin raw material is supplied to the mold forming surface of the slush mold and adhered and melted to form a molten resin layer,
Thereafter, the molten resin layer was cooled and cured to form a slush-molded skin material with the first and second protrusions facing downward and the tip of the third protrusion facing upward, respectively. Then, the manufacturing method of the slush molding skin material characterized by demolding the skin material. A slush molding die for forming a slush skin material by supplying a powder resin raw material to a heated mold forming surface and causing it to adhere and melt to form a molten resin layer, and cooling and curing the molten resin layer,
An outer projecting portion projecting outward from the mold is formed on the outer peripheral edge of the product shape portion of the mold forming surface, and a pair of first protrusions having a triangular cross section are formed on the mold forming surface side of the outer projecting portion. The protrusions are integrally protruded along the outer periphery of the product shape portion so as to be in parallel with each other, and the protruding amount between the first protrusions is smaller than that of the first protrusions. The second ridge is integrally projected so as to be parallel to the first ridge, and the first and second ridges are held in a posture in which the tip is directed downward during the cooling and hardening process of the molten resin layer. A slush mold characterized by being made. A slush molding die for forming a slush skin material by supplying a powder resin raw material to a heated mold forming surface and causing it to adhere and melt to form a molten resin layer, and cooling and curing the molten resin layer,
On the outer peripheral edge of the product shape part of the mold forming surface, an outer projecting part projecting outward from the mold and an inner projecting part projecting inward of the mold are formed, respectively, and the mold molding surface side of the outer projecting part is formed. The pair of first protrusions having a triangular cross section are integrally protruded so as to be juxtaposed in the proximity of each other along the outer peripheral edge of the product shape part, and the first protrusions are disposed between the first protrusions. A second protrusion having a triangular cross-section with a smaller protrusion than the protrusion is integrally projected so as to be parallel to the first protrusion, while on the molding surface side of the inner overhang, A third ridge portion having a triangular cross section is integrally projected along the outer periphery of the product shape portion, and the first and second ridge portions are oriented with their tips facing down during the cooling and hardening process of the molten resin layer. The slash is characterized in that the third protrusion is held in a posture with the tip facing upward. Form type.

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