JPH1119938A - Apparatus and method for molding foam molding with skin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an apparatus and method for molding a foam molding with a skin for reducing a product cost by eliminating trimming as much as possible without molding fault. SOLUTION: The apparatus for molding a foam molding with a skin comprises a lower mold 1 for sucking a skin material, and an upper mold freely mating with the mold 1 via an intermediate die 2 having an opening 2a substantially coincident with a cavity port of the mold 1 in such a manner that the mold 1 is loosely clamped at a loosely clamping surface 2a except part of a stopper part 5 to the die 2 with part of an edge of the material in an immovable state. The method for molding a foam molding with a skin comprises the steps of placing a previously cut skin material of the degree not necessary to be trimmed after molding on a lower mold, mating it with an intermediate die having an opening substantially coincident with its cavity port, loosely clamping a residual part of one edge of a peripheral edge of a skin material in an immovable state, conducting a lead-in molding the material, supplying of foam synthetic resin material, mating it with an upper mold, then foaming by an ordinary method, and molding the foam molding with the skin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus and a method for molding a foamed article with a skin.

[0002]

2. Description of the Related Art A conventional foamed molded article with a skin, such as an armrest for an automobile or a seat cushion for an automobile, is obtained by mounting a slightly cut skin material on a lower mold having a suction function so that it can be trimmed after molding. Then, the peripheral edge is clamped, and then the lower mold is subjected to a suction pressure to draw the skin material into the lower mold surface, draw in the molded material, supply the foamed synthetic resin material and mold the upper mold to form the foam. The synthetic resin material is foamed between the mold surface of the lower mold and the mold surface of the upper mold to form a foam molded article with a skin, but the skin material is drawn into the mold surface of the lower mold by the suction pressure described above. When molding, this pull-in does not occur uniformly, but it does not occur partially due to the shape of the mold, etc., and it becomes non-uniform.Therefore, if the clamp mechanism is a loose clamp type, it is necessary to provide sufficient margin for the crimped part , table Wood tends partially dislodged from the crimping surface, causing causing molding defects. In order to solve this problem, it is necessary to trim the part that protrudes from the peripheral edge of the molded product after molding, by making the skin material a large one with a considerable margin, which generates a large amount of waste. In addition, there has been a problem that the use amount of the skin material is increased and the product cost is increased.

[0003]

The object of the present invention is to solve the above-mentioned problems, to eliminate molding defects, to minimize trimming and to reduce the product cost, and to reduce the product cost. It is an object of the present invention to provide a molding apparatus and a method for molding a foam molded article with a skin.

[0004]

According to the present invention, there is provided a lower mold having a function of suction-holding a skin material on a mold surface, the lower mold having an opening substantially matching the shape of a cavity opening. An upper mold having a mold surface positioned in the cavity of the lower mold through the opening through an intermediate mold for covering the skin can be freely mated, and the mating surface of the lower mold and the middle mold is an edge of the skin material. A molding apparatus for a foam molded article with a skin, characterized in that a loose-clamping surface is formed by leaving a stopper portion for fixing only a part of the molded article in an immobile state. In the invention according to the first aspect, the stopper portion comprises a convex line formed on the lower surface of the intermediate die and a concave line formed on the upper surface of the lower die corresponding thereto. In the invention according to claim 1 or 2, The invention of claim 3 which is provided a setting position display lines of the skin material to. In addition, the skin material cut in advance so as to have a size that does not need to be trimmed after molding is placed on a lower mold having a suction function, and an opening substantially matching the shape of the cavity opening of the lower mold is provided. The intermediate mold for holding the skin is pressed, and only a part of the peripheral portion of the skin material is fixed in an immovable state between the mating surfaces with the lower mold, and the rest is loosely clamped. The suction material is applied to the mold to draw the skin material into the lower mold surface, form it, supply the foamed synthetic resin material, match the upper mold, and place this foamed synthetic resin material in the middle of the lower mold surface. 5. A method for molding a foamed article with a skin, comprising foaming a foamed article with a skin through an opening of the mold and between a mold surface of an upper mold located in a cavity of a lower mold. In the invention according to claim 4, According to a fifth aspect of the present invention, there is provided a method of forming a mold in a state in which an insert core material is temporarily held on a die surface of a mold, wherein a sealing material is attached to a peripheral end of the insert core material. The method according to claim 6 or claim 5, wherein the method according to claim 5 or 6, wherein the sealing material is made of urethane foam resin, according to claim 7, and the method according to claim 4 or claim 5. Alternatively, in the invention according to the sixth or seventh aspect, a method of forming an adhesive layer covered with release paper on the peripheral portion of the skin material is defined as the invention according to claim 8, and the adhesive according to the invention according to claim 8 is provided. A method using a double-sided tape as a layer is the invention according to claim 9.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, a preferred embodiment of the present invention will be described in detail with reference to FIGS. Reference numeral 1 denotes a lower mold formed by die-casting aluminum. The cavity 1a of the lower mold 1 is communicated with a vacuum chamber 1b inside the mold by a number of suction holes 1c provided on the mold surface. 2
Is an intermediate mold which is arranged on the upper surface of the lower mold 1 so as to be aligned with the upper mold. The intermediate mold 2 is formed by aluminum die casting similarly to the lower mold 1 and substantially matches the shape of the cavity opening of the lower mold 1. An opening 2a is formed, and the lower end of the intermediate mold 2 is a mating surface that presses the entire surface of a peripheral edge 4a for winding the skin material 4, which will be described later, and a large part thereof is a loose clamp surface 2b. The upper end is a mating surface with an upper die 7 described later. The opening edge of the opening 2a is tapered so as to spread upward so that the upper die 7 does not collide with the upper die 7. Further, the above-mentioned skin material 4
Is cut in advance to a size that does not require trimming after molding, and the material is soft vinyl chloride resin or other plastics-based sheets or fabrics. A film is laminated on the inner surface for blocking.

Reference numeral 5 denotes a stopper portion for fixing a part of the peripheral portion of the skin material 4 to the lower mold 1 in an immovable state, and the stopper portion 5 shown in FIG. It is composed of a concave ridge 5a formed on the rear upper surface and a convex ridge 5b formed on the rear lower surface of the opening 2a of the intermediate mold 2. When the intermediate mold 2 is combined with the lower mold 1, the concave ridge 5a is formed. Engagement with the ridges 5b causes a part of the skin material 4 located on the upper surface of the lower mold 1 to be held by the stopper portion 5 and fixed in an immovable state. Reference numeral 7 denotes an upper mold that is matched with the lower mold 1 via the intermediate mold 2,
If necessary, a core material 8 for the insert may be provided on the surface of the upper mold 7.
Can be attached. A sealing material 8a made of a polyurethane resin is wound around the periphery of the core material 8 for the insert so that urethane foam resin serving as a pad material during foam molding does not leak, and only foam gas is exhausted. To prevent molding failure due to foaming gas. Reference numeral 9 denotes an interval adjusting member formed on the mating surface of the lower mold 1 to release the thickness of the skin material 4, and 10 denotes a set position indicating line of the skin material 4. 4 can be arranged at the correct position.

[0007] As shown in FIG. 2, the skin material 4 is placed in the cavity 1 a of the lower die 1 in accordance with the set position indicating line 10 in the above-described structure. At this time, the skin material 4 held by the stopper portion 5 is arranged so as to be the reference position. Next, if the intermediate mold 2 is matched with the lower mold 1,
The peripheral part of the skin material 4 is sandwiched between the mating surfaces of the lower mold 1 and the intermediate mold 2, but at this time, only a part of the peripheral part of the skin material 4 is the stopper 5, that is, the lower part. Type 1
Of the skin 4 is fixed in an immovable state while being held by the concave ridges 5a and the convex ridges 5b of the intermediate mold 2, but the rest of the peripheral portion of the skin material 4 is loosely clamped slightly inside the edge by the loose clamp surface 2b. It will be. The fixed portion in the immovable state has a width that becomes the winding peripheral edge 4a after molding. In this state, the vacuum chamber 1b of the lower mold 1
When a negative pressure is applied to the skin material 4 through the suction hole 1c to apply a suction pressure, the skin material 4 is sucked along the mold surface of the lower mold 1 as shown in FIG. .

At this time, a portion of the peripheral edge portion of the skin material 4 which is not fixed by the stopper portion 5 is in a loose clamp state, and is pulled in against the pressing force of the intermediate mold 2. Although the loose clamp portion has a sufficient width, even if the amount of the surface material 4 to be pulled slightly fluctuates, the surface material 4 can be attached without being wrinkled. Is not partially released by the intermediate mold 2. Then, when the skin material 4 is brought into close contact with the mold surface, the winding peripheral edge 4a of the skin material 4 is pressed on the mold mating surface of the lower mold 1 without protruding into the loose clamp surface 2b of the intermediate mold 2. Next, a predetermined amount of a foamed synthetic resin material such as a foamed urethane resin material is supplied into the skin material 4 and, as shown in FIG.
When the mold is placed on the mold and the mold is fitted, the insert core material 8 attached to the mold surface of the upper mold 7 is positioned in the cavity of the lower mold 1 through the opening 2 a of the intermediate mold 2.

Then, the mold surface of the upper mold 7 and the lower mold 1 located in the cavity of the lower mold 1 through the opening 2a of the intermediate mold 2 by a conventional method such as heating the foamed synthetic resin material by clamping the mold. To form a foamed molded article with a skin. At this time, the foaming gas generated in the mold is exhausted through the sealing material 8a made of urethane foam resin attached to the periphery of the insert core material 8. After the completion of the foam molding, the upper mold 7 and the intermediate mold 2 are opened, and the foam molded article is released. After the mold release, an adhesive is applied to the periphery of the insert core material 8 integrated with the back periphery of the molded product, and then the winding periphery 4a protruding from the periphery of the molded product is removed. Then, a molded article with a skin as shown in FIG. 6 is completed.

In the preferred embodiment, the winding edge 4a of the skin material 4 is adhered with the applied adhesive. However, as shown in FIG. 8, an adhesive layer is formed on the winding edge 4a of the skin material 4. A double-sided tape 9 is adhered, and after foam molding, the release paper 9a is peeled off from the adhesive layer 9 as a double-sided tape adhered to the winding periphery 4a of the release molded article. 9 is wound around the rear edge of the molded body and pressed, the wound peripheral edge 4a is adhered by the exposed adhesive of the double-sided tape, so that an application step of applying an adhesive to the periphery of the molded body can be omitted, and The adverse effect on the human body due to the contained harmful solvent or the like can be eliminated. In the preferred embodiment, the skin material 4 has a substantially constant winding periphery along the opening edge of the lower mold 1.
It may be difficult to match the properties of the fabric to the mold shape due to differences in the properties of the fabric such as vertical fabric, horizontal fabric, etc.,
If the winding edge cannot be set accurately, it is a matter of course that the winding edge may be slightly cut. Further, in the preferred embodiment, the insert core 8 is attached to the upper die 7, but it is needless to say that the insert core 8 may not be provided. Further, in the preferred embodiment, the lower mold 1 and the intermediate mold 2 are manufactured by aluminum die-casting. However, it goes without saying that the material and the manufacturing method are not limited, such as manufacturing by molding, cutting, or electrolytic processing. is there.

[0011]

According to the present invention, as is apparent from the above description, an intermediate mold for covering the skin having an opening substantially matching the shape of the cavity opening of the lower mold is interposed between the lower mold and the upper mold. Since the mold is clamped and the mating surface of the lower mold and the intermediate mold is used as a loose clamp surface, leaving a stopper part to fix only a part of the edge of the skin in an immovable state, The shape of the skin material can be made to substantially match the size of the skin material covered with the product, and the trimming can be minimized. As a result, it is possible to reduce the amount of discarded skin material, to achieve a significant cost reduction, and to reduce the cost for disposal treatment. If the lower mold is provided with the set position indicating line, the skin material can be accurately arranged and fixed, so that the winding periphery does not become uneven. Furthermore, in the method of the present invention, if an adhesive layer covered with release paper is formed around the winding edge of the skin material, it is possible to omit the adhesive application step and prevent the working environment from being deteriorated by a solvent or the like. If the adhesive layer is made of a generally sold double-sided tape, the peripheral portion of the winding can be bonded at a lower cost. Furthermore, if a sealing material is attached to the periphery of the insert core material, gas can be vented during foam molding and molding defects can be prevented. Moreover, if the sealing material is made of a foamed polyurethane resin of the same type as the pad material to be foam-filled, the adhesiveness can be further improved. Therefore, the present invention greatly contributes to the development of the industry as a molding apparatus for a foamed molded article with a skin and a molding method for a foamed molded article with a skin that has solved the conventional problems.

[Brief description of the drawings]

FIG. 1 is a partially cutaway perspective view showing a preferred embodiment of the device of the present invention.

FIG. 2 is a partially cutaway perspective view showing a first step of a preferred embodiment of the apparatus of the present invention.

FIG. 3 is a partially cutaway perspective view showing a second step of the preferred embodiment of the apparatus of the present invention.

FIG. 4 is a partially cutaway perspective view showing a third step of the preferred embodiment of the apparatus of the present invention.

FIG. 5 is a partially cutaway perspective view showing a fourth step of the preferred embodiment of the apparatus of the present invention.

FIG. 6 is a sectional view of a product manufactured by the apparatus of the present invention.

FIG. 7 is a plan view showing a state in which a skin material is pressed by an intermediate mold according to a preferred embodiment of the present invention.

FIG. 8 is a cross-sectional view showing an example in which a winding edge is processed by a double-sided tape in a preferred embodiment of the apparatus of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Lower die 2 Intermediate die 2a Opening 2b Loose clamp surface 4 Skin material 5 Stopper part 5a Convex stripe 5b Concave stripe 7 Upper die 8 Insert core material 8a Seal material 9 Adhesive layer 9a Release paper

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification symbol FI B29K 105: 04 B29L 9:00 31:58 (72) Inventor Atsushi Nakayama 10-2 Koroku-cho, Moriyama-ku, Nagoya-shi, Aichi, Japan Towa Kasei Co., Ltd.

Claims (9)

[Claims] 1. A lower mold (1) having a function of sucking and holding a skin material on a mold surface, and an intermediate mold (2) for holding a skin having an opening (2a) substantially matching the shape of the cavity opening. The upper mold (7), whose mold surface is located in the cavity of the lower mold (1), through the opening (2a) through the opening (2a), and the lower mold (1) and the intermediate mold (2) can be aligned. The surface of the foam molded article with a skin is characterized in that the surface is a loose clamp surface (2b), leaving a stopper part (5) for fixing only a part of the edge of the skin material in an immovable state. Molding equipment. 2. A stopper (5) comprising a convex strip (5a) formed on the lower surface of the intermediate mold (2) and a concave strip (5b) formed correspondingly on the upper face of the lower mold (1). The molding apparatus for a foamed article with a skin according to claim 1, wherein the molded article comprises: 3. A set position indicating line (1) of the skin material is provided on the lower mold (1).
The molding apparatus for a foamed article with a skin according to claim 1 or 2, further comprising (0). 4. A skin material cut in advance so as to have a size that does not need to be trimmed after molding is placed on a lower mold having a suction function, and substantially conforms to a shape of a cavity opening of the lower mold. An intermediate mold for covering the skin with an opening to be mold-matched, and only a part of the peripheral portion of the skin material is fixed in an immovable state between the mating surfaces with the lower mold, and the remaining portion is loosely clamped, Next, a suction material is applied to the lower mold to apply the skin material to the lower mold surface, draw-mold the foam material, supply the foamed synthetic resin material, and match the upper mold. Forming a foamed molded article with a skin by foaming between a mold face and an upper mold face positioned in a cavity of a lower mold through an opening of an intermediate mold. . 5. The method of molding a foamed molded article with a skin according to claim 4, wherein the molding is performed in a state in which a core material for an insert is temporarily held on a mold surface of an upper mold. 6. The method for molding a foamed article with a skin according to claim 5, wherein a sealing material is attached to a peripheral end of the core material for the insert. 7. The method for molding a foamed article with a skin according to claim 5, wherein the sealing material is made of urethane foam resin. 8. The method of molding a foamed molded article with a skin according to claim 4, wherein an adhesive layer covered with release paper is formed on a peripheral portion of the skin material. 9. The method according to claim 8, wherein a double-sided tape is used as the adhesive layer.