JPS61211007A - Manufacture of molded body - Google Patents

Abstract

PURPOSE:To abolish the installation of an urethane pouring mold and an injection molding machine and remove man-hours to shift molded product from a slush molding mold to an urethane pouring mold by a method wherein the foaming process of foamed layer is effected by employing a ready-made core member in a mold, in which slush molding is effected, to form the foamed layer while the foamed layer is brought into close contact with the core member. CONSTITUTION:The slush mold 21 is heated and filled with skin power, then, the mold 21 is converted whereby a skin layer 22, adhered with skin powder, is obtained on the inner rear surface of the mold 21. The mold is filled with the foaming powder and the foaming powder 23 is adhered onto the skin layer 22. Here, the mold 21 is heated again to foam the foaming powder while an upper force 24 is closed with respect to the mold 21 to foam and the core member 25 is set. Foaming is effected under this condition and the foamed layer 23' is molded while the foamed layer 23' is brought into close contact with the core member 25.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing a molded article, particularly a method for manufacturing a slush molded article.

[Conventional technology]

Conventional two-layer slush molding will be explained with reference to FIG. Heat mold 1 in the shape of the product in advance (Step A)
, Stop heating and put the epidermal powder all the way into the mold.
After adhering the skin powder to the inner surface of mold 1 using the heat of the mold, turn the mold over and remove the powder that does not adhere to form skin powder 1 layer 2 (Step B) 0 Spread foaming powder on top of skin powder 1 layer 2 After filling the mold 1 completely and allowing it to adhere, the mold 1 is turned over to remove the powder that does not adhere to form a layer 3 of foamed powder (step C). Then, the mold 1 is heated once again to foam the foaming powder to obtain a foam layer 3' (step D), then the mold 1 is cooled (step E), and the molded product is taken out (step F). Next, the molded product taken out is placed in the urethane injection mold 4 (Step G), and urethane is injected to form the core material 5 (Step H). Finally, the completed molded product is demolded (Step I).

Next, conventional skin slush molding will be explained with reference to FIG. After welding the skin powder into the mold 6 to form the skin layer 7 in the same manner as in the case of the two-layer slush (step A
, B), cooling and step C), and demolding (step D). Type 6
Step E
), urethane (foam) 11, which is a soft material, is injected into the urethane injection mold 8.10 (step F). Finally, the completed molded product is demolded (Step G).

[Problem that the invention seeks to solve]

The conventional slush molding method described above requires a urethane injection mold, which increases equipment costs, and requires extra man-hours to transfer the molded product from the slush mold to another urethane injection mold. In addition to this problem, two-layer slush molding also has the disadvantage of requiring a large number of steps (9 steps).

[Means for solving problems]

In order to solve the above-mentioned problems, the present invention performs slush molding and then performs foaming treatment on the foam layer using an existing core material in the slush molding mold. At the same time, the foam layer and core material are brought into close contact with each other.

[For production]

According to this method, the foam layer can be formed in a slush molding mold, which eliminates the need for urethane injection molds and injection molding machines, and eliminates the man-hours required to transfer the molded product from the slush molding mold to the urethane injection mold. Moreover, the number of molding steps is fewer than that of two-layer slush molding (7 steps).
.

〔Example〕

An embodiment of the present invention will be described with reference to FIG.

Heat the slush mold 21 in step A), stop the heating, fill the mold 21 with skin powder, turn the mold 21 over, and the skin layer 2 with the skin powder welded to the inner back surface of the mold 21
2 is obtained (Step B). The mold is filled with foaming powder to adhere the foaming powder 23 onto the skin layer 22, and the excess foaming powder is removed by turning the mold 21 over (step C).

Here, the mold 21 is heated again to foam the foaming powder (step D), and during the foaming process, the upper mold 2 is placed against the mold 21.
4. Close and set the core material 25 (Step E). As the core material, a metal material such as an iron plate or a thermosetting resin or other heat-resistant resin is used. Foaming is performed in this state to form the foam layer 23', and the foam layer 23'
is in close contact with the core material 25. Since the foaming powder is being foamed, the foam layer 23' and the core material 25 are surely brought into close contact with each other by the foaming pressure. Then, the slush mold 21 is cooled down in step F.
), and the finished molded product 26 is taken out from the mold 21 (Step G).

In the above embodiment, after step C, the mold 21 is heated to foam the foaming powder 23, and then the upper mold 24 and the core material 2
As shown in FIG. 2, after step C, first set the upper mold 24 and core material 25 in step D'), then heat the mold 24 to foam the foaming powder 23.
While forming the foam layer 23', the foam layer 23' and the core material 2
5 may be placed in close contact with each other.

〔Effect of the invention〕

According to the present invention, a molded product having a slush-molded skin layer, a core material, and a foam layer between them can be manufactured using only a slush-molding mold, eliminating the need for a urethane injection mold or an injection molding machine, resulting in equipment costs. Since there is no need to transfer the molded product from mold to mold, the number of man-hours can be reduced, and the number of steps can also be reduced.

This molded product is useful as a slush molded product using a flexible material (foam) with an iron plate as the core material, for example, for impact-resistant passenger protection in door clubs, inside panels, knee pads, etc. in automobiles and other vehicles.

[Brief explanation of the drawing]

FIG. 1 is a process diagram explaining the method of the embodiment of the present invention, and FIG.
The figure is a partial process diagram explaining a modification of the embodiment shown in Figure 1, Figure 3 is a process diagram explaining a conventional two-layer slush molding method, and Figure 4 is a diagram explaining a conventional skin slush molding method. It is a process diagram. 1.6...Mold for slush molding, 2,7...Single layer of skin powder, 3...Foaming powder, 3'...Foaming layer,
4.8□ 10... Urethane injection mold, 5... Urethane (core material), 9... Core material, 11... Urethane (
foam), 21... mold, 22... epidermal powder, 2
3... Foaming powder, 23'... Foaming layer, 24...
- Upper mold, 25... Core material, 26... Molded product (finished product).

Claims (1)

[Claims] 1. In producing a molded article having a skin layer formed by slush molding, a core material, and a foam layer between the skin layer and the core material, after slush molding the skin layer with a mold,
Using a pre-molded core material as the core material, the foam layer is foamed in the mold for slush molding to form the foam layer, and the core material and the foam layer are integrally bonded. A method for producing a molded body, characterized by: