Adhesive bonding and miscellaneous chemical manufacture – Surface bonding means and/or assembly means therefor – With bending – folding – winding – or wrapping means
Reexamination Certificate
2001-02-20
2003-01-21
Ball, Michael W. (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Surface bonding means and/or assembly means therefor
With bending, folding, winding, or wrapping means
C156S580000, C425S520000, C425S521000, C425S400000
Reexamination Certificate
active
06508289
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for molding a laminated assembly and apparatus in which a surface skin member is integrally attached to the surface of a resin core member and having a folded part at a peripheral rim of the surface skin member, and more particularly, to a method for molding a laminated assembly and apparatus in which no load is applied to the folded part of the surface skin member when pushing up the laminated assembly, thereby reliably preventing the surface skin member from being peeled off, and consequently having a good appearance.
2. Description of the Related Art
FIG. 10
shows the structure of an automobile door trim in the interior of a door panel. In the automobile door trim
1
, a surface skin member
3
is integrally attached to the surface of a resin core member
2
formed to a desired curved shape, and an end of the peripheral rim
3
a
of the surface skin member
3
is folded over the back of the resin core member
2
at the entire length or part of the peripheral rim of the product for finishing.
As a manufacturing method for the automobile door trim
1
, a cold-press molding, a mold-press molding, or other molding methods can be used. The cold-press molding method will be described as an example. First, as shown in
FIG. 11
, when cold-press molding upper and lower molds (an upper mold
4
and a lower mold
5
) are opened, a surface skin conveying unit
6
on which the surface skin member
3
is placed is brought into the cold-press molding upper and lower molds
4
and
5
, and the surface skin member
3
is elevated with the motion of a cylinder (not shown) built in the surface skin conveying unit
6
, and is retained with a support pin
4
a
of the upper mold
4
.
A thermoplastic resin plate P that is a material of the resin core member
2
being softened by heat, is placed on the die surface of the lower mold
5
prior to supplying the surface skin member
3
. As shown in
FIG. 12
, by closing the upper and lower molds
4
and
5
each other, the resin core member
2
having a desired shape is molded from the thermoplastic resin plate P, and at the same time, the surface skin member
3
is integrally attached to the surface of the resin core member
2
.
In this instance, an excessive tensile force is applied to the folded part
3
a
of the surface skin member
3
held by the support pin
4
a
as the upper mold
4
moves downward.
Accordingly, recently, a surface skin holding means
7
shown in
FIG. 13
is proposed in order to prevent the excessive tensile force from being applied to the surface skin member
3
, particularly, to the folded part
3
a
when the cold-press molding is executed with the cold-press molding upper and lower molds
4
and
5
.
In this mechanism, a support frame
7
a
is supported by a support post
7
b
. The support post
7
b
penetrates in a through hole
5
a
of the lower mold
5
, and can be vertically moved. The support frame
7
a
is constantly urged upward with an urging spring
7
c
folded over an outer periphery of the support post
7
b
. When the support frame
7
a
is pressed downwardly, the support frame
7
a
moves downward if a pressing force larger than a spring force of the urging spring
7
c
is applied.
In addition, when the surface skin member
3
is placed, the support frame
7
a
is elevated to a position forming the same plane as the die surface of the lower mold
5
, and when the support frame
7
a
is at the elevated position, the surface skin member
3
is placed.
As shown in
FIG. 14
, when the upper mold
4
moves downward to the bottom dead center, and the resin core member
2
and the surface skin member
3
are integrated by closing the upper and lower molds
4
and
5
each other, the folded part
3
a
of the surface skin member
3
is held by the support frame
7
a
and the support pin
4
a
, and is subjected to an appropriate tensile force with the spring force of the urging spring
7
c.
However, when the surface skin holding means
7
comprising the support frame
7
a
, the support post
7
b
, and the urging spring
7
c
is used, as shown in
FIG. 15
for example, if the upper mold
4
moves upward after completion of press-molding, the urging spring
7
c
is released from an external force, so that the support frame
7
a
is elevated to the uppermost position with the spring force of the urging spring
7
c
. In this instance, since a laminated assembly a is positioned on the die surface of the lower mold
5
, an excessive load is applied to a peripheral rim
2
a
of the resin core member
2
from the folded part
3
a
of the surface skin member
3
, and as a result, a problem occurs in that the folded part
3
a
of the surface skin member
3
is peeled off at the position indicated as X.
Also, after the upper mold
4
moves upward, as shown in
FIG. 16
, the laminated assembly a is pushed up from the lower mold
5
with the pushing-up motion of an ejector pin
5
b
; however, in this case as well, an excessive load is applied to the peripheral rim
2
a
of the resin core member
2
from the folded part
3
a
of the surface skin member
3
, thereby the folded part
3
a
is liable to peel off at the position indicated as X.
Accordingly, in the surface skin holding means
7
, although an appropriate tensile force is applied to the surface skin member
3
with the urging spring
7
c
, an excessive load is applied to the base of the folded part
3
a
of the surface skin member
3
when the dies are opened after molding and when the surface skin member
3
is pushed up with the ejector pin
5
b
, with the result that problems occur in that the folded part
3
a
is peeled off and also a highlighted line cannot be clearly formed, thereby the appearance of the outline of the product is injured.
SUMMARY OF THE INVENTION
The present invention has been made in consideration of the above problems, and accordingly, it is an object of the present invention to provide a method for molding a laminated assembly and an apparatus, in which a surface skin member has a folded part at a peripheral rim, wherein when press-molding is executed, the surface skin member is subjected to an appropriate tensile force, so that molding property can be preferably maintained, and also when the dies are opened after molding and when the molded product is pushed up, no excessive load is applied to a base of the folded part of the surface skin member, and consequently, peeling off of the surface skin member can be remarkably prevented.
In order to accomplish the above objects, according to the present invention, there is provided a method for molding a laminated assembly, in which a surface skin member is integrally attached to the surface of a resin core member and a folded part of the surface skin member is folded over the entire length or part of a peripheral rim of the resin core member, wherein the surface skin member is placed above the resin material of the resin core member supplied to a die surface of a lower mold, and when press molding is executed, the folded part of the surface skin member is held with a surface skin holding means provided corresponding thereto, and after completion of the molding, the surface skin holding means moves upward in cooperation with a pushing-up motion of ejector means disposed at the lower mold so as to enable the folded part of the surface skin member to follow the laminated assembly.
As the molding method, there are a cold-press molding method and a mold-press molding method.
In the cold-press molding method, a polypropylene resin plate in which wood meal is mixed is extruded to form a sheet with a T-die extruder, and after the sheet plate is subjected to a hot softening process with a heater and is placed on a cold-press-molding lower mold, it is integrally molded together with the surface kin member supplied into the die by cold-press molding.
In addition, in the mold-press molding method, after the surface skin member is placed in the die, a molten resin is distributed on the die surface of a mold-press-molding
Ball Michael W.
Dickstein , Shapiro, Morin & Oshinsky, LLP
Kasai Kogyo Co. Ltd.
Musser Barbara J.
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